drill site plug n’ play and the reusable control system · drill site plug n’ play and the...

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www.xodusgroup.com

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Drill Site Plug n’ Play and The Reusable Control System

Gordon Anderson

22nd August 2017

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> What is Plug n’ Play?

– “conveys a message of interconnectivity and the ability to connect modular equipment in an

easy and effective way, to form a production system that is fit for purpose and rapid to

deploy”

> Plug n’ Play Aspiration:

– Rapid engineering & delivery of the project

– Full interconnectivity between modular subsea components

– Re-use of subsea equipment from field to field (the circular economy)

– Interoperability with present and future systems

– Flexibility to use a range of supplier specific subsea components

Drill Site Plug n’ Play

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> Key Assumptions

– UKCS

– 80/20 Rule (i.e. Design for majority, not all)

– Water Depth suitable for Diver intervention

– Minimal Fishing Protection

> Level 1 – Fundamental Design Philosophies

> Level 2 – High Level Equipment Functionality

Plug and Play Drill Centre


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> Layout - Manifold

> Construction - Diver+

> Subsea Xmas Tree - Standard / Basic

> Flow Management - Standalone Module

> Pressure / Temperature - 5000psi, 90°C (Prod.), 60°C (GL)

Level 1 – Fundamental Design Philosophies


Data reviewed from historic

developments across UKCS

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> Jumper Type - Unbonded flexible or Composite Pipe

> Production Jumper - 6” ID, 60m Long

> Gas Lift Jumper - 2.5” ID, 60m Long

> Connection System - Diver+ Quick Connect/Disconnect

Level 2 – Equipment High Level Functionality


Data reviewed from historic

developments across UKCS

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> Manifold Structure

– Standard design

– No test loop, metering or chemical injection

– Headers, branches and space for 2 x SCM

– Gravity based

– Slab-sided

> Flow Management Package

– Metering, Chemical Injection, Sampling

– Modular system to provide custom field

requirements

– Change-out modules as/if required

Level 2 – Equipment High Level Functionality


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> Key Objectives

– Guarantee equipment integrity

– Optimise offshore schedule

– Maximise vessel availability

> Solutions

– Monitored installation and recovery

– Gravity based structures

– Standard designs and installation methods

– Diver+ Quick Connect/Disconnect

– Subsea Jumper Carousels

Installation & Recovery


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Summary & Future Work


Summary

> There is an economic justification for plug n’

play drill site

> Technology is largely proven with little

development needed

> Requirement for greater monitoring during

installation, operation and recovery

Future Study Work

> Ownership model for re-usable equipment

> Installation methods that guarantee integrity

of components

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> What is the Reusable Control System?

– A system where all components are designed for recovery and re-use

– Designed to operate for 4-5 years before recovery / refurbishment / re-use

> Current practise combines topside and subsea equipment;

> Deploying the equipment at the drill site allows it to be recovered and easily moved to the next drill

site;

> Reusing the umbilical is a possibility however this study has concentrated on systems deployable

local to the drill site.

Reusable Control System

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> Expensive item of equipment to purchase and install;

> Considered to be a long lead item contributing to longer project executing times;

> Unlikely that the umbilical could be recovered and re-used multiple times;

> Umbilical failure would result in a full replacement being installed at considerable cost;

> Considerable cost to retrofit a J-tube to an existing host facility should there be no spare J-tubes

available to house the umbilical.


Benefits of removing the umbilical from a subsea control system

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The umbilical contains a number of hoses and cables providing the following services:

> Low and high pressure hydraulic supply lines;

> Chemical injection supply lines;

> Power supply lines;

> Communication supply lines.

What services does the umbilical provide?


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Block Diagram


Hydraulics

Unit

Subsea Control

Module

Chemicals

Unit

Subsea Tree

Power /

Communications

Unit

Signal Unit

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Power \ Communications Services:

> Example: EC-OG Subsea Power Hub

– Power generated by Ocean Current

– Power stored in batteries

– Communications Acoustic to a surface Buoy

– Dimensions: 5000 x 7000mm

– TRL 6.

> Example: OPT PB3 PowerBuoy.

– Power generated by Ocean waves


– Communications RS232, RS485 & Ethernet to payload and wireless or Satellite to host facility

– Dimensions: 12300 x 3300mm

– TRL 8.


Alternative options for providing the umbilical services

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Power \ Communications Services:

> Example: Current2Current C-Socket

– Power generated by Ocean Current


– Communications Acoustic to a surface Buoy

– Dimensions: 4000mm Height, 4250mm Diameter

– TRL 6.

Hydraulic Services:

> Subsea Hydraulic Power Unit;

– Example: Siemens SHPU

• 20 W Power Consumption

• Dimensions: 1690 x 2817 x 1092mm

• TRL 5.

> All Electric Tree.



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Chemical Injection Services:

> Subsea Chemical Injection Unit;

– Example HAI Technologies SCIU

• 15kW pump

• Chemicals bunkered in a integrated subsea tank.

• Dimensions Pump Unit: 2800 x 2800 x 8500mm

• TRL 5

Combined System Option:

> Production Control Buoy

– Example: Proserv Buoy

• Communications/ Hydraulics / Chemicals located on the Buoy

• Power supplemented by a subsea power unit

• Communications via line of sight, 3G/4G or satellite

• Services supplied to the Tree via a down line

• Buoy and Surface Equipment TRL 9



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Concept System Architecture

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> All concept options are deemed to be technically viable, demonstrating that there are several options for developing a reusable control system;

> The power requirements can be met using renewable power sources:

– Approximate peak power required 49kW, during start up;

– Normal operation approximate power required 100W;

– Renewable power sources can supply power ranging from 36kW to 600kW.

> High level costs for each type of architecture were generated for 10km Tie-back of the Future;

> Each concept option was assessed against the following criteria:

– System Robustness;

– Installability;

– Reusability;

– Maintenance Access;

– System Average TRL status;

– Cost Differential to least expensive.


Option Comparison

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Option

Criterion

System

Robustness

(3)

Installability

(2)

Reusability

(3)

Maintenance

Access

(1)

Average TRL

Status

(2)

Cost

Differential to

least

expensive (%)

(3)

Total

Weight

Score

√

Option Comparison

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Tie Back of the Future with Reusable Control System

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GA of The Tie Back to the Future with Reusable Control System

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Summary

> Reusable Drill Site Control Systems are feasible and an alternative to the umbilical;

> Equipment is better suited for re-use;

> Technology is in the latter stages of development.

Future Study Work

> Further study work into the communications network in terms of security and providing ESD

functionality;

> A study to look at optimising the power requirements of the subsea equipment.


Summary \ Future Work

drill site plug n’ play and the reusable control system · drill site plug n’ play and the...

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