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Offshore Subsea Oil & Gas
2nd Workshop on Innovative Engineering for Fluid Power2 Workshop on Innovative Engineering for Fluid Power Applications in Aircraft, Vehicles and Energy (02-03. Sep. 2014)
Offshore Subsea Oil & Gas:Offshore Subsea Oil & Gas:Application Challenges and Hydraulic Solutions
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Source Picture: FMC Technologies, Barclays, John Gremp, CEO
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Offshore Subsea Oil & Gas
World see depth landscapeWorld see depth landscape
Depth: 0 to 305 m (1.000 ft)( )
Depth: from 305 m (1.000 ft) to 1.830 m (6.000 ft)
Depth: from 1.830 m (6.000 ft)to 10 911 m (35 800 ft)
72% of the worlds surface is covered with water About 88% of the ocean is deeper than 1.000 m Deepest part of the ocean is in a depth of 10 911 m* (with 1 100 bar)
to 10.911 m (35.800 ft)
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Deepest part of the ocean is in a depth of 10.911 m* (with 1.100 bar)Source: www.ginkgomaps.com - http://de.wikipedia.org * deepste part of the ocean is Mariana Trench, see red dot
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Offshore Subsea Oil & Gas
Subsea oil & gas: what that means?Subsea oil & gas: what that means?
50 300 km
Consequences
Hi h t50 – 300 km • High extern pressures(> 300 bar)
• Long distances (> 300 Km)
• Higher weights(big vessels)
• Wave movements(big marine ( gcurrents)
• Remote control (full automation)
• Corrosive Co os eenvironment
• Explosive atmosphere
• Long service time (30a)
9/1/2014 | Wagner Mattos | DCBR | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Source - http://www.petrobras.com.br/en/about-us/profile/activities/oil-and-gas-exploration-and-production/
time (30a)
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Offshore Subsea Oil & Gas
Key Requirements & Available CompetenciesKey Requirements & Available CompetenciesOil & Gas Production
Offshore Application
Water Depth(> 3.000 m)
• Process industry (continuous flow )
• High productivity
• Huge dimensions• Corrosive
environment
• High pressures • Long distances• Low visibilityg p y
• High availability• Explosive
atmosphere
• Wave movements• Snow crust• Ecological system
o s b ty• Remote control
only (no manual)• New technologies
• Earth quake safe (mussels…) (unknown effects)
Condition MonitoringSubsea ExperienceTesting Methods
Functional Safety Reliability EngineeringCondition MonitoringSubsea Experience
S t A il bilitCorporate Research Bosch Engineering System
Testing Methods
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System AvailabilityCorporate Research Bosch Engineering System
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Offshore Subsea Oil & Gas
Subsea equipment landscapeSubsea equipment landscape
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Source: NORSOK standard U-009, Life extension for subsea systems
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Offshore Subsea Oil & Gas
Subsea equipment landscapeSubsea equipment landscapeBooster pumpDecrease back-pressure on well by
Subsea compressionTo compress gas to increase efficiency
Remote Operated Vehicle (ROV)To install, actuate and maintain equipmentsp y
compensating head losses
during transport
Manifoldsdesigned to transfer oil / gas from wellheads
Workover systemsTo enable any kind of of oil well intervention
/ gas from wellheads into a pipeline
Subsea separationSeparate liquids/liquids, liquids/gas gas/gas
Distribution unit, power packs (HPU’s)
Trees, wellheadsControl oil & gas flow
liquids/gas, gas/gas
T l t
+ Support systems (for installation, actuation or maintenance): especially
power packs (HPU s)Electric / hydraulic power distribution to subsea field
TemplateSteel structure to support and protect subsea equipment
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Remote Operated Vehicles (ROV) & Autonomous Underwater Vehicle (AUV)
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Offshore Subsea Oil & Gas
Subsea equipment landscapeSubsea equipment landscape The main function of the subsea equipment to produce oil or gas:
Oil or gasOil or gas production
Seabed equipment interface
Control the oil flow Oil pipe
Oil, gas and other liquid separating
Increase field
pressure Cluster the
oil wellsLift the oil or gas to the surface
Control volume flow Well closure Safety closure Inject
chemicalsMonitor
production parameters
Well control and test
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Offshore Subsea Oil & Gas
Subsea equipment landscapeSubsea equipment landscape The main function of the subsea process valve to produce oil or gas:
Control volume flow
controlled oil flow Oil flow
Auxiliary energy
Control oil Oil flow
controlled oil flow
Energy supply
flow
Transform energy
Control actuated energy
Realize actuationElectricity energy
Auxiliary energy for
ElectricityMechanical, Electrical
Mechanical, Hydraulic,Pneumatic
Mechanical, Hydraulic,Pneumatic,Electrical
Mechanical,Electrical
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Auxiliary energy for actuation control
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Offshore Subsea Oil & Gas
Subsea treesSubsea trees Schematic working principle:
9/1/2014 | Wagner Mattos | DCBR | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Source: Ocean Flow International in Wikipedia and Aker Solutions
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Offshore Subsea Oil & Gas
Subsea control systemSubsea control systema) Electro hydraulic multiplexed control system
b) All electric control system
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Source: CSystems, lightly modified
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Offshore Subsea Oil & Gas
Solutions – Pressure compensator Medium separation Absolute pressure in the reservoir is 1 bar
Solutions Pressure compensator
p Benefits of pressure compensation: Design pressure is ‘‘only‘‘ the hydraulic
pressure, not the static pressurepressure, not the static pressure Seals are less complicated
Hydraulic oil reservoirSea water
Spring force 1 bar
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Spring force 1 bar
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Offshore Subsea Oil & Gas
Solutions – Deep Sea Cylinder Welded instead of threaded design to avoid water penetration High pressure position transducer, encapsulated
Solutions Deep Sea Cylinder
Extra heavy design for cylinder bottom and thread for position encoder (600 bar at bottom and thread)
Sub sea electrical connector Special paint
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Offshore Subsea Oil & Gas
Solutions – Deep Sea Cylinder Rod seals pressure compensated Special wiper ring
Special (Double) Sealing:
Solutions Deep Sea Cylinder
Main seal not in contact with sea water
Pressure compensation
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Offshore Subsea Oil & Gas
Solutions – Electro Hydraulics Encapsulated manifold, oil filled and pressure compensated Sea water resistant seal for cover
Solutions Electro Hydraulics
Air has to be vented completely Specially developed on-off and prop.
valves with modified solenoids pole tubesvalves with modified solenoids, pole tubesand terminal strips
Sub sea electrical connector
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Offshore Subsea Oil & Gas
Deep Power UnitDeep Power Unit
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Offshore Subsea Oil & Gas
Deep Power Unit – Test in pressure chamberDeep Power Unit Test in pressure chamber
Tests up to 6,000 m water depth (ambient pressure 600 bar) have been successful
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Offshore Subsea Oil & Gas
Extract of Test Results – 1 Extend and retract time of the cylinder were approximately 1
second slower per 100 bar pressure increase
Extract of Test Results 1
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Offshore Subsea Oil & Gas
Service & Condition Monitoring SystemService & Condition Monitoring SystemSystem requirements Total remote operation 30 years service time “Without any failure”
(fatigue-resistant design)
How to monitor & test the equipment?q p
How to exchange a component in case of failure? With a special ROV? By changing the whole system ?
(e.g. Christmas tree)
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Offshore Subsea Oil & Gas
Deep Sea Hydraulics – Challenges and Solutions
Ambient pressure 1 bar per 10 m water depth
Deep Sea Hydraulics Challenges and Solutions
Challenges Equipment located in salt water
Ambient pressure 1 bar per 10 m water depth
Corrosion protection is indispensable
Avoid water penetration at all costs
Electro hydraulics does not work in salt water
Avoid water penetration at all costs
Diagnosis of operating conditions
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Offshore Subsea Oil & Gas
DC experience with Subsea applications: 30 examplesDC experience with Subsea applications: 30 examples
11965 1975 1985 1995 2005 2015Components # of app.
Hydr. Pumps 19
H d M if ld 20 10
100
Hydr. Manifolds 20
Hydr. Valves 13
Hydr. Cylinders 9
Hydr. Motors 101.000
10.000
Off h R b t (ROV/AUV) Mi i O E I f t t
y
Hydr. Power Unit 7
Hydr. Accumul. 5
Electr. Controls 10
Offshore Robot (ROV/AUV) Mining Ocean Energy InfrastructureMech. Gearbox 4
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Subsea Crawler Subsea Control ModuleSubsea Trencher CleanHull ROV
Buble Size – delivery scope complexity: : 1 single type of component; : 10 different types of components.
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Offshore Subsea Oil & Gas
Experience: 1972 TrencherExperience: 1972 Trencher
Pumps Control manifolds Control manifolds
Water depth 500 m
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Offshore Subsea Oil & Gas
Experience: 1984 Submersible Work SystemExperience: 1984 Submersible Work System
Under water pipeline repair riser connectionrepair, riser connection, construction assistance and maintenance
Pumps Control manifolds
Water depth 500 m
CCustomer: HDW
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Offshore Subsea Oil & Gas
Experience: 2013 Chain Tensioners forExperience: 2013 Chain Tensioners for Submerged Bouy
Power unit Power unit Control manifoldsWater depth 300 mCustomer : Subsea 7 Petrobras
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Customer : Subsea 7, Petrobras
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Experience: 2008 Subsea CrawlerOffshore Subsea Oil & Gas
Experience: 2008 Subsea Crawler Pumps Motors Valves Cylinders Electronics
Water depth 4000 m
Customer: Aker Wirth
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Offshore Subsea Oil & Gas
Remote Operated Vehicles Pumps Motors
Remote Operated Vehicles
Customer: SMD, FMC, Oceaneering,....
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Offshore Subsea Oil & Gas
Experience: Local Content – Brazilian ProjectsExperience: Local Content Brazilian Projects
Bosch Rexroth Ltda. Bosch Rexroth Ltda.
ADDRESSADDRESS
A. Tégula, 888 – Un. 13/14 Bairro Ponte AltaCEP 12952-440Atibaia, SP
Bosch Rexroth Ltda.R. Luiz Abry, 2.225 Caixa Postal 156CEP 98107-000Pomerode, SC
Phone: +55 11 4414 5600fax: +55 11 4414 5649
Phone: +55 47 387 9500fax: +55 47 387 2551
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Offshore Subsea Oil & Gas
Experience: HPU to supply Subsea Control Project : P55 - FMC Function :This unit has the function of supply with h dra lic fl id all the s bsea s stems
Experience: HPU to supply Subsea Control
hydraulic fluid all the subsea systems
Dimension: 6,5 x 2,5 x 3 mWeight: 18 TonFluid: HW 525 (Walter Base fluid)Fluid: HW 525 (Walter Base fluid)
Composed by:- Structure and Container : Stainless Steel - Set of Accumulators High Pressure and Middle Pressure - Pump and Special Valves - Project according with standards regulations :BV - Controls
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Offshore Subsea Oil & Gas
Manifolds Blocks and Test StandsManifolds Blocks and Test Stands
Tambaú – Oil Filed Tambaú – Oil FiledRoncador – Oil Field Global – Oil FieldPresalt – Oil FieldTotal: 154 OFF
Roncador – Oil FieldGlobalCiscTotal: 12 OFF
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Total: 154 OFF Total: 12 OFF
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Offshore Subsea Oil & Gas
Experience: HPU to supply Subsea ControlExperience: HPU to supply Subsea Control
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Offshore Subsea Oil & Gas
Derrick Moving System – PVIDerrick Moving System PVI
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Offshore Subsea Oil & Gas
Petrobras – Service HPU – P9Petrobras Service HPU P9
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Offshore Subsea Oil & Gas
HPU AHC – Ring Line – Drilling RingHPU AHC Ring Line Drilling Ring
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Offshore Subsea Oil & Gas
Water Fire Pump – P58/P62/P66-P77Water Fire Pump P58/P62/P66 P77
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Offshore Subsea Oil & Gas
Aux. Generator System for FPSO – P58/P62Aux. Generator System for FPSO P58/P62
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Skid Start – Compressor Gas System –Offshore Subsea Oil & Gas
Skid Start Compressor Gas System Replicants FPSO
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Presence Bosch Rexroth in FPSO Applications
Energy Main System Cranes Subsea HPU Chain Jack
Ti b l dGE
Siemens
Pelegrini
Husiman
Nov
Liebherr
Energy Aux. System
MTU
Dresser Rand
Caterpilar
FMC
AKER
Cameron
GE
Timberland
Aker
Nov
Husiman
RemazelAux. System
Offload
RemazelSMD
Scana
APL
NOV
IHC
Auxiliar Whinces
Imeca
Natec
EnquipExtinction Fire SystemThruster Enquip
Sthrauss
SAS
EPRON
NAVALSUL
y
Sulzer
Framo
Hamworthy
Cargo Pump
Framo
Hamworthy
Thustmaster
Voith
Wartsila
Roll Royce
Riser Winch
Imeca
Rolls Royce
H P
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Frames H P
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Offshore Subsea Oil & Gas
Questions? Contact:
Wagner Mattos [email protected]
Rogério Silva 011-4414-5640011 4414 5640 [email protected]
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Offshore Subsea Oil & Gas
Thank you all for your attention!
9/1/2014 | Wagner Mattos | DCBR | © Bosch Rexroth AG 2014. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
for your attention!
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