Offshore Subsea Oil & GasOffshore Subsea Oil & Gas ...cisb.org.br/wiefp2014/presentations/Session 8_Wagner.../ gas from wellheads into a pipeline Subsea separation Separate liquids/liquids,

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

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 Picture: FMC Technologies, Barclays, John Gremp, CEO

1


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)


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

2


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)


Source - http://www.petrobras.com.br/en/about-us/profile/activities/oil-and-gas-exploration-and-production/

time (30a)

3


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


System AvailabilityCorporate Research Bosch Engineering System

4


Subsea equipment landscapeSubsea equipment landscape


Source: NORSOK standard U-009, Life extension for subsea systems

5


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


Remote Operated Vehicles (ROV) & Autonomous Underwater Vehicle (AUV)

6


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

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.7


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


Auxiliary energy for actuation control

8


Subsea treesSubsea trees Schematic working principle:


Source: Ocean Flow International in Wikipedia and Aker Solutions

9


Subsea control systemSubsea control systema) Electro hydraulic multiplexed control system

b) All electric control system


Source: CSystems, lightly modified

10


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


Spring force 1 bar

11


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



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



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



Deep Power UnitDeep Power Unit



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



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



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)



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



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


Subsea Crawler Subsea Control ModuleSubsea Trencher CleanHull ROV

Buble Size – delivery scope complexity: : 1 single type of component; : 10 different types of components.

20


Experience: 1972 TrencherExperience: 1972 Trencher

Pumps Control manifolds Control manifolds

Water depth 500 m



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



Experience: 2013 Chain Tensioners forExperience: 2013 Chain Tensioners for Submerged Bouy

Power unit Power unit Control manifoldsWater depth 300 mCustomer : Subsea 7 Petrobras


Customer : Subsea 7, Petrobras

23

Experience: 2008 Subsea CrawlerOffshore Subsea Oil & Gas

Experience: 2008 Subsea Crawler Pumps Motors Valves Cylinders Electronics

Water depth 4000 m

Customer: Aker Wirth



Remote Operated Vehicles Pumps Motors

Remote Operated Vehicles

Customer: SMD, FMC, Oceaneering,....



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



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



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


Total: 154 OFF Total: 12 OFF

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Experience: HPU to supply Subsea ControlExperience: HPU to supply Subsea Control



Derrick Moving System – PVIDerrick Moving System PVI



Petrobras – Service HPU – P9Petrobras Service HPU P9



HPU AHC – Ring Line – Drilling RingHPU AHC Ring Line Drilling Ring



Water Fire Pump – P58/P62/P66-P77Water Fire Pump P58/P62/P66 P77



Aux. Generator System for FPSO – P58/P62Aux. Generator System for FPSO P58/P62


Skid Start – Compressor Gas System –Offshore Subsea Oil & Gas

Skid Start Compressor Gas System Replicants FPSO


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


Frames H P

36


Questions? Contact:

Wagner Mattos [email protected]

Rogério Silva 011-4414-5640011 4414 5640 [email protected]



Thank you all for your attention!


for your attention!

38

Documents

Offshore Subsea Oil & GasOffshore Subsea Oil & Gas ...cisb.org.br/wiefp2014/presentations/Session 8_Wagner.../ gas from wellheads into a pipeline Subsea separation Separate liquids/liquids,