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Subsea Distribution System
Intervention Riser System (IRS) HPU
Hull Ballast Control System
Smart HPU – Surface Hydraulic Control System
TUTA – Topsides Umbilical Termination Assembly
Ground Water Remediation Separator System and Well Field
ECRS – Environmental Controlled Release System
PROTEC was contracted by a major oilfield service and supply company to manufacture the Subsea Umbilical Termination Assemblies (SUTA) and the Subsea Distribution Units (SDU) for a deep water project offshore West Africa owned and operated by a major international oil company. The subsea field development is controlled via two main control umbilicals that transfer the hydraulic, chemical and electrical services to the subsea distribution network. The two main control umbilicals originate from the FPSO and terminate in two main SUTA’s which in turn are connected by flying leads and infield umbilicals to a series of other SUTA’s and SDU’s and then onward by flying leads from the SDU’s to the manifolds and individual wells. There are a total of six SUTA’s (plus a Dummy UTA for mock up ROV testing) and four SDU’s which were all manufactured by PROTEC along with a specialized mounting base for each SUTA and each SDU. The internal 316 stainless steel tubing network was extremely complex and space was limited so PROTEC generated detailed 3D drawings to guide the process of tube bending and fit up. Tube welding was performed primarily using autogenous welding machines. The SUTA and SDU frames and mounting bases are free flooding painted structures with cathodic protection anodes. All stabplates and electrical connectors are designed for ROV interface and appropriate ROV grab bars are installed.
For the project PROTEC performed manufacturing, fabrication, assembly engineering and assisted with design engineering. The equipment was built in accordance with customer specifications and PROTEC’s own ISO 9001:2008 manufacturing and testing procedures. FAT and EFAT were performed at PROTEC’s facility before shipment. SIT and SRT were performed on site in West Africa with the assistance of PROTEC service technicians. The SUTA’s and SDU’s were built on time and on budget and customer has complimented PROTEC for its high level of quality and workmanship.
PROTEC was contracted by a globally recognized oilfield service and supply company to design, manufacture and test an offshore IRS HPU. The HPU had to meet IEC 60079 Class 1, Zone 2 hazardous area classification requirements. The HPU is water/glycol based and meets NAS 1638 Class 6/SAE AS4059C Class 6 (B-F), cleanliness levels. All metallic material in contact with the hydraulic fluid is 316, 316L stainless steel. The hydraulic fluid reservoir is 316 stainless steel (350 Gal Supply, 150 Gal Return). The structural frame is carbon steel with offshore marine coating and the frame and lifting pad eyes are built in accordance with DNV 2.7-1. There is a 5,500 psig low pressure circuit with four 10-gallon bladder type accumulators and two 30 HP motor driven 5 GPM piston pumps and an air driven auxiliary pump. There is a 15,000 psig high pressure circuit with two 5-gallon piston type accumulators and two 25 HP motor driven 2 GPM piston pumps and an air driven auxiliary pump. The HPU contains a stand-alone PLC based control system with graphical operator interface station on the HPU control cabinet and provides for communication links to the master control station on the offshore platform. The HPU contains a separate PLC operated electrical over pneumatic over hydraulic ESD (emergency shut down) system with a dedicated uninterruptible power supply (UPS).
The HPU was built in accordance with customer specifications and PROTEC’s own ISO 9001:2008 manufacturing and testing procedures. The HPU was built on time and on budget and customer has complimented PROTEC for its high level of quality and workmanship.
A leading manufacturer of subsea trees contracted PROTEC to design, manufacture and test an air driven IWOCS HPU to be incorporated into their installation work over control system (IWOCS) for deepwater subsea trees. The PROTEC IWOCS HPU was designed and certified in accordance with DNV 2.7-1 / 2.7-3 and meets IEC 60079 Class 1, Zone 2 hazardous area classification requirements. The HPU is water/glycol based and meets NAS 1638 Class 6/SAE AS4059C Class 6 (B-F) cleanliness levels. All metallic material in contact with the hydraulic fluid is 316, 316L stainless steel. The hydraulic fluid reservoir is 316 stainless steel (75 gallons). The structural frame is 316 SS tubular construction. There is a 5,000 psig low pressure circuit with two 10-gallon bladder type accumulators and an air driven piston pump. There is a 15,000 psig high pressure circuit with one 5-gallon piston type accumulator and an air driven piston pump. There is one air driven back-up pump.
This PROTEC IWOCS HPU is now the customer’s standard air driven IWOCS HPU.
PROTEC was asked by a major oilfield service and supply company to design, manufacture and test a production HPU for deep offshore West Africa in accordance with the customer’s basic parameters. The overall philosophy was to maximize availability of the system and to minimize intervention for maintenance. The HPU is part of the topside control system and its purpose is to supply clean hydraulic fluid with sufficient pressures and flow to operate the valve actuators on the subsea trees and manifolds.
The HPU had to meet IEC 60079 Class 1, Zone 2 hazardous area classification requirements. The HPU is water/glycol based and meets NAS 1638 Class 6/SAE AS4059C Class 6 (B-F)cleanliness levels. All metallic material in contact with the hydraulic fluid is 316, 316L stainless steel. The hydraulic fluid reservoir is 316 stainless steel (400 Gal Supply, 300 Gal Return). The structural frame is carbon steel with offshore marine coating (zinc polyurethane epoxy 3-part coat system) and the frame and lifting pad eyes are built in accordance with DNV 2.7-1. There is a 5,400 psig low pressure circuit with four 15-gallon bladder type accumulators and two 20 HP motor driven 5.2 GPM piston pumps. There is a 10,000 psig high pressure circuit with two 7.5-gallon piston type accumulators and two 20 HP motor driven 1.3 GPM piston pumps. A local mechanical control panel is provided on the skid with all local monitor and control equipment (pressure gauges, valves, hydraulic regulators, etc.). The electrical panel is rated IEC 60079 Class 1, Zone 2 and is fully outfitted for control and monitoring purposes with supporting equipment for power and communication with the master control station.
For this same project PROTEC also manufactured the TUTA and a test and flushing HPU.
PROTEC was contracted to provide the hull ballast control system for the world’s largest semi-submersible production platform. The platform load varies as production volumes in the internal storage tanks increase and decrease. Also the impact of ocean currents and weather conditions on the platform must be compensated for to maintain desirable positioning. The hull ballast control system is used to control the buoyancy, yaw, roll and position of the platform relative to GPS coordinates by adjusting the buoyancy of individual elements of the hull structure. This is done by the use of over 200 hydraulically operated valves. Additionally a system had to be developed that was very reliable and capable of manual control in the event of catastrophic failure including power loss and the potential of hull breach of the platform. Control in an emergency had to be quick, safe and easy.
Since the platform uses over 200 hydraulically operated bilge and ballast valves to accomplish control of the hull position and15 water tight doors for emergency protection from catastrophic hull breach the customer chose a system design that would use automation to accomplish control of the myriad of valves. The system uses two sets of independent controls, each set consisting of an HPU, Solenoid PLC Panel and Accumulator Bank. The accumulator system had to be designed to provide surplus or reserve hydraulic supply that could provide control ability for weeks in case of power loss in the system.
PROTEC did not just build a customer’s design but actually developed the hydraulic control circuitry, emergency control components as well as all packaging of this very complex system. The resulting innovative design allowed for the customer to have emergency control that was at least 4 times as fast as anything produced in the market to date.
Besides the complexity of the system the equipment we provided met USCG and offshore equipment requirements and pressure safety factors of 4:1 or better. The third party QC inspector gave PROTEC significant accolades on the quality of work provided. And most importantly we provided the equipment on time and at a price that proved to be more economical than the customer’s original expectations.
HPU – for Hull Ballast Control System
Qty 2 HPU. The HPU was designed for oil hydraulics with dual motor lead/lag 250 gallon 316l tank. Level and pressure controllers and appropriate filtration with Hart protocol. All equipment valves were manifold mounted to provide compact and convenient control with reduced leak paths. HPU design and construction was by PROTEC
Solenoid Panel – for Hull Ballast Control System
Qty 2 Solenoid Panels. 248 circuit hydraulic pilot solenoid control with circuit pressure indicators, multiple port output, PLC control, manual control, and provision for auxiliary manual pump. Convertible manifold design for field modification of control circuitry. Design and construction by PROTEC. PLC programming by customer.
Accumulator Banks – for Hull Ballast Control System
• 2 units with 9 ea 15 gallon accumulator banks 3000 psi Top repairable SS pre-charge 900 psi for reserve hydraulic supply with integral block and bleed and USCG top and bottom relief system for each accumulator.
• 2 units with 4 ea 15 gallon accumulator banks 3000 psi Top repairable SS pre-charge 600 psi for reserve hydraulic supply with integral block and bleed and USCG top and bottom relief system for each accumulator.
PROTEC was provided with a general idea and asked to design and produce a Smart HPU with the ability to supply 10,000 psi control fluid distributed to a 5 output station control valve manifold that could be controlled from a customer’s office by field telemetry. The unit had to be compact enough to be delivered by air freight. The system had to have all the necessary automation ability to control and data log a complex pressurization sequence that will be infinitely varied. We managed control by a high end PLC interfacing with a dedicated HMI. PROTEC provided the design, construction and PLC programming. The customer provided the objective and manufacturing constraints and standards. The resulting PROTEC equipment meets the customer’s criteria and will provide them with a standard product that they can confidently market.
A major oil company along with a major engineering company contracted PROTEC to manufacture a TUTA for methanol injection, chemical injection and hydraulic supply. The engineering company provided the piping and instrumentation drawings and basic specifications which included very ambitious space requirements for the components. They left the packaging and construction to us. We chose to provide an all 316L stainless skid to improve upon problems encountered using normal offshore coatings. Additionally due to the depth of the wells the system pressures would require higher pressures than are typical requiring some creative design for the air actuated valves used in the system. This additionally required welding procedures that were critical for the 1.5” API socket welds that were used. Designs were made by PROTEC and accepted by the customer. Just prior to the initiation of fabrication the customer requested the addition of a block and bypass circuit to be added to the system for each umbilical connection. This required the addition of an additional 15 1 ½ “ flanged 6000 psi valves. The footprint constraints remained the same. New drawings were produced and approved with only a 10 day delay in construction. The customer ended up keeping the TUTA’s in storage at our facility for 30 days before they were ready to take delivery. The flexibility to meet the customers changing needs made the delivery of the project an on time reality.
PROTEC was provided a design for a contaminated ground water separation system. The skid measured in at 16’ wide by 35’ long by 18’ tall and weighed in at approximately 42,000 lbs. The unit was situated in Class1 Div 2 area and hade to be able to separate contaminated waste at a rate of up to 45 gallons per minute coming from 16 environmental pumps and a distribution system all designed constructed and managed by PROTEC personnel. PROTEC had to produce the separator system in 60 days after receipt of order to meet federal and state requirements. The logistics and manufacturing documentation as well as the construction had to be fast tracked. The unit was completed on time and at target budget. PROTEC additionally installed, commissioned and provided system management for the entire well field including the separation system.
A major university and the DOD wanted to develop a way to simulate conditions that might exist in an environmental remediation location such as a “Superfund site” or other contaminated water aquifer. They wanted to be able to reproduce the ground porosity and fluid hydrodynamics and be able to monitor the changing characteristics as remediation efforts were applied. This was done to better control the use and development of remediation methods to be used in the actual site or real world cleanup effort. PROTEC had to design and build a system that could accomplish this. We provided the system which is today being used for that application. The system consists of a tank containing a soil matrix with over a 100 sensors to sense a radioactive isotope introduced by an integral tank sparger and variable flow pump system. Process fluid characteristics were monitored via instrumentation located at an external control system with complex data logging equipment and interpretation software. The system was provided with an Instrument Building to provide a suitable environment for the scientist and their equipment. The success of the equipment generated a subsequent purchase for another unit to provide regional availability for both the eastern and western regions of the United States.