Over the past few years a specific programme has focused on the development of subsea separators and a subsea water treatment and injection process composed of several modules and requiring a certain amount of new subsea technology (subsea barrier fluid-less water injection pumps, filters, special water analyzers, etc.). One of these technologies is the all-electric subsea control system. The all-electric versus the electro-hydraulic solution was selected for its inherent capability to:enable long step-out distances;run logics such as sequences and fast closed control loops involving subsea proportional valves;handle high frequency of simultaneous valve actuations;implement safety functions, including SIL certified, when required. Within the ongoing industrialization programme of the new technologies, a Joint Development Agreement has been put in place between two partners for the qualification of the open framework platform for the control of subsea processes. The development is pursued according to the API 17N and DNV RP-A203 requirements. The subsea control system is developed according to the approach to interface standardization, which is aimed at guaranteeing:–the interchangeability of modules coming from different vendors;–the reduction of physical interfaces;–the optimization of IMR intervention time. The technology mainly consists of:a qualified basic component platform to be used for project-based assembly;a complete set of tools such as web-server, condition monitoring server, integrated software development environment, etc.;a standard and user-friendly approach for software application development, based on P&ID graphic, in order to facilitate the sharing of software information between contractor and clients;standard industrial communication protocols (no proprietary protocols) accessible to all users, which are designed for easy interfacing of the control system with third party equipment. The JDA activity has concluded the Q1 qualification tests of electronic components and Q2 tests of electronic assemblies, pursuant to API 17F, as well as all the other qualification activities (tests and analyses) relevant to the non-electronic components (e.g. 40kVA subsea electrical transformer), according to the relevant technology qualification plan. Additional software packages have also been developed and successfully tested using the Test Driven Development (TDD) method. The qualification will be completed by Q1 2019 with integration tests of:–Topside Control System;–Subsea Power and Communication Distribution Manager;–Subsea Control Unit. The integration tests will allow to reach TRL 4 of the above subsea equipment, in accordance with API 17N.
Subsea chemical storage and injection systems are a new technology that moves the chemical units from topside to subsea locations, close to the wells. It has been conceived for application on field development projects with long tiebacks, whenever the objective is to replace the expensive hydraulic umbilicals for chemicals distribution. Conversely, the new subsea technology needs only a power and communication link to the existing topside facilities. So that this can occur, a dedicated industrialisation programme was launched for developing all the building blocks of the technology to achieve a sufficient readiness level for the first industrial application. The core of the industrialisation has been the extensive qualification campaign, mostly based on experimental testing carried out in laboratory and workshop environments, as well as in simulated deep-water conditions. Due to the nature of the treated fluids, specific attention has been paid to the chemical compatibility testing of materials and fluids for long term applications in harsh environments. The available technologies have been reviewed through a comprehensive market assessment, to spotlight the gaps as well as the elements of novelty of the intended application. Several industrial partners have been engaged to jointly define and carry out relevant qualification plans. The basis of design for the development and qualification of equipment has been defined considering a range of possible applications in the subsea field development and subsea processing context. The information was used to build a map of the technology requirements including the chemical fluids to be managed, flowrate and injection pressure ranges. The map, combined with a set of process data and IMR scenarios, has been further elaborated to define the storage unit size, modularization philosophy and to set relevant reliability requirements. The qualification philosophy was based on the framework set by the international guidelines for technology qualification, i.e. DNV RP A203 and API 17 Q, through a documented risk-based approach. Whenever applicable, the components have been qualified to specific relevant standards, for instance API17 F and ISO 1817 for the electronic components and the effect of liquids on polymeric materials respectively. Programme execution included the construction of several prototypes of the key equipment: the subsea pump & motor unit, electrical actuator for small-bore valves, flowmeter and the storage unit. Most of the components were subject to endurance and cycle testing to provide quantitative data to support the results of the RAM analyses. In addition, the programme leveraged the control system components that have been industrialised as part of a previous qualification initiative addressing the requirements of several subsea processing applications. The paper will introduce the elements of technological novelty of the equipment and will describe the methodology, challenges and main results of the programme. The qualification activities will be completed by the end of 2020.
Given the increasing level of technology readiness associated with subsea processing equipment under the trust of ambitious and challenging subsea field development schemes, in order to allow or enhance the hydrocarbon production and/or to reduce topside space requirements, oil and gas Operators are more keen to sanction new projects involving active subsea equipment. The above scenario will most likely be the driver for a step-up towards a further communication link between subsea equipment (e.g. subsea pumps, compressors, separators, ancillary systems, etc.) and the end user. This link, enabled by a brand-new Condition Monitoring System, will be in addition to already consolidated subsea control system technologies and will pave the way for predictive maintenance operations of subsea processing systems. Through the acquisition of subsea processing systems specific parameters detected during their operation and comparison with the relevant normal (baseline) conditions associated with each piece of equipment and/or typical component failure modes, it will be possible to monitor the deterioration of the equipment. It will also be possible to understand if it is time to plan a maintenance campaign for the system or if it can be postponed or moved up with respect to the MTBM of the system. The condition monitoring system will collect a huge amount of data regarding system and components status, operating conditions and performances, and by tracking the collected information, it will be able to build a system history. This becomes the feed in a machine learning process that will regularly increase the level of confidence under real conditions of the subsea equipment laid far from the Operator's sight. This paper will focus on a condition monitoring system concept applied to Saipem technologies for subsea processing.
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