Modelling and simulation of subsea control systems

1 Introduction 3 Hydraulic power unit (HPU)

For more than 20 years the oil industry has been using computers for the dimensioning of hydraulic lines in umbilicals. The need for accurate calculations is heightened by the fact that the umbilical is one of the most expensive individual components in a subsea installation. If it is dimensioned incorrectly, it will result in major time and cost overruns. In this article we set out how a model for simulating this kind of system can easily be set up and designed using SimulationX software and the SimulationX subsea hydraulic library. The model example is based on available information from the various suppliers of this kind of components and systems. We have chosen to look at a system for the completion and work over of a subsea well. The principle is identical for traditional subsea production systems.

The Hydraulic Power Unit (HPU) for these systems is normally located on the deck of the vessel from which the operation is being controlled. There are different types of pumps, but the most common type uses accumulators that are charged by fixed pumps. These pumps which start and stop at various preprogrammed pressures, are controlled by a PLC. Figure 2 shows a simplified schematic diagram of a pumping unit as described above.

Figure 2.

System specification

Simplified schematic diagram of a pumping unit (HPU)

A typical completion and/or work over system for subsea wells consist of four main components. 1. 2. 3. 4. Hydraulic power unit (HPU). Umbilical. Subsea control module (SCM). Valve actuator.

The Surface HPU is an element in the SimulationX subsea hydraulic library and Figure 3 shows the graphical presentation of it.

Figure 1 shows a typical system with two valve actuators and return to sea.

Figure 3.

Surface HPU

All parameters of the different components in the Surface HPU element are easily accessed from the parameter window of the Surface HPU. Figure 4 shows one of the pages from the parameter window.

Figure 1.

System sketch Figure 4. Surface HPU properties

These components are the main components in the system and can be found as pre-made elements in the SimulationX subsea hydraulic library. By using a library like this, the user will benefit in shorter time for modeling and easier re-use of previous models.

As a general rule, to make models easy to reuse it is important to keep them tidy and clearly laid out. The documentation must be easily accessible so the next user quickly gets to know the structure of the model. Our experience is that many companies dont give this high enough priority which again results in difficulties sharing models between engineers.

www.iti.de

www.simulationX.com Page 1 of 6

www.agito.no

Modelling and simulation of subsea control systems

All the pre-made elements in the SimulationX libraries have extensive online documentation which explains the behaviour of the element in detail. This makes the different elements easy to understand both for new and experienced users. the restriction, inertia/acceleration of the fluid as well as the flow. Between each line element, the pressures are calculated as a function of the flow from the previous linear element, flow to the next linear element and the lines volumetric coefficient of expansion (Ve). By using this method in the Umbilical element, time delays in long lines can be calculated with high accuracy. This is important for systems in which the pressurisation and bleeding of lines are used as methods of Emergency Shut Down (ESD). These functions often have strict time requirements which now are possible to simulate with high accuracy.

Umbilical

All hydraulic communications go through separate hoses or pipes that are bundled together into an umbilical. In temporary systems, such as a Workover and Completion System, hoses are most common. These hoses have properties that must be taken into consideration in the simulation. The ability of hoses to accumulate liquid can be a disadvantage in systems that require rapid bleeding of the lines. But this property can also be turned into an advantage in systems where large actuators are to be operated. Using hoses with high volumetric expansion can in some cases replace subsea accumulators. The dimensioning of the umbilical is important to the performance and operation of the whole system. It is therefore important that the model of the hose is accurate, and that it includes the delays that are experienced in practice. Different umbilical elements are available in the SimulationX subsea hydraulic library, depending on the configuration of the system. There are different models depending on whether the umbilical is reeled up topside (Horizontal first, then vertical), or if the umbilical goes straight down to the seabed leaving the extra umbilical lengths subsea (vertical first, then horizontal). Figure 5 shows the two different umbilical options.

Figure 7.

Typical expansion curve for a 3/8, 7500 psi hose.

Figure 7 shows a typical expansion curve for a 3/8, 7500 psi hose. We can see that the curve is not linear. It is therefore wrong to use linear approaches in models such as constant bulk modulus or volumetric coefficient of expansion. SimulationX allows us to enter curves describing the volumetric expansion (Ve) across the whole pressure spectrum. Note that the Ve input is the derivate of the values found in the data sheet.

Figure 5.

Umbilical elements in SimulationX

Note that both options can be parameterized as either steel tube or flexible hose. In addition the elements can be parameterized with variable pressure depending on the water depth. To calculate accurate time behaviour in the umbilical element, a method called distributed line model is used where the line element internally is split into several separate elements as shown in Figure 6.

Figure 6. Distributed line model In simple terms, a distributed line model is a series of line elements in which each line element calculates
www.iti.de www.simulationX.com Page 2 of 6

Figure 8.

Input of the hose Ve

www.agito.no

Modelling and simulation of subsea control systems

5 Subsea control module 6 Valve actuator

Todays systems are usually designed with a subsea control module from which the valve is operated. There are many types of subsea control modules, but the majority include an incoming supply line, return line and several function lines that operate various types of actuators. The number of function lines depends on the type of application that is to be operated by the subsea control module. Figure 9 shows a simplified schematic diagram of a subsea control module.

The valve actuator for a subsea gate valve is often a linear actuator. Including the valve differential pressure across the gates/seat sealing, the model will be somewhat more complicated on account of the variable friction.

Unactuated

Actuated

Figure 12.

Typical gate valve in closed and open positions.

The SimulationX subsea hydraulic library contains pre-made elements for both gate valve and ball valve. Figure 13 shows the graphical presentation of the Gate Valve element. Figure 9. Simplified schematic diagram of a subsea control module. Figure 13. Subsea gate valve element

Subsea control systems often use water-based oils, and therefore allow return oil to be released into the sea in limited amounts. The simplified schematic diagram in Figure 9 shows this type of return system including the return volume compensator. The SimulationX subsea hydraulic library comes with a pre-made control valve for a subsea control module. The valve element includes operational parameters as opening, and closing time behavior, internal restrictions and a detailed description of the valve reset function.

These valve elements are built up of different physical sub-elements where each individual element represents a characteristic of the valve behaviour. As previously mentioned, with a differential pressure across the gates/seat the friction will be variable. Figure 14 shows a typical opening force curve for a gate valve with differential pressure. At point C the valve opens and the differential pressure is equalized resulting in a reduced friction force. In point I the valve closes and the friction force is increased when the differential pressure increases. This behaviour is important to include in the gate valve element since this influence on the opening/closing time of the valve.

Figure 10.

Subsea Control Module valve element in SimulationX

As previously mentioned, it is important to limit the number of elements in a model to the elements that are active in the sequences that we will be simulated. In Figure 11 shows a subsea control module modelled in SimulationX with the necessary number of valves, which is two in this example.

Figure 11.

Subsea Control Module modeled in SimulationX

www.simulationX.com Page 3 of 6

Figure 14.

Opening force curve for a Gate Valve

www.iti.de

www.agito.no

Modelling and simulation of subsea control systems

7 System model
The SimulationX subsea hydraulic library contains all main elements required for the model. The remaining elements such as restrictions in connectors, internal piping, check valves etc. are standard elements found in the standard SimulationX hydraulic library.

Figure 16.

Pressurisation of a line in the umbilical.

Figure 15.

System model

Figure 15 shows the complete system model as it appears in SimulationX. We can easily recognise it from the system diagram in Figure 1. The graphical presentation makes the models much easier to reuse and share with other engineers. 7.1 Results from the system model When the system model has been completed and all elements are parameterized, the simulation itself can start. It is important to clearly understand what you want to demonstrate through these simulations. Often it is sufficient to demonstrate that the requirements of standards and specifications are met. We have chosen to show three such sequences in this article. Pressurisation of an umbilical line Operation of a gate valve Emergency Shut Down (ESD)

The subsea equipment is at a depth of 500 metres, and with the chosen fluid, the initial pressure will be approx. 52 bar subsea. This can clearly be seen at the start of the blue line in Figure 16. The HPU header valve is commanded to open at t=1 second. The valve opening time is set to 0.2 seconds. The umbilical is fully pressurized and at steady state after 5 seconds. Operation of a gate valve During the operation of a gate valve, it is important to check whether the operation affects other valves in the system. This is done by operating a valve and at the same time monitor the pressure variation in the neighbouring gate valve actuator. If the pressure variation is too high, opened valves might start to close and an unwanted shut-down might be the result. The options that we then have are usually to increase the dimensions of the lines in the umbilical or to install a subsea accumulator. Both options will affect the time it takes to pressurize the umbilical, and to bleed it when shutting down. The model is set up with two gate valves and we operate one valve whilst the other is set in the open position.

Pressurisation of an umbilical line. The initial status is that the HPU is ready with full accumulators and the umbilical supply line vented to return. After 1 second the HPU valve opens and starts to pressurise the umbilical line. The umbilical is 600 metres long, and the line has an internal diameter of 3/8. Transaqua HT has been chosen as the hydraulic fluid.

Figure 17.

Pressure response curves when opening a 7 gate valve.

Figure 17 shows the pressure and position during the operation of a gate valve. The opening time is approx. 50 seconds and the minimum pressure differential over the actuator piston is approx. 62 bar
www.iti.de www.simulationX.com Page 4 of 6 www.agito.no

Modelling and simulation of subsea control systems

when opening and 61 bar when closing. I.e. the valve starts to close at a pressure difference of 61 bar across the piston.

Figure 20. Figure 18. Pressure response curves for the open gate valve.

Pressure response curves for the supply and return lines in the umbilical during an ESD.

Figure 18 shows the pressure and position for the open gate valve. We can see a clear drop in pressure when the neighbouring gate valve is opened. The pressure drop across the actuator piston is 71 bar which is above the pressure drop as the valve starts to close (found in Figure 17). This shows that our system is appropriately designed for these two valves. We must also investigate whether the drop in pressure between the supply line and the return line to the subsea control module is higher than the control valves re-set pressure, which is set to 60 bar in this model.

Figure 20 shows how the pressure in the umbilical is bled off during an ESD. After 1 second the HPU header valve is set vented at surface. The red curve in Figure 20 shows that the supply pressure drops rapidly at the surface. The blue curve shows the pressure to the subsea control module. This pressure falls rapidly, to approx. 123 bar. At this point the valve actuators start to close and the fluid from the valve actuators' open chamber is bled to the surface via the control module and the umbilical lines. After 159 seconds the gate valve is in its final position and the remaining pressure in the line falls rapidly to 52 bar.

Figure 21. Figure 19. Pressure response curves for the subsea control modules supply and return lines.

Pressure response curves and valve position for the gate valve during an ESD.

Figure 19 shows that the drop in pressure between the two lines is 69 bar which is above the valves re-set pressure. Emergency Shut Down (ESD) All systems of this type are built so they automatically shut down if an accident occurs. These shut downs should not be dependent on a power supply. The normal solution is to design the system in such a way that the gate valves close if the pressure is bled off up at the HPU.

We can see from Figure 21 that the gate valve is completely closed after approx. 159 seconds. If the system had been set up with more valves and subsea accumulators, more liquid would need to be bled off via the umbilical. Naturally, the whole shut down sequence would then take longer time. Comment to the results: These results are only to be seen as examples. Acceptance levels including safety margins are to be decided by the system suppliers and will vary from project to project.

www.iti.de

www.simulationX.com Page 5 of 6

www.agito.no

Modelling and simulation of subsea control systems

8 Summary

By using a simulation tool we can test a system virtually before putting it into production. Various alternative solutions can be tested, and the results will form the basis for choosing the components and dimensions to be used. When using a tool with existing libraries and a graphical interface, a good understanding of the system and of the individual components is much more important than detailed mathematical modelling knowledge. An understanding of the applications is particularly important when interpreting the results of the simulations. Simulation software will also allow you to test the systems in ways that are not practicable in real life. This may involve testing with pressures that are far higher than the system pressure, or with accumulators with severe gas leakage. If a company wishes to start using modelling and simulation, it is important to note that this will not replace part or all of the development process. It is, however, a supplement that will help engineers to design a better product at a lower cost. Author: Rune Lien Agito AS Postboks 792 3611 Kongsberg Norway +47 95199038 rune.lien@agito.no post@agito.no http://www.agito.no http://subsea.simulationx.com

Phone: Email: Internet:

www.iti.de

www.simulationX.com Page 6 of 6

www.agito.no