2017 4th International Conference on Information, Cybernetics

and Computational Social Systems (ICCSS)

Development of Subsea Production System and its

Control System

Yuzhe Zhang, Wentao Tang, Jialu Du

School of Information Science and Technology
Dalian Maritime University
Dalian, China

Abstract—Subsea production system is a key technique in been accepted by many oil companies. The Gulf of Mexico
the development of oceanic oil/gas resources, which has (GoM) in North America, the North Sea in Europe, Brazil
experienced a long-time evolution. Control system is the core along the South Atlantic coast and the western coast of Africa
technique of subsea production system, which is indispensable in are the areas with frequent offshore activities in which SPS
subsea production. We introduce eight typical control
architectures of different structures, including direct hydraulic
becomes increasingly popular and dramatically improves
control system, piloted hydraulic control system, sequenced economic benefits. Furthermore, SPS also provides the
hydraulic control system, direct electro-hydraulic control system, opportunity for developing marginal and remote oil and gas
multiplexed electro-hydraulic control system, all-electric control fields. The following paragraphs describe the development of
system, powered autonomous remote control system and subsea production system and its control systems.
integrated control buoy. We make a comparison of the above
eight control techniques in terms of emerging background,
II. EVOLUTION OF SUBSEA PRODUCTION SYSTEM
constituents, application ranges, characteristics, advantages and
disadvantages. Finally, the development trends of the subsea Since the first subsea well was completed and utilized
production system are presented. commercially in the 92 ft (26 meters) of water in the Gulf of
Mexico in 1968, SPS has seen remarkably advancement in the
Keywords—subsea production system,subsea control system, past several decades. From then on, full-field subsea
development trends developments were carried out in the Gulf of Mexico and
offshore California. The technology of SPS further developed
I. INTRODUCTION with two subsea wells in the Grand Isle Block 16 field, which
The constantly rising consumption of oil and gas resources were designed to simulate remote and deepwater installation
has a large proportion in global energy supply. In 2013, 55% and operation. Then, it turn over a new leaf for Europe when
of the world’s total energy consumption was provided by oil subsea oil/gas fields developments came on stream in North
and natural gas[1]. To guarantee the sustainable development Sea. The early SPS in the Ekofisk field installed in 1971
of the world energy supply, new approach needs to be symbolizes the first subsea field development in Europe.
discovered to cope with the offshore oil and gas exploration. Furthermore, the majority of subsea developments carried out
Therefore, the subsea production system(SPS) was introduced, in the Campos basin offshore Brazil represent another big
which comprises subsea control module, Xmas tree, manifold, application area for SPS except the North Sea. The first wells
riser, pipeline, umbilical, etc. SPS helps to produce were completed in the Enchova field In Campos basin in 1977.
hydrocarbons from one or more subsea wells and transmits to Among the innovations that have first been tested in Brazil
a given processing facility offshore (fixed, floating or subsea) are the layaway technique for subsea trees, standardization of
or onshore. Compared with the conventional diver assist subsea equipment, and equipment reuse. As the commercial
production system, the SPS features in robustness over developments proceeded throughout the world, great efforts
external environment, like changeable temperature and should be made to further develop and extend the technology
complex sea conditions. In addition, it greatly reduces the for remote, deepwater and ultra-deepwater(more than 6000ft)
load and area of topside platform, and allows for higher applications.
flexibility in subsea wells placement as they do not need to be Along with the growth in the number of subsea production
deployed directly under an offshore structure such as a systems, it has seen great advancement in production
platform or a ship. In a word, SPS highly improves the techniques, water depths records and tie-back distance from
exploration efficiency and economic benefits in the subsea the topside host facilities. Nowadays, the world’s deepest
production. Meanwhile, the outstanding characteristics of SPS subsea Xmas tree has been installed in the Tobago field, about
in improving oil/gas recovery ratio have become the main 200miles (about 322km) south of Freeport, Texas in the Gulf
reasons for the selection of resource development in of Mexico. The wellhead is located in the depth of 2934m.
deepwater. Nowadays, the advantages of high efficiency, Tobago field is operated by Shell company and produces
economic benefits and mature technique of SPS have already

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and Computational Social Systems (ICCSS)

through the Perdido drilling and production platform. The electric control system, powered autonomous remote control
record for the world’s longest tie-back of oil producing is system and integrated control buoy.
almost 70km. The Penguin A-E fields in the North Sea holds
the record, which is tied back to the Brent C platform. In the A. Direct Hydraulic Control System
case of gas producing tie-back, the length record is kept by Direct hydraulic control system is the simplest and earliest
Noble Energy’s Tamar field. Its subsea wellhead is tied back operated system for controlling and monitoring of a subsea
to the Tamar platform with the distance of 150km. Besides, production system. The switch of the control valve is directly
another notable development is the concept of Statoil Subsea regulated by the fluids pressure to the actuator. When it is set
Factory. It aims to combining and reusing the subsea to open, the system controls the fluids flows to the valve
production and processing technologies by a new approach. actuator with an opening pressure. Oppositely, the operator
For instance, long-distance transport of multiphase flow, regulates the control panel to vent the hydraulic fluids back to
floating production facilities as well as pipeline networks the reservoir to realize closing command.
have already been utilized to efficiently develop fields with
longer step-outs from offshore existing facilities in deepwater The topside control equipment of direct hydraulic control
and harsher environment[3]. The core of the above-mentioned system consists of hydraulic power unit, hydraulic control
subsea production systems is the control system that plays a board and topside monitoring system, meanwhile, the subsea
critical role in subsea production activities. Next, eight typical equipment involves umbilical connectors and hydraulic
subsea control systems will be described in terms of emerging distribution panel(no subsea control module). Topside
background, constituents, application ranges, characteristics, production equipment is placed on the production platform,
advantages and disadvantages. and subsea control equipment is installed on the subsea tree.
The characteristics of this control technique is that remote
III. SUBSEA PRODUCTION CONTROL SYSTEM
control valve on each of the subsea equipment corresponds to
a dedicate hydraulic control line[2].
The subsea production control system is the command
center of deepwater oil and gas resources development. It The advantages of direct hydraulic control system include
plays a critical role in ensuring the safe production and simple structure, high reliability and easy maintenance. It is
transmission of oil and gas resources, which is directly related typically used for workover applications and small systems,
to the efficiency of drilling and the economic benefits in the and is especially common in single-satellite oil/gas fields of
exploration procedure. The subsea production control system distances less than 15 km[7]. From the past, both Lithuania 11-
operates the valves and chokes on subsea trees, manifolds and 1 in South China Sea[8] and Kama oil field in Peru[9] use direct
pipelines. On the other hand, the location of control devices hydraulic control system. However, when the control distance
should be highly noticed. It is of great wisdom to make a increases, the hydraulic loss is serious and response speed
thoughtful consideration of the location of subsea control becomes slower. If the number of subsea actuators is
system because it can bring about a large reduction in the numerous, the cost of hydraulic control in the umbilicals will
amount of pipelines, cables and connections required, which accordingly increase. Moreover, the use of open-loop control
in turn will benefit on the subsea installation and retrieval system has been restricted for the sake of environmental
tasks[4]. protection. That is why direct hydraulic control system is
rarely employed currently.
Since the 1960s, the subsea production control system has
developed from direct hydraulic to piloted hydraulic, and then
sequenced hydraulic systems, which aims to improve the
system response time and meet higher requirement for remote B. Piloted Hydraulic Control System
tie-backs. At present, most of the subsea control systems With the increase of water depth and wellhead number in
utilize multiplexed electro-hydraulic control. This is exploration, direct hydraulic control system is restricted. In
essentially a subsea computer and communication system, order to improve the system response speed and to reduce the
consisting of hydraulic pilot valves. While the all-electric size of umbilicals, foreign country has proposed a solution
control system is completely distinguished from hydraulic called piloted hydraulic control system. In 1963, the company
control and electro-hydraulic control by the main principle of PAYNE of USA, developed a piloted hydraulic control
system driving, which makes it an attractive alternative to the system whose hydraulic energy stored in the seabed by
existing control systems. The all-electric control system utilizing subsea accumulator. Piloted systems have a delicate
considerably reduces the cost of topside power facilities and hydraulic pilot supply hose for each subsea function, and a
subsea umbilicals[5], and will become the mainstream for the hydraulic supply line connected to a simple subsea control
subsea production control strategy in the future[6]. module(SCM). At the SCM, a hydraulic accumulator provides
a reserve of hydraulic energy to speed up opening response
According to construction distinction, there are eight types
time of the tree valve. For each subsea function, one hydraulic
of fundamental control systems, including direct hydraulic
control system, piloted hydraulic control system, sequenced control pipeline is connected to a surface control valve and
hydraulic control system, direct electro-hydraulic control another subsea pilot control valve. Then the subsea drive is
system, multiplexed electro-hydraulic control system, all-

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 2017 4th International Conference on Information, Cybernetics
and Computational Social Systems (ICCSS)

powered up through the commonly-used subsea hydraulic D. Direct Electro-hydraulic Control System
fluids supply pipeline and subsea accumulator. Due to the lack of subsea detection function, hydraulic
The typical piloted hydraulic control system includes one control system cannot prevent the plugging phenomena within
SCM with a pilot valve, a subsea HPU and an accumulator the production channel, which may lead to not-in-production
supplied by a separate water pipeline. Compared with the of the system. Besides, the response speed of full hydraulic
direct hydraulic control system, there is only control signal of control system cannot meet the relevant requirements as
hydraulic pilot valve between the platform and the subsea oil system tie-back distance is further increased[11]. So, the cost of
tree when the piloted control system is working. Therefore, control umbilicals also soars accordingly. In the 1980s,
the system response time is greatly shortened. At the same however, the introduction of electronic control brought a
time, since the hydraulic power is directly from subsea technical leap to the subsea production control system.
accumulator, not from the platform, the system response time Compared with the hydraulic fluids control, the advantages of
is further reduced. Due to the existence of accumulator, the electrical control are the long transmission distance, fast
size of high pressure hydraulic pipeline is smaller than that of response and further reduction of the size of control
the direct hydraulic system, which extends the control path umbilicals. According to the transmission type of electrical
and increases the operating speed accordingly. Piloted signal, electro-hydraulic control system can be divided into
hydraulic control system is typically used in a single satellite direct electro-hydraulic control system and multiplexed
of short distances(4 to 25 km). Because of the slow signal electro-hydraulic control system.
time, however, there still exists the deficiency of slow Above-mentioned sequenced hydraulic control technique
response. Besides, the addition of subsea pilot valve and simplifies system structure and improves system reliability.
accumulator also increases the cost of installation and But when the water depth increases, the control pressure loss
maintenance of subsea equipment. Currently, the piloted of sequenced hydraulic control valves is serious, which will
hydraulic control system is rarely used[7]. result in inaccurate pressure and malfunction. Thus the system
response time is too long to meet the demand of emergency
C. Sequenced Hydraulic Control System treatment. In order to solve the problem of deepwater remote
As the tie-back distance of control system continues to real-time control, foreign country developed direct electro-
increase, the cost of umbilicals significantly ascends in the hydraulic control system. When this control system is
system. In order to further reduce the size of control working, hydraulic signal is replaced by the electric signal.
umbilicals, a sequenced hydraulic control system was devised The electric signal from topside MCS is transmitted to the
on the basis of piloted hydraulic control system in the mid solenoid valve in the SCM by controlling the wires in the
1970s. The sequenced hydraulic control system consists of umbilicals. When the solenoid valve opens, the accumulator
several sequence valves and accumulators. Various provides hydraulic fluids to the actuator through hydraulic
complicated program actions are designed by series-parallel line to control the opening and closing of the hydraulic valves
for sequence valves. The operation of a sequenced hydraulic on the subsea equipment[12].
control system is almost the same as that of piloted hydraulic
Compared with the full hydraulic control system, the
system.
remote response speed of direct electro-hydraulic control
Compared with two types of previous hydraulic control system is significantly improved, and subsea data monitoring
systems, the sequenced hydraulic control system reduces the function is added, such as valve position, production low path,
number of hydraulic control pipelines, thus the weight and the nozzle pressure, temperature, pressure and corrosion.
cost of umbilicals and subsea installation are cut down Moreover, the reduction of hydraulic wire in umbilicals also
abundantly. Nevertheless, the switching sequence of hydraulic decreases the requirements for hydraulic functional modules.
actuator is pre-set so that it cannot separately operate the However, each monitoring function needs a pair of wires,
hydraulic actuator. In that case, the system flexibility is which results in the complexity of umbilicals and that
undesirable so it is unsuitable for complex logic controls. enhances the manufacturing cost. If the distance between
Furthermore, the high requirements for subsea pilot valves subsea tree and production platform increases, the loss of
under particular activation pressure(usually in 400psi steps) electricity in the cable will be sensitive and considerable. So
[38]
are prone to lead to operational error. As for the response higher demands for the structure of umbilicals are proposed.
time of sequenced system, it is almost as slow as that of Generally, controlling distance of such system is 7km, which
piloted hydraulic system[10]. The control distance of is limited by the development of satellite fields[13].
sequenced hydraulic system is relatively short, usually 2-3km.
Besides, the control function is limited by the development of E. Multiplexed Electro-hydraulic Control System
oil and gas fields in satellite well. As a result, sequenced The development of deep-water oil/gas fields is
control system usually acts as a standby system for characterized by large-scale, low ambient temperature, high
multiplexed electro-hydraulic control system. fluids temperature/pressure, and big differences of fluids
temperature/pressure among different wellheads. So in the
process of developing large fields in complex conditions, the
four above-mentioned control techniques are restricted to a

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great degree. To solve the problem, a foreign oil company accumulators to charge. This system is typically used in
developed multiplexed electro-hydraulic control system which complex field and marginal fields of long distances(usually
was then justified to be a good solution to meet the greater than 5 km).
requirements of oil and gas field development, especially in
If the subsea valve is desired to open, the MCS should be
deepwater block.
operated to request the valve action with an instruction. A
The topside equipment of multiplexed electro-hydraulic coded message sent from MCS to SEM interprets the
system consists of hydraulic power unit, electrical power unit, instruction and energizes the appropriate relay operated pilot
hydraulic power unit, topside umbilical termination assembly, relay, which allows electric power to energize the tree valve
etc. And the subsea equipment involves umbilical, subsea actuator[18].
control module, subsea distribution unit, jumper hose, jumper
The advantages of all-electric control systems are
assembly, etc[14].
conspicuous in two aspects--increased reliability and
The master control station(MCS) is manipulated by a enhanced functionality. The developments undertake the
computer, and exchanges information with the microprocessor principle that they will offer significant technical and
in the subsea electronics module(SEM). As the intermediary economic benefits over hydraulic controls, especially for
between the MCS and SEM, the microprocessor receives deepwater and long step-out structures[35]. Compared with the
instructions from MCS and performs command functions. typical electro-hydraulic control system, all-electric control
SCM facilities are permitted to be connected to both the system is expected to be simpler because of the simplification
electrical and hydraulic supply lines, which lead to the fact of umbilicals. Thanks to the lower cost of umbilicals, it is
that many subsea wells can be controlled by only one simple favorable to use all-electric system when developing marginal
umbilical terminated at a subsea distribution unit(SDU). The fields with long distances from a topside processing facility.
connections between the SDU and the individual well and the Moreover, when expending an existing system, all-electric
SCM’s are made with jumper assemblies[15]. technique provides a higher degree of flexibility to deal with
it. Electrical actuation of control valves and chokes within a
The prominent features of multiplexed electro-hydraulic
subsea control system has guaranteed the real-time feedback,
control are real-time system response, virtually no distance
which enables effective and continuous system condition
limitations, maximum reduction of umbilical size and high
monitoring and performance evaluation. Accordingly, the
level of operational flexibility, which make this control
response speed and control distance of all-electric are
technique become the core in oil/gas industry development.
optimized compared with other control techniques. Finally,
Multiplexed electro-hydraulic control system is typically used
due to the removal of the hydraulic system, environmental
in complex fields of long distances (more than 5 km), and can
and economic problems relevant to the leakage of hydraulic
up to 8km. Normally, the speed of subsea communication is
control fluids can be omitted, so is the complex working with
low to medium (1,200 to 9,600 baud) due to the small amount
hydraulic fluids[19].
of information needed. But with the addition of fiber optics in
umbilicals, operators on the platform can obtain more reliable In the 1990s, the subsea valve with electric actuator was
and accurate data of pressure, flow rate and temperature. applied[20], and subsequently the industrial trial of the first set
However, there still exists some defects, which include of all-electric subsea production system was initiated[21].
material compatibility, susceptibility to hydraulic fluid Cameron corporation used all-electric subsea tree for the first
cleanness, hydrostatic effect in deep water and restrictions time in the K5F field in the North Sea of Netherlands in
over long-distance tiebacks[37]. 2008[22]. FMC first used an all-electric control system in the
Tyrihans field in the North Sea in Norway in 2010[23]. All-
China's Ledong subsea wellhead project, Norway's Barents
electric control system technique is currently at the stage of
Sea Snohvit gas field[16], the Gulf of Mexico’s Mensa gas
industrial trial and tests. However, with the help of the second
field[17] all use multiplexed electro-hydraulic control system.
generation DC system, all-electric technique has the
However, as the system structure is complex, the cost of
capability to transmit 3000V DC up to 200km from the host
equipment investment, installation and maintenance is
platform[36], which provides a powerful method for ultra-
relatively high, so higher requirements are needed to the
deepwater development of seafloor resource exploration. With
reliability of system components. Currently, the technology of
joint effort and gradual improvement of reliability and key
multiplexed electro-hydraulic control system remains to be
technique on the all-electric control system, it is foreseeable
improved and further evolved.
that all-electric control system will soon substitute electro-
hydraulic control technique and dominate the market in the
F. All-electric Control System
coming future.
The all-electric control system has realized a great
conversion from a conventional control system based on G. Subsea Powered Autonomous Remote Control
typical hydraulic control to a brand-new control system based System(SPARCS)
on all-electric technique. The elimination of hydraulic power
With oil development moving towards marginal fields and
means that any control system command information is sent
the limitation of conventional SPS in marginal fields
in rapid succession without the usual lag time required for
development by high cost of umbilicals, foreign countries

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have adopted subsea powered autonomous remote control marginal field are the cases[27]. The East Spar gas field in the
system(SPARCS). It is proved to be a cost-effective solution west of Barrow Island, offshore Western Australia[28] and well
to subsea development in marginal fields[24]. 4-ALS-39, offshore the state of Alagoas, northeast Brazil[29],
both employed autonomous buoy control system.
SPARCS is highly creative as it controls subsea wellheads
without the use of umbilicals. The system electrical power is
produced by a Turbine Generator fitted to a water injection IV. DEVELOPMENT TRENDS IN SUBSEA PRODUCTION SYSTEM
flowline or alternatively a Thermo-electric Generator fitted to
a production flowline[25]. Hydraulic power for operating both A. Transition from Multiplexed Electro-hydraulic Controls to
the wellhead and the downhole safety valves is produced from All-electric Controls
a subsea unit with communication signals for valve control Since the world’s first all-electric production system was
and sensor monitoring by utilizing acoustic telemetry. operated in the Dutch sector of the North Sea in 2008,
valuable feedback has constantly been receiving and lessons
As SPARCS utilizes innovative technology, which does
learned have been implemented for the future generation of
not require electro-hydraulic umbilicals from the platform to
all-electric technology. All-electric control is operating on the
control subsea wellhead, it indicates great economic savings
subsea production system via electrical signal, eliminating the
in single satellite subsea developments. In that case, the load
influence of open-loop hydraulic control system on the
on the topside equipment is greatly reduced, and system
environment. Meanwhile, the reliability and flexibility are
reliability is highly improved accordingly, which makes it
dramatically improved compared with the previous
appropriate to develop large-scale marginal field. For instance,
generations of hydraulic control. The principle and the
Luna27 gas field in Lonian Sea[26] is the case. However, its
transition process of all-electric control technique have
subsea turbine generating technique and thermo-electric
mentioned before. It is foreseeable that all-electric controls
technique remain to be optimized. Besides, what should be
will dominate in the ultra-deepwater resource exploration.
noticed is that the deeper the water depth and the more severe
Accordingly, multiplexed electro-hydraulic controls will be
the gradient of water temperature are, the more severe the loss
gradually replaced in the coming future.
of acoustic signal will be in the process of acoustic
communication. Therefore, the subsea autonomous system is
B. The Application of Subsea Production Technology in
only applicable to marginal fields of medium and long
Polar Regions
distance.
Polar regions are so rich in oil and gas resources that the
H. Integrated Control Buoy(ICB) companies of Russia, Norway and other countries close to the
Arctic have set out to develop oil/gas resources in polar area.
When developing ultra-deep water and ultra-remote
However, polar environment is so poor that low temperature
marginal fields, the subsea autonomous control system is
and icebergs have become the main threats to conventional
limited due to the immaturity of subsea telecommunication
topside production facilities. Fortunately, the SPS is under the
technique and subsea generating technique. If we use several
water that it is partly resistant to the polar environment. Hence,
previous control techniques equipped with umbilicals, it will
the SPS has a competitive edge on the polar oceanic
request ultra-long distance tie-backs, which will increase
engineering development. Polar subsea production technology
development cost and influence system reliability. To solve
needs special materials to resist severe environment and to
the problem, the integrated control buoy(ICB) is proposed.
avoid the impact of icebergs through trenching and
The technique is to install all necessary controlling and monitoring. In addition, mobile protection at low temperature
monitoring equipment in a relatively small buoy (6 meters is one of the most critical aspects. Because of the relatively
diameter and metes high) moored adjacent to the subsea fragile ecological environment in polar region, the cost of
wellhead, which is connected to the subsea tree via a short, follow-up processing work caused by gas leakage is huge. So
vertical, hydraulic and signal riser. The control systems on the it proposes higher requirements to the reliability of subsea
buoy are then supervised, via a radio link, from a nearby production system[30].
master control station situated on a platform board or floating
production facility. C. The Transition of Electric Power Supply
ICB integrates the reliability of control system equipped The power supply of subsea production system by topside
with umbilicals and the advantage of self-provided and electric power unit is gradually transformed into subsea high-
wireless communication in SPARCS. Conventional electro- voltage AC/DC power supply. Many large power supply
hydraulic umbilicals are used in short-distance connection equipment on the topside platform will be installed and
between buoy and subsea equipment. So the cost of control applied under the water. Large subsea processing facilities can
equipment is not affected by offshore distance. The system reach tens of megawatts of power, while the traditional low-
configuration of ICB is convenient and flexible, not restricted voltage cannot meet such huge demand for electricity load. At
by the tie-back distance, which makes it applicable to the present, the electric power of marginal oil and gas fields must
development of ultra-remote satellite well and short-term be guaranteed by high-voltage transmission. The Ormen
fields. For example, experimental oil and gas field and small Lange field has deployed subsea high voltage circuit breakers

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