Design of Safe, Reliable and Efficient Electro-Hydraulic Systems for Subsea Applications

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Joan Morton
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Applications Wagner Mattos / Alexandre Orth, Bosch Rexroth

1 We are the Drive & Control Company Design of Safe, Reliable and Efficient Electro-Hydraulic Systems for Subsea Applications Wagner Mattos / Alexandre Orth, Bosch Rexroth LASHIP / UFSC, Florianopolis SC BR, 26 th October

2 Subsea Bosch Rexroth Topics The Company The Motivation The Application The Concept Further Research 2

We are the Drive & Control Company Bosch Rexroth: Part of Bosch-Group Bosch-Group

6 billion euros in sales 374,778 associates 59% share of sales Industrial Technology

and Building Technology Leading manufacturer of security technology Global market

sales Consumer Goods Leading supplier of power tools and accessories Leading

3 We are the Drive & Control Company Bosch Rexroth: Part of Bosch-Group Bosch-Group Mobility Solutions One of the world s largest suppliers of automotive technology 70.6 billion euros in sales 374,778 associates 59% share of sales Industrial Technology Leading in drive and control technology, packaging, and process technology Energy and Building Technology Leading manufacturer of security technology Global market leader of energy-efficient heating products and hot-water solutions 41% share of sales Consumer Goods Leading supplier of power tools and accessories Leading supplier of household appliances Original excerpt Presentation of the Bosch Group C/CCB; C/CCD April

4 We are the Drive & Control Company Marine & Offshore: Our World 5

5 Subsea Bosch Rexroth Topics The Company The Motivation The Application The Concept Further Research 6

Bosch Rexroth experience with subsea applications World see depth landscape: 2/3 underwater!!! Depth: 0 to 305 m (1.000 ft) Depth: from 305 m (1.000 ft) to 1.830 m (6.

6 Bosch Rexroth experience with subsea applications World see depth landscape: 2/3 underwater!!! Depth: 0 to 305 m (1.000 ft) Depth: from 305 m (1.000 ft) to m (6.000 ft) 7 72% of the worlds surface is covered with water About 88% of the ocean is deeper than m Deepest part of the ocean is in a depth of m* (with bar) Source: * deepste part of the ocean is Mariana Trench, see red dot Depth: from m (6.000 ft) to m ( ft)

7 Bosch Rexroth experience with subsea applications Market sees Subsea as major trend in offshore Verbatim s of key stakeholders: (Why not?) Statoil* - Subsea Factory: We are taking subsea longer, deeper and colder aim to develop the elements required for a subsea factory by Petrobras** - Subsea Prod.: Future Perspective: 2030 the production is subsea Pre-Salt fields require new innovative solutions DNV GL*** All Subsea: The question for the subsea sector therefore is not whether it will grow, but rather by how much The future is subsea 8 Source: *Statoil The Subsea Factory ** Pretobras Presentation of Mr. Camerini at IEPUC (BR) *** DNV GL All Subsea White Paper

8 Bosch Rexroth experience with subsea applications Subsea Hydraulic Cylinder Pressure Compensation: work pressure Special (Double) Sealing: pump Sea water Hydraulic oil reservoir Spring force 1 bar 9

9 Bosch Rexroth experience with subsea applications Subsea Hydraulic Power Unit (HPU) 10

adapted for Subsea Encapsulated manifold,

water resistant seal for cover Air has to be

10 Bosch Rexroth experience with subsea applications Electro-Hydraulics Controls adapted for Subsea Encapsulated manifold, oil filled and pressure compensated Sea water resistant seal for cover Air has to be vented completely Specially developed on-off and prop. valves with modified solenoids, pole tubes and terminal strips Sub sea electrical connector 11

11 Subsea Bosch Rexroth Topics The Company The Motivation The Application The Concept Further Research 12

12 Application Subsea Trees & Manifolds Subsea oil & gas: what that means? km Consequences High extern pressures (> 300 bar) Long distances (> 300 Km) Higher weights (big vessels) Wave movements (big marine currents) Remote control (full automation) Corrosive environment Explosive atmosphere Long service time (30a) Source

13 Application Subsea Trees & Manifolds Subsea equipment landscape The main function of the subsea process valve to produce oil or gas: Oil flow Auxiliary energy Control volume flow controlled oil flow controlled oil flow Oil flow Control oil flow Electricity Energy supply Mechanical, Electrical Transform energy Mechanical, Hydraulic, Pneumatic Control actuated energy Auxiliary energy for actuation control Mechanical, Hydraulic, Pneumatic, Electrical Realize actuation Mechanical, Electrical 14

14 Application Subsea Trees & Manifolds Key Requirements & Available Competencies Oil & Gas Production Offshore Application Water Depth (> m) Process industry (continuous flow ) High productivity High availability Explosive atmosphere Earth quake safe Huge dimensions Corrosive environment Wave movements Snow crust Ecological system (mussels ) High pressures Long distances Low visibility Remote control only (no manual) New technologies (unknown effects) Testing Methods Subsea Experience Condition Monitoring Functional Safety Reliability Engineering Corporate Research Bosch Engineering System System Availability 15

15 Subsea Bosch Rexroth Topics The Company The Motivation The Application The Concept Further Research 16

adjustable mounting hydraulic cylinder IndraDyn servomotor IndraDrive frequency converter to control the

16 Application Subsea Trees & Manifolds Self-Contained Hydraulic Actuator - Industry Self-contained electro-hydraulic servo axis: suitable for Subsea? adjustable mounting hydraulic cylinder IndraDyn servomotor IndraDrive frequency converter to control the drive adjustable mounting Control block with integrated pump optional with: installed digital valve to control pressure or positioning by drive stand stills (with Safety Functions) 17

Application Subsea Trees & Manifolds Force in Gate Valve (Fail-Safe Close): 3 2 4 2 1 6 5 3 Adapted

17 Application Subsea Trees & Manifolds Force in Gate Valve (Fail-Safe Close): Adapted Mashiba (2011) f f Oil Flow F at = F hydraulic F spring +F sea F ingate F drag f f

18 Subsea Bosch Rexroth Topics The Company The Experience The Application The Concept Further Research 19

19 Subsea Fluid Study Types of hydraulic fluids Environment Industry fluids Subsea fluids Water Water free Water free Water based Organic Mineral oil Ester Polyolefin Glycol Manufactures M P W X Y Z Type M1 P1 P2 W1 X1 X2 Y1 Y2 Z1 All these fluids are environmental friendly and approved for application in subsea conditions! 20

20 Subsea Fluid Study Approach based on API 17F / ISO

21 Subsea Bosch Rexroth We never give up until the right solution is found Further Information: Thank you for your attention! 22

22 Subsea Bosch Rexroth We never give up until the right solution is found Thank you for your attention! 23

16/09/2014. Introduction to Subsea Production Systems. Module structure. 08 Production Control Systems

16/09/2014. Introduction to Subsea Production Systems. Module structure. 08 Production Control Systems OIL & GAS Introduction to Subsea Production Systems 08 Production Control Systems September 2014 DNV GL 2013 September 2014 SAFER, SMARTER, GREENER Module structure Section 1 Introduction to control systems