OTC 20633

Current Trends and Design Limitations of Subsea Control Hardware

A. Beedle, and J. Stansfield, DUCO Ltd.

Copyright 2010, Offshore Technology Conference

This paper was prepared for presentation at the 2010 Offshore Technology Conference held in Houston, Texas, USA, 36 May 2010.

This paper was selected for presentation by an OTC program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The material does not necessarily reflect any position of the Offshore Technology Conference, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Offshore Technology Conference is prohibited. Permission to
reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of OTC copyright.

Abstract

The challenges associated with the deployment of subsea hardware used to interface between an umbilical system and subsea
production system are greatly compounded when installed in deep and ultra deep water. The challenges are further amplified
due to the current trend towards the incorporation of complex integrated foundation structures and the increased robustness of
the hardware to account for installation and service loads. Two specific deep water projects are explored within this paper.

Introduction

Umbilicals

Subsea production continues to play an increasing role in the global offshore recovery of oil and gas as extraction moves
Figure 1: Typical Umbilical Types
umbilical types are shown in Figure 1.
towards ever deeper water depths and more remote geographical
locations. Umbilical systems are critical links in subsea production
systems and the impact on hydrocarbon recovery due to total or partial
loss of functionality results in a significant loss of revenue for an
operator.
An umbilical is a group of fluid conduits (thermoplastic hoses and/or
metallic tubes), cables (electrical and fibre optic), power cores either
on their own or with combinations of each other, cabled together for
flexibility and over-sheathed with an extruded polymer or
polypropylene rovings for identification and mechanical protection.
Armouring layers can also be added for mechanical strength, impact
protection or increased mass for seabed stability or dynamic
performance. Umbilicals can be employed in static or dynamic
applications and they are typically used for the control of subsea wells,
injection of chemicals, gas lift, data acquisition, telecommunications
and electrical power for subsea pumping and separation. Some typical

Umbilical Hardware

Typical items of subsea hardware include Umbilical Termination Assemblies (UTA), Subsea Distribution Units (SDU),
Gravity Base Foundation Structures (mudmats), Tether Clamps, Weak Links, Repair Joints and Flying Leads. These hardware
designs are typically performed in accordance with DNV Rules for Planning and Execution of Marine Operations(1).
2 OTC 20633

Subsea Distribution Units

The SDU performs two primary functions:

Distribute umbilical functionality during
service.
Transfer axial load from the umbilical
during installation.
Designs of SDU vary depending on functionality,
distribution requirements and installation method.
A typical SDU is shown in Figure 2. The final
SDU design is driven by the project specific
operational requirements; the common features are
described as follows: Figure 2: Typical SDU Construction
Primary lifting point, used to transfer the
load from the installation rigging to the umbilical during final deployment of the structure.
Secondary lifting points, positioned around the SDU framework to allow ease of packing and manoeuvring during
deck handling operations.
Termination interface, the means of mechanically attaching the umbilical load bearing components (metallic tubes,
armour wires, etc.) to the SDU structural framework.
Umbilical curvature control, used to eliminate over bending of the umbilical at the termination interface as the rigid
SDU structure transitions to the flexible umbilical. This curvature control is sized based upon the installation and
service requirements and can take the form of a polymer bend stiffener or interlocking bend restrictor elements
depending upon the design conditions.
Remotely Operated Vehicle (ROV) grab handles are used for all deep
water operations as diver intervention is not possible. The grab handles
are positioned around the key interface points and are used to anchor the
ROV in position during the various installation operations.
Functional interfaces, stab-plates and individual connectors are used to
transfer fluids, electrical power/signal and data from the umbilical
components to the secondary distribution arrangements (i.e. umbilicals or
flying leads). These interfaces vary greatly depending upon the control
system operated in the field and the bespoke functional components of the
umbilical. The design of the SDU is therefore primarily driven by the
number of distribution interfaces required.

Project Overview

To best examine the design challenges faced with deep water umbilical hardware Figure 3: Project #1 SDU and Gravity
Base
design, two project specific examples are explored in detail, and these are
described as follows:
Project #1 (Shown in Fig 3)
o Water depth: 1,450m
o Location: Offshore Angola, West Africa
o Hardware Scope: All-in-one installation, requiring the
SDU to be fitted to the foundation structure prior to
final deployment.
Project #2 (Shown in Fig 4)
o Water depth: 1,650m
o Location: Offshore Nigeria, West Africa
o Hardware Overview: Pre-installed foundation
installation involving the installation of the foundation
structure prior to the fitment of the SDU, typically
during a different installation campaign.

Figure 4: Project #2 SDU and Gravity Base

OTC 20633 3

Project #1 Case Study

The design concept for Project #1 comprised of an integral SDU and installation of the foundation structure. In addition, in-
line distribution was used to reduce the number of joints within functional components, only breaking out components when
required along the length of the umbilical. For this project three SDU units were
daisy chained together. This complicated the installation as multiple in-line
SDU structures were suspended in the water column during laying operations,
this installation configuration is illustrated within Figure 5.
Hence, the primary design challenge was to produce a lightweight design of
SDU and foundation structure, without compromising the functional
requirements, structural integrity and seabed stability.
Due to the water depth
at the field, the
installation employed
the vertical lay system
(VLS) method for
laying operations. This
influenced the SDU size
envelope significantly
and to ensure
installation could be
achieved easily and Figure 5: In-line SDU Daisy Chain
efficiently, the frame Installation (Project #1)
was designed to pass through the open VLS tracks.
Prior to the SDU passing through the vessel moon pool the
foundation structure was then attached, therefore, an easy to operate
mechanism was required for this attachment. This also needed to be
ROV operable to enable future SDU recovery if necessary.
To reduce the splash zone loads on the structure and to allow the
SDUs to pass through a moon pool, the SDU units were designed to
pivot at the interface with the foundation structure and installed in a
vertical configuration. Once through the splash zone the gravity base
was rotated through ninety degrees to achieve the final installation
configuration. The foundation structure and SDU are shown being
Figure 6: Foundation Structure Attachment (Project #1) deployed in Figure 6.

Project #2 Case Study

The design concept for Project #2 was based upon a pre-

installed foundation structure, with the fitment of the SDU
planned during a subsequent installation campaign. In addition
to this fundamental design constraint, a number of additional
design challenges needed to be overcome:

A levelling system was incorporated to account for a

sloping seabed topography observed during survey.
The levelling system was adjusted to the required
mudmat pitch and roll orientation on deck prior to
subsea installation.
Parking arrangement below the SDU for pre
installation of flying leads.
The SDU and mudmat had to be capable of recovery, Figure 7: Exaggerated Displaced Shape of Foundation
mudmat adjustment (roll and pitch) and the ability to Structure due to Soil Breakout Loads (Project #2)
reinstall. To minimise the disturbance to the seabed soil the structure should be set down once. However, there was a
requirement to recover and adjust the pitch and roll foundation pedestal and reinstall in another undisturbed area.
Recovery of the mudmat dramatically increases the loading on the structure. The exaggerated displaced shape due to
breakout loads is shown in Figure 7; this is taken from a Finite Element Analysis (FEA) exercise.
Folding winged base for reduced vessel transport footprint (5m by 3m) due to the large scope of the project. The
delivery of 36 foundation structures drove this constraint.
4 OTC 20633

Weight restrictions, due to the installation vessel lifting capacity. The result was the requirement for an efficient
structural design, capable of withstanding the significant recovery loads discussed previously.
As with Project #1, the same VLS installation constraints needed to be considered.

SDU Design Philosophy

Functional Design

With increasing water depths the reliance upon the VLS method of installation becomes more common. The influence this has
upon SDU design is significant and the primary design constraint for the SDU becomes the envelope size, to ensure
installation can be achieved easily, efficiently and with minimum risk. The
result of this constraint is a design that is refined in collaboration with an
installation contractor. The SDU utilises a standardised framework that can
be adjusted in length to suit the amount of distribution the field layout
demands. The fabrication of such a unit is a balancing act between
functional requirements and assembly access for steel tube welding, cable
termination and inspection. The congestion of pipe routing can become
extremely challenging, as depicted in Figure 8, with in excess of 400 pipe
welds per SDU not uncommon. The further difficulties this congestion
causes during fabrication can be observed in Figure 8, with the structural
cross-member shown welded into position after the pipe routing was
completed to aid access.
The commercial benefits of a compact and easy to handle unit during
offshore installation typically outweigh the fabrication and assembly
termination difficulties. This design of unit is common to both projects, the
variations simply being the distribution requirements and field specific
stab-plates and electrical connectors. Figure 8: SDU Piping Congestion (Project #2)
Future developments of this structure include a more flexible framework
assembly utilising bolted members, allowing the easy removal and replacement of key members to aid assembly. Such units
have been installed on subsequent projects, but this method presents significant challenges for ultra-deep water developments
as the load transfer and overall strength requirements need significant consideration for this more complex method of
fabrication.

Structural Design

The primary mechanical consideration for the SDU is the capacity to withstand the significant axial loads experienced during
deep water installation and high bending loads when passing through a VLS. The SDU is terminated directly to the umbilical
and is therefore the primary anchor arrangement for lifting or lowering for the umbilical during deployment. During over
boarding of the last end of the umbilical the SDU needs to support the
catenary of umbilical suspended within the water column. The tension is
then a function of the increasing water depth, submerged weight of
umbilical and dynamic loading (vessel and environment specific). The
loads generated can be further complicated by the requirement to support
additional hardware such as the foundation structure (when installed in the
all-in-one condition). Project #1 is an example of this type of installation;
this project also provides an example of the trend towards in-line
distribution which further amplifies this installation tension. The influence
this has upon the SDU and mudmat designs is to drive reductions in
weight and size while maintaining a strong focus upon the structural
strength of the frame. The frame must be able to carry the loads, but
Figure 9: SDU Frame Bending Analysis, deflections under maximum loadings must be minimal to ensure load is
Exaggerated Displacement Shape (Project #2)
not transferred to the internal rigid piping. For the installation of small
structures, installation through the moonpool is often preferred which can reduce the dynamic loadings on such structures.
Analysis is undertaken using both classical techniques and finite element methods to confirm structural integrity. Structures
are typically assessed for a variety of loading scenarios including the following:
Tensile and bending loads during deck handling operations (an example of the FEA output for this load case is show
within Figure 9).
Tensile loads during over-boarding operations.
In service loads from umbilicals, Flying Leads/Cobra Heads and currents.
OTC 20633 5

Accidental Scenarios

Further to the planned load cases discussed previously, it is also necessary to

make provision for unplanned scenarios, which include ROV and dropped
object impact loads. Figure 10 shows a dropped object impact analysis
undertaken for an SDU frame and cover plate.

Cathodic Protection

SDUs and foundation structures are typically protected by a surface coating

system together with a cathodic protection system. The requirements of the
cathodic protection system are determined by calculation in accordance with
DNV-RP-B401 Cathodic Protection Design(2). This recommended practice
is widely employed and recognised throughout the marine industry and is
therefore considered to be a de-facto standard.
Hardware is generally coated using a combination of zinc plating, marine
paint, or thermal spray. These coatings have the effect of reducing the level
of sacrificial anode otherwise required for hardware subjected to free
corrosion and provide a clear durable finish which is generally resistant to
bio fouling. To achieve this high standard of coating finish, hardware is
prepared in accordance with NORSOK M-501 Surface Preparation and
Protective Coating(3), which includes provision for pre qualified paint
systems. Figure 10: SDU Frame and Cover Plate Impact
FEA Plots (Project #2)
Foundation/Mudmat Design Philosophy

Design Concept

The method of installation and soil properties are the primary driving factors for determining the design concept of a
foundation structure. The method of installation can be dependent upon a
number of factors, such as installation contractor preference or capabilities,
installation campaign logistics etc.
The foundation structure design can be categorised into two fundamental
types:
All-in-one installation, requiring the SDU to be fitted to the
foundation structure prior to deployment as per Project #1.
Pre-installed foundation structure installation which involves the
installation of the foundation structure, prior to the fitment of the
SDU, as per Project #2, typically during a different installation
campaign. Figure 11 illustrates the deployment of a mudmat prior
to deployment of the SDU.

Geotechnical Design Figure 11: Pre-Installed Foundation Structure

and Parking Arrangement During Deployment
The Geotechnical design of the foundation structure is critical for the (Project #2)
successful installation as well as the long term service stability, two principle standards are utilised:
DNV Classification Notes 30.4, Foundations. 1992(4).
API (RP2A-WSD), Recommended Practice for Planning, Design and Constructing Fixed Offshore Platforms(5).
The foundation structure design is governed by the geotechnical parameters, with correct selection of soil profile as the most
critical aspect. If this is incorrect, subsequent design activities will be compromised. Subsea soil is usually considered as an
un-drained clay (defined by the un-drained shear strength) or drained sand (defined by the friction angle). These key
parameters determine the design and provide the required geometry of the mudmat and skirts to sustain the vertical load,
horizontal shear and overturning moments to which the structure will potentially be exposed.
6 OTC 20633

Prior to the design analysis, the loading on the foundation structure must be determined; this will usually consist of the
following:
Dead load, includes buoyancy and self weight in addition to static loading from external structures.
Imposed loading, includes static and dynamic loading from umbilicals, snag loads, etc.
Impact loads, includes dropped object and side impact loads.
Hydrodynamic loads due to wave action and sea bed currents.
Environmental loads,
The analysis will then usually consider the following:
Load distribution.
Bearing capacity.
Stability.
Sliding resistance.
Skirt Penetration (if applicable).
Long and short term settlement.
Scouring (if applicable).
Some further recent developments have identified a requirement for
uneven and out-of-level seabed profiles to be accommodated within
the foundation design. The design produced for Project #1 included
the ability of the pre-installed foundation to have an adjustable
pedestal arrangement prior to deployment (this is shown during
trials in Figure 12). A seabed survey was performed in each of the
touchdown locations, and the foundation pedestal was then adjusted Figure 12: Adjustable Foundation Structure Levelling
on the vessel deck (using a separate pitch and roll adjustment Trial (Project #2)
mechanism). This ensured that once the installation was complete,
the foundation pedestal and parking arrangement was level and ROV operations could be executed efficiently. The advantage
of this technique is the ability to tolerate greater seabed slope, reducing the amount pre-installation ground work, a significant
advantage with deepwater installations. This also allows late decisions to be made regarding the final location of the
foundation, as this can be decided just prior to deployment if required.
A further advancement of this concept is to allow the levelling of the structure to take place when installed subsea, this
involves the pitch and roll mechanism being adjusted via ROV intervention.

Installation Analysis

As structures are becoming heavier and more complex, it is becoming increasingly necessary to undertake more complex
installation analysis to reduce much of the conservatism that exists within current traditional analytical techniques. The
installation of foundation structures may require an analysis of the following scenarios:
Lift off deck and manoeuvring.
Splash zone analysis.
Lowering to seabed.
Location.
Impact.
For the projects discussed, analysis was typically undertaken in accordance with DNV Rules for Planning and Execution of
Marine Operations(1). A new Recommended Practice document (DNV-RP-H103 Modelling and Analysis of Marine
Operations(6)) has recently been introduced (April 2009). This new Recommended Practice provides guidelines for the
modelling and analysis of marine operations, with particular focus upon lifting operations through the wave zone, lowering of
objects in deep water and, landing on the seabed. However, this Recommended Practice provides minimal information for the
selection of hydrodynamic coefficients. Simplified formulae for crane tip motions based upon roll, pitch and heave motions
have been removed. As a result, a more refined analysis is now often required. An installation analysis may be undertaken
using commercially available FEA software packages such as OrcaFlex(7), Deeplines(8), FlexCom(9), etc. Tension in the
lifting slings, maximum motion, velocity and accelerations of the structure can then be derived in more detail. In order to
perform this work accurately, hydrodynamic properties (including added mass and damping coefficients) need to be defined.
Consideration is now given to undertaking model testing and Computational Fluid Dynamics (CFD) on structures to determine
these coefficients and interaction effects for non-standard geometric structures.
OTC 20633 7

Transportation Design

A major consideration of the foundation design is the

transportation requirements (road and sea transport), a critical
factor is the efficient delivery of the project scope. Recent deep
water multi-well developments have increased the requirements
for infield umbilicals with significant distribution requirements,
resulting in multiple foundation and SDU structures.
The scope of supply for Project #2 required the design and
delivery of 36 foundation structures, therefore the footprint and
mass of each unit were critical design factors when balancing
these requirements with the geotechnical and structural design
parameters discussed previously. Due to the volume of units
supplied, deck space was at a premium, therefore the use of wings
were essential, to maintain the required foundation area for
service, while increasing storage efficiency.
Figure 13 shows the foundation structures, folded and prepared for
Figure 13: Foundation Structures Prepared for Loadout
vessel loadout.
(Project #2)

Conclusion

With the trend towards deeper water developments comes more demanding challenges within the design of SDUs and
foundation structures. The loads on the structures are becoming more significant as umbilical catenary lengths increase. The
requirements to reduce the size envelope of the equipment to ease installation is also becoming increasingly important,
extending current fabrication principles to the limit.
The impact this has upon design is to increase the level of detailed analysis required to ensure fully fit for purpose structures
can be designed, with a reduced scope for the conservatism that is still inherent in shallow water structural designs.
What the industry needs to consider, for deep water and harsh environmental service is that umbilical terminations are no
longer a simple and clumsy interface for connecting and distributing service function. They are highly engineered structural
arrangements playing a major role in the deployment of the installation or the umbilical. Failure to take cognisance of this fact
will potentially lead to serious consequences.

Acknowledgements

Dr Alan Dobson, DUCO Ltd.

Peter Fellows, DUCO Ltd.

References

(1) DNV Rules for Planning and Execution of Marine Operations 1996
(2) DNV-RP-B401 Cathodic Protection Design 2005
(3) NORSOK M-501 Surface Preparation and Protective Coating 2004
(4) DNV Classification Notes 30.4, Foundations. 1992
(5) API (RP2A-WSD). 2000
(6) DNV-RP-H103 Modelling and Analysis of Marine Operations 2009
(7) OrcaFlex-Finite element program used for the analysis of static and dynamic systems used in the offshore industry.
Developed by Orcina Ltd.
(8) Deeplines-Finite element program used for the analysis of static and dynamic systems used in the offshore industry.
Developed by Principia.
(9) Flexcom-Finite element program used for the analysis of static and dynamic systems used in the offshore industry.
Developed by MCS.