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This paper was prepared for presentation at the 2009 Offshore Technology Conference held in Houston, Texas, USA, 47 May 2009.
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
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Abstract
Aker Solutions is the main contractor for the engineering, procurement, construction and installation of the subsea
compressor station being built as part of the Ormen Lange pilot project. The compression station pilot is a full scale 12.5 MW
compressor train which is equal to one of the four trains required for the permanent subsea compression station for the Ormen
Lange gas field.
This paper describes the system design, equipment and subsea technology developed for the compression station pilot. The
main part of the project has been to design equipment and technology fit for installation at 900 meters water depth and to
ensure that the stringent requirements for reliability and robustness are fulfilled.
The process system is exposed directly to the wellstream at Ormen Lange and is designed to handle varying gas-condensate
rates, liquid slugs and sand production. The main process equipment is the separator, compressor, pump and cooler.
The high voltage power distribution system includes subsea circuit breakers, subsea transformers and frequency converters to
drive the subsea compressor and pump. The electrical equipment is included in subsea enclosures with high voltage mating
mechanisms between the units.
The control system is key component for the subsea compression station. The long tie-back of 120 km and the requirement
for high speed closed loop control and high bandwidth communication to shore initiated development of new technology
solutions. An all electrical control system is developed with subsea uninterruptible power supply and electrical actuators. A
SIL2 rated Process Shut-Down System (PSD) is also included for additional protection of the subsea components.
Communication subsea to shore is via fibre optic lines in the power umbilical.
Introduction
The Ormen Lange gas field is located off the northwest coast of Norway. The field has been developed with subsea wells and
export pipelines for multiphase transport of gas-condensate to the onshore processing plant. The subsea production templates
are located at around 900 meters waterdepth and the tie-back distance to shore is 120 km. The production from Ormen Lange
started October 2007 and the maximum gas production rate is 70 MSm3/sd. The exploitation is by depletion utilizing the
natural reservoir pressure. The reservoir pressure will decrease gradually until pressure boosting is needed around 2016 to
maintain plateau production and increase the total recovery from the reservoir.
Subsea compression is an alternative to a compression platform for boosting the gas and condensate at the Ormen Lange
field. A full scale subsea compression train pilot is currently being built and will be tested for 2 years before the final
decision whether to go for subsea compression or a topside compressor platform will be taken in 2012.
The subsea compression station is planned to be installed at 859 meters waterdepth at a location close the existing production
templates. The location close to wells is beneficial for reducing the back-pressure on the wells and maximizes the recovery of
the reservoir. The subsea compression will maintain the flowrate required to avoid severe slug production in the gas-
condensate export pipelines to shore.
Installing a subsea compression station instead of a platform will eliminate the need for offshore manning, helicopter
transport and offshore supply and will increase offshore safety. Offshore operation is only required during installation and for
retrieval and replacement of subsea modules for maintenance and repair.
There are no emissions or disposals from the subsea compression station. The only hazardous fluids present on the subsea
compression station is MEG used for hydrate inhibition and the hydrocarbon gas-condensate being produced.
Calculations show that carbon dioxide emissions will be reduced by 60 per cent in the construction of the subsea station
compared with building a floating platform.
Each of the compressor trains comprises the following main retrievable process and power modules:
The system design and arrangement of the compression station is shown in figure 3 on the next page. The station is 70 m
long, 54 m wide and 14 m high (excluding suction anchors) and the total dry weight is 6500 tonnes. The station is designed
for installation down to 900 meters water depth.
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Anto surge
Recycle valve
cooler
M
UPS
Scrubber M UPS
Compressor
Pump
P-294
VSDs Circuit
M Breakers &
Utility
Power
Transfomer
Main step-down
transformer
M
UPS
M UPS
Bypass
Figure 2: Subsea compression station system Figure 3: Subsea compression station arrangement
The system design is developed with focus on robustness and reliability. The availability requirement for the subsea
compression station is 97.6%.
The process system is directly exposed to the wellstream and the process equipment is designed to handle varying
composition of unprocessed hydrocarbon gas and liquid, produced water, sand production and chemicals injected at the
wellheads. The main design principle for the process system has been to include an inlet separator/slug catcher that protects
the compressor against liquid and sand/fines that would lead to excessive wearing and reduced availability. The liquid and
sand/fines removed in the separator is boosted by a variable speed driven centrifugal pump.
The process equipment and piping is arranged to avoid pockets/dead legs and prevent build-up and clogging of solids in the
liquid piping and ensure that any liquid condensation in the gas lines is sloped back to the separator vessel. The pump module
is elevated below the separator module to satisfy the net positive suction head (NPSH) requirement. Subsea mechanical
connections and ROV operated isolation valves are included to allow for separate retrieval of the process modules. The
mechanical clamp connectors used are a variation of both single and multi bore types depending on the function and size of
the connecting piping.
The arrangement of the power modules is made to simplify the interfaces between modules and to reduce both cable lengths
and high voltage electrical wet mate connections where possible. The arrangement of the high voltage wet mate connection
mechanisms has been designed to allow for separate retrieval of each power module.
The pilot station modules will be installed and tested in a test pit at Nyhamna within the Ormen Lange onshore terminal. The
test pit is 28 meters wide, 42 meters long and 14 meters deep. A cooling water system provides continuous flow of seawater
into and out of the test pit for cooling of the subsea equipment during operation.
The pilot will be operated with the real wellstream composition received from the Ormen Lange onshore facilities, and the
test facilities are equipped to emulate slug production, sand production and other operating conditions for the future Ormen
Lange subsea compression station.
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The electrical power from the test facilities is provided in a power cable to the pilot main transformer unit located in the test
pit. The main transformer is connected to the 22 kV circuit breaker module, which includes circuit breakers for the
compressor and pump variable speed drives.
The system design and arrangement of the pilot is shown in figure 4 and 5 below. The pilot is 30 m long, up to 18 m wide
and 13 m high and the total dry weight is approximately 900 tonnes. The process and power module arrangements are
identical to the future subsea compression station to ensure that all aspects of the process equipment, electrical power
equipment and overall system operation are qualified.
Figure 4: Subsea compression station pilot Figure 5: Subsea compression station pilot system arrangement
system design
The equipment from the different suppliers will be transported to Egersund for assembly into the modules. The exception is
the pump which is delivered as a complete module. After mechanical completion and testing of each module they will be
assembled into the pilot system. The complete pilot will be subject to extensive dry testing to verify all mechanical, electrical
and control system functions.
After final testing of the pilot it Egersund, the pilot will be disassembled and transported to Nyhamna for installation in the
test pit and ready to start the 2 year testing period.
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Separator Module
The vertical separator is designed for two-phase separation. The separator vessel is 3m ID and 7 m T/T. The separator
module arrangement is shown in figure 6 and fabrication of the separator vessel is shown in figure 7.
The separator will work as a slug catcher and has the required volume to accumulate the slugs being produced due to well
start-up, pressure transients and terrain induced slugging. The internals are designed to withstand the forces generated by the
expected slugging for the lifetime of the separator.
The liquid level is detected by instrumentation, and is controlled by variable speed operation of the liquid pump in the
compression train.
The gas demisting is performed by devices that have an open flow path sufficient for clogging not to occur. The performance
of the gas demisting is very conservative relative the compressor acceptance for liquid entrainment in the gas phase to the
compressor.
The solids in the wellstream are separated out in the separator together with the liquid. The separator design must ensure that
no solids are accumulated in the gas demisting device or in the bottom of the separator. Extensive sand testing has been
performed to qualify the separator and internals, see figure 8 below.
Testing of the cooler performance in seawater is performed as part of the Ormen Lange subsea compression pilot project
Figure 10 show the testing of the cooler in a test pit at Aker Solutions in Norway. The cooler performance may degrade over
time due to biological growth and contaminates caused by mineral deposition and the cooler heat exchanging surface must be
increased to take this into account.
Figure 9: Anti-surge cooler module Figure 10: Testing of subsea cooler heat transfer at Aker
Solutions facilities in Norway
Compressor module
The GasBoosterTM compressor module is designed for high reliability and includes a 12.5 MW motor-compressor designed
for subsea operation. The subsea design development has resulted in a vertical unit and a common hermetically sealed
enclosure for the motor and compressor. The enclosure is pressurized and a barrier system separates the compressor and
motor volumes ensuring a clean operating atmosphere for the electrical motor and magnetic bearings. The motor cooling gas
is circulated in the motor enclosure by an impeller mounted on the motor shaft and then cooled in an external seawater
cooler. The closed motor cooling loop means that the motor is significantly less exposed to the unprocessed gas being
compressed in the compressor. The only utility supply required to the motor-compressor is the low voltage power to the
magnetic bearings.
Figure 11: Subsea compressor module Figure 12: Motor-compressor casing at General Electric in Massa
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The vertical configuration gives a smaller footprint which is beneficial for the subsea station arrangement as well as subsea
installation and intervention of the compressor module. The electrical motor is physically located above the compressor with
optimum protection against any liquid or seawater accidentally leaking into the unit. The vertical arrangement facilitates any
liquid droplets and solids particles to settle by gravity, and be collected at the bottom of the compressor vessel. The vertical
configuration draws advantage of the fact that gravity will drain all liquids from the motor-compressor to a common
extraction point located at bottom of the compressor.
Pump module
The 400 kW LiquidBoosterTM pump from Aker Solutions is a vertically
orientated multistage centrifugal pump with liquid filled motor. The
complete unit is enclosed in a pressure-retaining casing. The pump is
equipped with a barrier fluid pressure control system capable of following
rapid process pressure variation, to avoid leakage of process fluid into the
pump motor. The system will maintain an overpressure compared to the
process pressure during all conceivable process system transient
operations. The barrier fluid is glycol/water which will be supplied from
the existing production facilities at Ormen Lange and no dedicated utility
supply from shore is required.
System Overview
The main function of the high voltage (HV) electrical system is to ensure steady power transmission from shore and an
accurate speed / torque control of the subsea high speed compressors and pumps. Aker Solutions has the total power system
engineering, design, marinisation and construction responsibility, including the following:
Interfaces with 132kV main bus on onshore gas plant and 420kV National Grid
System behavior (load flow, short-circuit harmonics, transients analyses) and detailed simulations between shore and
subsea station, including implementation of an On-load Tap Changer (used to adjust for subsea load changes), Static
VAR Compensation unit and phase compensating reactors (used to compensate up to approx 90MVar reactive power
from cable in no-load operation)
Subsea HV power system detailed requirement specifications
Electromagnetic compatibility (EMC) and earthing design (which can be particularly challenging in subsea HV systems)
Marinised design of the high voltage equipment for 900m water depth
In above diagram the overall power system for the subsea compression station is described. In addition to the total system
design, Aker Solutions are delivering the equipment in the lowest blue box above. In the middle blue box the delivery scope
is done by Vetco/GE (based on Aker Solutions system specifications).
Another aspect of importance is high system availability and reliability, while still maintaining an optimized weight / size of
equipment. To ensure the high robustness goal of (minimum) 5-10 years continuous operation without maintenance / 30 years
lifetime the electrical system building blocks include the following main features:
Auxiliary low voltage (LV) supply by redundant uninterruptible power supply (UPS) units
Implementing a fully redundant control system with passive cooling and no fans
Using 1-atm enclosures that allow well proven components to be used. Minimizing number of flanges/penetrators
towards sea pressure, and using testable body flange and penetrator flanges with metal seals
Earth fault tolerant design: Possibility for continuous operation with an earth fault on one of the three phases in the HV
and LV systems (allows for planned replacement of failed modules, keeping production going while waiting for offshore
installation vessels). This means that 6.6kV systems have IEC (international eletroctechnical commission) insulation
system rating of U0/U(Um) = 6/10(12)kV, and similarly 22kV operational voltage implies 18/30(36)kV insulation.
Extensive focus on electromagnetic properties of various steel qualities used in the system, ensuring no potential
problems with eddy currents in single phase cables/connectors/penetrators.
Ensuring no electromagnetic compatibility problems with high current connections, especially focusing on the right way
of grounding cable screens and modules
Focus on thermal balance and verification of thermal models
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This has lead to the following number of Ormen Lange Pilot Test Single Line Diagram
components for the Subsea Compression Station: Test Pit supply from 132/22kV 20MVA transformer
1 off LSPS (long step-out power system) Step- Circuit Breaker Module
down Transformer (by others)
2 off Subsea Circuit Breaker (CB) Modules, 22kV / 50 Hz
36kV
each with supply/protection for 2 trains 22kV CB
hardware:
1 off CB Module, supplying one compression M M
12.5MW 400kW
train and two UPS units 6.6kV 2.5kV
distribution systems ensuring full redundancy Figure 15: Subsea Compression Station Pilot single line diagram.
In the following sections the main Electic Modules for the Pilot Station are described, and differences with the final Subsea
Station are highlighted.
Figure 16: Subsea Circuit Breaker Module. Figure 17: CB enclosure under fabrication.
The main purpose of the pre-charge system is to pre-energize approx 100kVA power to the CVSD/PVSD before closing the
main 22kVkVac power to the VSD. If the pre-charge was not included, the long cable from shore and limited short-circuit
10 OTC 20030
power available subsea would have resulted in too high inrush current to the transformers (typically up to 10x nominal
current), resulting in a voltage drop that would trip the subsea power supply and damage the VSD DC capacitors. By using
this pre-charge system the VSDs are soft-started in a few seconds, before closing the main 22kV breakers, and by this the
inrush current is reduced significantly.
The pre-charge circuit is also very simple and robust, only consisting of a step-down transformer from 22kV, two 400V low
voltage breakers, and a step-up transformer to 22kV (see Figure 15). A special design of the impedance in this circuit is also
what eliminates pre-charge solutions based on more complicated power electronics / thyristors.
The main CBs and HV connections are rated at 36kV, which allows the 22kV busbar to be operated with an earth fault, and it
also comprises an earth fault monitoring system for each outgoing feeder, as well as provisions for a differential protection
system for the LSPS transformer. The Pilot CB module is dimensioned for two compressor trains, but includes only 3 of 4
22kV breakers for one train and two UPS units, as the CB and subsea HV connection system for train 2 is not included during
the pilot test phase.
The CB Enclosure is nitrogen filled at 1-atm, allowing ruggedized and proven standard industrial components from
Schneider Electric to be used, including a fully redundant control and protection relay system. The unit is cooled by natural
convection. Total weight is approx 140 T, with an enclosure diameter of 2.8m and length of approx 17.6m.
Figure 18: Subsea Compressor VSD Module. Empty space cassette on Figure 19: VSD internal power electronic Rack.
top of VSD Transformer Module (grey item, lower right hand of module) is Sections from top to bottom: controllers, rectifiers,
allocated for the separately retrievable Pump VSD Module. To the right the inverter section, DC link capacitors, filter reactors and
ROV operated retractable wet mate connection arm is shown. cooling unit.
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Pump VSD
This 6-pulse drive is based on mainly the same subcomponents
as the CVSD, and the main architecture originates from the
Converteam MW 7306 series, rated for up to 3.3kV/6MW.
Since the load is a 2.5kV/120A/400kW motor at conventional
frequencies (0-70Hz), the reliability, availability and
maintainability (RAM) study made it possible to eliminate the
extra N+1 IGBT redundancy due to the inherent voltage margin
and current margin (<10% power loading), allowing for
simplicity, high robustness and maintained reliability.
Apart from this, the redundant water cooling, VSD control,
power interface board and gate drive redundancy is the same in Figure 21: Subsea Pump VSD Module. Internal power
both drive solutions. Module size is approx 2.8m x 2.8m electronic rack shown to the right.
footprint, 6.3m height and a weight of approx 40T.
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UPS Module
Each of the two redundant UPS modules includes a back-up battery and
distribution system to all low voltage subsea consumers, e.g. anti-surge
valves, control modules, magnetic bearing systems, CB, VSDs, etc.
In case one UPS Unit fails, productions can be maintained in normal mode
without any shut-down, as the control/loads are automatically transferred to
the other UPS unit is a safe and bumpless way. The main reason why this is
possible is that all consumers have double A/B supply connections. In
addition, the UPS output LV feeders are equipped with isolating
transformers, allowing operation with single phase earth fault.
Lithium-ion technology is used in the battery system, and the main reasons
why this is most suitable is related to the fact that these batteries are
maintenance free, no gas is released, energy/volume ratio is high and they
are well proven from other special applications like telecom systems,
satellites and electric vehicles. The battery package is dimensioned to power
the main parts of the subsea control system during a shutdown sequence (in
particular the magnetic bearing system during compressor run-down) in
case of loss of the main power supply. If needed the UPS system can be
commanded to go to sleep for up to one month and revert back for a
system check and startup. If required for any reason, the back-up battery can
be recharged by an ROV after which a black start can be performed.
HV Connectors
Another challenge has been to design a large enough HV Connection
System for 36kV/900A/50Hz used for the 22kV distribution and
12kV/1600A/0-200Hz for the VSD and 6.6kV compressor motor (see figure
23). To undertake this job, Deutsch (France) was brought into the team, and
have over the last two years brought forward a complete set of single phase
penetrators, jumpers and wet mate connectors, which are also earth fault
tolerant for this purpose. Figure 22: Subsea UPS Module. Enclosure
domes under fabrication
Among the key obstacles that have been overcome, one may mention rapid
gas decompression in the compressor (which potentially could transform
plastic insulating parts into popcorn) steel quality to avoid heat problems
due to potential eddy currents, as well as partial discharge free cable
interfaces. Since these components are relatively big and heavy, Aker
Solutions have also designed ROV operated mating mechanisms to couple
the connectors and high voltage power supply between the modules
together.
Aker Solutions subsea marinisation experience, system engineering capability and project execution excellence together
with Converteams key knowledge about unique power electronic components and systems for special applications have also
been among the key factors for the subsea power system and Electrical Modules prototype development.
At the moment this team is also doing front-end engineering and design work for other similar applications, including subsea
VSD and CB technology for even deeper water down to 3000m water depth. Spin-off applications like offshore floating wind
power and tidal water power applications that require subsea CBs and transformers are also being explored, with an
increasing interest from various market players.
Control System
Overview
To operate the subsea compressor system, including manifold valves, an all-electric control system is implemented. The
onshore equipment will connect to the subsea equipment via a high voltage electrical cable also containing fiber optic cables
for communication to shore.
The design of the subsea compressor control system has been established to fulfill the requirements and need for:
Normal operation monitoring and control, inclusive of facilities for maintenance control
Emergency monitoring and control, including procedures for emergency alarming and locally implemented shutdowns
Communication between the interface parties
Interface towards potential future expansions
SIL2 rating for critical shutdown loops
Segregation between control, shutdown and condition monitoring functionality
The compressor operating modes that have been implemented into the control system design are:
Slug production and other process upsets
Liquid level control of the scrubber
Anti-Surge/Recycle Operation
Load Sharing between two and up to four compressors
Start-up and Shut-down
Emergency Shut down
Normal Operation
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Control Overview
A subsea Ethernet LAN and Industrial Communication Bus system interfacing the SCM to the following equipment
o UPS System
o Compressor controller
o Magnetic bearing controller
o Compressor VSD
o Compressor circuit breaker
o Pump VSD
o Pump circuit breaker
o Subsea Electrical Actuators
Acknowledgement
We wish to acknowledge the Ormen Lange License partners
StatoilHydro
Shell
ExxonMobil
Dong Energy
Petoro
References
1. OTC 20028, Ormen Lange Subsea Compression Pilot System, Bernt Bjerkreim/StatoilHydro, 2009