Subsea Master Control Station Redundancy
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Solution Overview
Problem
The existing subsea control systems for offshore production are limited by the expansion capabilities, ease of use, maintainability, remote monitoring, and interfacing with third-party equipment of Programmable Logic Controllers (PLCs), which can impact the reliability and safety of subsea production operations.
Innovation Solution
A multiple location redundant Master Control Station (MCS) system is implemented, utilizing a Linux-based operating system with continuous data traffic flow and active redundancy, allowing seamless transfer of control between servers and enabling control from multiple locations, including both offshore and onshore.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional single-location MCS system using PLCs is used, then the system structure is simple, but the expansion capabilities, ease of use, maintainability, and remote monitoring are limited
Solution Approach 1:
The patent divides the single MCS system into multiple geographically distributed MCS locations (offshore and onshore), allowing the control system to be segmented across different physical locations while maintaining functional integration through redundant communication channels and synchronized control logic
Solution Approach 2:
The MCS system is designed with multi-functional capabilities including programmable logic control, continuous data traffic flow handling, remote monitoring, and interface with third-party equipment, making it adaptable to various control scenarios and expansion requirements
2Ease of operation
If a traditional single-location MCS system is used, then the device complexity is low, but the ease of operation and maintainability are reduced
Solution Approach 1:
The patent introduces a standardized communication interface and protocol layer between the control logic and field equipment, serving as an intermediary that simplifies operation by providing uniform access methods while handling the complexity of multiple communication channels and device types
3Adaptability or versatility
If a traditional single-location MCS system is used, then the system configuration is simple, but the remote monitoring and interfacing with third-party equipment are limited
Solution Approach 1:
The MCS system incorporates universal communication interfaces and standardized protocols that enable interfacing with multiple third-party equipment types and remote monitoring functions, making the system adaptable to various external systems while managing communication complexity through standardized architecture
4Reliability
If active redundancy with multiple MCS locations is implemented, then the fault tolerance and reliability are improved, but the system complexity increases
Solution Approach 1:
The patent implements active redundancy by pre-configuring multiple MCS locations (offshore and onshore) with identical control capabilities and real-time synchronization, providing beforehand cushioning against single-point failures and ensuring continuous operation even if one location fails
Solution Approach 2:
Each MCS location is configured with location-specific optimization (offshore for rapid local response, onshore for enhanced monitoring and maintenance access) while maintaining identical core control logic, allowing each site to leverage its local advantages without compromising overall system reliability
5Reliability
If continuous data traffic flow between redundant MCS servers is implemented, then the data transparency and uninterrupted operation are improved, but the communication requirements and system complexity increase
Solution Approach 1:
The patent implements continuous data traffic flow between redundant MCS servers through dedicated communication channels, ensuring uninterrupted control and monitoring by maintaining constant data exchange and real-time synchronization of control states across all locations
Data Source
AI summary
A subsea production system for producing fluids from a subsea well in a subsea field. The production system includes a production facility and a production umbilical connecting the subsea well with the production facility. The production system also includes a control system for controlling production from the subsea well. The control system includes a first redundant master control station system (redundant MCS) at a first location, the redundant MCS capable of controlling production from the subsea well. The control system also includes a second redundant MCS at a second location, the second redundant MCS capable of controlling production from the subsea well. The redundant MCSs are synchronized to keep the same electronic data at both locations and to prevent conflicts in control signals from the redundant MCSs.