Scope

A leading oil field services company needed a custom-designed Surface Hydraulic System (SHS) and Well Control Module (WCM) for an offshore rig, considering ease of transportation and space constraints, and compliance with ATEX zone-1 rating requirements for explosion-proof equipment.

Design Requirements

1. 1. A single Surface Hydraulic System with a footprint of 43.5 x 43.14 x 30 inches, compliant with ATEX zone-1 rating.
2. 2. A Well Control Module meeting NEMA-4X requirements with a footprint of 31.25 x 24.6 x 28.5 inches, capable of controlling 5 and 6 zones.

Solution

From Concept to Production Release

1. 1. Developed a single-source SHS and 5 & 6 line WCM that met the footprint and maintenance access requirements.
2. 2. Designed the system to comply with National Electrical Manufacturers Association (NEMA-4X) standards.
3. 3. Optimized the SHS cabinet volume by externally mounting the bladder accumulator.
4. 4. Reduced costs and volume by using a lower-cost junction box (E model instead of D model) by relocating all spark-prone components to the control room and connecting them with armored cables.

Features

1. 1. New SHS design compatible with both 5 and 6 zone WCM.
2. 2. Provided alternative lifting options with a forklift for the SHS.
3. 3. Externally mounted 2.5-gallon accumulator to save space.
4. 4. Access doors included for easy maintenance.

Benefits

Reduced volume and material costs by $1,000 per SHS unit by placing the accumulator outside the cabinet and utilizing the space above it for tubing and cables.

Results

1. 1. Design optimization saved $1,000 per SHS unit, totaling $7,000 for seven units.
2. 2. Changing the junction box to Ex (e) from Ex (d) saved $1,000 per WCM unit, totaling $22,000 for 22 units.