HYDRIL

SUBSEA CONTROL MODULEFOR OIL WELL BLOW-OUT PREVENTER

(BOPs)

Team 3BMatt Hewitt – Project Manager

Devin Welch – Configuration ManagerPaul Jaramillo – CorrespondentNhat Pham – Financial Officer

Project Requirements

• Design and build an electronics module to monitor and control the operation of a single ram blow-out preventer (BOP) located sub sea.

• Test the module with a set of actual or simulated control system equipment.

Solenoid Control

• The electronics module must independently trigger two solenoids when commanded.

Continuous Monitoring

• Flow (in GPM) of Hydraulic Fluid

• Ram Position via LVDT

• These values must be transmitted to the computer on the ship.

Additional Features

• Self Test Circuitry

• Redundancy

• Networkability for single and double ram BOPs

• Functional at ambient 6700 psi

Requirements met

• Built prototype control module

• Tested module with Hydril supplied solenoids

• Continuously sampled Flowmeter and LVDT data with A/D chip

Requirement work in progress

• Communication with topside computer

• Communication with other modules

• Incorporate Self Test Circuitry

• Incorporate Redundant Circuits

• Functionality at 6700 psi

Devin Welch

Configuration Manager

Functional Block Diagram

Functional Block DiagramOverview

Control Module

Topside

Computer

Input

Sub sea

Sensor

Input

Topside

Computer

Receiver

Sub sea

Self-Test

Output

Functional Block DiagramInputs to Control Module

High Pressure Flow Meter

0 175 GPM

LVDT

Ram Position Measurement

Topside Signals and Power

Power and Control Lines

Analog = 52V

Digital = 5V

Hydraulic Flow Analog Data

Analog Data

Functional Block DiagramControl Module

Data Acquisition and Transmission

Control Logic

Solenoid Activation

Solenoid Drivers

52V, 1/2A

Solenoid Coil Monitoring

“Self-Test”

Data Output

ON/OFF

#1 / #2

Solenoid #1

Solenoid #2

Control

Lines

Flow meter

LVDT

Solenoid #1 Coil Output

Solenoid #2 Coil Output

Functional Block Diagram

Solenoid #2

Computer

Received Output Signals

Data Transmission Lines

Solenoid #1Solenoid #1 Control Line

Solenoid #2 Control Line

Control Module Outputs

Solenoid #1 Coil Output

Solenoid #2 Coil Output

Control Module

2nd Level Block Diagrams

Data Acquisition

Flow meter

LVDT

Analog

Signal

0-5V

Analog

Signal

0-10V

A/D

Converter

A/D

Converter

FPGA

Data

Out

Data

Out

Control

In

Control

In

Digital Circuit Board

Flowmeter A/D Converter

+5V

ADS8509

18

16

14

13

12

134

56

9

158

1711

PDN

CS

TAG

DATA

DATACLK

R1INR2INR3IN

CAPREF

EXT/INT

R/CSB/BTC

BUSYSYNC

FPGA Sync

Gnd

Ccap

2.2uF

0

R2100

Flowmeter Input

FlowmeterVcc

Rin233.2k

Cref

2.2uF

FPGA Clock

+5V

A/D #1

Flowmeter Input

FPGA Control Line0

Output to FPGA

Digital Data

Rin1200

00

Flowmeter Input Range 0-5V

0

0

LVDT A/D Converter

Output to FPGA

0

LVDT Input

+5V

FPGA Clock

Cref

2.2uF

Gnd

Rin1200

Vcc

LVDT Input

0

+5V 0

Digital Data

0

Ccap

2.2uF

A/D #2

Rin233.2k

FPGA Control LineADS8509

18

16

14

13

12

134

56

9

158

1711

PDN

CS

TAG

DATA

DATACLK

R1INR2INR3IN

CAPREF

EXT/INT

R/CSB/BTC

BUSYSYNC

LVDT

0

0

LVDT Input Range 0-10V

R2100

FPGA Sync

Solenoid Driver Power +52V

FPGA Signal +3.3V

Solenoid Coil

DPDT Relay

0

0

R

A/D

FPGAData

Out

Control

In

Relay Coil Control

Solenoid Coil Self-Test

FPGA Control Logic

FPGA

Digital Flow meter Data

Flow meter A/D Control

Digital LVDT Data

LVDT A/D Control

Topside Computer

Control Lines

Solenoid #1 Control Line

Solenoid #2 Control Line

Spartan XC3S400

Inputs/Outputs

Digital Coil Data

Coil A/D Control

Solenoid Drivers

Solenoid Activation

Solenoid

Driver

Solenoid

Driver

Vcc

Gnd

Vcc

Gnd

Solenoid

#1

Solenoid

#2

FPGA

Control

Line #1

FPGA

Control

Line #2

Driver Control line

Vcc=52V

Analog Circuit Board

Driver Control line

Solenoid Driver Schematic

Paul Jaramillo

Correspondent

VHDL Structure

Two Components:

State Machine

16-bit Shift Register

Serial In Parallel Out (SIPO)

State Machine Function TableState Machine Function Table

Inputs Outputs

RESETN CLK COMMAND SYNCH FLOW HOLD CLOSED SOL1 SOL2

L X XX X X X L L L

H ↑ 01 ↓ > (0.04 V)* L L H L

H ↑ 01 ↓≤ (0.04

V)* L H L L

H ↑ 10 ↓ > (0.04 V)* L H L H

H ↑ 10 ↓≤ (0.04

V)* L L L H

H ↑ 00 ↓ X X L L L*User Specified Voltage

State Machine TransitionState Transition Table

Inputs State

RESETN CLK COMMAND SYNCH FLOWHOL

D Present Next

L X XX X X X S00 S00

H ↑ 01 ↓ > (0.04 V)* L S00 S01

H ↑ 01 ↓ ≤ (0.04 V)* L S01 S00

H ↑ 10 ↓ > (0.04V)* L S10 S10

H ↑ 10 ↓ ≤ (0.04 V)* L S10 S00

H ↑ 00 ↓ X X S00 S00State Translation

S00 Wait (Initial)

S01 Close BOP

S10 Open BOP

S11 Not Used

16-bit Shift Register

Shift Register Function Table

Inputs Function Outputs

CLRN CLK SERIAL_IN SHIFT COUNT   HOLD P_OUT Q

L X Data X 0 Reset Q U U Hi Z

H ↑ Data H COUNT +1 Shift in Data H U Data

H ↑ Data H 15 Output Data Parallel L Q Data

H ↑ Data L U Not Used U U U

A 2 D Converter Timing

Read/Convert Process

A-2-D R/CN Generator

Inputs Output

RESETN CLK COMMAND COUNT

L X XX L

X X 00 L

L ↑ 01 COUNT +1

L ↑ 10 COUNT +1

L ↑ 11 COUNT +1

A-2-D Data Latch

A 2 D Data Latch

Inputs Outputs

BUSYN CLK EN SER1

↓ ↑ H DATA

↓ ↓ L Hi Z

↑ ↓ L Hi Z

↑ ↑ L Hi Z

Nhat Pham

Financial Officer

Parts cost

Parts Budgeted Actual

Flow meter (x2) $1245.00 $0

Development boards (x2) $788.00 $788.00

Dual full bridged drive (x4) $26.68 $26.68

A/D converter (x4) $150.00 $150.00

Flow meter sensor (x2) $2246.00 $0

Misc. items $50.00 $50.00

Total $4505.68 $1024.68

Labor cost

Hours Overhead rate Cost

Budgeted 446 $41.80/hr $18,642.80

Actual 340 $41.80/hr $14,212.00

Remain 106 $41.40/hr $4,388.40

Actual Budget

Total Hours 340 hours

Overhead rate $ 41.80/hour

Total labor $ 14,212.00

Total parts $ 1,024.68

Travel cost $ 600.00

Total $ 15,836.68

Budget difference

Previous Budget $23,748.48

Current Budget $15,836.68

Money Saved $7,911.80