HYDRIL SUBSEA CONTROL MODULE FOR OIL WELL BLOW-OUT PREVENTER (BOPs) Team 3B Matt Hewitt – Project Manager Devin Welch – Configuration Manager Paul Jaramillo – Correspondent Nhat 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

Overview Control Module Topside Computer Input Sub sea Sensor Input Topside Computer Receiver Sub sea Self-Test Output

Functional Block Diagram Inputs 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 FlowAnalog Data

Functional Block Diagram Control 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 #1 Solenoid #1 Control Line Solenoid #2 Control Line Control Module Outputs Solenoid #1 Coil Output Solenoid #2 Coil Output

Control Module 2 nd 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

LVDT A/D Converter

Solenoid Driver Power +52V FPGA Signal +3.3V Solenoid Coil DPDT Relay 0 0 R A/D FPGA Data 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 Table InputsOutputs RESETNCLKCOMMANDSYNCHFLOWHOLDCLOSEDSOL1SOL2 LXXXXXXLLL H ↑ 01 ↓ > (0.04 V)*LLHL H ↑ 01 ↓≤ (0.04 V)* LHLL H ↑ 10 ↓ > (0.04 V)*LHLH H ↑ 10 ↓≤ (0.04 V)* LLLH H ↑ 00 ↓ XXLLL *User Specified Voltage

State Machine Transition State Transition Table InputsState RESETNCLKCOMMANDSYNCHFLOW HOL DPresentNext LXXXXXXS00 H ↑ 01 ↓ > (0.04 V)*LS00S01 H ↑ 01 ↓≤ (0.04 V)* LS01S00 H ↑ 10 ↓ > (0.04V)*LS10 H ↑ 10 ↓≤ (0.04 V)* LS10S00 H ↑ 00 ↓ XXS00 State Translation S00 Wait (Initial) S01 Close BOP S10 Open BOP S11 Not Used

16-bit Shift Register Shift Register Function Table InputsFunctionOutputs CLRNCLKSERIAL_INSHIFTCOUNT HOLDP_OUTQ LXDataX0Reset QUUHi Z H ↑ DataHCOUNT +1Shift in DataHUData H ↑ H15Output Data ParallelLQData H ↑ LUNot UsedUUU

A 2 D Converter Timing

Read/Convert Process A-2-D R/CN Generator InputsOutput RESETNCLKCOMMANDCOUNT LXXXL XX00L L↑01COUNT +1 L↑10COUNT +1 L↑11COUNT +1

A-2-D Data Latch A 2 D Data Latch InputsOutputs BUSYNCLKENSER1 ↓ ↑HDATA ↓↓ LHi Z ↑ ↓ L ↑↑L

Nhat Pham Financial Officer

Parts cost Parts Budgeted Actual Flow meter (x2) $ $0 Development boards (x2) $ Dual full bridged drive (x4) $26.68 A/D converter (x4) $ Flow meter sensor (x2) $ $0 Misc. items $50.00 Total $ $

Labor cost Hours Overhead rate Cost Budgeted 446 $41.80/hr $18, Actual 340 $41.80/hr $14, Remain 106 $41.40/hr $4,388.40

Actual Budget Total Hours 340 hours Overhead rate $ 41.80/hour Total labor $ 14, Total parts $ 1, Travel cost $ Total $ 15,836.68

Budget difference Previous Budget $23, Current Budget $15, Money Saved $7,911.80