SUBSEA CONTROLS
Reliable and flexible systems that never become obsolete
Metering Control Systems
Measurement Solutions
Sampling Solutions
For the Energy Industry
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| Operation Parameters | ||
|---|---|---|
| Sample volume | 600 ml | |
| Maximum working pressure | 15,000 psi at 180°C | 356°F |
| Length | PDS 3,680 mm SPS 5,054 mm |
12'1" 16'7" |
| Weight | PDS 28 kg SPS 34 kg |
61.6 lb 74.8 lb |
| Outside diameter | 43 mm | 1 11/16" |
| Material | 17-4PH stainless steel (AISI 630) aluminium bronze CA 104 |
|
| Proserv’s subsea sampling cylinder offering includes | |
|---|---|
| Volume | up to 2 litres |
| Design pressure | 1,379 bar |
| Design temperature | -29ºC to 177ºC |
| Single phase | Yes |
| Multi-phase | Yes |
| Sour service | Yes |
| Certification | PED / DOT |
| API 17D hyperbaric test | 3,000 m |
| Specification | ROV | Diver |
|---|---|---|
| Volume (per run) | 12 litres | 12 litres |
| Design pressure | 1,379 bar | 690 bar |
| Design temperature | -20°C to 110°C | -20°C to 110°C |
| Isothermal | Yes | Yes |
| Isobaric | Yes | Yes |
| Chemical injection | Yes | Yes |
| Slops containment | Yes | Yes |
| Sour service | Yes | Yes |
| Connection | Hot stab | Any |
ECG™
Holistic Cable Infrastructure Management System
Testing & Calibration
Specialist Solutions
| Product | Description |
|---|---|
| Standard test gauges | 10” dial ½” BSP & NPT male lower connection (adaptions available), 0.25% FSD, ranging from minus 1 barg (vacuum) to 2,000 barg (30,000 psi)/dual. C/W transit case |
| Digital pressure gauges | Keller Leo and Leo record digital gauges. Small, compact and durable digital gauges, ranges from 0-1,000 bar, accuracy of 0.1% FS |
| Euro pre-charge kit | Containing 0 to 400 barg (6,000 psi) gauges, 2.5 metre charging hose, accumulator connections, C/W transit case |
| Mechanical pressure recorder | Portable 12” circular chart, single pen mechanical chart drive, ranging from zero to 2,000 barg (30,000 psi) with adaptations to suit, 1/3, 2/8 & 24 hour to 7 day chart drives |
| Mechanical dual range recorder | Portable 12” circular chart, ranging from zero to 2,000 barg (30,000 psi), temperature -20 to +100ºC (adaptations to suit), configurations of pressure/temp available |
| Mechanical temperature recorder | Portable 12” circular chart, single pen mechanical chart drive, ranging from -20 to +100ºC |
| Hydrostatic test pumps, DA/DHDA | Single or twin acting air driven high volume pumps with hydraulic output, fill/test rig fitted with all air and hydraulic controls, ranges from 414 to 1,590 barg (6,000 to 23,000 psi), 0 to 10 barg (145 psi) air drive |
| Hydrostatic hydratron AZ type test pumps | Suitable for oil or water applications, mini pak, range 400 to 2,000 barg (5,800 to 30,000 psi) |
| Hydrostatic Haskel type test pumps | Suitable for oil or water applications, mini pak, range up to 1,000 barg (15,000 psi) |
| Over pressure protection skid | Can be set to clients’ requirements, ranging up to 700 barg (10,000 psi) |
| Gas booster test pumps | Suitable for all gas testing up to 1,379 barg (20,000 psi) |
| Hand pump | Hydraulic pump ranging up to 700 barg (10,000 psi) |
| Test manifolds | Working pressure 700 to 1,500 barg (10,000 and 22,500 psi), 5 or 7 port options are available, built in thermowell with ½” npt (f) connection |
| Block and bleed valves | Providing 3 ports up to 700 barg (10,000 psi) |
| HP hose assemblies | 1,800 barg (26,100 psi), 3 to 30 metres, ¼” bsp (f) ends |
| Pressure relief valves | Ranges from 0 to 1,700 barg (25,000 psi), suitable for gas and fluid services, range of connections to suit |
| Product | Description |
|---|---|
| Hydraulic filter pod | Ranges up to 1,000 barg (14,500 psi) |
| Flushing rigs general purpose safe area | Electrically driven, suitable for mineral oils and water-based glycol subsea control fluids, flow rates up to 35 litres per min. and pressures to 345 barg (5,000 psi) |
| Beckman Coulter HIAC PODS+ particle counter | Portable liquid particle counter measuring fluid cleanliness and optimising flushing time to compliment maintenance programmes, reporting standards include ISO 4406, NAS 1638 and SAE AS4059 |
| Pamas SBSS particle counter | High resolution digital system for analysis of water and oil based fluids with NAS 1638 and SAE AS 4059 and ISO 4406 classifications |
| Pamas S40 particle counter | Portable high resolution digital system for analysis of water and oil based fluids with NAS 1638, SAE AS4059 and ISO 4406 classifications |
| Product | Description |
|---|---|
| Datalogger | GX20 allows paperless datalogging with up to 10 channels |
| Thermocouple assembly | Type T and K, suited for measurements in the -200 to +1,350°C range, suitable for use with above datalogger |
| Megger insulation tester high voltage | Performs insulation resistance tests up to 5kV with an accuracy of ±5% |
| Calibrator, Druck DPI 615 | Battery powered portable pressure and mA calibrators, ranges from -1 bar to 20 bar (vacuum 290 PSI) and 4 - 20 mA |
| Multimeter (Fluke) | 87-V and 787 process multimeter |
| Low Resistance ohmmeter megger | DLRO 10X |
| Temperature/humidity meter | Testoterm 610, measuring range -10 to +50°C, accuracy ±0.5°C |
| Pressure transducers/ pressure transmitters | Ranges from vacuum -1 to 4,000 barg (60,000 psi), range of connections to suit |
| Subsea reel | 250 metres C/W digital temp indicator |
| Wireless datalogging system | Squirrel 1,000 series, multi-channel wireless datalogger for real time monitoring of hydraulic pressure and electrical continuity of insulation resistance, ranges as per clients’ specifications |
| Time domain reflectometer | Bicotest model T625 with a range of 0 to 20 kilometers, suitable for any metallic cable C/W kyoline printer |
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| Model No. | Size | Max Volume GPH/LPH | Max Discharge Pressure PSIG/BARG | Max Suction Lift/m |
|---|---|---|---|---|
| B25 | 1" | 2160 / 8175 | 1-1 Ratio | 7.6 |
| B50 | 2" | 7920 / 30000 | 1-1 Ratio | 7.6 |
| PD05P | 1/2" | 780 / 2952 | NA | 4.5 |
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| Model Number @ Air/Gas Supply Pressure | Max Volume GPH/LPH | Volume Per Stroke | Stroke Length | Strokes Per Minute (Range) | Max Discharge Pressure (PsiG / BarG) | Max Air Consumption SCF Per Day |
|---|---|---|---|---|---|---|
| CP125V12S @ 100 PsiG | 0.07 / 0.27 | 0.1 cc | 0.5" | 1-45 | 8650 / 5964 | 180 |
| CP250V22S @ 100 PsiG | 0.57 / 2.16 | 0.8 cc | 1" | 1-45 | 7200 / 4964 | 1150 |
| CP250V300 @ 100 PsiG | 0.57 / 2.16 | 0.8 cc | 1" | 1-45 | 13100 / 903.2 | 2100 |
| CP500V22S @ 100 PsiG | 2.30 / 8.71 | 3.2 cc | 1" | 1-45 | 1750 / 120.7 | 1150 |
| CP500V300 @ 100 PsiG | 2.30 / 8.71 | 3.2 cc | 1" | 1-45 | 3250 / 224.1 | 2100 |
| CRP500V400 @ 100 PsiG | 2.30 / 8.71 | 3.2 cc | 1" | 1-45 | 6300 / 434.4 | 3584 |
| CRP500V400 @ 150 PsiG | 2.30 / 8.71 | 3.2 cc | 1" | 1-45 | 9200 / 634.3 | 5250 |
| CRP750V400 @ 100 PsiG | 5.00 / 18.9 | 7.0 cc | 1" | 1-45 | 2600 / 178.3 | 3584 |
| CRP750V400 @ 150 PsiG | 5.00 / 18.9 | 7.0 cc | 1" | 1-45 | 4000 / 275.8 | 5250 |
| CRP1000V400 @ 100 PsiG | 9.18 / 34.75 | 12.9 cc | 1" | 1-45 | 1520 / 104.8 | 3584 |
| CRP1000V400 @ 150 PsiG | 9.18 / 34.75 | 12.9 cc | 1" | 1-45 | 2300 / 158.6 | 5250 |
| CRP1000V600 @ 100 PsiG | 9.18 / 34.75 | 12.9 cc | 1" | 1-45 | 3400 / 234.4 | 7190 |
| CRP1000V600 @ 150 PsiG | 7.11 / 26.91 | 10.0 cc | 1" | 1-35 | 4700 / 324.0 | 10210 |
| CRP1000V800 @ 100 PsiG | 9.18 / 34.75 | 12.9 cc | 1" | 1-45 | 6300 / 434.4 | 12342 |
| CRP1000V800 @ 150 PsiG | 7.11 / 26.91 | 10.0 cc | 1" | 1-35 | 9100 / 627.4 | 18150 |
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| Model No. @ Air/Gas Supply Pressure | Max Volume GPH / LPH | Volume Per Stroke | Stroke Length | Strokes Per Minute (Range) | Max Discharge Pressure (PsiG / BarG) | Max Air Consumption (SCF per Day) |
|---|---|---|---|---|---|---|
| CRP1500W400 @ 150 PsiG | 22.90 / 86.40 | 36 c.c. | 1 1/4" | 1-40 | 600 / 41 | 11,543 |
| CRP1500W600 @ 150 PsiG | 22.90 / 86.40 | 36 c.c. | 1 1/4" | 1-40 | 1950 / 134 | 26,000 |
| CRP1500W800 @ 150 PsiG | 22.90 / 86.40 | 36 c.c. | 1 1/4" | 1-40 | 3450 / 238 | 46,000 |
| CRP2250W600 @ 150 PsiG | 90.00 / 336.00 | 160 c.c. | 2 1/2" | 1-35 | 900 / 62 | 46,000 |
| CRP2250W800 @ 150 PsiG | 90.00 / 336.00 | 160 c.c. | 2 1/2" | 1-35 | 1800 / 124 | 81,000 |
| Model Number @ Air/Gas Supply Pressure | Max Volume GPH/LPH | Volume Per Stroke | Strokes Per Minute (Range) | Max Discharge Pressure (PsiG / BarG) | Max Air Consumption (SCF per Day) |
|---|---|---|---|---|---|
| CLD100-316-TFE @ 100 PsiG | 0.75 / 2.8 | 1.0 cc | 1-45 | 80 / 5.52 | 20 |
| CLD100-TFE-TFE @ 100 PsiG | 0.75 / 2.8 | 1.0 cc | 1-45 | 75 / 5.17 | 20 |
| CLD200-316-TFE @ 100 PsiG | 10.0 / 37.8 | 14.0 cc | 1-45 | 98 / 6.76 | 255 |
| CLD200-TFE-TFE @ 100 PsiG | 10.0 / 37.8 | 14.0 cc | 1-45 | 93 / 6.41 | 255 |
| CLD400-316-TFE @ 100 PsiG | 45.0 / 170.3 | 63.0 cc | 1-45 | 93 / 6.41 | 1200 |
| CLD400-TFE-TFE @ 100 PsiG | 45.0 / 170.3 | 63.0 cc | 1-45 | 90 / 6.20 | 1200 |
| Maximum Air Supply 125 psi (8.5 bar), Single Air Head - 6 HP (4.5 kw) | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|
| Model | Ratio Dash No | Actual Area Ratio | Maximum Rated Output Pressure | Displacement / Cycle | Connection Ports | ||||||
| Continuous | Intermittent | ||||||||||
| PSI | Bar | PSI | Bar | CU IN | ML | Air Drive | Inlet | Oulet | |||
| GWD, GSFD, DGFD, DGSFD, DGSTVD | -12 | 14.8 | 8000 | 552 | 10000 | 690 | 15.9 | 260.0 | 3/4" | 1 | 1/2" |
| *GW, DGF, GSF, DGSF, DGSTV | -35 | 40.3 | 4375 | 302 | 4375 | 302 | 6.0 | 98.0 | 3/4" | 1 | 1/2" |
| -60 | 69 | 7500 | 517 | 7500 | 517 | 3.5 | 57.0 | 3/4" | 1 | 1/2" | |
| -100 | 115 | 8000 | 552 | 10000 | 690 | 2.1 | 34.0 | 3/4" | 1 | 1/2" | |
IWOCS
Intervention workover control systems
| Low pressure system | 3,000 psi max working pressure |
|---|---|
| High pressure system | 10,000 psi max working pressure |
| Low pressure lines | LP1 - LP7 |
| High pressure lines | HP1 - HP2 |
| Low pressure flow (@3,000 psi) | 10 l/min |
| High pressure flow (@1,000 psi) | 1.2 l/min |
| Low pressure flow totaliser | |
| High pressure connections | JIC 4 |
| Low pressure hot line | Suitable for addition of accumulator bank |
| Low pressure pump | Haskel GSF60 |
| Low pressure connections | JIC 6 |
| High pressure pump | Haskel AW100 |
| Recirculation filter | 3 micron return filter and sample point |
| Reservoir Capacity | 60 litres |
| Gross weight | 500 kg |
| Dimensions | 1,390 × 600 × 1,200 mm |
| High pressure circuits | 10,000 psi max working pressure |
|---|---|
| Low pressure system | 3,000 psi max working pressure |
| Very high pressure | 20,000 psi max working pressure |
| Dimensions | 3,000 × 2,420 × 2,650 mm |
| Fluid compatibility | Suitable for both water-based glycol and light oil-based hydraulic fluid types with kinematic viscosity <15 cSt @ 40°C. |
|---|
| Min pressure | 100 psi |
|---|
| Tare | 2,500 kg |
|---|---|
| SWL | 7,050 kg |
| Gross | 9,550 kg |
| 2 × HP | 2,600 psi (variable) |
|---|---|
| 4 × HP | 1,812 psi (variable) |
| Electrical input | CTE 110VAC, 16 Amp, 1ph, 50/60Hz |
|---|
| High pressure system | 10,000 psi MWP |
|---|---|
| High pressure lines | HP9 – HP16; HP Hot Lines HP17 – HP20 |
| High pressure output | 1 LPM |
| Min working pressure | 7,500 psiG |
| Max working pressure | 10,000 psiG |
| Filter size | 3 micron |
| Low pressure system | 3,000 psi MWP |
|---|---|
| Low pressure lines | LP1 – LP8 |
| Low pressure output | 35 LPM |
| Min working pressure | 3,000 psiG |
| Max working pressure | 4,000 psiG |
| Filter size | 3 micron |
| Minimum air pressure | 75 psiG |
|---|---|
| Electrical requirements | CTE 400VAC, 24 Amp, 3ph, 50/60Hz |
| Input connector type | 130VAC 16A-4H 2P+E |
| Dimensions | 3,660 × 2,400 × 2,750 mm |
| Weight | |
| Tare | |
| SWL | |
| Gross |
| Reservoir | 700 litres |
|---|---|
| Low pressure accumulator | 4 each × 37 litres |
| Low pressure max working pressure | 5,000 psi |
| High pressure accumulator | 2 each × 12 litres |
| High pressure max working pressure | 10,000 psi |
| LP and HP pumps (two each) | Haskel air driven pump |
| Lighting | 220 volts |
| Tare weight | 3,500 kg |
| Net weight | 1,500 kg |
| Gross weight | 5,000 kg |
| Proof load | 10,000 kg |
| Dimensions | 320 × 250 × 270 cm |
| Standards | Lloyds Bs 7072 / IEE |
| Rated zone | Zone 1 |
| Assembly no | AW-60 |
|---|---|
| Nominal ratio | 60:1 |
| Max pressure | 9,800 psi liquid |
| Date manufactured | August 2007 |
| Model number | ACD-62 |
|---|---|
| Type | Single stage double acting |
| Max gas in | 9,000 psi |
| Max gas out | 9,000 psi |
| Assembly & serial no | AW-100 / 807-921 |
|---|---|
| Nominal ratio | 100:1 |
| Max pressure | 16,500 psi liquid |
| Date manufactured | August 2007 |
| Charged to | 4,200 psi |
|---|---|
| Size | 12 litres |
| Model | 1205K-DC-694 |
| Max working pressure | 690 bar |
| Assembly number | ATV-4 |
|---|---|
| Nominal ratio | 4:1 |
| Max pressure | 1,200 psi liquid |
| Manufacture | August 2007 |
| Charged to | 2,300 psi |
|---|---|
| Size | 37 litres |
| Model | AC-3703F-CZ-344 |
| Max working pressure | 345 bar |
| Drum capacity | 350 m × 20 way umbilical |
|---|---|
| Connectors | 24 Way Walter stab plate and live center |
| Drive System | 18 HP air motor with SAAR multi disc brakes |
| Brake pull test | @ 1 Ton |
| Reduction mechanism | 60:1 Gearbox |
| Bearing ratings | 14,000 kgf dynamic and 10,000 kgf static load |
| Umbilical length | 300 m |
| Air supply | 120 psi |
| Working pressure | 10,000 psi |
| Dimensions | 300 × 300 × 300 cm |
| Tare weight | 3,400 kg |
| Max gross weight | 10,000 kg |
| Certification | Australian standards Built to Lloyds BS7072/IEE |
| Max volume | 60 cfm |
|---|---|
| Max pressure | 8 bar (120 psi) |
| Dimensions | 1,420 × 1,450 × 1,550 mm |
| Tare weight | 800 kg |
|---|---|
| Payload weight | 4,000 kg |
| Gross weight | 4,800 kg |
| High pressure system | 10,000 psi (690 bar) MWP |
|---|
| Minimum volume | 60 cfm |
|---|---|
| Maximum pressure | 16 bar (232 psi) |
| Dimensions | 1,810 × 1,600 × 1,840 mm |
|---|---|
| Tare weight | 1,500 kg |
| SWL weight | 2,500 kg |
| Gross weight | 4,000 kg |
| Dimensions | 2.9 × 2.84 × 3.15 m |
|---|---|
| Weight | Gross 10,000 kg, Tare 6,000 kg |
| Lifting options | Slings and forklift pockets |
| Spooler access | Open from front and rear, caged restriction from sides and above |
| Power supply | Pneumatic |
| Fitting | 1" Crows foot connection |
| Motor type | Globe RM310 motor |
| Motor RPM maximum | 1,800 rpm |
| Power output | 7.5 kW at 8 bar |
| Max torque at 6 bar | 43 Nm at 1,800 RPM |
| Gearbox type | Brevini EC4090 / MNI / 400 / 00 / B3 |
| Gearbox ratio | 400:1 |
| Drive sprocket | 12B-1 X33T WP |
| Chain size | 3/4" pitch |
| Motor operation pressure | 6 bar |
| Motor max pressure | 8 bar |
| Motor max flow rate | 440 cfm |
| Operational controls | Mechanical pneumatic |
| Unit colour | Proserv yellow / grey |
| Lubricant | Kilfrost 400 |
| Dimensions | 2.9 × 2.89 × 3.27 m |
|---|---|
| Weight | Gross 10,000 kg, Tare 6,000 kg |
| Lifting options | Slings and forklift pockets |
| Power supply | Pneumatic |
| Fitting | 1" Crows foot connection |
| Motor type | Globe RM310 motor |
| Power output | 7.5 kW at 8 bar |
| Max torque at 6 bar | 43 Nm at 1,800 RPM |
| Gearbox type | Brevini EC4090 / MNI / 400 / 00 / B3 |
| Gearbox ratio | 400:1 |
| Drive sprocket | 12B-1 X33T WP |
| Chain size | 3/4" pitch |
| Motor operation pressure | 6 bar |
| Motor max pressure | 8 bar |
| Motor max flow rate | 440 cfm |
| Operational controls | Mechanical / pneumatic |
| Unit colour | Proserv yellow / grey |
| Lubricant | Kilfrost 400 |
| Tare weight | 150 kg |
|---|---|
| SWL weight | 450 kg |
| Gross weight | 12,000 kg |
| Dimensions | 2.70 × 0.88 × 1.30 m |
Subsea Services
Supporting long-term performance and reliability
Core Services
What We Work On
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Obsolescence & Upgrades
People & Expertise
- Gas end valve assemblies
- LP accumulators
- Filter assemblies
The challenge was clear: complete essential maintenance activities without disrupting production. A maintenance strategy and detailed set of procedures were developed to ensure safe and effective delivery.
Our engineering teams’ expertise across both hardware and software ensured effective planning and execution, minimising risk and maximising efficiency while maintaining full production.
With in-house subsea maintenance, factory acceptance testing (FATs), master control station (MCS) upgrades, and over 250 site integration tests successfully completed, Apache gained full confidence that every system was deployment ready.
Topside Controls
Systems and Services
Calibration Services
Facilities & Equipment
Certification & Traceability
Service Options
Proserv manufactured the wellhead control panel (WHCP) that controlled the six original wells for Umm Al Dalkh. The panel had been running reliably and without incident for several years. This fact, coupled with our recent success remanufacturing OEM control panels for the operator in a nearby field, convinced ADNOC of our controls expertise. What’s more, we were able to offer an alternative solution that significantly reduced CAPEX and installation downtime over the alternative. As a result, ADNOC recommended that the contractor engage Proserv for this project.
Rather than scrap and replace the existing Proserv WHCP, which was still performing well, Proserv proposed to supply an additional six slot WHCP with a built-in 12 slot hydraulic power unit (HPU) that could integrate with the existing WHCP to support the operation of the entire 12 wells. By integrating the two Proserv WHCPs with the HPU, the entire WHCP worked as a single panel, simplifying operations and enabling the customer to reduce the components under frequent maintenance.
Pamas s40
To meet the customer's requirements a trial run was conducted at our TCM and Flushing Facility in Nigeria, to establish if two identical pumping units could be coupled in parallel to meet the flow rates required by the client, as none of our current rigs could individually deliver the required level of output flow rate.
Two Harben flushing rigs, each capable of delivering 38L/min (10.03 gal US/min) flow rates, were coupled in parallel through a check valve and flow manifold. A series of gauges and pressure sensors then run, to establish working flow consistency and performance. The results confirmed that the desired flow rate exceeded the client requirement of 60 L/min (15.85 gal US/min) and all within the system’s working pressure limits.
Following this successful trial, Proserv was awarded the contract and the Chevron site team witnessed the flushing. 3 micron filters were used to record fluid cleanliness using the NAS 4.5 spec. This was above the NAS 6 levels required.
Due to the large bore size of the pipe being flushed, flow rates of 90 L/min (170 bar / 23.77 gal US/min @ 2465.64 psi) were achieved on site, all within the specifications requested by the client.
The high flow rates achieved, along with the more efficient 3 micron filters allowed us to record fluid cleanliness levels of NAS 4.5 well above the NAS 6 levels required.
The electronic control panels (WHCP) and RTUs provided the ability to control and monitor the instrumentation and wellhead valves for each well.
Proserv had already supplied our own wellhead control panels to the same field, which were still fully functioning with no reliability issues. As a result, they awarded the contract to Proserv to identify the cause of the failures and repair the OEM panels.
Upon inspection of the tube and fittings used in the high-pressure (HP) header, Proserv discovered that the OEM had used off-the-shelf components. As a result, the fittings were operating too close to the maximum working pressure of the line, causing frequent failure and fatigue. In addition, the fittings were not suitable for the application, undermining the pressure issue, hence why they kept failing.
Proserv replaced the incorrect tube and fittings in the HP (20k psi) rated components. Proserv also installed a pressure intensifier to ensure that the HP and pump discharge header matched the existing components’ pressure rating.
Furthermore, Proserv identified that the installed tubing for the pump discharge header was too small. This was causing the pump start/stop controls to sense a false line pressure and send a stop command to the pump, even before it reached the desired header pressure. Proserv installed the proper tube sizing in the pump discharge header, ensuring that the equipment sensed the correct pressure.
Panel 2 – 38 weeks
Based on this expertise, and our longstanding relationships with Baker Hughes and Aker Solutions, Proserv was awarded a contract for the supply of two remotely operated Intelligent Well Control Panels for new platforms. Ekofisk Z/4 2/4L and Eldfisk 2/7, both operated by ConocoPhillips and situated in Scandinavian waters, North Sea.
Once the sub-assembly of the panels were completed in Dubai, they were shipped to Stavanger for factory acceptance testing (FAT). This process was carried out at Proserv’s facility, with Baker Hughes in attendance, to ensure equipment compatibility and compliance with all contractual specifications.
Baker Intelligent Production Systems
At the Holford gas storage site, each of the eight storage caverns has a dedicated wellhead with associated control equipment, one control panel per cavern. This setup aligns with the facility being designed around eight wells drilled to access the salt caverns. The panels regulate injection and withdrawal of gas, managing valve actuation and flow rates.
The work included mounting, cable routing, functional testing, integration with site SCADA systems, and verification under site-specific operating conditions.
Each year, the team conducts a scheduled planned maintenance routine on the panels to ensure their continued safe and reliable operation.
Each panel undergoes a detailed inspection and servicing routine, which includes:
These outcomes collectively contribute to the Holford facility’s role as one of UK’s most flexible underground gas storage assets, capable of rapid response to daily fluctuations in gas demand.
Flowline pilot calibration
Hydraulic supply fluid sampling
Housekeeping
This structured approach ensures the continued safe and efficient operation of the wellhead control panels, aligning with industry best practices and regulatory standards.
- New Installations & Completions
- Workovers
- Decommissioning activities
- Installation & Completion
- Workover
- Decommissioning
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- Panel installation, retrofits, and upgrades
- System integration testing
- As-built documentation and operator handover
- SBT & control system flushing (up to 3”)
- Rapid deployment of expert field engineers
- Local and remote delivery support
- Upgrades to replace obsolete components
- System redesign and modernisation
- Milton Roy pump repair and reconditioning
- EPC collaboration
- Custom work packs and training materials
- Extended asset life through modernisation
- Reduced risk through proactive diagnostics
- Faster execution through remote and local delivery
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The client was therefore looking for a high function, highly technical, bespoke system that required significant engineering competence and collaboration to effectively develop, all while ensuring the highest standards in reliability and quality, given the critical safety operations it needed to perform.
The bespoke aspects of the DPR system ruled out an OEM solution and, because a DPR is such a safety critical system, our client needed to engage an established, industry-recognised controls expert. Based on our previous track record with the client, combined with our market leading capabilities in the subsea field, Proserv was awarded the contract to supply nine control systems for the DPR project.
The use of a DPR system enables installation and workover on vertical trees in open water without the use of a drilling riser. Annulus services were provided by a 1.5" 10k high collapse resistant core within the umbilical.
Overall project execution, along with engineering and build of the control systems was carried out at Proserv’s subsea controls centre of excellence in Great Yarmouth, with the accompanying hydraulic power units (HPUs) delivered from our manufacturing facility in Malaysia.
The Proserv DPR subsea control module (SCM) operated up to 40 functions on the subsea tree stack up at three separate pressure levels supplied from the umbilical. An automatic disconnect valve and shut-down functionality ensured safe disconnection should the floating drilling unit lose position or the umbilical become severed. Proserv’s specialist dual electronics within the SCM provided redundancy and, with an ROV recoverable SCM, the system was optimised for workover up-time.
This was a completely new system providing Crude Oil Custody Transfer Metering & plant status monitoring.
OGS offices are located in Ely, Cambridgeshire, UK. OGS have their own fabrication facilities (approx. 3900 m2) in Gorseinon, Swansea, UK.
This is then exported via the Ninians Pipeline to the Sullom Voe Terminal in the Shetland Islands. The platform also receives dry gas production from the Sullom Voe Terminal, which is commingled with the export gas from the platform and re-exported into the North Leg Gas Pipeline.
This project replaced the existing fiscal metering system which dated back to the late 1990s & also took in allocation and environmental metering previously handled by the site's aging DCS system. The Export Oil Skid was also modified from turbine meters with bi-directional proving to Coriolis meters with Master Meter proving.
1 x Jet Mix Sampling & Analysis System - Export Oil
Virtual Metering Tech & Dynamic Uncertainty Software
This scope was carried out by Oil & Gas Systems Limited who have more than ten years experience providing bespoke metering systems to the oil & gas industry.
OGS offices are located in Ely, Cambridgeshire, UK. OGS have their own fabrication facilities (approx. 3900 m2) in Gorseinon, Swansea, UK.
This flexibility proved crucial, as the project scope eventually expanded to include an additional flow computer. As a result, we had to redesign the metering system’s control panel after the equipment had already been delivered to site. Rather than pulling the equipment back to our measurement center of excellence in Cumbernauld, Scotland, which would have significantly extended the project and added cost, we designed the modifications remotely. The team then reworked the panel and relocated some of the HMI equipment to an area adjacent to the panel on site, all while the vessel was still docked.
This project further strengthened our relationship with the client and proves again that we can provide an alternative to some of the OEM’s metering control systems.
This new system performs metering calculations that were previously done in the existing SAS system, as well as an extension to the system through a PVT package.
The projects involve EoS modeling of all types of reservoir fluids, including natural gas, gas condensates, near critical fluids, black oils and heavy oils.
This system allows flow meters at various sites around the Rumaila oil field in Iraq to be calibrated without having to be taken to a dedicated facility.
As the system is used at different sites, it had to be designed for use with different sizes of meters, different reference conditions and report in both metric and US customary units.
The site is relatively remote from Proserv’s UK base and therefore provision of support was a key design consideration.
Proof results are displayed / reported in both metric and US customary units at reference conditions of 15°C and 60°F respectively.
Reports are archived on a site basis.
At the Holford gas storage site, each of the eight storage caverns has a dedicated wellhead with associated control equipment, one wellhead control panel per cavern. This aligns with the facility being designed around eight wells drilled to access the salt caverns. The panels regulate injection and withdrawal of gas, managing valve actuation and flow rates.
(Proserv Great Yarmouth)
At the Holford gas storage site, each of the eight storage caverns has a dedicated wellhead with associated control equipment, one wellhead control panel per cavern. This aligns with the facility being designed around eight wells drilled to access the salt caverns. The panels regulate injection and withdrawal of gas, managing valve actuation and flow rates.
Each year, the team conducts a scheduled planned maintenance routine on the panels to ensure their continued safe and reliable operation.
(Proserv Great Yarmouth)
The faulty SCM was returned to Proserv’s Great Yarmouth facility for detailed inspection and root cause analysis.
- Gas end valve assemblies
- LP accumulators
- Filter assemblies
To safeguard ongoing performance and reliability, Proserv was engaged to carry out a Preventative Maintenance Review (PMR) under live operating conditions. The challenge was clear: complete all essential maintenance activities without disrupting production. A tailored maintenance strategy and detailed procedures were developed to ensure safe and effective delivery.
Our engineering team’s expertise across both hardware and software ensured effective planning and execution, minimising risk and maximising efficiency while maintaining full production.
Over many years, Proserv’s Great Yarmouth facility has become a long-standing engineering and equipment partner to Apache in the North Sea. Together, they’ve delivered subsea control solutions that support maintenance and life extension of Apache’s offshore assets. While recent activity has slowed due to wider UK sector developments, the partnership remains grounded in trust, performance, and shared commitment to long-term reliability.
With in-house subsea maintenance, factory acceptance testing (FATs), master control station (MCS) upgrades, and over 20 site integration tests successfully completed, Apache gained full confidence that every system was deployment-ready.
