Fully Integrated Subsea Valves and Motion Control System for a South American Mining Project

CHALLENGE:

The project required a fully integrated subsea valve system capable of handling compressed air passage under the sea while meeting demanding operational, environmental, and safety requirements. The system had to operate reliably 365 meters offshore and 25 meters below sea level, in a seismic area, with precise control, fast response, and multiple operational modes. The client also required full integration with their onshore control room, ensuring safe and redundant operation under extreme conditions.

SOLUTION:

AMPO POYAM VALVES delivered a complete Integrated Smart Solution (ISS) designed, manufactured, assembled, and tested in Idiazabal. The system included:

• Final Elements:Six highly engineered subsea ball valves installed 365 meters from the shore and 25 meters below sea level, operated by hydraulic actuators.
• SUTU (Subsea Umbilical Termination Unit) and Subsea Connector:Ensures subsea electrical interconnections.
• Umbilicals:Two 365-meter-long subsea connections of hydraulic lines and electrical cables linking the final elements with the HPU and control panel.
• JB (Junction Boxes):Onshore units for electrical and hydraulic interconnections.
• HPU (Hydraulic Power Unit):Powers the valve actuators with a redundant system of two motor pumps and two accumulators, designed to operate the valves within six seconds.
• Redundant Control System (RCS):Monitors oil volume, pressure, temperature, motor start/stop, and electrovalves controlling the hydraulic actuators. Fully integrated with the client’s control room via TCP/IP, it enables remote operation of the subsea valves.

Installed in a seismic area, the system’s HPU, control panel, and supporting structures were reinforced with a specially designed structure to ensure safe and reliable operation under extreme conditions.

The system offers three operation modes: remote control from the client’s control room, local control panel operation, and manual mode.

This achievement highlights AMPO’s expertise in delivering customized ISS solutions, truly a place where intelligence meets valves.