Lifecycle Extension and Modernization of Subsea Electronics Systems

The client faces significant technical challenges due to aging electronics modules within their subsea systems, including obsolete hardware components and undocumented legacy communication protocols. These issues threaten system reliability and increase operational risks, necessitating modernization without complete redesign. Specific problems include the migration from outdated microcontroller architectures, handling component obsolescence, and reverse engineering legacy communication hardware to ensure continued functionality.

A large-scale oil and gas company specializing in subsea production systems seeking to upgrade aging electronics to extend operational lifespan.

• Enable software migration from legacy 16-bit microcontrollers to modern 32-bit ARM Cortex architecture, ensuring compatibility and future-proofing.
• Identify and source replacement components that meet long-term durability and performance requirements to prevent obsolescence risks.
• Reverse engineer undocumented legacy communication hardware and port core functions to modern FPGA platforms for seamless communication continuity.
• Migrate HDL code from older CPLD platforms to contemporary FPGA architectures while maintaining protocol integrity.
• Extend the operational lifespan of subsea electronics modules to support ongoing and future deployments without full system redesign.
• Achieve system reliability and reduce maintenance/risks associated with aging hardware and undocumented subsystems.

• Migration of control software to support new 32-bit ARM Cortex processors, with library reuse and modification as needed.
• Component sourcing strategy to replace obsolete parts with long-term durable alternatives.
• Reverse engineering of legacy communication chips to recreate core functionality on FPGA platforms.
• HDL code migration from CPLD to FPGA, supporting existing communication protocols and functions.
• Integration of FPGA-based communication modules with existing systems ensuring seamless interoperability.
• Obsolescence management planning for sustainable hardware lifecycle support.

• Legacy communication protocols for seamless system compatibility
• Hardware components and libraries for obsolescence management
• Testing and simulation tools for HDL and software validation

• System reliability exceeding 99.9% uptime in subsea conditions
• Hardware longevity targeting at least 10-15 years lifespan
• Real-time communication support with minimal latency
• Robustness against environmental stresses such as pressure, temperature, and corrosion
• Security measures to safeguard communication and control modules from cyber threats

The project aims to extend the operational lifespan of critical subsea electronics modules, enabling ongoing deployment without comprehensive redesign. Expected outcomes include reducing obsolescence-related risks, ensuring higher system reliability, and supporting long-term operational sustainability. This approach will provide the client with a resilient, modern platform capable of supporting future subsea system expansions, thereby minimizing downtime and maintenance costs across an estimated 10-15 year life cycle.