Embedded, Hardware, Software
Oil & Gas
UK

Mid-life Upgrade for SEM Electronics Modules

Confirming the longevity of subsea systems

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About the client

Our client, a global leader in the oil and gas industry, operates in subsea production systems. As part of their efforts to extend the operational lifespan of their electronics modules for SEM. Both of these components are critical for ensuring reliable communication and control in challenging subsea environments.

Business challenge

The Client faced several interconnected technical challenges for both the Controller Card and Communication Card projects:

Controller Card:

- Software Porting: The primary challenge was migrating software from an obsolete 16-bit microcontroller to a modern advanced 32-bit ARM Cortex architecture. The migration process required a thorough analysis to identify differences between the two platforms and assess which code libraries could be reused or needed modification.

- Obsolescence Removal: Many components were no longer in production, which necessitated identifying replacements that would meet the new system’s lifetime and performance requirements.

- System Functionality: The upgraded components needed to replicate the original system’s functionality within a modern, reliable hardware framework.
Communication Card (Legacy Copper Modem):

- Reverse Engineering: One of the key challenges was the absence of source code or documentation for a communication chip used in the system. This required reverse engineering of the chip’s functionality and its porting to a modern FPGA-based design.
- HDL Porting: Another challenge involved migrating HDL code from the outdated CPLD platform to a new FPGA platform, while ensuring seamless communication compatibility.

Team composition

Electronics Design Engineer
Embedded Software Developer
Hardware (FPGA/PLD) Engineer
QA Engineer

Our solution

Controller Card:
- Software Migration: Our team performed an in-depth software analysis to evaluate the differences between the legacy 16-bit microcontroller and the 32-bit ARM Cortex architecture. We were able to streamline the migration process by identifying and reusing compatible libraries and adjusting necessary areas to support the new hardware.

- Component Replacement and Obsolescence Management: We sourced new components that met the client’s lifetime and performance requirements, ensuring that the system could continue to operate without risk of future obsolescence.
Communication Card (Legacy Copper Modem):
- Reverse Engineering: Due to the lack of documentation, our engineers reverse-engineered the existing communication chip. By carefully analyzing its performance, we recreated the core functionalities on a modern FPGA platform, ensuring seamless communication compatibility.

- HDL Migration: The HDL code was successfully migrated from the CPLD platform to FPGA, maintaining the necessary communication protocols and ensuring the system’s continued functionality.

Technologies used in this project

Controller Card Project:
- Altium Designer, LTSpice, C/C++, ARM Cortex M4
- Xilinx PLD/FPGA, Infineon XMC Microcontrollers
- AVCOM, Silicon Expert, FMECA
Communication Card Project:
- Altium Designer, LTSpice, HDL (ABEL, VHDL, Verilog)
- Xilinx PLD/FPGA, Analogue Circuits
- AVCOM, Silicon Expert, FMECA

How about repeating the /success/ of our clients?

Value we added

Both projects enabled the client to extend the life of their subsea systems without resorting to a complete system redesign.

For the Controller Card Project, the successful migration of software and hardware allowed the client to continue using their existing hardware while ensuring that the system could meet the operational demands of future deployments. The obsolescence management effort provided long-term sustainability.
For the Communication Card Project, reverse engineering and HDL migration ensured that the client could maintain the legacy modem’s functionality on modern hardware, reducing the risks associated with aging technology and missing documentation.

Overall, both projects provided the client with insights into future technical requirements, enabling them to plan for the next stages of system development, including risk management and technical resource estimation.

Future perspective

Through these upgrades, the client was able to assess and mitigate future development risks, ensuring the longevity of their subsea systems. The improvements made in both projects provide the foundation for long-term operational reliability in subsea environments. The successful execution of these projects also sets the stage for continued collaboration and future enhancements in the client’s subsea systems, as the industry continues to evolve.