Customer Challenge

Surface Hydraulic System and Well Control Module (WCM)


A major oil field services company required a custom design Surface Hydraulic System (SHS) and Well Control Module (WCM) for offshore rig with ease of transportation and space constraints complying to ATEX zone-1 rating requirements (explosion proof). 


  • Design
  • Single Surface Hydraulic System with a footprint of 43.5 X 43.14 X 30 Inch, ATEX zone-1 rating compliant
  • Well control module meeting NEMA-4X requirements with a footprint of (31.25” X 24.6” X 28.5”) and 5 and 6 zone controllable WCM


  • Concept to production release design of single source SHS and 5 & 6 line WCM meeting footprint requirements with maintenance access
  • Design compliant to National Electrical Manufacturers Association (NEMA-4X) rating
  • Optimized SHS cabinet volume by mounting bladder accumulator outside the cabinet
  • Lower cost and volume junction box - E model instead of D model (explosion proof) by moving all spark able components to control room and connecting them with armored cable



  • New SHS design compatible for both 5 and 6 zone WCM
  • Alternate lifting with Fork lift provided for SHS
  • Externally mounted 2.5 gallon accumulator for space saving
  • Access doors provided for ease of maintenance


  • Reduced volume and material cost ($1,000 per unit of SHS) by having the accumulator outside the cabinet and utilize the space above it for tubing and cables


  • Design optimization resulted in saving of $1,000 per unit of SHS. Total saving $7000 (7 units)
  • Changing Junction box to Ex (e) from Ex (d) led to save $1,000 per well control module. Total saving $ 22,000 (22 units)