Subsea Hydraulic Manifold System
Subco designed three bespoke hydraulic manifolds for a subsea system while the client's own engineers were stretched across other projects. Acting as an extension of their team, we delivered the subsea valve bank assemblies, pressure-compensated stainless-steel housings for water depths up to 50m, and the drawings and commissioning documentation needed for manufacture, assembly and commissioning, on schedule.
Subsea Hydraulic Manifold System
Subco Engineering were engaged to design three hydraulic manifolds for a subsea system at a time when internal engineering resources were stretched across multiple projects. Acting as an extension of the client's engineering team, Subco delivered the detailed design of subsea valve bank assemblies and pressure-compensated subsea housings, together with the documentation required for manufacture, assembly and commissioning.
Overview
The subsea system required three bespoke hydraulic manifolds with different functional requirements.
To support subsea deployment, the valve banks required robust pressure-compensated housings capable of protecting sensitive hydraulic and electrical components from seawater exposure whilst maintaining reliable operation during deployment and service.
Subco delivered the complete mechanical and hydraulic design package, including manifold layouts, subsea enclosure designs, manufacturing drawings and commissioning documentation.
The Challenge
The project combined offshore hydraulic manifold design with subsea equipment engineering, requiring solutions that balanced functionality, manufacturability and environmental protection. Key challenges included:
- Designing three bespoke manifolds with different operating requirements.
- Developing pressure-compensated stainless-steel housings capable of protecting subsea equipment in water depths up to 50m.
- Optimising the housing design to withstand external pressure whilst remaining practical and cost-effective to manufacture.
- Integrating hydraulic and electrical interfaces within compact subsea assemblies.
- Producing a complete documentation package that would allow the client to procure components, manufacture the equipment and commission the final system with confidence.
Our Approach
Subco worked closely with the client throughout the design process to develop the manifold layouts and subsea enclosures in parallel.
For the subsea valve banks, pressure-compensated housings were designed from stainless steel to minimise differential pressure loading whilst providing protection against corrosion and seawater ingress.
The hydraulic manifolds were developed to integrate cartridge valves, filtration and instrumentation into compact assemblies while maintaining serviceability and ease of manufacture. Particular attention was given to routing, maintenance access and lifting considerations, helping ensure the equipment could be assembled, installed and maintained efficiently.
In addition to the mechanical design work, Subco generated the commissioning documentation required for the subsea systems, providing a complete engineering solution rather than standalone design drawings.
Deliverables
Subco delivered:
- Manifold designs.
- Subsea manifold designs forming independent valve banks.
- Pressure-compensated subsea housing designs.
- Assembly drawings for all manifolds.
- Manufacturing and fabrication drawings for the subsea housings.
- Commissioning documentation.
Outcome
The project was delivered on schedule, providing the client with a complete engineering package to support procurement, manufacture, assembly and commissioning of the subsea system. The final deliverables included manifold designs, subsea housing assemblies and a comprehensive documentation package.
Beyond the technical solution, the project demonstrated the value of Subco's flexible engineering support model. During a particularly busy period for the client, Subco was able to provide additional engineering resource and specialist subsea design expertise, allowing critical development work to progress without impacting the client's internal workload.
This is exactly where Subco adds value for its customers. Whether delivering complete equipment designs or supplementing existing engineering teams, we provide scalable engineering capability that helps clients maintain momentum, meet project deadlines and focus their internal resources where they are needed most.
Image: illustrative stock image from the HydroMan hydraulic manifold design software, not the manifolds designed on this project.
Sector:
Frequently Asked Questions
What did Subco design for this subsea system?
Three bespoke hydraulic manifolds forming independent subsea valve banks, the pressure-compensated stainless-steel housings that protect them, and the assembly drawings, manufacturing and fabrication drawings and commissioning documentation needed to build and commission the system.
Why use pressure-compensated housings for subsea valve banks?
Pressure compensation minimises the differential pressure across the housing, so the enclosure does not have to resist the full external water pressure. Built from stainless steel, the housings also protect the hydraulic and electrical components inside from corrosion and seawater ingress.
What water depth were the subsea housings designed for?
The pressure-compensated stainless-steel housings were designed to protect the subsea equipment in water depths up to 50m, while staying practical and cost-effective to manufacture.
What went into the hydraulic manifold design?
Each manifold integrates cartridge valves, filtration and instrumentation into a compact assembly. We paid particular attention to routing, maintenance access and lifting, so the equipment can be assembled, installed and maintained efficiently.
Can Subco provide commissioning documentation as well as design drawings?
Yes. On this project we produced the commissioning documentation for the subsea systems alongside the mechanical and hydraulic design, giving the client a complete engineering package rather than standalone drawings.
Can Subco support an engineering team that is already stretched?
Yes. Here we acted as an extension of the client's engineering team during a busy period, providing extra engineering resource and specialist subsea design expertise so critical development work could progress without adding to their internal workload.