Introduction to Subsea Production System_Rev P1

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Subsea Production SystemsPresented by: Mohd Zaini Kadir – Product Project ManagerEmail: [email protected] February 2012

Subsea Field Developments

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Content1. Part II: Subsea Production System

Subsea Control Systems

Flowline Connection

Systems (Tie-In System)

Manifold StructureXmas Trees Systems

Steel TubeUmbilical

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Field Architecture

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What is Subsea?

Definition: The ability to

produce hydrocarbon

f i l t dfrom reserviors located

under water without the

well being directly

connected by a riser to

the host facility.

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Why Subsea ?The water depth may be too great to use a surface well platform.

FixedPlatform

(500 m)

Compliant Tower(900 m)

Mini - TLP(1100 m)(1100 m)

Floating ProductionSystems(FPSO, FPS)(2300 m)

TensionLeg Platform(TLP) (1370 m) SPAR

(2300 m) SubseaSystems(3000 m)

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Why Subsea ?Full Field Life economics;

Development CAPEX for a platform may not pas economic hurdles

S b i ll l h Pl fSubsea options normally lower than a Platform.

Subsea generally will give earlier first gas or first oil hence better returns.

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Why Subsea ?Improved HSE performance:

Removes people from offshore, potential to reduce visual and environmental impact.

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Why Subsea ?

Deviated drilling from surface well may not be able to reach the entire reservoir. – Reservoir area are too large and shallow.g

May required multiple host facilities.

Uncertainty over numbers of well to complete the reservoir development.

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Subsea Xmas Tree

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Interface Considerations

Four interfaces govern tree design

• The Well– Tubing Size, Pressure,

Temperature, Material ClassThe Well

• Controls– Direct, Piloted, E-H, Different

Vendors

• Flowlines– Pipeline Size, Pressure,

Connection Type, Different Vendors Wellhead

Flowline Connection

•Pressure

•Flow Rates

•Fluid PropertiesControls

The Well

S• The Wellhead

– Mudline, Clamp Hub, Mandrel, Different Vendors

•Mudline vs. Subsea

•External Profile & Gasket

•Casing Strings & where are they

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PSVXOV

PWVASV

INTERNAL TREE CAP

CROWN PLUG

TREE CAP TEST / VENT

Subsea Tree Types VXT V’s HXTSubsea Xmas Tree

PWV

AWV

PRODUCTION OUTLETANNULUS / SERVICEOUTLET

ASV

DHSV

AMV

VX TEST

PMV

DHSV

PMV PWV

VX TEST

PAAV

AMV

AWV

ANNULUS / SERVICEOUTLET

PRODUCTIONOUTLET

WELLHEAD SYSTEM

SUBSEA TREE ASSEMBLY

XOV

TREE CAP TEST / VENT

P

CONVENTIONAL SUBSEA TREE HORIZONTAL SUBSEA TREEVERTICAL SUBSEA TREE

Typical HXT with FCM (Roof is withdrawn) (Statoil)

Guideline-less VXT with Insert Technology (Girassol)

Subsea Xmas Tree

Vertical Tree Horizontal Tree

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Xmas Tree Functions:• Safety barrier

• Safely stop produced or injected fluid

Subsea Xmas Tree

• Injection of chemicals to well or flowline

• Allow for control of downholevalves

• Allow for electrical signals to downhole gauges

• To bleed of excessive pressureTo bleed of excessive pressure from annulus

• Regulate fluid flow through a choke (not mandatory)

• Allow for well intervention Xmas Tree

PSVXOV

PWV

AWV

ASV

XT Schematic

PMV Production Master Valve

PWV Production Wing Valve

AMV A l M t V l

Subsea Xmas Tree

PRODUCTION OUTLETANNULUS / SERVICEOUTLET

DHSV

AMV

VX TEST

PMV

AMV Annulus Master Valve

AWV Annulus Wing Valve

ASV Annulus Swab Valve

XOV Cross Over Valve

SCSSV Surface Controlled Subsurface Safety Valve

PTT Pressure/Temperature T ittTransmitter

SCSSV

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SUBSEA CONTROL MODULETREE CAP PARKING

RECEPTACLE

Subsea Xmas Tree

ANNULUS WING VALVE

ANNULUS CROSSOVER VALVE

ANNULUS SWAB

FLOWLINE CONNECTOR

PRODUCTION SHUT DOWN VALVE

ANNULUS MASTER VALVE CONNECTOR /

SCSSV ROV PANEL

SWAB VALVE

Subsea Xmas Tree

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Subsea Manifold (PLEM / PLET)

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• The primary function of a subsea manifold is to “channel” flowsfrom several individual wells into single or multiple flowlineheaders.

Subsea Manifold

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Subsea Manifold

Manifold Introduction

Definition: Subsea Production Manifold

A subsea structure containing valves and pipework designed toA subsea structure containing valves and pipework designed to combine the fluids of one or more subsea production Christmas trees and to direct the fluids down one or more export flow lines.

Definition: Subsea Injection Manifold

A subsea structure containing valves and pipework designed toA subsea structure containing valves and pipework designed to distribute injection fluids from one or more injection flow lines to one or more subsea injection Christmas trees. Injection fluids may be water, natural gas or both.

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Subsea Manifold

General Design Features

• Subsea installable and often subsea retrievable as well.

• Pipework rated to the full shut-in temperature and pressure of the• Pipework rated to the full shut-in temperature and pressure of the subsea Xmass trees.

• ROV accessible for all subsea operations.

• Compatible with any subsea control system.

• Interface with foundation structure.

• Housed connection equipment. (Tie-in system)

• Gas lift for low-pressure or deep subsea development.

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Manifold Types

Template Manifold – a drill-through structure designed to house multiple subsea christmas trees.

Subsea Manifold

Cluster Manifold – a stand-alone structure designed to direct fluids for multiple subsea Christmas trees placed around it.

Pipeline End Manifold (PLEM) – a simpler version of a cluster manifold generally designed to direct fluids for only or two subsea Christmas trees. A PLEM generally connects directly to a subsea fl li ith t th f i li d t i ti (PLET)flow line without the use of a pipeline end termination (PLET).

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Subsea Manifold

Template Manifold

Features• Complex and very heavy p y y

structure.• No well jumpers required• Cost effective.• Suitable for specific field

requirements.• Horizontal connections.• Tree drilled only on

t l ttemplate.

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Subsea Manifold

Cluster Manifold

Features• Simple and relatively light p y g

structure. • Easy in installation .• Cost effective.• Horizontal or vertical

connections.• Trees drilled at distance.

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Subsea Manifold

Cluster Manifold – Azurite (Congo)

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What is PLET?• PLET is used as termination points for the flowline.• When the length of the flowline is large, thermal expansion in it can lead tobending and buckling failure.

Subsea Pipeline End Termination /Manifold (PLET / PLEM)

• PLET is meant to accommodate the Thermal Expansion in the flowline.What is a PLEM?• PLEM is an extended version of PLET.• It posses all the features of PLET but with more number of hubs (more thanone) for various purposes, like- more than one Well Jumper connection, orWater injection.

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PLETPLEM

Subsea Pipeline End Termination (PLET)

PLET

ManifoldFlowline

Jumpers

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Subsea Manifold - Components

Majors components: 1. Structure Frame2. Piping System

Control System

p g y3. Connection System4. Leveling System5. Control System

Piping System

Structure Frame

Leveling System

Piping System

Connection

System

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Manifold Structure Frame

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Branch Valve Cluster

Internal Structure of Manifold: Piping System


Small-bore envelope

Connection System

Header

Branch

Manifold Structure Consists of Valve, Small and Large Bore piping.

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Connection System


Universal Tie-in System ROVCON STABCONUniversal Tie-in SystemUTIS

ROVCON STABCON

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Manifold

Leveling System


Vent./suction hatch

Suction anchor

Mono-post

Funnel-down

Suction anchor

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Control System

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Subsea Control Module (SCM)- Controls Actuated Valves- Gather data from sensors (PT, PP/TT, APD, ASD, etc.)

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Deployment Methods

Vessels

Drill Rig : Through moon pool or keel-hauled on drill string.

Subsea Manifold/PLEM

Heavy Lift vessels (Derrick Barges): Through moon pool or over side

Work-class vessels: over side on crane or winch.

Equipment

Manifold hydraulic installation tool.

Sli t ith i th ti fibSling sets, either wire rope or synthetic fiber.

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Manifold Installation Lift Offshore


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Moon Pool Deployment


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Work Vessel Deployment


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Foundation Types

Mud Mats – A simple foundation resting directly on the seabed, generally with a short skirt around the perimeter to resist lateral loads.

Subsea Foundation

Piles – long cylindrical structure embedded into the soil intended to hold a subsea structure above the seabed. Foundation may utilize one or more individual piles.

Jetted Piles

Suction Piles / Anchors

Intermediate Structure – an intermediate structure can be used to interface a subsea manifold with a pile foundation to reduce weight on the manifold structure or to ease retrieval on the manifold. Intermediate structures can be either retrievable or permanent structures.

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Types of Foundation: Mudmat

Subsea Foundation – Mudmat

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Design Codes:• API RP 2A WSD (geotechnicaland structure)• AISC

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• Suction pile is a Manifold foundation. It penetrates the soil under its own weight

Suction piles / anchors

Subsea Foundation – Suction Anchor

and due to the subsea head.

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Installation-Subsea Foundation – Suction Anchor

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Manufacturing: • Material: Carbon Steel

• Corrosion Protection:

• Coating & Cathodic Protection (at top)

Subsea Foundation – Suction Anchor

(at top)

• Under Mud Line (rest of the body)

4141


OvertrawlableStructure

• Dual 20” headers 45 33 14

• Dual 20” headers 45 33 14• 45m x 33m x 14m

• 657 metric tonnes• 45m x 33m x 14m• 657 metric tonnes Suction Piles

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Subsea Connection System & Jumper

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Equipment found in a typical subsea field:

Trees

Subsea Connection System

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Introduction

Definition: Flowline tie-in – Connection of a flowline to a subsea facility.


This includes connection to any of the following subsea facilities; Trees, Manifolds, PLET and PLEM.

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Jumper Functionality

Connect flowlines to manifolds and manifolds to trees

Contain rated working pressures.

A d t th l i t ti d i li t


Accommodates thermal expansion, contraction and misalignment.

Insulated for hydrate prevention

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Flowline Jumpers (Connects Manifold, PLET, PLEM, SLED)

Well Jumpers (Connects Tree to Manifold)Types

(According to use)

Subsea Jumper

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Flowline Jumper Well Jumper

Note: Flowline Jumpers are rounded at corners for pigging

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WellJumpers

FlowlineJumper

Subsea Well and Flowline Jumper Connections

Jumper being lowered subsea with connectors on either side

Sled/Manifold

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Jumper ConnectorsReasoning behind the various

connection systems:

C diff t ti i th d f

Subsea Jumper

– Cover different tie-in methods from shallow to ultra-deep waters

– Be applicable from flexible pipe to rigid steel pipe

– Be suited for seabed conditions from hard to very soft soil

– Driven by cost factors/functionality

MAX MechanicalCollet Connector

(Vertical)

Torus Hydraulic Connector(Vertical)

– Allow for independent installation order of subsea stations and flowlines

– Be adaptable to the preferences of different Installation Contractors and Oil Companies

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KC4 ColletConnector

Single or Twin Screw

Clamp Connector

Vertical or Horizontal

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Vertical Jumper Spool deployment

Steps of jumper deployment

Jumper on Shipping Stands Lifting & Lowering Jumper Offshore or Quayside

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Land First End on PLET (or Tree) Land Second End on Manifold

Steps of jumper deployment (cont’d)


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Retrieve Spreader Bar Remove Hub Protection Cap



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Lock & Test Connector Retrieve CAT



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Connector Actuation Tool (CAT)

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Subsea Control System

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What does a Control System Do?

Typical Subsea devices connected to the system

Down Hole Gauges


Multiphase & Wet Gas Flow Meters

Venturi Flow meters

Sand Detectors

Hydrocarbon Leak Detectors

Ch i l i j ti lChemical injection valves

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What does a Control System Do?

Subsea items Controlled by the system

Low pressure Valves ( tree, manifold)


High Pressure Valves (downhole safety valves)

Chokes

Chemical Metering Valves

Subsea items Monitored by the system

Temperature

Pressure

Choke Position

Flow rates Oil & Gas & Multiphase

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1. Direct Hydraulic System

2. Direct Piloted Hydraulic System

3 Direct Electro Piloted Hydraulic System

Subsea Control – Control System Types

3. Direct Electro Piloted Hydraulic System

4.4. Mini Multiplex Electro Hydraulic ControlsMini Multiplex Electro Hydraulic Controls

5. Multiplexed Electro Hydraulic System

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Simple and Reliable

Low Control System Equipment Cost

Standardized Field Proven Equipment

1. Direct Hydraulic Control System

q p

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2. Direct Piloted Hydraulic Control SystemSimple and reliable

Economical system for extending offset distances for Direct Hydraulic Systems

Standardized field proven equipment

Faster response rate than Direct Hydraulic system.

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Simple and reliable

Instantaneous Venting of Underwater Safety Valve at the Xmas Tree with minimal Control System equipment costs

Faster response rate than Piloted Hydraulic

3. Direct Electro Piloted Control System

Faster response rate than Piloted Hydraulic

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4. Direct Electro Piloted Control SystemInstantaneous Hydraulic Venting an Actuation

Increased Instrumentation Capabilities

Modular Design

ROV Retrievable SCM with Running Tools

SUBSEACONTROL

UNITMINI-SEM

POWER ON COMMUNICATION

PRESSURESENSOR

TEMPSENSOR

Mini-SCM

PLATFORM UMBILICAL TREE

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5. Multiplex Electro Hydraulic Control

Dual Redundant Electronics

Increased Instrumentation Capabilities

Modular Design

ROV Retrievable SCM with Running Tools

Instantaneous HydraulicInstantaneous Hydraulic Venting an actuator

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Electro Hydraulic Control System

Chemical Injection

Control System

TUTA - Topside Umbilical Termination Assy

SDU - Subsea Distribution Unit

EFL Electrical Flying Lead

TUTA

SDU Manifold

Umbilical

Hydraulic Power Unit

(HPU)Master Control Station (MCS)

Electrical Power

Unit (EPU)

EFL – Electrical Flying Lead

HFL – Hydraulic Flying Lead

HPUTree Tree

EFL / HFL

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Injection

HydraulicPower unit (HPU)

Electro Hydraulic Control SystemMasterControlStation (MCS)

SubseaInjectionChemicals

XmasTree

ElectricCables

Umbilical

H d li d SCM

ElectricPower Unit (EPU)

SubseaDistributionUnit (SDU)

HydraulicActuatorsUmbilical

Cross Section

Hydraulic and Chemical Lines

SCM

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Subsea Umbilical

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Subsea Umbilical

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Subsea Umbilical

What is Control Umbilical?

Connection between the topside and communication

i t d th bequipment and the subsea control system.

Hydraulic power and control lines are individual hoses or tubes manufactured from steel or thermoplastic materials and encased in the

bili l b dlumbilical bundle

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Subsea Umbilical

Thermoplastic Hose Umbilical

• Various hose bore sizes (1/4”- 2 ½” ID) and hose working pressures (3k – 15K PSI) are available to provide a field proven, cost effective solution for

b fi ld li tisubsea field applications.

Steel Tube Umbilical

• Umbilical containing steel tubes for conveyance of hydraulic control fluid, injected chemicals and high pressure subsea tie-back application. Various types of tube materials are available ranging from coated carbon steel 316L stainless steel and super duplex.

Hybrid Umbilical

• Hybrid umbilical containing a combination of steel tubes for methanol or chemical injection, and thermoplastic hoses for hydraulic fluid supply. Integrated Umbilical containing electrical cables, steel tubes and/or thermoplastic hoses are also available for dynamics applications.

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Subsea Umbilical – Umbilical Termination Assembly.

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Subsea Umbilical – Umbilical Termination Assembly.

The deployed umbilical must have a distribution point, commonly called an Umbilical Termination Assembly (UTA) for distribution to more than one Xmas Tree or Manifold.

HydraulicDistributionUnit (HDU)

ElectricalDistributionUnit (EDU)

Umbilical Termination Head (UTH)

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Mudmat

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Subsea Umbilical

Umbilical can range from 2.5 km on spooling reels up to 50Km for production umbilical.

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Subsea Field Architectures

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Field ArchitecturesSatellites – Well off by itself.

Daisy Chain – Wells linked together in series.

Subsea Field Architecture

Integrated Template – Wells drilled thru manifold structure.

Cluster – A group wells surrounding manifold.

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1. Satellite Wells

XMT #1XMT #2

XMT #3

Subsea wells installed individually on the seabed, with dedicated flowlines back to a surface processing facility.Advantages:


#3

XMT #4

Advantages:Flexible“Pay as you go”Field proven technologyExpandable

Disadvantages:Dedicated flowlines/ Umbilicals

Platform

Dedicated flowlines/ Umbilicals.Complex flowline hook-upComplex controls distribution.

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Development of satellite fields

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2. Daisy Chain Wells

XMT#1

Subsea wells installed separately and linked to an adjacent subsea well, possibly sharing a test flowline.Advantages:


XMT#2XMT#3

Similar to satellitesFlexibleExpandablePossibly fewer flowlines than for satellites

Disadvantages:

Platform

Complex controls distributionFlowline needed for each wellDeviated drilling may be needed.

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2. Daisy Chain Wells


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3. Integrated Templates

nifo

ld

XMT#

2

XMT#

13 4

Subsea wells installed on a pre-positioned drilling template on the seabed. Each well having a dedicated flowline to surface.


Man

XMT#

3

XMT#

4 Advantages:

Common datum for wells.

Flowline porch for multiple connections.

Manifold can be added later.

Disadvantages:

Dedicated flowlines / Umbilicals may be

Platform

Dedicated flowlines / Umbilicals may be used.

Limited slots available.

Pre-production investment in template necessary.

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3. Integrated Templates


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XMT#1

XMT#3

4. Cluster Manifold Subsea satellites wells installed individually linked to a central manifold where production is commingled.

Advantages:


XMT#2

Manifold

Flexibility of satellites.

Fewer flowlines.

Centralized controls system.

Advantageous for dropped object avoidance.

Disadvantages:

Platform

Complex flowline connection.

Limited “Slots” for production tie-in.

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4. Cluster Manifolds


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Questions???

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Introduction to Subsea Production System_Rev P1

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