2/27/2014

Subsea Field Development - Challenges and Solutions

for Tie-In and Connection Systems
Session: Focus on Technology
Subsea Australasia Conference
19-21 February 2014
Zahid Hasan
AOG 2014
Outline
Subsea Field Development- Introduction, Top Down Approach
and Options
Tie-In and Connections Systems- Introduction and Options
Comparison and Selection of Tie-In and Connection Systems
Field Development with alternate Tie-In and Connection
systems
Available Connection Systems (New Generation )
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AOG 2014
Subsea Field Development
Custom configuration of Subsea equipment
providing a variety of system designs
Develop field architecture
Well design and placement
Host facilities and specification
Configuration and routing of flowlines, umbilicals
and risers
Installation Options
Reduce risk with credible and proven solutions
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AOG 2014
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Reservoir
& Field
System Solution
Sub-system solution
Available Products
The proposed system solution will
be based on
Technical decision factors,
Location and Geographical
condition
Regulatory and political factors
Operators preference
Contractors preference
Individual suppliers preferences
Available products and
competence
Subsea Field Development- Top Down Approach
AOG 2014
Subsea Field Development Top Down Approach
Level Main Factors Tie-in & Connection topics
Reservoir, Field,
location +
Government and
Company
requirements (=
Design Basis)
Reservoir parameters (pressure, temperatures,
gas/oil, size, water depth, well locations etc)
Process requirements
Geographic location/Environmental conditions
Availability of vessels in region
Connection parts qualified for parameters
Connection system meets installation and
operational requirements
Can be used/maintained from small vessels
in remote locations
System Solution Flow assurance philosophy
Hydraulic and injection distribution philosophy
Pigging/commissioning requirements
Retrieval of modules without pulling
jumpers/spools
Injection volumes, thermal insulation
Multibore vs Monobore System
Subsea Parking of jumpers/spools for
module
Pre-installation and/or batch setting of
jumpers/spools.
Sub-system
solution
Horizontal and/or vertical System
Simple, complex tooling or hydraulic connectors
Guiding, installation requirements
External forces (installation and operation)
Rigid- and/or flexible lines and umbilicals
Qualified and preferably field proven
solutions
Injection and/or hydraulic distribution
through connectors
Swivel functionality to handle torsion in
flexible lines
Available Products Sizes and capabilities (pressure, temp, capacity,
insulation etc)
Qualification requirements, track record
Installation vessel, methods and procedures
Commissioning requirements
Contingency operations
Qualified and preferably field proven System
Handling, installation, guiding
Connectors, seals, caps, tools
Procedures
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Typical Subsea Field Developments Options
Satellite Tieback
Cluster Manifold
Cluster Manifold with
Satellite Tieback
Mixture of Manifold
Cluster and
remote/inline tiebacks
Daisy Chained
Tieback
Integrated Template/Manifold
AOG 2014
Outline
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Subsea Field Development- Introduction, Top Down Approach
and Options
Tie-In and Connections Systems- Introduction and Options
Comparison and Selection of Tie-In and Connection Systems
Field Development with alternate Tie-In and Connection
systems
Available Connection Systems (New Generation )
AOG 2014
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What is a Tie-In and Connection System
In reference to Oil and Gas Industry the connection
system:
Joins two pieces of equipment (e.g. tree to wellhead,
jumper to hub, etc.)
Prevent fluid leakage to the environment
Establish and maintain a seal on a gasket
Withstand external loading (internal pressure,
bending, tension, torsion)
AOG 2014
Tie-in and Connection System Options
Orientation Application Connector type/actuation
Horizontal Pipe sizes
Non insulated
Insulated
Mono-bore
Multi-bore
Mechanical w/large tool
Mechanical w/small tools
Hydraulic w/contingency
Vertical Pipe sizes
Non insulated
Insulated
Mono-bore
Multi-bore
Mechanical w/large tool
Mechanical w/small tools
Hydraulic w/contingency
Small-bore Injection lines ROV installation, FLOT +
Torque tool or hydraulic
Flying leads Hydraulic distribution
and/or injection lines
El/FO jumpers
ROV installation, FLOT +
Torque tool
Module
connectors
Sizes
Non insulated
Insulated
Mono-bore
Multi-bore
Mechanical small tool
Hydraulic w/contingency
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AOG 2014
Outline
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Subsea Field Development- Introduction, Top Down Approach
and Options
Tie-In and Connections Systems- Introduction and Options
Comparison and Selection of Tie-In and Connection Systems
Field Development with alternate Tie-In and Connection
systems
Available Connection Systems (New Generation )
AOG 2014
Selection of Connection System
Challenges:
Design Basis and Customer
Requirements
Many needs in one field
Intervention Strategy
Reuse of existing tooling
Cost evaluation criteria
Interfaces
Internal interfaces in Subsea
Production System
Interfaces to pipeline/flowline
External forces
Physical interfaces
Handling and installation
Installation procedures
Knowledge and experience of involved
personnel
Personal and cultural preferences based
on experience
Reservoir, Design
Basis, Field layout
System, Flow
assurance, Hydraulic
and injection fluid
distribution
Pipe sizes
Horizontal
Multi-bore or Flying
Leads+ small-bore
Insulated connectors
Not insulated
Vertical
Multi-bore or Flying
Leads+ small-bore
Insulated connectors
Not insulated
Module
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AOG 2014
Vertical vs Horizontal Tie-In Systems Selection
Regional preferences and customer preferences
Total installed cost
Field architecture (on-template wells, off-template well clusters
and wide area distribution wells)
Ease of fabrication (onshore/ offshore)
Lifting capacity of the installation vessel
Ease of performing jumper installation
Ease of Tree and / or Manifold retrieval
Regional requirement for overtrawlability and hence minimum
height protection structures (i.e. North Sea applications).
Avoidance of trapped water and potential hydrate formation
Multi-phase and Wet Gas meters location (Need to be in a vertical
leg for proper performance)
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Rigid Vs Flexible Jumpers
Selection of Rigid or Flexible jumpers is dependant on
Field Layout
Design Requirement (Pressure, Temperature etc.)
Material Philosophy
Insulation Requirement
Fluid in bore
Total Installed Cost
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AOG 2014
Outline
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Subsea Field Development- Introduction, Top Down Approach
and Options
Tie-In and Connections Systems- Introduction and Options
Comparison and Selection of Tie-In and Connection Systems
Field Development with alternate Tie-In and Connection
systems
Available Connection Systems (New Generation )
Typical Production DC Layout Vertical Mono-bore
connections
SDU
SRM
UTH
EFL and HFL jumpers
(elec, hyd, chem)
FCM
EHXT
SCM
M spools and
vertical connections
10 PLET Jumpers
(Vecon Connectors)
MCM
Manifold
10 Flowline (PIP)
10 Flowline (PIP)
UTH
Methanol 2 jumpers
KC4-3 vertical connections
Umbilical
(elec+fibre+hyd+chem+ 5x1.5 for methanol)
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Typical Production Drill Centre with vertical connections
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Drill Center with Vertical Rigid Spools
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Typical Production DC Layout with
Horizontal multi-bore well jumpers/connectors
No SDU (Distribution in manifold)
All horizontal connections
Multi-bore connections (XT to manifold)
Umbilical
(elec+f ibre+hyd+chem+ 5 x1.5 f or methanol)
SRM
FCM EHXT
SCM
XT Jumpers
6 prod + 2 methanol + elec + hyd
UCON multi bore horizontal
10 PLET Jumpers
(UCON mono bore horizontal)
MCM
Manifold
10 Flowline (PIP)
10 Flowline (PIP)
SCM
MCM
Manifold
Mono-bore DC
Multi-bore DC
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Typical Production Drill Centre with horizontal connections
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Drill Center with Horizontal Rigid Spools
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Drill Centre with Vertical Rigid Spools
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As Built Drill Centre
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AOG 2014
Outline
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Subsea Field Development- Introduction, Top Down Approach
and Options
Tie-In and Connections Systems- Introduction and Options
Comparison and Selection of Tie-In and Connection Systems
Field Development with alternate Tie-In and Connection
systems
Available Connection Systems (New Generation )
Different Connection Systems
Historical - Integral Hydraulic
and Mechanical / CAT Tie-in Systems
UCON ROV-Tool
Mechanical Tie-in System
TORUS IV
ROVCON
STACON
TORUS III MA! - CAT " CAT-#ite
UTIS
Used Large tools
Longer installation time
UCON-H
UCON-V
Collet or Clamp
Clamp
Collet
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AOG 2014
Standard Connection Systems
Connection
Systems
Horizontal
UCON-H
UCON-H-12
UCON-H-12
INS
UCON-H-18
UCON-H-18
INS
UCON-H-22
Stabcon MK2 Rovcon MK2
Vertical
UCON-V-KC UCON-V--KL
KLV-8 (MAX) KLV-10 KLV-14 KLV-16
Torus-III
Smallbore
Module
Connectors
Manifold
System
Well
Completion
Systems (XTs)
Well Access
Systems
(Riser)
Process
UCON Family
UCON-H, Horizontal
UCON-V, Vertical
Based on the same family of standards
Collet Connectors (KC)
Clamp Connectors (KL)
The core collet and clamp connectors use the same mono-bore and multi-bore
hubs/connector bodies and Seals
The design and qualification philosophy is that qualified seals can be used in all
connectors.
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KC/KL connector family
KC4-10
KC4-12
KC4-14
KC4-27
KL4-10
KL4-12
KL4-18
KL4-27
KC4-34
KC4-18
KL4-16
Max pipe OD (Inches)
KC4-16
KL4-14
KC4-22
12.75 14 16 18 20 24 30 36
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UCON-H Product Family
4 versions available today
UCON-H-22 is available Q1 2014
UCON-H-22
UCON-H-18
UCON-H-12, insulated
UCON-H-12
UCON-H-18, insulated
Basic ROV manipulator held tooling
Mono-bore and Multi-bore
Integral Insulated or non-insulated
Horizontal or Vertical
Guideline or guideline-less operations
No interface with seabed during
installation and connection
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UCON-H Multibore Connections
Umbilical
Termination
Head (UTH)
Insulated Multibore Welljumper
Termination Head
(6 + 2x1.5 + 8 HL)
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UCON-H Connection System
Multi-bore KC4
Connector
6 + 2x1.5 + Hyd + chem + EL
Stroke-in and connect
Rigid Spools (mono/multi bore)
Flexible lines / umbilicals
Pig Launchers /Receivers
Pig Loops
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Connection System Installation
UCON-H System
ROVCON System
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UCON-H Video
AOG 2014
Installation/Parking of Connection System without
Production Equipment
Tubing Head (U Loop)
Flowbase System (Flexible Flowloop)
Tubing Head (Without U Loop) for UCON System
Simpler Parking/pre-installation of well
jumper
Direct interface with Tree hub
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Installation of UCON System without Production
Equipment
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Conclusions
Tie-in and Connection system selection is fundamental to an
economic field development
Vertical & or Horizontal tie-ins with rigid and or flexible pipe may be
selected feature common connectors and hubs
UCON Connection system reduces total installed cost
Simplified ROV deployed Tooling reduces installation time
Integral Thermal Insulation available vs. adding dog houses
improves thermal performance and reduces cost
Subsea parking & pre-installation of jumpers without Subsea
production equipment is enabled
Reduced personnel onboard vessels and simplified maintenance
Wide Pipe range available
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Thank You