Beruflich Dokumente
Kultur Dokumente
Offshore Operations
William H. Silcox, Chevron Corp.
James A. Bodine, Chevron Corp.
Gerald E. Burns, Chevron Corp.
Carter B. Reeds,* Chevron Corp.
Donald L. Wilson, Chevron Corp.
Edward R. Sauve, Chevron Corp.
Introduction
Offshore petroleum operations emerged in the 20th century and brought new dimensions of challenge and excitement to oil exploration
and production.
When a
structure taller than a lOO-story building is launched from
a barge, or when a small city is built and placed offshore
in 2 years, those involved deserve their feelings of pride
and accomplishment.
In nearly every corner of the globe, thousands of offshore installations with payloads from 5 to 50,000 tons
are producing gas and oil today in water depths from 10
to 1,000 ft. Although subjected to winds and waves up
to hurricane intensity, earthquakes, sheet ice, severe tides
and currents, or shifting foundations, surprisingly few
structures have succumbed to the environment despite the
difficulty in predicting environmental
forces, equipment
failure, or reservoir behavior.
This chapter can only scratch the surface of offshore
operations; detailed procedures for design and construction of structures, equipment, and facilities would require
volumes. Furthermore,
such volumes would be obsolete
before they were published. Because there is no concise
reference or set of references, this chapter describes the
fundamentals of standard practice in several disciplines
and offers guidance for the selection of appropriate offshore codes of practice and technical references.
Historical Review
In 1859, Col. Edwin Drake drilled and completed the first
known oil well near a small town in Pennsylvania.
This
well, which was drilled with cable tools, started the
modern petroleum industry. Drilling methods and tools
remained in their infancy for more than 40 years, until
hydraulic rotary drilling techniques were first used to drill
*Droeascd
the Spindletop well in 1901. By then, the petroleum industry was already moving offshore.
In 1897, near Summerland, CA, H.L. Williams extended an onshore oil field into the Santa Barbara Channel
by drilling a submarine well from a pier. This first offshore well was drilled just 38 years after Col. Drakes
well. Five years later, more than 150 offshore wells were
producing oil. Production from the California piers continues even today.
From this start, offshore drilling actually turned inland
with activity in the Great Lakes, Caddo Lake in Louisiana,
and Lake Maracaibo in Venezuela. Initially, wells were
drilled from shore-connected piers and later from wooden single-well platforms. During this period of inland offshore drilling, platform technology remained basic. The
one step forward was the change from wooden platforms
to concrete structures in Lake Maracaibo.
In the late 1920s, steel production piers that extended
a quarter of a mile into the ocean at Rincon and Elwood,
CA, were built and new high-producing wells stimulated
exploration activity. In 1932, a small company called Indian Petroleum Corp. determined that there was a likely
prospect about 1/2mile from shore. Instead of building
a monumentally
long pier, they decided to build a portion of a pier with steel piles and crossmembers. Adding
a deck and barging in a derrick completed the installation. By Sept. 1932, the 60x90-ft
steel island was
completed in 38 ft of water with a 25-ft air gap. This first
open-seas offshore platform supported a standard 122-ft
steel derrick and associated rotary drilling equipment.
Successful drilling with largely unsuccessful results was
carried on intermittently on the steel island until 1939,
when the third well was completed on the pump at 40 B/D.
In Jan. 1940, a Pacific storm destroyed the steel island.
During the subsequent cleanup, divers were used for the
first time to remove well casing and to set abandonment
plugs.
18-2
PETROLEUM
ENGINEERING
HANDBOOK
18-3
OFFSHORE OPERATIONS
Progress is not always the result of new ideas or concepts but often a step-by-step improvement in existing
technology. For example, the skirt pile that is currently
part of most steel deepwater structures was first implemented in 1955, but the idea had been patented in the
19th century. The North Sea gravity structure had a precedent in a gravity platform constructed offshore in California more than 30 years ago. The guyed tower was patented
before the turn of the century. The tension-leg platform
was invented during World War II as a seadrome or floating airport. Current improvements in computerized design, transportation, and installation equipment, coupled
with an ever-increasing need for new oil supplies, is the
driving force for technological advance.
During the evolution of offshore platforms, the new
ocean engineering discipline also evolved. Ocean engineers are versed in structural engineering, soil mechanics, the hydrodynamic effects of waves and currents,
structural dynamics, statistical analysis methods, and reliability analysis techniques.
The equipment, methods, and techniques for completing, producing, and maintaining wells on the ocean floor
have also undergone tremendous advancements since the
first subsea wells were completed in the late 1950s. Early
subsea Christmas trees were made up of the same conventional valves and flanges as trees for land wells. The
one concession to underwater operations was fail-safe
hydraulic actuators on remote-control valves. These early trees were usually diver-installed and connected by
Bowlines to shore. One company developed a swimming
hydraulic wrench that was fitted with television cameras
and maneuvering thrusters. This system, integrated into
the wellhead system, was successful to a degree. It was
the first attempt to eliminate divers from subsea operations. Over the past 25 years, there has been a continuous effort to reduce dependency on divers, but divers are
still a very important part of the offshore oil industry.
Complex multiwell systems have been installed on the
ocean floor. Single-well completions have been made in
1,300 ft of water. Control systems that involve hydraulic. electronic multiplex, and acoustic signal transmission
systems are now common. Unmanned, remotely operated vehicles now are being developed that will become an
integral part of the subsea completion system. Much has
been accomplished in the past 25 years, but with exploratory drilling being done in 6,500 ft of water, even more
remains to be done in this area of subsea completions.
The search for offshore oil and gas reserves has directed
the petroleum industry to the ice-covered waters of the
Arctic. In 1963, the first commercial oil field was discovered in the upper Cook Inlet of Alaska. For the first time,
ice driven by extreme tidal currents produced loads on
the production facilities far in excess of other environmental forces. By the end of 1968, 14 platforms were
producing oil and gas from the inlet.
The onshore oilfield discoveries of Prudhoe Bay in 1968
and Kuparuk in 1969 established the Alaska North Slope
as an oil province. In 1977, construction of the TransAlaska Pipeline System was completed, and oil began
flowing directly to the ice-free port of Valdez. This development has inspired extensive exploration activity in
the Arctic offshore continental shelves of the U.S. and
Canada.
Offshore Drilling
The Introduction brought us quickly from the very early
days of the oil industry to todays jackup drilling units,
semisubmersibles, and drillships. This section will discuss the planning, preparation, and equipment necessary
to conduct a typical floating drilling operation (see Fig.
18.1). Focus will be primarily on floating drilling because
operations from jackups, submersibles, and platforms
generally follow land drilling practices. The last portion
of the section will be devoted to special considerations,
such as deepwater and high-current drilling and considerations for cold and hostile environmental conditions. For
a general discussion of the technology of offshore drilling, completion, and production, see Ref. 2.
Planning and Preparations
Site Conditions and Considerations. The culmination
of the sometimes arduous and complex task of geologic
evaluation of a potential offshore play is for the exploration geologist to put a finger on the map and say drill
1a-4
PETROLEUM
ENGINEERING
HANDBOOK
OFFSHORE OPERATIONS
Rig-Selection Considerations
Rig-selection criteria and rig types were discussed briefly earlier. In this section, we will discuss the differences
in four rigs that are used for offshore drilling: jackups,
submersibles, semisubmersibles, and ships. We will also
consider drilling equipment, mooring systems, and procedure manuals.
Rig types. Jackup rigs (see Fig. 18.2) consist of bargeshaped hulls with three or four (sometimes more) structural or tubular legs. Jackups must be towed to location
or loaded on specially built ships for major moves. Ship
transportation of jackups is becoming more frequent as
new special transport vessels become available. Ship
transport is considerably faster for long moves (6 to 8 vs.
2 to 3 knots) and much less risky. Loading and offloading the jackup requires a calm-water site at both ends of
the move. Once the jackup is in its jacked-up position,
drilling proceeds in a way similar to land or platform operations. However, several subtle differences should be
mentioned.
First, water conditions must be relatively calm
generally less than 6- to 7-ft waves-before the rig can
jack its hull out of the water. Major concerns are impact
and lateral loading on the legs just as it comes in contact
with the ocean floor. If the rig is rolling and pitching beyond specified limits, the jacking operation must be suspended until calmer conditions prevail. The same logic
applies when the rig is jacking down.
Second, once the rig is jacked up to working position
with a safe air gap between the ocean surface and the underside of the hull, primary concerns are lateral loading
on the legs and scouring around the leg mats caused by
current. Excessive current can cause troublesome vibration, and scouring can lead to foundation failure. Both
conditions are monitored closely, and corrective actions
are taken when necessary.
18-6
Third, the drilling operation is similar to a land operation after the outer casing is driven or drilled and cemented
in place. Surface BOP and conventional drilling equipment are used.
Fourth, the casing extending from the ocean floor to
the rig is a structural member and should be analyzed before installation. Wall thickness and strength of the pipe
should be specified (and will vary if a mudline suspension system is used) to ensure that it will withstand the
lateral loads of the current and the axial loads of the surface BOP and successive casing strings.
Submersible rigs (see Fig. 18.3) are limited to shallowwater drilling. Once the rig is on location and ballasted
to sit on the ocean floor, drilling operations proceed as
on a land site. Foundation considerations are as important here as in jackup operations. Logistics and supply
considerations are common to all offshore operations, so
jackups and submersibles can be just as severely hampered
by fog and bad weather as floating drilling rigs.
Semisubmersible rigs (see Fig. 18.4) evolved from submersibles. Some semisubmersibles can operate when resting on the ocean floor or in their normal semisubmerged
18-7
OFFSHORE OPERATIONS
terminology.
18-8
PETROLEUM
ENGINEERING
HANDBOOK
20
I
.
Fig. 18.7-Vessel
response-roll.
Fig. l&8-Vessel
TABLE
l&l-DRILLING
VESSEL
OPERATING
Heave
Limit
Operation
Anchoring, running riser,
landing BOP
Running casing, coring,
well testing
Drilling, tripping, logging
Circulate and condition mud
-- ft
LIMITS
Roll
Limit
Time
Criterion
Applied
Per Well
(deg.)
(04
1.8
10
IO
12
20
3.0
3.6
6.1
3
6
10
40
30
20
response-heave
An additional item normally not included in the motionrelated operating limits is wind. High winds frequently
result in shutdown because the rig crane cannot safely handle casing or riser. This is a valid input to the rigs overall performance
and should be included in the final
downtime comparison.
Occurrences other than severe
weather also cause operating downtime. Equipment breakdown and repair downtime (sometimes the result of severe weather, but not always) must be determined from
experience and operating history with a particular rig or
company. This increment of downtime is unpredictable
and difficult to estimate.
Mooring Systems (Stationkeeping).
Once the engineers
are satisfied that a particular rig or group of rigs is capable of handling the environment of a specified offshore
location, other equipment systems must be evaluated and
compared.
Mooring equipment provided to keep the rig on location is of major significance. Major questions to be answered regarding
mooring
equipment
include the
following: (1) is the mooring line (chain, wire, or a combination of chain and wire) strong enough to withstand
the loads during the strongest anticipated storm; (2) does
the rig have sufficient wire or chain on board or available for the water depth at the specified location; (3) do
the anchor handling or supply boats that are being considered have adequate pennant-wire-handling
equipment
on board (lengths must be greater than the water depth
and sufficiently strong to handle the 30- to 40-ton anchors
and can approach 2.5 to 3 in. diameter); (4) does the vessel have adequate instrumentation
to monitor mooringline loads; and (5) does the rig have adequate chain-locker
capacity to hold the desired amount of chain, or must part
or all of the chain be stored on supply boats? (Vessels
that dont carry their own chain have greater in-transit
deck-load capability but normally will require longer to
moor up because of the additional chain-handling
requirements.)
OFFSHORE
OPERATIONS
18-9
_I
VESSEL
OFFSET
\
A
A
400
>
AJ
SYMMETRIC
NINE LINE
SYMMETRIC
EIGHT LINE
44
SYMMETRIC
1, /
,,-
ZERO ANGLE
30-70
Fig. 18.9-Optimum
TEN LINE
45O-90
45-90
vessel position.
EIGHT LINE
Fig. 18.10-Typical
30-60
spread mooring
EIGHT LINE
patterns,
4.:
:&!
These questions must be answered to specify an adequate mooring system properly. Mooring analysis, which
is necessary to answer several of the questions, will be
discussed later in this section.
Adequate stationkeeping (keeping the vessel within acceptable limits on the location) is a result of a properly
designed and operated mooring system. Why is stationkeeping important? Ideally, the vessel should be located
directly over the well. However, wind and current forces
can cause the vessel to take an offset downstream from
the wellhead location. Waves cause the vessel to oscillate around that offset position.
It is important to keep the vessel reasonably close to
the wellhead position for several reasons: (1) the subsea
drilling equipment can accommodate angular offsets of
up to lo, but beyond that the equipment mechanically
locks up; (2) drillpipe that is rotating in the ball joint at
the top of the BOP can cause rapid and excessive wear
if the angular offset exceeds 1 to 2 for an extended length
of time; (3) excessive vessel offset can cause increased*.
riser sag, compounding both the ball-joint offset and the
wear problems. Proper monitoring of the ball-joint angle
and adjustment of the mooring system will result in a vessel offset upstream of the current and wind that will
minimize the lower ball-joint angle. Optimum vessel offset
would yield a zero ball-joint angle (see Fig. 18.9).
There are many variations in mooring patterns. Differently shaped vessels will require different mooring patterns (see Fig. 18.10).
One criterion in mooring-system
design is that the
restoring forces should be able to withstand nearly the
same storm conditions from any direction.5 The mooring pattern is designed to fit the vessel and particular environmental conditions anticipated at the site.
18-10
PETROLEUM
ENGINEERING
HANDBOOK
r-@---i
VESSEL
I
WATER LINE
-
VESSEL
-(9f
f
I
/
@
--
0S
I
ANCHOR
LINE ,
/
/
/
D
BL
TOTALhNE
/
/
@
LEGEND
HORZONTAL FORCE AT VESSEL.
0E
/
NOTE
ANCHOR
Fig. 18.11-Typical
catenary
I
i
-
._-,_--;
10
20
30
DISPLACEMENT,
Fig. 18.12-Single-line
catenary
displacement.
40
50
FT.
NOTE:
horizontal
REMAINING ON BOTTOM
KS1
= PSI
X 1000
D B E AREZERO UNTIL
BECOMES ZERO
configuration.
OFFSHORE
18-11
OPERATIONS
TABLE
18.2-DESIRABLE
CRITERIA
Operational:
Minimal weather
Maximum vessel excursion
Nonoperational,
But Riser-Connected:
Maximum weather condition
Maximum line tension
Minimum line remaining on bottom
Maximum vess%l excursion
Riser-Disconnected:
Weather conditions
Maximum line tension
Minimum line remaining
OF STATIONKEEPING
on bottom
are the BOP, the flex joint, riser, riser slip joint, riser
and guideline tensioners, drillstring motion compensator,
guidelines, and control system.
BOP. The subsea BOP stack is a major change from
land or platform drilling operations. Drilling riser, extended kill and choke lines, remote hydraulic and electrohydraulic
control systems, and subsea wellhead
equipment are all product modifications needed because
the BOP was relocated on the ocean floor. The wells
major pressure-containing
components were put on the
ocean floor because of the need to compensate for vessel
motion.
A BOP stack, whether located on the surface or subsea, is considered a last resort for preventing a well kick
from becoming a blowout. Several steps are taken to control unusual well conditions before use of the well shutin device (BOP). If the previous steps have failed and it
becomes necessary to shut the well in, the shut-in equipment must be highly reliable. BOP equipment is designed
with reliability as its ultimate criterion. Because of its relative inaccessibility,
the subsea BOP requires additional
redundancy and reliability.
The BOP stack is a combination of individual BOPs
designed to shut in a well under pressure so that formation fluids that have mov&l into the wellbore can be circulated out while continuous
control of the well is
maintained.
A description of the BOP stack components is included
below (see Fig. 18.14).
Rum Preventers. The massive steel rams have rubber
seals, and are hydraulically actuated to seal off the wellbore. Pipe rams seal the annulus around the drillpipe and
are designed so that an entire string of drillpipe and collars can be suspended from a pipe joint landed on a ram.
The ram seals must be the correct size to seal; 3-in. seals
cannot be used for 5-in. drillpipe. Conventionally,
three
pipe rams are used. A fourth ram, a blind-shear ram, is
used to seal over the open hole and to shear drillpipe when
necessary: Shearing pipe is, of course, one of the last
resorts in an emergency situation. 5 Variable-bore rams
are an option that is offered$or tapered drillstrings.
Annular Preventers. Annular preventers are comprised 9
of specially designed, reinforced rubber elements that can
seal around any tubular or near-tubular objects that &ill
go through the BOPs. They will also seal over the open
hole and can pass drillpipe tool joints without severely
GUIDE LINE
TENSIONER
4 EA
4. 6, OR 6 EA
TYP
TOP
FLEX
FLEXIBLE
HOSE
CONDUCTOR
SURFACE
CASING
CASING
l
Fig. 18.13-Floating
drilling
JOINT
STORAGE
TO KILL 8 CHOKE
system.
TYP
REEL
18-12
damaging the sealing element. Annular preventers are actuated by an annular piston that squeezes the seal into the
bore. The piston area is large relative to the other functions on the stack and, except for initial closure, should
be operated at pressures lower than the other stack functions. This decreases the possibility of extruding the rubber seal out of the preventer. 5 Frequently, two annular
preventers are used. One normally will be located above
the upper hydraulic connector so that it can be retrieved
with the riser.
Hydraulic Connectors. 3 Hydraulic connectors provide
the main pressure seal between the wellhead housing and
the BOP and between the top of the BOP and the lower
marine riser package (LMRPusually contains the top
annular preventer, flex joint, control system, and crossover to the bottom riser joint). The high-pressure wellhead housing is the male portion of the connector. It will
be a mandrel or a hub type. The connector is the female
portion and consists of a series of hydraulic cylinders that
actuate locking dogs into grooves machined into the wellhead housing or collet fingers that clamp over the wellhead housing hub. Both types of connectors use metal-ring
seals. This provides continuous metal-to-metal sealing up
through the BOP.
Kill-and-Choke Valves. These valves are the subsea
shutoff of the high-pressure kill and choke (K&C) lines
that run from the BOPs to the choke manifold on the rig.
K&C valves are hydraulically controlled from the surface and are designed to close by spring action when opening pressure is released. Some valves close hydraulically
OFFSHORE
18-13
OPERATIONS
Fig. 18.15-Riser
tensioner
unit.
small change in the hydraulic pressure. Variation in tension on the riser can be kept to less than 5% by proper
design.
The tensioning unit (see Fig. 18.15) consists of a series of large air storage tanks that are connected to the air
or gas side of an accumulator that serves as the interface
between the air and hydraulic systems. The tensioner is
a cylinder/piston arrangement that has wire-rope sheaves
mounted on the lower end of the cylinder and on the upper end of the piston rod that extends out of the cylinder.
A wire rope that is dead-ended on a storage reel is reeved
through the sheaves over alignment sheaves and is attached
to the outer barrel of the slip joint. As the drilling vessel
heaves up, it pulls on the line, which pulls the piston into
the cylinder, displacing fluid into the accumulator against
the large volume of air. The air is precharged to give the
desired tension. Similarly, when the vessel moves down,
the gas pressure displaces hydraulic fluid against the
piston, extending the piston rod and maintaining a constant pull on the riser.
Guideline tensioning systems, developed to keep constant tension in the guidelines, operate in much the same
manner as the riser tensioners. The only difference is that
they are smaller because less tension is required on the
guidelines.
Drillstring Motion Compensators. Without drillstring
motion compensation, 3 the drill bit would be constantly
lifting off and banging down into the bottom of the hole
as the drilling vessel heaves up and down. Weight control on the bit under these conditions without some type
of motion compensation is next to impossible. Bumper
subs (trombone-type
slip joints) in the drillstring above
the drill collars were used initially to provide some relief
from vessel motion. However, with bumper subs, once
the drillstring was in the hole, the weight on the bit (WOB)
(weight of the drill collars) was fixed and could be changed
PETROLEUM
18-14
Fig. 18.18-Drillstring
motion compensator
ENGINEERING
HANDBOOK
OFFSHORE
OPERATIONS
18-15
This system, while functionally satisfactory, was timeconsuming to run and test, so another method was developed. This method was to make the K&C lines integral
with the riser. The tops of the K&C joints were fitted with
a female seal pocket filled with chevron packing, and the
lower end fitted with a male seal nipple. When the riser
was run, the seal nipples dropped vertically into the female seal assembly. No rotation or screwing was required.
The joints were held together by the riser couplings.
Some manufacturers of flexible high-pressure pipe now
are proposing to provide long K&C lines that would be
stored on reels and paid out with the BOP stack when it
is run down to the ocean floor. On the larger vessels now
in service, there is space for the large hose reels required.
Control Systems. The simplest way to operate an actuator in a hydraulic control system is to connect hydraulic
lines from a pressure source through control valves directly to the actuator. 3 Some actuators require two lines to
complete the control cycle; others, such as spring-return
fail-safe actuators, require only one line.
Subsea BOPs were controlled this way during the start
of floating drilling. An early stack consisting of a hydraulically actuated connector top and bottom, K&C valves,
four ram preventers, an annular preventer, and a pressurebalanced ball joint would require as many as 17 control
hoses. These hoses, bundled together, were stored on a
large hose reel. All hoses first were connected directly
to their function on the stack, then pressure- and functiontested before the stack was run. Improperly tagged hoses
led to many hours of troubleshooting
to get the stack to
work properly. This time-consuming job had to be done
each time the stack was run.
Eventually, male and female multifunction stab plates
were developed that reduced some of the hookup time,
but the same problem of larger hose reels in deeper waters
resulted. In addition, as BOPs became more complex,
as many as 30 to 40 hoses were included in the hose bundles, doubling and tripling their size. To solve the problem of large hose reels, multihose bundles, and their
slower actuator response times in deeper waters, two new
types of control systems were developed: the piloted allhydraulic control system and the direct-wired electrohydraulic control system.
Backup Control Systems. In spite of the best-laid plans
and even with two control pods providing 100% redundancy, problems or failures still occur in the most modern
control systems. It is desirable to have reliable backup
systems if the primary controls fail. This has led to development of two types of backup control systems: the
acoustic control system and the last-chance hydraulic stab
system. 3
The acoustic backup system uses acoustic signals
through the water as the control link between the drilling
vessel and the BOP stack on the ocean floor. Energy to
power the acoustic signal receiver and to position control valves is provided by dry-cell batteries. Hydraulic
energy to power selected functions on the BOP stack
comes from accumulators mounted on the BOP stack.
These accumulators are kept charged because they are part
of the normal control system. Typical functions are to
close shear rams, to close pipe rams, and to disconnect
the riser at the lower marine-riser package.
An acoustic transmitter located on a surface vessel,
drilling vessel, work boat, or other vessel is used to send
PETROLEUM
18-16
MSSEL
CHARACTERISTICS
BATtM?3RY
rl
HORIZOifIAL
FORCE KIRIZONIAL
DISPlAC'd%V
Operating
PRIVARYMSSEL
WEtiTtER
DATA
KORING REW:+t3.UATlON:
!V,
,,IU,;WMXl
f'D3RING
LINETO DC"3Y
,:i,T,,?i
OFEUTING TtUSlON
,PRCUFOR lEJ7 TEXiON
Fig. 18.17-Mooring
analysis
HANDBOOK
LOCATIIX?
KIIRINGLINE
CHARACTERISTICS
ENGINEERING
method.
Manuals
and Emergency
Procedures
OFFSHORE
OPERATIONS
Commercial programs are available to do riser analysis. As with mooring analysis, some companies have developed their own programs. API RP 2Q addresses riser
design* and API RP 2K discusses riser use and maintenance. 9 Papers written on riser-analysis procedures are
referenced at the end of the Floating Drilling section. The
following discussion covers riser-analysis
criteria and
operational considerations, but not details of the complex
analysis.
The items considered in riser analysis are riser stress,
ball-joint angle, top tension, riser top angle, tensioner line
angle, sheave friction, and riser pipe collapse.
Riser Pipe Stress. Static and dynamic stresses in riser
pipe are calculated by the riser-analysis program. Static
loads are caused by the riser weight, mud weight, currentinduced hydrodynamic forces, the applied top tension, and
deflection of the top of the riser. Deflection of the top
of the riser is caused by vessel offset. Dynamic loads result from wave-induced water-particle motion and vessel
surge/sway motion. Wave-induced
surge/sway motion
produces dynamic riser deflections and hydrodynamic
forces because of the relative motion of the riser and the
water.
The criteria for acceptable static and dynamic stress levels is shown in Fig. 18.18. For purely static loads (no
dynamic load applied), stresses up to 50% of the pipematerial yield strength are allowed for normal operations
and stresses up to 67% of yield strength for limited or
emergency operations. These allowable stresses have factors of safety of 2.0 and 1.5, respectively. For purely dynamic stresses, the allowables have been reduced to 25 %
of the pipe-material yield strength and 25 % of the pipematerial ultimate strength because of fatigue considerations. Combined static and dynamic stress states must fall
within the recommended range indicated on the graph.
High stresses occur in the pipe-to-connector
weld and at
the base of the groove in the connector pin. These two
areas should be inspected frequently.
Bull Joint Angle. To minimize wear by the drillpipe,
the angle of approach of the riser to the BOP stack should
be kept as small as possible. Problems are minimized if
this angle is maintained to less than lo--a goal readily
attainable in a mild environment.
With moderate to severe environments, establishing an allowable ball-joint angle of 3 is a compromise between wear problems and
the application of criteria too restrictive to permit economical drilling operations.
The lower ball-joint angle is affected by many variables. Of these, rig personnel can readily adjust only riser
top tension and vessel position. The rigs riser-angle indicator should be monitored continuously and the vessel
position and/or riser tension adjusted accordingly. Changing the vessel location relative to the wellhead is the best
method of minimizing ball-joint angle. The lower balljoint (flex-joint) angle is the most important operating
criterion to maintain.
Top Tension. For long-term operations, it is not desirable to work riser-tensioner
systems at more than about
75 % of their rated capacity. To do so will result in premature failure, generally in the tensioner lines. Tension requirements can be reduced by the use of buoyancy.
Sufficient tension/buoyancy
should be specified to prevent drastic consequences should one tensioner fail. After ball-joint angle, this criterion is the most restrictive
18-17
Fig. 18.18-Recommended
stress ranges.
on tension requirements.
When operating at the recommended tension, failure of one tensioner should not cause
increases in ball-joint angle past 3) and stress should remain in the recommended range for normal operations
(see Fig. 18.18).
Minimum operating tension should always be sufficient
for emergency disconnect. An overpull at the lowermarine-riser package connector of about 50,000 lbf is recommended to ensure that the lower-marine-riser
package
and riser will retract sufficiently to clear the top of the
BOP.
Increasing riser top tension within the specified range
can reduce bottom ball-joint angle. Increased tension beyond the maximum recommended, however, will significantly increase pipe stresses and have very little effect
on decreasing ball-joint angle. At that point, the vessel
must be moved to correct excessive ball-joint angle.
Riser Top Angle. Although the lower ball-joint angle
is the most critical, the top angle must also be controlled.
Tensions selected for drilling operations include a top angle of less than 4.
Tensioner Line Angle and Sheave Friction. Variation
in tensioner line angle generally has very little effect on
riser tension. Sheave friction, however, may be substantial in some systems. If so, its effect should be compensated for in the tensioner control system so that the desired
tension is maintained on the top of the riser.
Riser Pipe Collapse. Riser-pipe material strength and
wall thickness should be sufficient to prevent collapse owing to seawater hydrostatic pressure when the riser is completely void. Reduction in collapse strength because of
axial loading and bending stress should be included. In
general, collapse considerations
become important in
water depths greater than 800 ft.
The objective of riser analysis is to specify recommended top tensions that keep the system within safe
working limits under all anticipated conditions, as described in Table 18.3.
Field Operations
With the major planning and preparation completed, we
will now discuss the sequential steps of drilling a well from
a floating vessel. The sequence of events in this description is not necessarily followed for every well drilled from
a floating vessel, but it is a method that has worked in
the past and will work in the future.
18-18
PETROLEUM
TABLE
18.3~-RECOMMENDED
Ball-Joint
Angle Range
oto
OPERATING
LIMIT
Comments
10
1 to 30
3O and increasing
5O and increasing
Location
The Well
HANDBOOK
Establishing
ENGINEERING
30-in. Casing
In Step 3, the structural casing (with the permanent guidebase attached and the guidelines threaded through the
guideposts) is run down the guidelines into the hole. 3
Care must be taken while the 30-in. casing is run to ensure that it is tilled with water. Should this be overlooked,
it is possible to collapse the 30-in. casing. It is run on,
and cemented through, the drillpipe lowering string. Cement returns are taken on the ocean floor and may be observed on TV. To ensure a good cement job for this
critical casing string, the cement may be overdisplaced
by as much as 100%.
In Step 4, hole is drilled for the conductor casing. If
the soil the structural casing was set in is competent, a
riser is run and latched into the permanent guidebase, and
drilling returns are taken on the drilling vessel. Riser top
tension should be sufficient only to minimize lower balljoint angle. Too much top tension could result in pulling
the 30-in. casing out of the ground. If the soil is not competent, the riser is not run and returns are taken on the
ocean floor. If the riser were used with incompetent soil,
the hydrostatic head of the drilling fluid could break down
the soil at the shoe of structural casing, resulting in lost
circulation. The conductor hole may range in depth from
298 to 499 ft. The size of conductor casing commonly
used has a 20-in. OD. If the riser has been used, it is pulled
before the conductor is run.
Running
20-in. Casing
In Step 5, the 20-in. conductor is run down the guidelines on drillpipe, landed in the housing on the structural
casing, and cemented back to the ocean floor. 3 The top
of the 20-in. conductor is fitted with a 163/4- or 185/,-in.
high-pressure
wellhead housing prepared internally to
receive subsequent casing strings. The size of the casing
head is determined by the size of the BOPs on the drilling vessel. The external profile on the upper end of the
casing head is prepared to match the type of wellhead connector installed on the BOP stack. A metal-on-metal seal
ring provides the pressure seal between the connector and
wellhead.
Running
the BOP
OFFSHORE
18-19
OPERATIONS
I
iI
-LOWERING
STRING
GUIDE
I DRILL
LINES
STRING
GUIDE
POSTS
.;OWERING
RUNNING
STRING
TOOL
-PERMANENT
GUIDE
LEVELING
BULLSEYE
-FLEX
GUIDE
BASE
ARMS
JOINT
aTEMPORARY
MUDLINE.
GUIDE
1
BASE
MARINE
RISER
FLEX
JOINT
LOWER
RiSER
MARINE
PACKAGE
BLOWOU
1
PREVENTER
STACK
Fig. 18.19-Floating
drilling-subsea
systems.
18-20
is run. Each riser connection must be checked for correct makeup. The total weight of the BOP is supported
by each connection. Integral K&C lines (and hydraulic
supply line if it is hard-piped) should be pressure-tested
every second or third joint to avoid an unnecessary pulling of the BOP for leak repair. In addition to careful riser
inspection, riser handling tools and the riser spider should
be inspected for cracks or damage. The riser handling tool
supports the total weight of the BOP and riser each time
another joint is added to the string. The top of the riser
is fitted with a slip joint to accommodate vessel heave and
offset. The slip joint lands in a diverter housing immediately under the rotary table. Riser tensioning lines are connected to the slip-joint barrel so that tension can be applied
to the riser when the stack is landed on the wellhead. Once
in place, the stack is function- and pressure-tested, and
all is ready to begin drilling to total depth (TD). As hole
is drilled, additional casing strings may be run through
the riser and BOPs. Periodic BOP testing after the first
casing string is landed in the wellhead housing must be
done carefully. A leaking casing-hanger-seal assembly
could collapse the casing if test pressure exceeds casingcollapse pressure. API RP 536 includes testing guidelines. If the well is to be put on production, the tubing
string also is run through the BOPs and hung off in the
casing head.
Drillstem Testing
Drillstem testing (DST) requires specific equipment not
normally installed on floating vessels. An inside-the-BOP
production tree includes redundant master valves and a
surface-actuated hydraulic latch for emergency disconnect, high-pressure piping and valves from the choke
manifold to production-equipment area, test trap with
metering equipment, storage tanks with transfer pumps,
and a flare boom. This equipment requires considerable
space. Storage-tank location may require beefing up the
local deck structure. Flare booms require special foun-
Special Considerations
Deepwater Drilling
Maximum water depths continue to extend. During 1983,
a well was drilled in approximately 6,800 ft of water off
the U.S. east coast. Locations in water depths greater than
OFFSHORE
18-21
OPERATIONS
_,-
. .
-I
R1
Fig. 18.21-Thirty-inch
2,000 ft should be considered deep water. Mooring becomes more difficult, subsea equipment is heavier, collapse under hydrostatic
conditions
becomes critical,
equipment performance under emergency disconnect conditions, and well-control procedures require additional
considerations.
The major differences in shallow vs. deepwater floating drilling equipment are station-keeping (moored vs. dynamic positioning),
riser design (material strength vs.
buoyancy needed), BOP control systems (hydraulic vs.
multiplex), and backup systems (diver vs. unmanned).
Deepwater operations require longer calm-weather periods and improved weather forecasting to accomplish specific tasks. Running and retrieving BOPs can take just
a few hours in shallow water. In deep water, 2 or even
3 days may not be unreasonable. Relatively calm sea conditions are required during that time.
Dynamic-positioning
(DP) systems have extended
station-keeping capabilities to depths of more than 10,000
ft. DP systems consist of acoustic beacons located on the
ocean floor, hydrophones mounted on the vessels hull,
thruster units fore and aft, and an on-board computer system for control. Dynamically positioned drilling vessels
are equipped with from 12,000 to 20,000 hp for stationkeeping. Increased fuel consumption while operating in
the DP mode is a major cost increment in a rigs day rate
(see Fig. 18.20).
Cold Environment
A few special cold-weather drilling vessels are available
However, most rigs operating in cold environments
today were not designed with low-temperature
steel requirements. Highly loaded or highly stressed components
-such as the derrick substructure, lifting subs, riser running tools, riser connectors, and elevators-must
be fabricated from steels with low-temperature resistance (Charpy
impact values comparable to the temperatures encountered) if they are to function safely. Material specificatoday.
Drilling
PETROLEUM
18-22
NOTE:
Structures
Background
and Philosophy
Classification
As indicated in the Historical Review, many types of offshore structures are in service. Some are better suited to
certain environmental
and operational criteria; some are
limited by availability of construction sites; and some are
chosen simply by subjective preference of an owner/operator. Selecting a structure type is the first major structural design task after environmental and operational criteria
have been defined and might require preliminary design
of several concepts before a choice is made.
Template/Jacket.
Template
was derived from the
function of the first offshore structures: to serve as a guide
for the piles. The piles, after being driven, are cut off
vortex
HANDBOOK
KT = KNOTS
D
Fig. 18.22-Riser
ENGINEERING
= DIAMETER
shedding.
OFFSHORE
OPERATIONS
rest, usually floating horizontally, it is upended by ballasting members at the lower end. Once upright, it is
moved onto the final site and lowered to the seabed by
continued ballasting.
To date, the maximum water depth feasible for a singlepiece jacket appears to be about 1,000 ft. The constraint
is a result of construction equipment and facility limitations, although contractors are quick to point out that capability can be extended quickly if the business climate
warrants. Meanwhile, an alternative for deeper water is
the multipiece structure. These structures are built in either
two or three pieces that are launched from separate barges.
The pieces can be mated while floating horizontally, like
the Hondo t* platform, or stacked vertically and grouted
together with pin piles, like the Cognac platform. Mating of large structural sections has proved to be expensive and involves added risk over single-piece structures,
so plans are under way to extend single-piece construction to water depths beyond 1,000 ft.
Yard facilities are tailored to build structures in the
horizontal position. Lifting equipment is huge in both capacity and reach because a deepwater structure might have
a base width of more than 200 ft, which would require
lifts to be placed to the height of a 20-story building! A
structure for 1,200 to 1,500 ft of water could have a base
width of more than 300 ft, which is beyond the reach of
todays equipment.
Since 1975, several large transportation barges have
been built with lengths of more than 600 ft and capacities
of 40,000 tons. Such a barge was used to place the singlepiece Cerveza I4 platform in 935 ft of water. Several installation contractors now have plans for super barges
with lengths of 900 to 1,000 ft and the capability of transporting jackets more than 1,500 ft long.
The increased pile loads on deepwater structures have
necessitated advancements in pile-placing technology. In
1960, driving a 48-in. pile to 300 ft penetration for an
axial capacity of 2,500 tons was a major feat. In 1984,
a designer can plan for an 84-in. pile driven to about 400
ft to develop an axial capacity of 15,000 tons. Most of
the advancement has come in the area of pile hammers.
Hammers can be built to energy levels of 1.2 million ftlbf, nearly 10 times that of the hammers used in 1960.
Also, underwater hammers are becoming more dependable, which has the advantage of eliminating pile guides
and followers for skirt piles and saving the energy normally lost through the follower.
Concrete Gravity Structures. As the name implies, these
structures have large mat foundations instead of piles and
are heavy enough to resist overturning and base shear
from lateral wave and wind loads. Whereas steel template/jacket technology was largely a product of the U.S.,
the concrete gravity structures were European designs.
Three reasons are offered for the emergence of these designs: (1) the European countries with offshore oilfields
demanded a high percentage of national content-i.e.,
design and construction money had to be spent within their
borders; (2) European design expertise, construction facilities, and construction skills leaned heavily toward concrete and away from steel; and (3) template/jacket
technology was not prepared for the huge payloads and
severe environment of the North Sea. The first major steel
structure met with severe design changes and inadequate
18-23
18-24
Once on site, ballasting will set the structure on bottom, and grouting fills any voids under the base. Offshore
construction and hook-up time can be held to a minimum
because onshore deck construction should have included
commissioning most of the systems.
Guyed Towers
The guyed tower is intended for use in deep water
perhaps 1,000 to 2,000 ft. It applies the principle of compliancy to wave forces. Wave forces are cyclic in nature, pushing a structure first in the wave direction and
then against it. By pinning the structure to the seafloor
instead of making it a fixed cantilever, the guylines allow the structure to sway back and forth with the wave
force, transmitting only small loads to the foundation. The
guyline system holds the tower upright and resists the
steady forces from wind and current. Depending on the
size and configuration of the guyline system, the tilt an-
OFFSHORE
OPERATIONS
18-25
cally has the least concrete or steel. Construction facilities and skills in the area are important, and often the
operators preference will prevail. Here are some guidelines, though, on the four concepts discussed.
Special-Service
Structures
Selection
Template/Jackets.
Around the U.S., these structures are
the norm for water depths from 10 to 1,000 ft. Most U.S.
offshore structures have a payload based on less than
50,000 B/D production. These small payloads are conducive to templates and jackets. Future technology might
push these structures to 1,500 ft of water; limitations will
be based on the structures natural period and cost.
Design Process
18-26
Fig. 18.24-Jacket
members
Fig. 18.25-Jacket
PETROLEUM
ENGINEERING
HANDBOOK
design-key
environmental
data inputs.
OFFSHORE
18-27
OPERATIONS
Fig. 18.26-In-situ
static
Fig. 18.27-Analysis
analysis.
F,,
F,,
=(6.1
=tdN.
procedure
Offshore
Production
Operations
PETROLEUM
18-28
ENGINEERING
EACH WA STATE
Fig. 18.28-Deterministic
Platform
procedure
analysis.
Production
Well systems and crude-oil and gas process facilities installed on platforms account for more than 99% of current offshore production capacity. A small number of
wells are completed on manmade islands. From a design
and operating standpoint, these island wells are handled
the same as platform wells. Wells that are completed subsea number fewer than 300 worldwide and will be discussed separately.
Well Completions. Except for a few innovative installations, wellheads and Christmas trees on platforms are basically the same as for land wells (Fig. 18.30). Control
valves, safety valves, and piping outlets are configured
the same and use the same or similar components. Some
of the valves probably will have pneumatic or hydraulic
actuators to facilitate remote and rapid closure in an emergency. Also, some Christmas trees may have composite
block valves instead of individual valves flanged together.
The major difference, however, between land and platform well completions is the economic incentive on platforms to reduce equipment weight wherever possible and
to minimize space requirements.
Simply put, lighter,
smaller equipment and more compact installations result
in less-expensive platforms. A good example is the use
of composite block valves to reduce Christmas-tree size
and weight. Another example is the spacing of wellheads
as close together as drilling operations will permit, with
just enough room for safe and efficient operation of tree
valves, control valves, and well-workover
equipment.
Typically, this means centerline distances of 6 to 10 ft
between wellheads.
Where only one drilling rig is on a platform, all the
wellheads usually are located in one bay. Larger platforms
that are designed to accommodate two drilling rigs may
have two well bays (one for each rig) with two or more
rows of wells in each bay.
Fig. 18.29-Spectral
fatigue analysis
HANDBOOK
EACH mnEcTloN
procedure
OFFSHORE OPERATIONS
18-29
On larger platforms with more wells, drilling and production operations generally are carried on concurrently. In this case, well workovers are performed by the
drilling rig if it is still on the platform. Depending on the
urgency of the workover and on economic considerations,
the work typically is scheduled to follow completion of
the well that is currently being drilled. Wireline repairs
can be performed without interfering with drilling operations unless the two wells involved are too close together
for safety considerations.
Even on the largest platforms, drilling rigs normally
are removed after all scheduled wells have been drilled.
Depending on the number of wells and the amount of
downhole work anticipated, a special workover rig may
be installed permanently on the platform. An economic
comparison between using a portable rig and using a permanently installed rig should be the basis for selection.
Crude-Oil Disposal. In the great majority of cases, crudeoil production is shipped from platforms by subsea
pipelines. Because most offshore producing areas involve
multiple platforms and more than one operating company, the pipelines are generally common carriers.
In the simplest of installations, where a pipeline transports only one type of crude oil from a single platform,
an optimum pipeline design and installation can be involved and expensive. Numerous factors must be evaluated, such as seawater temperature, seafloor profile and
geologic features, water currents between surface and
PETROLEUM
18-30
Fig. 18.31-Platform
ENGINEERING
HANDBOOK
OFFSHORE
18-31
OPERATIONS
Fig . 18.32~Subsea
tree-dry
18-32
OFFSHORE
OPERATIONS
18-33
Fig. 18.35-Sequence
drawings for drilling and completing
subsea well and for well re-entry workover.
Fig. 18.38-Seafloor
manifold
seafloor can be made because of local regulations or obvious hazards. Generally, however, the pros and cons for
burial and the overall costs and economics should be
evaluated carefully before a decision is made to bury
flowlines. If the answer is not clear-cut, leaving the lines
unburied is probably best. Unburied lines cost less to install, are less expensive to repair, and are easier to inspect for leaks and damage.
Conventional
welded steel pipe is used for most
flowlines. It can be protected against external corrosion
by either anodes, a corrosion coating, or a combination
of both. Cathodic-protection
methods should be compat-
for satellite
subsea wells.
18-34
PETROLEUM
ENGINEERING
HANDBOOK
for circulating
the tools. A decision favoring either
wireline- or TFL-servicing
procedures for an oil well
should be based on a full evaluation of operating conditions, anticipated downhole service requirements,
the
availability of trained personnel, and an economic comparison of installed costs and servicing costs.
Well Workovers. Work on subsea wells that requires the
tubing to be pulled or is otherwise beyond the scope of
wireline or TFL tools is a major undertaking and requires
extensive planning and preparation.
Unless a specialpurpose vessel is available that is suitable for workovers,
a semisubmersible
or ship-shaped drilling rig must be
scheduled and mobilized with a workover riser and running tools specially designed for the Christmas tree and
tubing hanger. This equipment is needed in addition to
a regular drilling riser and BOP stack, which must have
a hydraulic connector that is compatible with the wellhead. Space limitations on some drilling vessels may
preclude their use, which further complicates
the
workover.
Floating Production
Facilities
OFFSHORE
18-35
OPERATIONS
Fig. 18.37-FPF
with flexible
Fig. 18.38-FPF
composite
loading
PETROLEUM
18-36
Fig. 18.39-Flow
diagram
for one-well,
long-term
ENGINEERING
HANDBOOK
test.
Pipelines
OFFSHORE
OPERATIONS
18-37
SIDE VIEW
IWZ-~ODAT~ON
FRONT VIEW
Fig. 18.40-Conventional
DFCK
LAWUT
pipe-lay barge.
Reel Capacity
Fig. 18.41-Work
reels
PETROLEUM
18-38
ENGINEERING
HANDBOOK
-_r
Fig. 18.42-J-lay
flowlines
the seafloor. A procedure particularly applicable to subsea wells in very deep water is the J-lay first-end connection (Fig. 18.42), where the flowline is run vertically to
the tree base from the drilling rig, stabbed into a receptacle, and then laid down into a horizontal position as the
drilling rig or pipe-lay vessel moves away from the wellsite toward the platform. A trunnion-type assembly on the
end of the flowline permits the line to be laid down without
bending. The mating of the flowline to the Christmas tree
is made after the line is fully horizontal.
Many different devices and procedures have been developed for making the actual connection between the
Christmas tree and the flowline. In shallow water, divers
can install a piping spool with flanges or couplings on each
end. Diverless connections usually have some type of
hydraulically actuated device that is operated remotely
from the drilling rig.
Larger Pipelines. Pipeline diameters from 8 to 36 in. or
more are used extensively for the transfer of crude oil
and gas from offshore fields to land sites. Installations
typically have been made with conventional
pipe-lay
barges as described previously, but reel barges also are
used extensively for the smaller sizes. Both bottom tows
and surface tows are used in limited applications where
logistics favor them. As discussed previously, a pipeline
can be the single most expensive element of an offshore
installation, sometimes exceeding the cost of one or more
platforms. Numerous factors must be considered when
Arctic
Production operations in the offshore Arctic regions are
within the reach of existing technology. Procedures used
onshore and offshore in less hostile regions, however,
must be modified to meet the challenges of the harsh climatic conditions in these remote locations. I5
In the last decade, the major areas of industry interest
have been the offshore regions of Alaska I6 and Canada.
The environmental
conditions vary significantly in each
of these regions. Major factors that affect normal offshore
operations are extremely cold temperatures,
fog, gusty
winds, short open-water seasons, permafrost, and the persistence of ice. The specific production system that is
selected must be tailored to each unique combination of
these factors to ensure safe oilfield development.
Environmental
Conditions
OFFSHORE
OPERATIONS
Ice Loading. Ice exerts the predominant forces on Arctic offshore structures. Extensive laboratory and field tests
have been conducted on small- and large-scale specimens
to determine in-situ strength characteristics for design.
From the results of these tests, the mechanical properties
of ice are predicted that consider its salinity, temperature,
crystallographic
structure, and loading rate.
Newly formed sea ice is relatively warm-only
a few
degrees above seawater temperature-and
high in salinity. As the ice sheet grows, the temperature at the surface
reduces to the ambient air temperature, while the bottom
remains near the seawater temperature. The salt in the
crystal structure of the sheet begins to consolidate into
brine droplets. These droplets migrate down through the
thickness of the sheet, creating drainage channels and lowering the overall salinity. Fresh water, from precipitation
or melting snow cover, fills these channels and refreezes,
thereby further reducing the salinity. The result is an ice
feature with varying strength, strongest at the surface and
reducing through the thickness with increasing salinity and
warmer temperature. For multiyear ice, this process ap-
18-39
18-40
Production Structures 16
Artificial Islands. Artificial islands already are used in
many shallow-water areas throughout the world for permanent drilling and producing facilities. The islands that
are currently being used for drilling in the Arctic consist
of either unretained or retained beach slope systems, as
shown in Figs. 18.43A and 18.43B. Because of the short
summer construction season and, in some areas, the lack
OFFSHORE
18-41
OPERATIONS
+ermafrost
cement
Fermafrost
cement
cement
Permafrost
Non
ydraulic
set
liner
cement
freezing
fluid
hangers
Safety
valve
Non freezing
insulating
fluid
-Class
G cement
Stage
KeStage
collar
collars
Permafrost
cement
hanger
-+ 9000
TV0
Class
--Class
---Safety
G cement
G cement
joint
Hydraulic
set
packer
i 9700'
TVD
BP Alaska
hole-casing
Arco
program
Fig. 18.44-Hole
casing programs,
hole-casing
program
Alaska.
18-42
PETROLEUM
Fig. 18.45-Vertical-sided
ENGINEERING
HANDBOOK
structure.
Fig. 18.46-Arctic
mobile
structure.
drilling
structure:
sloping-sided
Systems
OFFSHORE
18-43
OPERATIONS
structures, and land-based facilities in much the same manner as in conventional offshore locations. The principal
factors affecting the construction and operations of Arctic pipelines are the short open-water seasons, subsea permafrost, scour, and ice gouging of the seafloor.
Pipelines can be placed directly on the seabed in deep
water, in trenches in areas susceptible to ice gouging or
scour, and on causeways or elevated bridges at shore
crossings. In areas of extreme ice gouging, redundant lines
may be used to lower the risk of interrupted production.
In deepwater, moderate-ice areas of the Bering Sea, the
lines will be laid directly on the seabed by conventional
lay-barge methods. The 6- to 9-month open-water season, extreme summer wave conditions, and logistics of
operating several hundred miles offshore reduce the efficiency of the construction process. The distance from
shore or an offshore loading terminal may also require
pump stations along the pipelining route.
Marine pipelines in the Arctic Ocean are considered
feasible but will require the greatest challenge to existing
technology. The open-water season lasts approximately
1 to 3 months a year. In shallow-water locations, the keels
of ice features may gouge the seafloor for several miles
in a single ice-movement event. Pipelines must be buried
in trenches that are deep enough to ensure no damage.
Offshore permafrost may also cause difficulty in obtaining the desired trench depth and may require the use of
cutter-suction dredges to remove the ice-rich soil. Once
the pipeline is installed, refrigeration of the trench may
be required to ensure no subsequent thawing of the permafrost. Nearshore pipelines may also have to be designed
for wave-induced erosion or strudel scour. Strudel scour,
which is common at the mouth of rivers, is the process
in which river-water outwash flows over the nearshore
sheet ice and floods down through holes and cracks in
the ice. This jet of water could create large, eroded pockets in the seabed and produce long, unsupported spans
of pipe.
Marine Terminals and Tankers. Transportation
of
crude-oil products from many of the remote Arctic oil
fields also can be accomplished by offshore terminal and
tanker systems. The systems could consist of an interfield
pipeline-gathering
network with processed crude shipped
directly to shore. Once onshore, the crude could be stored
until it is loaded onto tankers and shipped to market.
Another form of marine terminal system is direct shipment of processed crude from offshore platforms to
tankers through single-point mooring systems.
The design, construction,
and operation of these systems have been proved in many sub-Arctic areas. However, some of the components must be modified for the
cold temperatures and persistence of ice. Loading arms
must be designed to ensure that hoses remain elevated
above the ice mantle and can accommodate loading of
tankers from any location around the terminal. Tankermooring systems must be designed for both wave- and
ice-loading conditions. Extreme ice areas may require offshore loading directly from fixed platforms or from subsea facilities, making maneuvering
and stationkeeping
very difficult. Icebreaker assistance vessels may also be
required to ensure safe access and departure from the terminal by tankers.
To travel through the offshore Arctic regions, purposebuilt icebreaking tankers may be required. The amount
Fig. 18.47-Piled
structure.
Electrical, Instrumentation
Control Systems
and
Offshore production facilities have the same basic requirements for electric power and control systems as onshore
facilities. These are a power source with a reliable distribution system, instrumentation
to control and to monitor
production operations, and a safety shutdown system
tailored for the installation.
Although offshore and onshore installations have similar needs in these areas, the two operations are significantly different in other respects. As pointed out earlier,
deck size and payload significantly affect offshore structure costs. Consequently, offshore electrical facilities must
PETROLEUM
10-44
Authorities
ENGINEERING
HANDBOOK
Loads
With the exception of the hotel loads that serve accommodations and personnel needs, normal platform loads
are not greatly different from the normal assortment of
onshore loads. Processes are likely to be concentrated in
a single location offshore, and the loads are appropriately
higher. Loads usually consist of a mix of transfer pumps,
compressors, fans, and heaters as well as utilities (air compressors, sump pumps, fire water pumps, water makers,
sewage facilities, etc.). Other typical loads include pumps
and gas compressors associated with shipping, artificial
lift, secondary recovery, and pressure-maintenance
operations. Depending on platform type and production facilities and rates, the loads on any given platform in a
field can range from less than 25 kVA to more than 40
MVA.
Layout of Facilities
Considerations that govern layout of offshore electrical
facilities are similar to those for land installations, but the
options are more restricted because of the space limitations. The primary requisite is to separate to the maximum extent possible the sources of ignition from the
process facilities. Electrical equipment should be kept out
of hazardous areas when economically feasible. Primary
electrical switch gear is frequently grouped in a pressurized, central electrical-equipment
room. Remote motorcontrol centers (MCCs) sometimes are used to reduce
the amount of platform wiring. Installing MCCs near load
concentrations
and supplying the MCCs with highvoltage feeders shortens branch circuits that feed individual loads. Remote MCCs frequently must be purged or
pressurized because of their location. The design approach
appropriate in each individual case must be based on practicality and economics.
Detailed load analyses must be made early in the design stage. Each analysis must consider both initial and
anticipated future load. Results of the analysis should control design of primary power facilities, layouts of conduit or cable ways, switchgear space, and distributionequipment layouts. Designs must allow for expansion in
each of these areas. The designer must carefully consider
possible future system expansion and pay particular attention to possible future artificial-lift and water-injection
requirements. Hydraulic pumping and electric submersibles can add significantly to the ultimate electrical load.
It is important to consider the potential for future changes
in facilities as reservoir conditions change and possible
increased demand on the electric power system.
Primary
Electric
Power
OFFSHORE
i a-45
OPERATIONS
The primary source of generated power usually consists of one or more brushless synchronous generators with
either diesel-engine or turbine prime movers. Turbines
may be gas- or diesel-fueled or they may be dual fueled.
Dual-fueled turbines generally are set up to run on diesel
initially and then to cut over to produced gas as production builds to a stable supply. Turbines offer the advantages of lighter weight and the opportunity for the use of
waste heat in oil production processing. Turbine-generator
packages, however, are very costly, require more maintenance, and in some cases, may require more deck space
than internal-combustion-engine-driven
generators of the
same capacity. In addition, primarily because of the somewhat limited selection of turbine sizes available, it can
be more difficult to match turbine generator packages to
the electrical system loads.
The second source of offshore power, submarine cable, offers an efficient means of electrification if adequate
sources are located nearby. Depending on the loads and
the distances involved, cable-system voltages can range
between 480 and 35,000 V. Submarine-power-cable
technology is well established. Power cables generally include
one or more pairs of small-gauge wires dedicated to
telecommunications
or telemetry and also are protected
with torque-balanced
double layers of galvanized armor
wires that may be plastic-coated for additional protection.
Power cables may be buried, depending on local conditions or regulations. Tubular risers are required at each
platform served by submarine cables to protect the cables as they rise from the seabed to the platform deck.
The riser generally should be filled with a corrosioninhibiting fluid to preserve the long-term integrity of the
armor wires. When the submarine cables originate on
land, they must be buried and suitably protected through
the surf zone. Mechanical protection is frequently provided by additional armor or by the installation of heavywall pipe through this area.
Secondary/Back-up
Power
Essential loads on offshore facilities must remain energized even when the main power source fails. These loads
usually fall in the category of navigation lights (ship and
aircraft), foghorns, communications,
emergency lighting,
and possibly some selected hotel loads. In some instances
where marine regulatory bodies have jurisdiction,
the
emergency system may have to be expanded to serve other
loads related to the safety of personnel on board.
High-volume oil and gas facilities are frequently designed to shut in completely in the event of power failure,
in which case process or shipping loads do not have to
be considered in determining backup power loads. Some
smaller facilities, such as wellhead platforms, are designed
to continue production operations without any electrification other than lighting, navigation lights, and foghorns.
Emergency power generally is derived from onboard
generators, storage batteries, or both. The generators
usually are small (less than 500 kW) and diesel-engine
driven. Diesel engines that are used in emergency service normally are equipped with automatic starters. These
engines also are equipped with cooling water and lubeoil heaters to ensure that they will start reliably and instantaneously
(within 10 seconds) on loss of primary
power.
Fig. 18.48-Typical
electrical one-line
emergency generator.
diagram
System
Offshore power-distribution systems and associated equipment do not differ substantially from land-based operations. Depending on load sizes, distribution voltages will
normally range from 120 to 2,400 V. Distribution systems with 4,160 V and higher are rare except on very
PETROLEUM
18-46
large platforms with high horsepower loads. As with landbased systems, accepted good practice and system capacity
determine the maximum allowable horsepower for individual loads and the appropriate supply voltages.
Motor-control centers and switchgear usually are installed inside pressurized or purged enclosures or modules. The pressurizing or purging frequently is required
to ensure a nonhazardous operating environment for the
electrical equipment so that air-break switching equipment
can be used safely. Code requirements for purging are
prescribed in the Natl. Electrical Code I9 and Natl. Fire
Protection Assn. Bull. NFPA 496. * As indicated in the
references, interlocks usually are provided either to sound
an alarm or to shut down all supplies when a loss of pressurization or purge occurs. Depending on the particular
operations involved, a simple alarm may be permissible
if shutdown of the process could create a greater hazard
than continuing operation during a short-term loss of pressurization or purge protection. Each installation is sitespecific and must be considered on its own merits.
System transformers may be installed either indoors or
outdoors. Both single- and double-ended line-ups are used
offshore, depending on the nature of the operation.
Double-ended 100%~capacity supplies with bus tie breakers are frequently used for increased reliability and continuity of service in the event of equipment failures.
Hazardous
Areas
The possibility of fire or explosion because of the ignition of leaking gas or liquids is a concern in all producing facilities. The concern is even greater offshore because
of the concentration of personnel and facilities in a relatively confined area where fire can be difficult to extinguish and platform evacuation can be a complex problem.
The requirements for classifying areas according to their
degree of hazard and for selecting equipment for the various areas are covered in API RP 500B* ; Section 500
of the Natl. Electrical Code19; and USCG Regulations
46 CFR, Chapter I, Subchapter I-A, Part 108 and SubParts 110-l 13. *
chapter J, Electrical Engineering,
Certifying agencies outside the U.S. have some different
rules and categories, but in general, they are no more strict
than the U.S. rules for the same situation.
Wiring Methods
and Equipment
Enclosures
Several wiring methods are applicable to offshore installations, and opinions differ as to whether conduit-and-wire
or cable-and-cable-tray
systems are best. Each has advantages and disadvantages. If the installation complies with
the appropriate procedures as outlined in the Natl. Electrical Code I9 and API RP 14F,20 each method is safe
and reliable. Rigid steel conduit and wire systems provide the maximum mechanical integrity, but the conduit
and fittings should be coated with plastic (PVC) to eliminate corrosion effectively. PVC-coated fittings and accessories are readily available in most locations. Copper-free
aluminum conduit systems have been used successfully
in lieu of galvanized steel. Aluminum systems require special wrapping of the conduit wherever steel support clamps
are used to prevent setting up corrosion cells where dissimilar metals would come in contact. Overall, conduit
systems provide excellent protection for wiring systems,
but they have the disadvantage of being bulky and relatively expensive to install, maintain, and modify.
ENGINEERING
HANDBOOK
General Instrumentation
The primary guide for the instrumentation of offshore installations is API RP 14C. 24 In conjunction with the applicable U.S. OCS Orders, 2s,26 the API guide provides
an excellent reference for guidelines in the design of monitoring and control systems for offshore-production
facilities. Most offshore installations have local control
panels for packaged equipment, such as gas compressors,
low-temperature gas separation (LTS) units, and electrical generators. Beyond this, the choice of individual local display/controllers
or centralized control rooms with
field transmitters and local displays depends on the nature of the facility, the complexity of the operation, economics, and preference of the operator. Most large,
modern offshore facilities are planned with centralized
controls. The one design principle that must be followed
regardless of the overall design philosophy is that all systems should be designed to be fail-safe so that loss of a
signal represents an alarm or shutdown condition.
Even when a centralized control room has been provided, continuous remote, closed-loop (analog) control is seldom used. Remote, closed-loop controls usually are
OFFSHORE
OPERATIONS
considered only when the process includes complex separation processes, sulfur removal and handling, or gas
processing. Most oil/gas handling processes are sufticiently simple and straightforward that local control loops are
satisfactory.
Centralized controls can be based on conventional instrument and relay control panels, but advances in electronics
have increased
the use of programmable
controllers and microprocessor-based
instrument systems.
These advanced system designs have multiplexed monitoring and control systems that frequently offer significant savings in wiring costs and space for a complex
installation. They are more compact and much more flexible than conventional control panels.
Offshore instrumentation
is very similar to onshore instrumentation. Process controls frequently include a combination of pneumatic, hydraulic, electric, and electronic
instrumentation. Process variables that must be monitored
and/or controlled include level, pressure, temperature,
flow, oil/water interface, and gas/oil interface. In most
offshore installations, the considerations in designing instrument systems to accommodate these variables are identical to those for their land-based equivalent. Foam, gas
cutting, sand, wax, and HzS are typical considerations.
Radios are used extensively for offshore communications,
and radio interference can present some unique problems.
Some electronic-based
sensors are sensitive to radiofrequency interference and may give false alarms or shutdown signals when high-powered radios are keyed nearby.
Most operators prefer to separate emergency shutdown
circuits from alarm and control circuits. Typical examples are high- and low-level shutdowns on tanks or separators, high/low pilots on manifolds, and gas and fire
detectors.
Regardless of the level of complexity of an instrument
and control system, a conscientious, well-disciplined, and
well-documented
program of regular testing and maintenance is essential. Offshore instrument systems are not
overly complicated, and given adequate maintenance and
correct initial installation, every instrument should perform its intended function reliably over the life of the facility.
Safety Systems
Separation of process-related shutdowns from instrumentcontrol loops was mentioned earlier. Process shutdowns
generally involve process-related variables that have exceeded preset limits. Other key safety-related systems
should be kept separate. These systems are covered in various U.S. Coast Guard Regulations and OCS Orders. 26
Examples of these systems are combustible-gas detectors,
poisonous-gas sensors, fire detectors, surface-controlled
subsurface safety valves (SCSSVs), surface safety valves
(SSVs), and emergency shutdowns (ESDs). Proper design and installation of these systems is perhaps the single most critical aspect of offshore instrumentation
and
control systems. (Safety shut-in systems are covered in
more detail in Chap. 3).
Combustible-gas detection systems are required in most
offshore operations. They are intended as early warming
devices to alert operators to potentially hazardous conditions where none normally exist. Modern systems have
catalytic sensing heads whose electrical characteristics depend on the concentration of hydrocarbon gases surround-
18-47
PETROLEUM
18-48
Facilities
ENGINEERING
HANDBOOK
by shut-ins-and
the complexity of the subsea facility determine the optimal design of the control system.
Subsea facilities require two separate sets of controls.
Production controls provide day-to-day operational control of the subsea equipment. Initial completion and subsequent workover of subsea wells require controls
designed specifically for installation/maintenance
functions. Completion/workover
systems generally provide
control over more functions than the associated production system. Production controls normally exclude control over hydraulic connectors, test ports, and vertical
access valves.
Reliability/Maintainability
Reliability of a control system can be considered to be
the probability that the control will not malfunction in such
a manner as to preclude performing an intended function.
Reliability usually is quoted over some specified period,
such as the intended operating life of a particular project
or the planned time between scheduled maintenance. For
any system, the probability that the system will fail to perform its intended functions over a given time period is
a function of the design, quality of the system components,
built-in redundancy,
and the quality of manufacture.
Regardless of how well a system is designed and built and
how short an operating period is considered, there will
be a finite probability that it may malfunction during that
period.
The likelihood of a failure can be minimized, but it can
never be completely eliminated. Consequently, rather than
going to great lengths and expense to design a system that
cant fail, it may be more cost-effective to set realistic reliability goals and to concentrate on designing the
equipment for maximum maintainability.
This approach
is aimed at minimizing the effect of a problem instead of
trying to avoid the inevitable and generally results in a
sound design that maximizes ease of retrieval and reinstallation. How best to implement increased reliability and
maintainability
should be determined by the incremental
cost involved and the benefits to be derived.
Redundancy
A system fault generally results in a well shut-in, and
recovery of the control equipment for repair and reinstallation is then required before the well can be returned to
production. The ultimate cost of the repairs is reflected
in the expense of mobilization for repair, the repair, and
subsequent demobilization.
One of the most economic and effective means of increasing system reliability is to include active backup for
weaker elements within the basic subsea control module
or, in the extreme, to provide a completely redundant
module.
This approach may be cost-effective in situations where
field conditions could impose severe economic penalties
or pose a safety hazard in the event of a control system
malfunction. The value of deferred/lost production and
the possibility of premature well work necessitated by the
shut-in also must be taken into account in evaluating the
economics of providing redundancy.
Redundancy does not eliminate the ultimate need for
repairs, but it may permit postponing them to take advantage of favorable weather windows, contracting rate
trends, or vessel availabilities,
all of which can work to
OFFSHORE
OPERATIONS
substantially
reduce repair costs. In addition, built-in
redundancy allows operations personnel to schedule the
work on the basis of convenience without incurring unnecessary production losses or potential well damage.
Although potentially economical,
redundancy is not
free. The decision on the extent to which it should be included in a design must be based on a careful examination of the cost impact on the project and the potential
benefits.
Operational
Considerations
18-49
There are currently two primary approaches to the control of subsea equipment-all
hydraulic and a hybrid of
electric and hydraulic (electrohydraulic).
Each offers a
number of variations with unique advantages, disadvantages, and associated costs that must be considered and
18-50
PETROLEUM
ENGINEERING
HANDBOOK
SUPPLY
CONTROLLER
SUBSEATREE
AND
Fig. 18.49-Direct
hydraulic
Control
Direct hydraulic control (Fig. 18.49) is the most straightforward design approach. It uses a single three-way surface control valve-a
single, relatively large-diameter,
dedicated high-pressure control line between the surface
control valve and the subsea tree hydraulic-valve
actuator and the valve actuator. When the surface control valve
is operated, high-pressure fluid is introduced into the control hose, causing the subsea valve actuator to open the
tree valve. When the surface valve is deactivated, the fluid
that opened the subsea valve is returned to the surface
fluid reservoir. The advantages of this system are simplicity, discrete remote control over each subsea function,
subsea control.
/
COMMON
VALVE
ACTUATOR
H P SUPPLY
PILOT
VALVE
(1 PER FUNCTION)
1
I
SUBSEA
AND
k------i
I
I
Fig. 18.50-Discrete-piloted
hydraulic
subsea control
TREE
ACTUATOR
VALVE
OFFSHORE
OPERATIONS
18-51
Fig. l&51--Sequential-piloted
Discrete-Piloted
Hydraulic
Discrete-piloted control (Fig. 18.50) has a single threeway control valve at the surface for each subsea function,
a corresponding
subsea pilot control valve, and single
small-diameter dedicated signal line between the two control valves. A single common high-pressure line provides
hydraulic supply from the surface to the tree. When the
subsea pilot valve is actuated, it switches high-pressure
fluid from the supply line to the subsea valve actuator.
When the pilot valve is deactuated, it vents the actuator
fluid subsea rather than returning it to the surface.
The advantages of this design are its relative simplicity, discrete remote control over each subsea function, inherent inferred feedback on subsea operations, relatively
low-cost hardware, and relatively fast response compared
to the direct hydraulic design. The disadvantages are that
cost and response time are both proportional to distance
just as they are with direct hydraulics, but the effects are
significantly less. The pilot lines are dead-ended, but cor-
hydraulic
subsea control.
Hydraulic
1 ATMOS
POD
1 ATMOS
AMBIENT
SOLENOID
VALVE \
-I----
COMMON
ELECTRICAL
POWER
OR OIL FILLED
COMP
POD
SUPPLY
ACCUMULATOR
COMMON
H P HYDRAULIC
SUPPLY
SUBSEATREE
VALVE WITH
HYDRAULIC
ACTUATOR
Fig. l&52-Multiplexed
valve actuators.
1 B-52
PETROLEUM
Electrohydraulic
Control
References
I. Rintoul, B.: Drilling
From The Steel Island,
Pcrcific Oi/
World/Annual, Petroleum Publishers, Brea. CA (Jan. 1980) 73,
18-28.
ENGINEERING
HANDBOOK