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SUBSEA MANIFOLD DESIGN FOR PENDULOUS INSTALLATION METHOD IN ULTRA DEEP WATER

Mario L. P. G. Ribeiro FMC CBV Subsea Milton V. B. Segura FMC CBV Subsea Jos A. N. Ferreira PETROBRAS

Summary
Subsea manifold main features and components Current manifold installation methods P52 manifold design Manifold structural analysis FEA Hydrodynamic analysis Closing remarks

Subsea Manifold
Functions:
Oil production Gas production Gas lift injection Water injection

Objectives:
Optimize the subsea layout arrangement Reduce flowlines cost Reduce the quantity of risers connected to the platform Full production in advance

More than 20 Diverless Subsea Manifolds Manufactured in Brazil

1996 Albacora Phase 1 2 Unit. 640m WD

1997 Albacora Phase 2 5 Unit. 400m WD

1998 Marlim 2 Unit. 820m WD

2001 Namorado 1 Unit. - 200m WD

2002 Roncador Phase 1 1 Unit. 1,892m WD

2002 Bijupira & Salema 5 Unit. 800 WD

2004 Marimb Leste 1 Unit. 715m WD

2004 Viola 1 Unit. 300m WD

2006 Roncador Phase 2 2 Manifolds on going

Subsea Manifold Main parts


SCM

Structure with piping Flowlines Hubs Sensors

Flowmeter

Marimb Leste Manifold

Mud mat

Pig Diverter Valve

Check Valves

Chokes

Manual & Hydraulic Actuated Gate Valves

Manifold Installation Methods in Brazil


Conventional procedures
Installation by cable
with AHTS with Crane Barge

up to 1000 m WD

Installation by drilling riser

Non-conventional procedures

over 1000 m WD

Sheave Installation Method (Roncador Manifold Phase 1) Pendulous Installation Method (PIM)
To be used in the next two P52 Manifolds

Conventional Installation Methods


AHTS

Work wire
(w/o heave motion compensation)

Crane Barge

Drilling Riser

Sheave Installation Method


Offshore facilities:
SS rig: Provides heave motion compensation AHTS 1: Lift the Manifold together with the SS rig AHTS 2: Orient the Manifold
AHTS 2 SS rig AHTS 1

Roncador Manifold 1 1885m WD

Pendulous Installation Method


By pendulous
Barge and AHTS

F U L L

S C A L E

T E S T

P52 Manifold
Dimensions: 16.5m (L) x 8.5m (W) x 5.2m (H) Weight in air: 280 tons WD installation: 1900m CG: 3.15m

P52 Manifold: Retrievable Modules


Almost all components are retrievable One SCM per X-Tree, six in total

Top view

Pig Diverter Module

Gas Lift Module

P52 Manifold: SCM


Subsea Control Module (SCM)
Electrical components: vibrations and pressure rate

Manifold Structural Analysis FEA


Structure life
Construction steps: manufacture, assembly, integration test Road and sea transportation Installation Operation

Loads
Permanent loads Operational loads Enviroments loads

Dynamic Amplification Factor (DAF): 2

Manifold Structural Analysis Global Model


Global model: AISC - LRFD checking

Lifting condition: AISC checking for axial load plus bending moment

Manifold Structural Analysis Local Model


Local model: von Mises checking
60% of yield strength 345Mpa

Lifting condition: von Mises stress distribution (MPa)

Hydrodynamic analysis
Excessive Oscillations (initial instability)
CG position Munk effect Drag Lift Vortex shedding

Hydrodynamic effect

Hydrodynamic analysis (Cont.)


Increase hydrodynamic stability
additional buoyancy in the line installation (1) a hydrodynamic-adapted geometry, e.g., vertical or near vertical panels around equipment (2) and open holes in the mud mat (3) dead weight at the manifold mud mat
(1) (2) (3)

Hydrodynamic analysis (Cont.)


Mechanism to avoid initial instability
Polyester Rope

BGL-1 (Crane Barge)

Mechanical fuse

Chain

Closing Remarks
For increasing the manifold reliability most of all components are retrievable; The assumed value for DAF (2) is enough to cover all the operational conditions; SCM supports installation loads; Counterweight is essential for avoid oscillations; Additional work for next manifold project is required in order to develop a hydrodynamic structure to avoid the excessive oscillations during initial moments.

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