OIL AND GAS PRODUCTION FROM SUBSEA WELLS

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SUBSEA or SURFACE ?

PRODUCTION FACILITIES

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Metering & Control Systems

Tension Leg Platforms

Floating Production Storage & Offloading Vessels

Turret Mooring Systems

Surface Well Systems

Light Well Intervention

Subsea Drilling Systems Standard Subsea Trees Subsea Processing

Smart Well Control Systems

Subsea Manifold Subsea Template Systems

Guidelineless Deepwater Trees

ROV Tie-In Systems

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SUBSEA TO BEACH Ormen Lange

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WELLS INCLUDING X-MAS TREE

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WELL CONSTRUCTION
RKB 30 - 36 Hole 30 - 36 Conductor 26 Hole 20 Surface Casing Time (days)

16 Hole 13 3/8 Intermediate Casing

Depth

12 1/4 Hole

Gas
7 Production Liner TVD 8 1/2 Hole TD

Oil

MD Roy.johnsen@ntnu.no

HORISONTAL X-MAS TREE

No valves in the vertical bore All valves on the sides / horizontal plane Tubing Hanger orients, land and lock inside HXT Well head

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VERTICAL X-MAS TREE

Production Master and Swab Valves in the vertical bore Tubing Hanger installed in WH Well Head

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Connect well to X-MAS tree

18 3/4 UWD15 Wellhead Housing Metal-to-Metal Annulus Seal Assembly 7 Casing Hanger 10 3/4 Casing Hanger 30 Conductor Housing 13 3/8 Casing Hanger

WELL HEAD

Permanent Guide Base

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CASING STRING
Casing run after each section of drilled hole to:
Prevent caving of unstable formations Protect weak formations Isolate abnormal pressure zones Seal off lost circulation zones Complete and produce the well efficiency Structural support for BOPs and wellheads

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WELL COMPLETION
TRSCSSV
FLX4 - AVLDM ASV

7" Production Tubing

Stand alone screens w/ICD, Zone control and Annulus flow prevention Upper and Lower completion installed

Multi-position GLV

P/T Gauge Hanger

PBR Completion packer Seal Stem to PBR 10 3/4" x 7" Screen Hanger w/PBR 6 5/8" Stand alone screen OCRE FBIV Swell packer M-Pas open hole packer 10 3/4" Casing Shoe Shale Sand Sand Sand Shale Sand ICD Bull nose

7" Liner

Shale

Sand

Sand

Shale

Sand

Sand

Shale

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DOWNHOLE TOOLS

Flow Control System Sub-Surface Safety System Packer System Sand Control Liner Hangers Instrumentation Chemical Injection

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API TUBULAR GRADES

H-40 J-55 K-55 N-80* L-80 C-90 C-95* T-95 P-110* Q-125* V-150* Used for large diameter casing only. Normally used if adequate (some normalize) Casing only N&T, C-Mg steel. HRC >24 Q&T, Cr-Moly steel. HRC <23 Q&T Type 1. HRC <25.4 C-Mg steel. HRC >25 Q&T Type 1. HRC <25.4 Replaced P-105. HRC 35 High strength steel Extra high strength steel

* Not H2S SSC resistant unless temp high

AWBRoy.johnsen@ntnu.no

16

SAND SCREEN

Consists of base pipe with drilled holes, wire wrapped screen jacket, consolidated prepack material, outer shroud with punched holes Jacket and outer shroud are welded or mechanically attached to base pipe Prepack material thickness ranges from .34 to .41 depending on size

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Material Challenges
Hydrocarbon mixture High temperature High pressure Solids/sand Different well intervention fluids
Completion and packer brine fluids Mud acids (HCl - hydrochloric acid, HF hydrofluoric acid) Stimulation fluids Scale inhibitors Chemicals to dissolve scale Methanol CO2, H2S, salts,

DOWN HOLE

Local flow condition due to narrow gaps Difficult to monitor and inspect without retrieving the tubing
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Material Challenges, cont. Experience: In most of the oil companies Well & Well completion are treated by a special group of people. These people are working separate from the materialand corrosion group in the company. This is a challenges due to transfer of experience and knowledge

DOWN HOLE

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MATERIALS SELECTION FOR WELLS

NORSOK M-001

ISO/CD 21457

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DOWN HOLE
Used materials Casings made from carbon steel Tubings made from

Downhole completion equipment

CS 13Cr Higher alloyed SS for aggressive hydrocarbon mixtures Different types of materials both CS, SS and Ni-alloys

Challenge for new high pressure, high temperature sour wells

Sour service requirement to be fullfilled for the actual CRA (Corrosion Resistant Alloy) Probability of hydrogen embrittlement (HE)
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Reference article:

P.R.Rhodes et.al.: Pushing the limits of metals in corrosive oil and gas well environments. CORROSION Vol. 63, No. 1 2007

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THROUGH TUBING ROTARY DRILLING

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SUBSEA PRODUCTION SYSTEMS, PIPELINES AND RISERS

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TEMPLATE AND MANIFOLDS

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MANIFOLD

27

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Ormen Lange Mating of manifold and foundation structure

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Manifold for Baobab during fabrication

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Example of piping manifold (Oseberg J) during fabrication

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SUBSEA X-MAS TREE

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CHOKE

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GATE VALVE

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SLAB GATE

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FLEKSIBLE PIPE

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FLEXIBLE PIPE

Design

1. Stainless steel carcass 2. Thermoplastic liner 3. Carbon steel pressure armour 4. Carbon steel tensil armour, two centrawound layers 5. Thermoplastic outer sheath

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SUBSEA PROCESSING
Definition:
Subsea Processing is any active handling and treatment of produced fluids at or below the seabed.

To date, the following have been given most attention:

Boosting / pumping Separation processes Wetgas boosting / compression

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SUBSEA PROSESSING
Why?
Tieback to platforms enable use of existing infra structure Enable longer tiebacks Bulk separation and re-injection of produced water Boost flowing well head pressure Gas compression

Raw seawater injection Hydrate suppression

Re-injection Export

Remove water from well stream

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TORDIS OIL/WATER SEPARATOR

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SUBSEA PROCESSING
Cooler

Needed equipment

Water Injection Pump Solids Separator Separator Tank

Liquid Pump HV Transformer

Compressor

Ultrasonic Level Indicator

Control Module

Control Valve

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SUBSEA GAS COMPRESSION

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SUBSEA PRODUCTION
Challenges
Water depths between 100 m and 3000 m Reservoir pressures up to 15.000 psi (1035 bar) Temperatures;
-200 C to + 1500 C normally ( -500 C to + 2000 C in extreme cases)

Design life of 20 years + (up to 50 years)

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SUBSEA PRODUCTION
Challenges
Material technology and fluid compatibility Flow assurance & insulation Long distances to topside Process equipment subsea
Increased complexity

Environment protection
Zero emission Fishing Decommissioning

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TYPICAL SUBSEA EQUIPMENT

Wellheads & X-mas trees for well control Piping manifolds (large-bore piping for hydrocarbons and water injection, small-bore piping for hydraulics and chemical injection.) Pipe spools, flowlines (pipelines) Connectors Structures Riser, workover equipment, tools Control system (hydraulic, electrical) In future, more and more complex equipment, such as separators and gas compressors will be located subsea.
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SUBSEA APPLICATION
Requirements
All subsea applications have very high quality requirements, since possibilities for inspection and maintenance are very limited, and replacement costs for non-conforming equipment are very high. Limited possibilities for monitoring and replacements
Seals and other non-metallic materials must be designed and qualified for full lifetime of field (typically 10-50 years) Metallic materials must in general be resistant to internal corrosion for the full lifetime of the field (pipelines with simple and predictable flow conditions may be in carbon steel with corrosion allowance combined with corrosion inhibitors.)

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MATERIAL SELECTION
Principles Materials must be selected based on:
Strength (yield, tensile) and hardness Ductility Fracture toughness (Normally Charpy-V, sometimes fracture mechanics testing) Price Availability (Small quantities, global fabrication) Fabrication methods (welding, induction bending, cold bending etc.), industry experience Decision on solid material or low alloy steel with CRA cladding where corrosion resistance is required

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ENVIRONMENTAL EFFECT
External corrosion Internal corrosion
Seawater Hydrocarbon system Injection water

Internal erosion Wear

De-oxygenated seawater Raw-seawater Produced water

Due to solids (sand) in the fluid Due to relative motion between components

Hydrogen Induced Stress cracking (HISC) or Hydrogen embrittlement (HE)

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HYDRROGEN EMBRITTLEMENT
H2S corrosion sour service in oil & gas systems, controlled e.g. by hardness (max 22HRC for carbon steels). Guideline for material selection given in ISO15156/ NACE MR0175. (This is the same effect whether the equipment is subsea or topside.) For submerged equipment, cathodic protection reactions may in addition give atomic hydrogen on steel surface. Critical for carbon/ low alloy steels with a hardness above approximately 35HRC or SMYS above appr. 700 MPa, or for duplex steels if highly stressed.

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FOINAVEN

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FOINAVEN HUB FAILURE 1996-1997

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GISLE RRVIK, STATOILHYDRO Presentation at NTNU, October 2008

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What is important?
Access to hydrogen Welding and CP (plus internal corrosion (H2S)) Certain strain/stress level (global and local) Load and geometry Microstructure Selected material

HISC

HYDROGEN

STRESS/STRAIN

MATERIAL

All these are needed at the same time!

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A PHONE CALL FROM A SUPPLIER

Im going to supply a subsea clamp to an oil company and am aware of the HE problem. My clamp is made from a polymer material probably GRP. This clamp is attached to the subsea unit by use of bolts made from 25% Cr SDSS. Which bolt tension (stress) can I accept and still avoid HE to damage the bolts?

HYDROGEN

STRESS/STRAIN

No HE

MATERIAL
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HOW CAN WE PREVENT HE?

Hydrogen Embritlement of 25% Cr SDSS

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DESIGN
STRESS/STRAIN

Design with acceptable local stress / strain

For duplex stainless steel

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ACCESS OF HYDROGEN
Reduced protection potential Welding with low hydrogen input Always bake bolts or other components with HDG or electrolyttic zinc coating (2500C / 4 hours) Use coating that prevent hydrogen to penetrate into the metal
HYDROGEN

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Subsea template retrieved after 4 years

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HOW BIG IS THE HE PROBLEM SUBSEA?

STATOIL: From early 1990s
Several subsea fields developed with 22% Cr DSS and 25% Cr SDSS in Piping, Manifolds, Valves Instruments 25% Cr SDSS standard for umbilical tubes

Today
275 wells + 50 subsea templates > 1000 km small bore umbilical tubing
Source: .Strandmyr, Duplex 2007, Grado Italy Roy.johnsen@ntnu.no Subsea template with SDSS piping

NORSOK M-001 Subsea

External protection
Chapter 4.3.4, 4.3.5, 4.3.6

Weld overlay (e.g. flange surfaces)

Chapter 4.4

Pipelines
Chapter 4.3 (Corrosion evaluation), 4.5, 4.6, 5.6.1 (Bolting materials), 5.7, 5.8

Chains and mooring systems

Chapter 5.9

Structural materials
Chapter 6.2
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ISO/CD 21457
Subsea External protection
Chapter 4.5.1, 4.5.4

Weld overlay (e.g. flange surfaces)

6.11

Pipelines
Chapter 4.3 (Corrosion evaluation), 4.5.4, 4.6, 5.5, 6.2, 6.3, 6.4, 6.5.1, 6.8.1, 6.8.2, 6.9, 6.10, 6.13

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MATERIALS SELECTION Subsea

NORSOK M-001

ISO/CD 21457

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MATERIAL SELECTION FOR X-MAS TREE

Composite valve block (CVB):
Low alloy steel w/ Inconel 625 overlay on all wetted parts or F6NM (13Cr 4Ni) martensittic stainless steel w/ 625 overlay in seal areas.

Production wing block

As for CVB or solid 25Cr superduplex stainless steel.

Annulus valve block and X-over flowloop:

Carbon/ low alloy steel w/ 625 overlay in seal areas.

Metal gaskets:

Inconel 625, Incoloy 825 or other CRA.

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MATERIAL SELECTION FOR X-MAS TREE, cont.

Valve internal parts:
Variuos types of nickel alloys and stainless steels.

Seal surfaces:
Overlay welded with Inconel 625.

Components not exposed to well fluid: Normally carbon or low alloy steel.

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TYPICAL MATERIALS USED

Subsea

Piping systems (oil/ gas/ water injection):

Carbon steel or low alloy steel (typically ASTM A350 Grade LF2, AISI 8630 or ASTM A182 Grade F22) with UNS N06625 overlay weld on components like hubs and valves. For smaller dimensions, use of solid stainless steel forgings may be more economical. HIP (Hot Isostatic Pressing) may be an alternative to forged material. Martensittic stainless steel type F6NM (13%Cr 4%Ni) may be used where high strength is required. Has limited corrosion resistance, normally overlay welding with Inconel 625 is required on all seal surfaces. 22Cr/ 25Cr duplex stainless steels may also be used.
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TYPICAL MATERIALS USED

Subsea

Smallbore piping systems (hydraulics and chemical injection), typically 3/8 to :

AISI 316 where low strength is acceptable. (Alternatively cold drawn AISI 316 where higher strength is required, and if welding is not required). 22Cr Duplex or 25Cr Superduplex where extra strength is required. This has been standard material selection for more than 10 years. Cold bending (min. bending radius 2,5xD, max hardness 360 HV) used in fabrication, and has never caused problems with hydrogen embrittlement.
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MATERIALS FOR SEAWATER

Seawater resistant materials are used for piping systems for raw seawater (i.e. seawater with high oxygen content) and for components where cathodic protection (CP) cannot be ensured or where CP have to be avoided (e.g. due to problems with calcareous deposits). 25Cr superduplex (Note: With PRE-value and other properties according
to Norsok M-630.)

6Mo UNS N06625 (Inconel 625) Titanium Fibre Reinforced Epoxy

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MATERIAL SELECTION TO AVOID HISC

In later years, we have seen an increased focus on risk for HISC (Hydrogen Induced Stress Cracking) from several oil companies. This has resulted in additional requirements on several projects, such as: Restrictions on use of HISC-sensitive materials, such as 22Cr- or 25Crduplex. Alternatives are C-steel with internal overlay weld (typically UNS N06625/ Inconel 625) or alternatively austenittic stainless steels. Austenittic stainless steels are often impractical due to low strength. Detailed design requirements with restrictions on local stresses and strains, smooth cross sectional changes, restrictions on cold bending of pipes etc. (Ref. e.g DNV (Draft) RP-F112 and Norsok WA-01.) Special coating on all duplex piping, such as vulcanized polychloroprene rubber, to prevent hydrogen formation on the steel surface.

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CAN SOMETHING GO WRONG?

Use of wrong material not according to specification No Cathodic Protection applied not electrical contact between sacrificial anodes and structure HISC due to a combination between stress, hydrogen and susceptible material Solids in the fluid causing catastrophic metal loss followed by a leak Composition of process fluid out of control causing severe corrosion Corrosion inhibitor not supplied or mal-functioning causing severe corrosion
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CAN SOMETHING GO WRONG?

continue

Fatigue due to system vibration (including free span of pipelines) Fatigue in wellhead/casing due to overload during work-over operation No or wrong inspection program implemented .

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Electrical penetrator
25% Cr Duplex material Subsea without CP 30 - 35 % sigma phase due to incorrect heat treatment Severe corrosion attack due to the sigma phase (In this case, the correct material had been selected, but due to incorrect heat treatment, material had not got the required properties.)
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EXAMPLE

CORROSION PROTECTION IS IMPORTANT TO SECURE STRUCTURAL INTEGRITY!

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USE OF ELASTOMERS OFFSHORE

Thermal insulation Seals Cable and flowline protection Bearing systems Fendering and buoyancy Hoses ++

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FAILED ELASTOMER SEALS

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ALEXANDER KIELLAND ULYKKEN

27. mars 1980 123 mennesker omkom

EN SLIK ULYKKE VIL VI IKKE HA IGJEN!

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