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Subsea Production Systems

Presented by: Mohd Zaini Kadir Product Project Manager
Email: mohdzaini.kadir@fmcti.com
18th February 2012

Subsea Field Developments

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Content
1. Part II: Subsea Production System

Xmas Trees
Systems

Flowline
Connection
Systems
(Tie-In System)

Manifold Structure

Steel Tube
Umbilical

Subsea Control
Systems

Field Architecture

What is Subsea?
Definition: The ability to
produce hydrocarbon
f
from
reserviors
i
located
l
t d
under water without the
well being directly
connected by a riser to
the host facility.

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

Fixed
Platform
(500 m)

Compliant Tower
(900 m)
Mini - TLP
(1100 m)
Tension
Leg Platform
(TLP) (1370 m)

SPAR
(2300 m)

Floating Production
Systems
(FPSO, FPS)

(2300 m)

Subsea
Systems
(3000 m)

Why Subsea ?
Full Field Life economics;
Development CAPEX for a platform may not pas economic
hurdles
Subsea
S b
options
i
normally
ll llower than
h a Pl
Platform.
f
Subsea generally will give earlier first gas or first oil hence
better returns.

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Why Subsea ?
Improved HSE performance:
Removes people from offshore, potential to reduce visual and
environmental impact.

Why Subsea ?
Deviated drilling from surface well
may not be able to reach the
entire reservoir. Reservoir area
g and shallow.
are too large
May required multiple host
facilities.
Uncertainty over numbers of well
to complete the reservoir
development.

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Subsea Xmas Tree

Interface Considerations
Four interfaces govern tree design

The Well
Tubing Size, Pressure,
Temperature, Material Class

The Well

Controls
Direct, Piloted, E-H, Different
Vendors

Pressure
Flow Rates

Controls

Fluid Properties

Flowlines
Pipeline Size, Pressure,
Connection Type, Different
Vendors

The Wellhead
Mudline, Clamp Hub, Mandrel,
Different Vendors

Flowline
Connection

Wellhead
Mudline vs. Subsea
S
External Profile & Gasket

Casing Strings & where are they

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Subsea Xmas
Tree
Subsea
Tree
Types VXT Vs HXT

INTERNAL TREE CAP

CROWN PLUG

XOV
PSV

ASV

TREE CAP TEST / VENT

PWV
P

AWV

DHSV

AMV
ANNULUS / SERVICE
OUTLET

XOV
P

PRODUCTION OUTLET

AWV

AAV

PMV

PWV

PMV

AMV
DHSV

VX TEST

ANNULUS / SERVICE
OUTLET

VX TEST

PRODUCTION
OUTLET
SUBSEA TREE ASSEMBLY

WELLHEAD SYSTEM

HORIZONTAL SUBSEA TREE

VERTICAL SUBSEA
TREE
CONVENTIONAL
SUBSEA
TREE

Subsea Xmas Tree

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

Guideline-less VXT with Insert

Technology (Girassol)

Horizontal Tree

Vertical Tree

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Subsea Xmas Tree

Xmas Tree Functions:

Safety barrier

Safely stop produced or injected

fluid

Injection of chemicals to well or

flowline

Allow for control of downhole

valves

Allow for electrical signals to

downhole gauges

To bleed of excessive pressure

from annulus

Regulate fluid flow through a

choke (not mandatory)

Allow for well intervention

Xmas Tree

Subsea Xmas Tree

XT Schematic
PMV

Production Master Valve

PWV

Production Wing Valve

AMV

A
Annulus
l M
Master
t V
Valve
l

AWV

Annulus Wing Valve

XOV

PSV

ASV

Annulus Swab Valve

XOV

Cross Over Valve

SCSSV

Surface Controlled
Subsurface Safety Valve

PTT

Pressure/Temperature
Transmitter
T
itt

ASV

PWV

AWV

AMV
ANNULUS / SERVICE
OUTLET

PRODUCTION OUTLET
PMV

DHSV

VX TEST

SCSSV

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Subsea Xmas Tree

TREE CAP PARKING
RECEPTACLE

SUBSEA CONTROL
MODULE

ANNULUS
CROSSOVER
VALVE
ANNULUS
WING VALVE
ANNULUS
SWAB
VALVE
ANNULUS
MASTER
VALVE

PRODUCTION
SHUT DOWN
VALVE

FLOWLINE
CONNECTOR

CONNECTOR /
SCSSV ROV PANEL

Subsea Xmas Tree

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Subsea Manifold (PLEM / PLET)

17

Subsea Manifold
The primary function of a subsea manifold is to channel flows
from several individual wells into single or multiple flowline
headers.

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Subsea Manifold
Manifold Introduction
Definition: Subsea Production Manifold
A subsea structure containing valves and pipework designed to
combine the fluids of one or more subsea production Christmas
trees and to direct the fluids down one or more export flow lines.

Definition: Subsea Injection Manifold

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

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Subsea Manifold
General Design Features
Subsea installable and often subsea retrievable as well.
Pipework rated to the full shut-in temperature and pressure of the
subsea Xmass trees.
ROV accessible for all subsea operations.
Compatible with any subsea control system.
Interface with foundation structure.
Housed connection equipment. (Tie-in system)
Gas lift for low-pressure or deep subsea development.

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10

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Subsea Manifold
Manifold Types
Template Manifold a drill-through structure designed to house
multiple subsea christmas trees.
Cluster Manifold a stand-alone structure designed to direct fluids
for multiple subsea Christmas trees placed around it.
Pipeline End Manifold (PLEM) a simpler version of a cluster
manifold generally designed to direct fluids for only or two subsea
Christmas trees. A PLEM generally connects directly to a subsea
fl
flow
line
li without
ith t the
th use off a pipeline
i li end
d ttermination
i ti (PLET)
(PLET).

21

Subsea Manifold
Template Manifold
Features
Complex
p
and very
y heavy
y
structure.
No well jumpers required
Cost effective.
Suitable for specific field
requirements.
Horizontal connections.
Tree drilled only on
t
template.
l t

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Subsea Manifold
Cluster Manifold
Features
Simple
p and relatively
y light
g
structure.
Easy in installation .
Cost effective.
Horizontal or vertical
connections.
Trees drilled at distance.

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Subsea Manifold
Cluster Manifold Azurite (Congo)

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Subsea Pipeline End Termination /Manifold

(PLET / PLEM)
What is PLET?
PLET is used as termination points for the flowline.
When the length of the flowline is large, thermal expansion in it can lead to
bending and buckling failure.
PLET is meant to accommodate the Thermal Expansion in the flowline.
What is a PLEM?
PLEM is an extended version of PLET.
It posses all the features of PLET but with more number of hubs (more than
one) for various purposes, like- more than one Well Jumper connection, or
Water injection.

PLEM

PLET
25

Subsea Pipeline End Termination (PLET)

PLET

Flowline
Manifold

Jumpers

26

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Subsea Manifold - Components

Majors components:
1. Structure Frame

Control
System

2. Piping
p g System
y
3. Connection System
4. Leveling System
5. Control System

Piping System

Structure Frame
Connection
System

Leveling System

27

Subsea Manifold - Components

Manifold Structure Frame

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Subsea Manifold - Components

Internal Structure of Manifold: Piping System
Branch Valve Cluster

Small-bore envelope

Connection
System
Header
Branch
Manifold Structure Consists of Valve, Small and Large Bore piping.
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Subsea Manifold - Components

Connection System

Universal Tie-in System

UTIS

ROVCON

STABCON

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15

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Subsea Manifold - Components

Leveling System
Manifold

Funnel-down
Mono-post

Vent./suction hatch

Suction anchor

31

Subsea Manifold - Components

Control System

Subsea Control Module (SCM)

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

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Subsea Manifold/PLEM
Deployment Methods
Vessels
Drill Rig : Through moon pool or keel-hauled on drill string.
Heavy Lift vessels (Derrick Barges): Through moon pool or over
side
Work-class vessels: over side on crane or winch.
Equipment
Manifold hydraulic installation tool.
Sling
Sli sets,
t either
ith wire
i rope or synthetic
th ti fib
fiber.

33

Subsea Manifold/PLEM
Manifold Installation Lift Offshore

34

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Subsea Manifold/PLEM
Moon Pool Deployment

35

Subsea Manifold/PLEM
Work Vessel Deployment

36

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Subsea Foundation
Foundation Types
Mud Mats A simple foundation resting directly on the seabed,
generally with a short skirt around the perimeter to resist lateral
loads.
Piles long cylindrical structure embedded into the soil intended to
hold a subsea structure above the seabed. Foundation may utilize
one or more individual piles.
Jetted Piles
Suction Piles / Anchors
Intermediate Structure an intermediate structure can be used to
interface a subsea manifold with a pile foundation to reduce weight
on the manifold structure or to ease retrieval on the manifold.
Intermediate structures can be either retrievable or permanent
structures.

37

Subsea Foundation Mudmat

Types of Foundation: Mudmat

Design Codes:
API RP 2A WSD (geotechnical
and structure)
AISC

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Subsea Foundation Suction Anchor

Suction piles / anchors
Suction pile is a Manifold foundation. It
penetrates the soil under its own weight
and due to the subsea head.

39

Subsea Foundation Suction Anchor

Installation-

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40

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Subsea Foundation Suction Anchor

Manufacturing:

Material: Carbon Steel

Corrosion Protection:
Coating & Cathodic Protection
(at top)
Under Mud Line (rest of the
body)

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41

Subsea Manifold/PLEM
Overtrawlable
Structure

Dual 20 headers
45 x 33
45m
33m x 14
14m
657 metric tonnes

Suction Piles

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Subsea Manifold/PLEM

43

Subsea Connection System & Jumper

44

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Subsea Connection System

Trees

Equipment found in a typical subsea field:

45

Subsea Connection System

Introduction
Definition: Flowline tie-in Connection of a flowline to a subsea
facility.
This includes connection to any of the following subsea facilities;
Trees, Manifolds, PLET and PLEM.

46

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Subsea Connection System

Jumper Functionality
Connect flowlines to manifolds and manifolds to trees
Contain rated working pressures.
A
d t th
i
t ti and
d misalignment.
i li
t
Accommodates
thermall expansion,
contraction
Insulated for hydrate prevention

47

Subsea Jumper
Types

Flowline Jumpers (Connects Manifold, PLET, PLEM,

SLED)
Well Jumpers (Connects Tree to Manifold) (According to use)

Well Jumper

Flowline Jumper
Note: Flowline Jumpers are rounded at corners for pigging

48

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Subsea Well and Flowline Jumper Connections

Flowline
Jumper

Well
Jumpers

Jumper being
lowered subsea
with connectors
on either side

Sled/Manifold

49

Subsea Jumper
Jumper Connectors
Reasoning behind the various
connection systems:
C
Cover different
diff
t ti
tie-in
i methods
th d from
f
shallow to ultra-deep waters
Be applicable from flexible pipe to rigid
steel pipe

Torus Hydraulic
Connector
(Vertical)

MAX Mechanical
Collet Connector
(Vertical)

Be suited for seabed conditions from

hard to very soft soil
Driven by cost factors/functionality
Allow for independent installation order
of subsea stations and flowlines
Be adaptable to the preferences of
different Installation Contractors and
Oil Companies

Single or
Twin Screw
Clamp Connector

KC4 Collet
Connector

Vertical or Horizontal

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Vertical Jumper Spool deployment

Steps of jumper deployment
Lifting & Lowering Jumper
Offshore or Quayside

Jumper on Shipping Stands

51

Vertical Jumper Spool deployment

Steps of jumper deployment (contd)
Land First End on PLET (or Tree)

Land Second End on Manifold

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Vertical Jumper Spool deployment

Steps of jumper deployment (contd)
Remove Hub Protection Cap

Retrieve Spreader Bar

53

Vertical Jumper Spool deployment

Steps of jumper deployment (contd)
Lock & Test Connector

Retrieve CAT

54

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Vertical Jumper Spool deployment

Steps of jumper deployment (contd)

Connector
Actuation
Tool (CAT)

55

Subsea Control System

56

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Subsea Control System

What does a Control System Do?
Typical Subsea devices connected to the system
Down Hole Gauges
Multiphase & Wet Gas Flow Meters
Venturi Flow meters
Sand Detectors
Hydrocarbon Leak Detectors
Chemical
Ch i l iinjection
j ti valves
l

57

Subsea Control System

What does a Control System Do?
Subsea items Controlled by the system
Low pressure Valves ( tree, manifold)
High Pressure Valves (downhole safety valves)
Chokes
Chemical Metering Valves
Subsea items Monitored by the system
Temperature
Pressure
Choke Position
Flow rates Oil & Gas & Multiphase

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Subsea Control Control System Types

1. Direct Hydraulic System
2. Direct Piloted Hydraulic System
3 Direct Electro Piloted Hydraulic System
3.
4. Mini Multiplex Electro Hydraulic Controls
5. Multiplexed Electro Hydraulic System

59

1. Direct Hydraulic Control System

Simple and Reliable
Low Control System Equipment Cost
Standardized Field Proven Equipment
q p

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2. Direct Piloted Hydraulic Control System

Simple and reliable
Economical system for extending offset distances for Direct Hydraulic
Systems
Standardized field proven equipment
Faster response rate than Direct Hydraulic system.

61

3. Direct Electro Piloted Control System

Simple and reliable
Instantaneous Venting of Underwater Safety Valve at the Xmas Tree
with minimal Control System equipment costs
Faster response rate than Piloted Hydraulic

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4. Direct Electro Piloted Control System

Instantaneous Hydraulic
Venting an Actuation

Modular Design
ROV Retrievable SCM with
Running Tools

Increased Instrumentation
Capabilities

SUBSEA
CONTROL
UNIT

POWER ON COMMUNICATION

MINI-SEM

PRESSURE
SENSOR
TEMP
SENSOR

Mini-SCM
PLATFORM

TREE

UMBILICAL

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5. Multiplex Electro Hydraulic Control

Dual Redundant Electronics

Modular Design

Increased Instrumentation
Capabilities

ROV Retrievable SCM with

Running Tools
Instantaneous Hydraulic
Venting an actuator

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Electro Hydraulic Control System

Chemical
Injection

Electrical
Power
Unit (EPU)

Master
Control
Station
(MCS)

TUTA

Hydraulic
Power Unit
(HPU)

Umbilical
Control System
TUTA - Topside Umbilical Termination Assy

SDU

SDU - Subsea Distribution Unit

Manifold

EFL Electrical Flying Lead

HFL Hydraulic Flying Lead

EFL / HFL
Tree

Tree

HPU

65

Electro Hydraulic Control System

Master
Control
Station (MCS)
Hydraulic
Power unit (HPU)
Injection
Chemicals

Subsea
Distribution
Unit (SDU)

Electric
Power Unit (EPU)

Umbilical

Xmas
Tree

Hydraulic
H d li and
d
Chemical Lines

SCM

Electric
Cables

Hydraulic
Actuators

Umbilical
Cross Section

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Subsea Umbilical

67

Subsea Umbilical

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Subsea Umbilical
What is Control Umbilical?
Connection between the
topside and communication
equipment
i
t and
d the
th subsea
b
control system.
Hydraulic power and control
lines are individual hoses or
tubes manufactured from
steel or thermoplastic
materials and encased in the
umbilical
bili l bundle
b dl

69

Subsea Umbilical
Thermoplastic Hose Umbilical

Various hose bore sizes (1/4- 2 ID) and hose

working pressures (3k 15K PSI) are available to
provide a field proven, cost effective solution for
subsea
b
field
fi ld applications.
li ti

Steel Tube Umbilical

Umbilical containing steel tubes for conveyance of

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

Hybrid Umbilical

Hybrid umbilical containing a combination of steel

tubes for methanol or chemical injection, and
thermoplastic hoses for hydraulic fluid supply.
Integrated Umbilical containing electrical cables, steel
tubes and/or thermoplastic hoses are also available
for dynamics applications.
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Subsea Umbilical Umbilical Termination

Assembly.

71

Subsea Umbilical Umbilical Termination

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

Electrical
Distribution
Unit (EDU)

Hydraulic
Distribution
Unit (HDU)

Umbilical
Termination
Head (UTH)

Mudmat

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

73

Subsea Field Architectures

74

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Subsea Field Architecture

Field Architectures
Satellites Well off by itself.
Daisy Chain Wells linked together in series.
Integrated Template Wells drilled thru manifold structure.
Cluster A group wells surrounding manifold.

75

Subsea Field Architecture

1. Satellite Wells
Subsea wells installed individually on the
seabed, with dedicated flowlines back to
a surface processing facility.

XMT #1
XMT #2
XMT #3

Advantages:
Flexible
Pay as you go

XMT #4

Field proven technology

Expandable
Disadvantages:
Dedicated flowlines/ Umbilicals.
Umbilicals
Complex flowline hook-up
Complex controls distribution.
Platform

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Development of satellite fields

77

Subsea Field Architecture

2. Daisy Chain Wells
XMT#1

Subsea wells installed separately and

linked to an adjacent subsea well,
possibly sharing a test flowline.
Advantages:
Similar to satellites

XMT#3

XMT#2

Flexible
Expandable
Possibly fewer flowlines than for
satellites
Disadvantages:
Complex controls distribution
Flowline needed for each well
Deviated drilling may be needed.
Platform

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Subsea Field Architecture

2. Daisy Chain Wells

79

Subsea Field Architecture

XMT#4
4 XMT#2

Man
nifold

XMT#3
3 XMT#1

3. Integrated Templates
Subsea wells installed on a pre-positioned
drilling template on the seabed. Each well
having a dedicated flowline to surface.
Advantages:
Common datum for wells.
Flowline porch for multiple connections.
Manifold can be added later.
Disadvantages:
Dedicated flowlines / Umbilicals may be
used.
Limited slots available.
Platform

Pre-production investment in template

necessary.

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Subsea Field Architecture

3. Integrated Templates

81

Subsea Field Architecture

4. Cluster Manifold

Subsea satellites wells installed

individually linked to a central manifold
where production is commingled.

XMT#3

Advantages:

XMT#1

Flexibility of satellites.
Fewer flowlines.
Centralized controls system.

Manifold

Advantageous for dropped object

avoidance.
XMT#2

Disadvantages:
Complex flowline connection.
Limited Slots for production tie-in.

Platform

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Subsea Field Architecture

4. Cluster Manifolds

83

Questions???

84

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