FLR2564 Module 2

FUNDAMENTALS OF SUBSEA
ENGINEERING
MODULE 2
Wellheads, Xmas Trees and

Manifolds
AUTHOR
John Preedy PhD

Associate, Azur Offshore Ltd
CONTENTS
Learning Outcomes..................................................................................................... 4
1. Introduction ..................................................................................................... 5
2. WELLHEADS ...................................................................................................... 7
2.1 Subsea Wellhead and Guide Base .................................................................. 7
2.2 Tubing Hanger System (Conventional Dual-bore Trees) .................................. 13
2.2.1 Tubing Hanger ................................................................................. 13
2.2.2 Wellhead Conversion Assemblies ....................................................... 14
2.3 The Blowout Preventer (BOP) ...................................................................... 15
2.3.1 The Blowout Preventer Systems ......................................................... 17
2.3.2 Annular Blowout Preventer ................................................................ 17
2.3.3 Ram Blowout Preventer .................................................................... 18
2.4 Choke and Kill ........................................................................................... 21
3. SUBSEA XMAS TREES ...................................................................................... 23
3.1 Xmas Trees ............................................................................................... 23
3.1.1 General .......................................................................................... 23
3.2 The Conventional Dual-bore Tree ................................................................. 26
3.3 The Horizontal or Spool Tree .................................................................... 32
3.4 Comparison of Tree Types .......................................................................... 38
3.5 Materials .................................................................................................. 39
3.5.1 Specifications for Trees and Wellheads ............................................... 39
3.6 Subsea Valves and Actuators ...................................................................... 39
3.6.1 Valve Components ........................................................................... 39
3.6.2 Actuators ........................................................................................ 40
3.7 Subsea Control System Interfaces ............................................................... 42
3.8 Scope of Supply ........................................................................................ 43
3.9 Shallow Water Guideline and Deepwater Guideline Guidance Running Systems .. 43
3.10 Tree Protection .......................................................................................... 45
3.11 All-electric Tree ......................................................................................... 47
3.12 Drill Through Spool Tree ............................................................................. 49
4. SUBSEA MANIFOLDS AND TEMPLATES ............................................................ 54
4.1 Introduction .............................................................................................. 54
4.2 Drilling Templates ...................................................................................... 60
4.3 Template Manifolds .................................................................................... 60
4.4 Well Clusters Around a Manifold................................................................... 61
4.5 Design Considerations ................................................................................ 63
4.5.1 Number and Type of Wells ................................................................ 64
4.5.2 Inspection, Maintenance and Repair ................................................... 64
4.5.3 Water Depth and Seabed Conditions .................................................. 65
4.5.4 Flow and Production Considerations ................................................... 67
4.5.5 Operational Requirements ................................................................. 67
4.5.6 Protection ....................................................................................... 68
4.5.7 Installation/Decommissioning ............................................................ 71
4.6 Manifold Components ................................................................................. 72
4.6.1 Valves ............................................................................................ 73
4.6.2 Chokes ........................................................................................... 73
4.6.3 Control Modules ............................................................................... 74
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4.6.4 Instrumentation ............................................................................... 74
4.6.5 Pipework and Materials ..................................................................... 75
4.7 Future Developments and Trends ................................................................ 75
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3
LEARNING OUTCOMES
Learning Outcomes:
On successfully completing this module you will have an understanding of:
The background factors that led to the development of offshore production systems.
How and where oil and gas can form in the Earth and how it is located.
The importance of geological information to predict how oil will flow.
How a well is drilled.
Different types of oil flow.
The factors that will make oil flow from the source to the production facility.
Flow assurance issues, which must be correctly assessed for each development.
On completing this module you will have an understanding of:
o The functions of the following:
Subsea wellhead
Tubing hanger system
Subsea Xmas trees
The subsea systems interface
The drilling template and manifolded systems
Well clusters.
o A comparison between the dual-bore tree, horizontal (spool) tree and the
advantages of the electric tree.
o Design issues involved in the choice of a template or manifolded system.
o The effect of the IMR (inspection, maintenance and repair) philosophy on the well
design.
o The factors that affect oil flow and design requirements to maintain flow.
You will also be able to:
o Describe the elements of:
The subsea wellhead
The tubing hanger system
The subsea valves and actuators of the Xmas trees.
o List the potential hazards to the subsea equipment and the relative probability of
the hazard together with the protection techniques.
o List and describe the components of the manifold.
You will also have an insight into the symbols used in flow diagrams and have practice
of making a simple diagram.
4
1. INTRODUCTION
Figure 2.1: Summary of Wellheads, Xmas Trees and Manifolds as part of Subsea Engineering
Components
Source J E & P Associates and Azur Offshore Ltd
In the age of reduced margins, frame agreements and alliancing, all subsea engineers are trying to
achieve the goal of cost reductions and are looking at initiatives to accomplish this, in various forms.
High on the agenda of Subsea Xmas Tree manufacture is the achievement of STANDARDISATION and
MODULARISATION, both with respect to the operator cost reduction, and design simplifications relating to
manufacturing costs. A similar standardisation is occurring with manifolds. The Back to Basics
engineering approach is producing Xmas trees for subsea field developments, using functional
specifications (and not the engineers preferred design with all the bells and whistles), and utilising up-
to-date metallurgy and materials selection philosophy.
This module covers wellheads, trees and manifold systems. These are normally supplied under part of
the subsea production systems (SPS) contract (which includes subsea control systems covered separately
in Module 4). The headline companies supplying SPS equipment are the following (in no particular
order):
CAMERON (Now OneSubsea, combining Cameron and Slumberger) - USA
FMC Technologies - Norway
GE(Oil & Gas) VETCO - USA
AKER SOLUTIONS - Norway
DRIL-QUIP - USA
5
Figure 2.2: Illustration of Subsea Engineering Components
Illustrating Xmas trees and manifolds in a field development.
Source GE Power
Directed Learning:
Go to Google and find the websites of the five main companies providing SPS
equipment and collect equipment pictures and specifications for your own files.
6
2. WELLHEADS
Figure 2.3: Typical Subsea Wellhead

Wellhead general arrangement with casing tubulars:
(a) outer conductor casing 30;
(b) inner conductor with wellhead welded at its top;
(c) 13 casing on wellhead casing hanger;
(d) 10 casing on wellhead casing hanger;
(e) 7 liner casing on wellhead casing hanger;
representation of the two proprietary wellhead profiles.
Source GE Power and Cameron
2.1 Subsea Wellhead and Guide Base
The subsea wellhead is the main structural component which supports the loads generated during drilling
operations and during production operations. Whilst drilling or work-over is taking place the wellhead is
the main support item in the completed well.
The three main functions of a wellhead can be considered as follows:
i. To provide a location for suspension of casing strings

Each of the casing strings which runs up through the well is physically suspended within the
wellhead housing. Should the well be used for production, the production tubing is
additionally supported and locked in position in the wellhead via the tubing hanger.
ii. To provide sealing and pressure containment

This sealing and containment takes place in two distinct areas, between the well and the
environment and to provide isolation between the casing and downhole structures.
During drilling operations a blowout preventer (BOP) is installed on the wellhead at the base of
the marine drilling riser. The BOP is mandatory and used to protect the rig and the
environment at the seabed level in case of gas kick from the well, to avoid a blowout.
7
iii. Allows the installation of flow control equipment
Should the well be converted from an appraisal well into a future production (normal case) or
water injection well, the subsea Xmas tree can be installed to provide flow control from the
well or from the injection line or manifold.
Figure 2.4: Subsea Wellhead Functions

Including example of a blowout preventer (BOP).
Source Azur Offshore Ltd
For subsea wells, the wellhead is supported through the 30-inch housing/conductor which is cemented
into the first/primary soil formation. The 30-inch housing then supports the internal wellhead housing
with the subsequent internal casing strings, each one supported via a casing hanger at the wellhead with
a seal mechanism. The 30-inch housing supports the permanent guide base which forms the main
guidance mechanism for equipment being deployed subsea to the wellhead, during drilling and
completion operations. Four guide posts and guide lines are used down to 500 m. For deeper waters,
guide lines are not practical and other guidance systems are in use with exploration drilling now reaching
2,800 m.
8
Figure 2.5: Wellhead Housing Joint
Function and details of external connection components.
9
Figure 2.6: Permanent Guide Base
Function and example of a permanent guide base locked into wellhead and outer conductor. Note this is
a guide base for shallow water developments because it is illustrated with guide posts as part of the
landing and orientation requirement for a BOP or tree.
Figure 2.7: Shallow Waterguide Base with 4 Guide Posts
10
Figure 2.8: Deepwater Guide Base
BP Greater Plutonio Permanent Guide Base Deep water Angola
Source BP plc
The BOP stack and subsequently the Xmas tree are connected to the wellhead by a hydraulic-operated
connector. Over recent years two connection profiles have become the most frequently used. These are
proprietary designs known as Vetco H-4 and the Cameron Clamp Hub profiles. Most UK drilling rigs
are equipped with a single high pressure stack, though two stack systems were previously in use, to
provide a low pressure connection at the 20-inch and high pressure for the 13-inch casing. A single
connection of the BOP stack to the wellhead is the generally accepted method.
11
Figure 2.9: Subsea Wellhead Types
Representation of the two proprietary wellhead profiles
(A) Cameron Hub Profile
(B) Vetco Grey H-4 Profile
These are patented by the respective companies but are freely allowed to be used by the whole industry
The primary environmental loading on the wellhead occurs during the drilling phase, when a high varying
bending moment is transmitted through the riser onto the wellhead housing and then to the 30-inch
housing/casing/formation through current, wave loads and drilling vessel movement. It is now common
policy to run the two top joints of 1-inch wall thickness joints of 30-inch to provide the resistance to the
anticipated loads; previously only 1-inch casing was considered. The wellhead housing is locked into the
30-inch wellhead, and loads on the wellhead are transmitted into the 30-inch conductor.
In addition to the drilling loads the wellhead may be subjected to impact and snagging loads associated
with construction activities and accidental incidents such as fishing trawl board impacts and pull-over
forces. These loads are transmitted through the production tree into the wellhead connector and through
into the 30-inch conductor.
12
Figure 2.10: Wellhead Design Loads
As part of the drilling process the casing tubulars will be cemented into the ground formation to form a
firm bond. The reason for this is that the wellhead and its connected components (that is, trees and
casings) will be subject to high loads during operations. Such loads could arise from the hydrostatic
forces from the reservoir or impact loads from hardware hitting the tree.
Source J E & P Associates
Materials
The wellhead housing and casing hangers are made from low alloy steels, and the guide frames structure
from BS 4360 50D type material (this is the British standard for a grade of steel). Inlay materials (that
is, Inconel 625 or stainless steel) can be used on the sealing surface to provide wear and corrosion
resistance.
2.2 Tubing Hanger System (Conventional Dual-bore Trees)
2.2.1 Tubing Hanger
The tubing hanger provides the interface between the downhole completion tubing equipment and the
subsea tree. The tubing is supported in the wellhead by the tubing hanger which seals in the wellhead.
The seal about the tubing hanger isolates the production tubing from the annular cavity about the tubing
the annulus. Access to the annulus can be required to:
Assist in monitoring the well for pressure increases and losses.
Allow the installation of control lines for a downhole safety valve, a chemical line for chemical
injection and electrical line for downhole gauges.
Allow the injection of gas to injection points in the tubing for gas lifting.
Allow for cleaning fluid circulation.
13
The tubing hangers can be concentric (that is, non-oriented) or oriented. Where minimal access is
required to the annulus, or for connection into the tubing downhole, then a concentric design would be
suitable. For most applications the oriented design is generally preferred as it allows direct vertical
access to the annulus. This allows the installation of tubing plugs in the tubing hanger prior to Xmas tree
removal.
For the installation of downhole chemical injection and downhole gauges, the oriented design requires the
use of standard hydraulic connections and standard electric connectors.
Figure 2.11: Sub-surface Completions Schematic

For production a 5 production tube will be suspended from the hanger, with its flow path connecting to
the flow path in the tree. It is through this that the reservoir fluids will flow once the casing at the
reservoir is perforated.
2.2.2 Wellhead Conversion Assemblies
In several cases the manufacturer of the tubing hanger and the Xmas tree is different from the wellhead
supplier. The wellhead profile and sealing area may not be suitable for both suppliers.
In addition, the well may have been drilled a number of years prior to the installation of the tubing
hanger. In these cases, it is more economical to design a well conversion assembly than mixing
equipment types. Such an assembly provides the means of running the tubing hanger and tree in a size
and configuration compatible with the development wells. A separate new wellhead sealing profile is
provided by the installation of a wellhead conversion assembly (WCA) on the existing wellhead.
14
The WCA generally consists of a connector spool, which latches to an existing wellhead, with a new
wellhead profile for future tree connection. The well is completed after the WCA has been installed.
Spools for flowline connection can be included to allow remote retrieval of the tree without the need for
flowline disconnection.
Particular attention must be paid to the method of testing the tubing hanger seals after running. This
often means modification of standard cap testers or the specification of a suitable purpose-built tool.
The major penalties to be paid, however, are an increase in the height of the completed well, increase in
potential leak paths and the necessity of having two wellhead connectors (with a cost increase).
2.3 The Blowout Preventer (BOP)
A blowout preventer is a large, specialised valve used to seal, control and monitor oil and gas wells.
Blowout preventers were developed to cope with extreme erratic pressures and uncontrolled flow
(formation kick) emanating from a well reservoir during drilling. In addition to controlling the downhole
(occurring in the drilled hole) pressure and the flow of oil and gas, blowout preventers are intended to
prevent tubing (e.g. drill pipe and well casing), tools and drilling fluid from being blown out of the
wellbore when a blowout threatens. Blowout preventers are critical to the safety of crew, rig (the
equipment system used to drill a wellbore) and environment, and to the monitoring and maintenance of
well integrity; thus blowout preventers are intended to be fail-safe devices.
On a platform well (surface well) the BOP is located immediately below the drill floor on a fixed platform,
SPAR/TLP drilling host and jack-up rigs.
For subsea wells the BOP is located on the wellhead at seabed level.
Figure 2.12: Operation of a Subsea BOP
Source Wikimedia Commons
The drilling mud forms the first line of defence against kicks and blow-outs. The second and last line of
defence is the blow-out preventer stack. This is a collection of large, high-pressure valves which is fitted
on the top of the wellhead in a vertical tier and which can be controlled remotely from any of several
positions on the drilling unit.
15
Through the middle of the BOP stack is a hole wide enough for large drilling tools to pass up and down
during the course of normal operations. The width of the opening is determined to some extent by the
stage at which the stack is intended to be first used in the well programme. An 18 3/4 stack is the
common size for drilling subsea wells.
While the drilling operation is in progress a control system, connecting the topsides drillers to the seabed
BOP system, provides a safety shut down capability.
In drilling a typical high-pressure well, drill strings are routed through a blowout preventer stack towards
the reservoir of oil and gas. As the well is drilled, drilling fluid, mud, is fed through the drill string down
to the drill bit, blade, and returns up the wellbore in the ring-shaped void, annulus, between the outside
of the drill pipe and the casing (piping that lines the wellbore). The column of drilling mud exerts
downward hydrostatic pressure to counter opposing pressure from the formation being drilled, allowing
drilling to proceed.
When a kick occurs, rig operators or automatic systems close the blowout preventer units, sealing the
annulus to stop the flow of fluids out of the wellbore. Denser mud is then circulated into the wellbore
down the drill string, up the annulus and out through the choke line at the base of the BOP stack through
chokes (flow restrictors) until downhole pressure is overcome. Once kill weight mud extends from the
bottom of the well to the top, the well has been killed. If the integrity of the well is intact drilling may
be resumed. Alternatively, if circulation is not feasible it may be possible to kill the well by bullheading,
that is, forcibly pumping, in the heavier mud from the top through the kill line connection at the base of
the stack. This is less desirable because of the higher surface pressures likely needed and the fact that
much of the mud originally in the annulus must be forced into receptive formations in the open hole
section beneath the deepest casing shoe.
If the blowout preventers and mud do not restrict the upward pressures of a kick, a blowout results,
potentially shooting tubing, oil and gas up the wellbore, damaging the rig, and leaving well integrity in
question.
Since BOPs are important for the safety of the crew and natural environment, as well as the drilling rig
and the wellbore itself, authorities recommend, and regulations require, that BOPs be regularly inspected,
tested and refurbished. Tests vary from daily test of functions on critical wells to monthly or less
frequent testing on wells with low likelihood of control problems.
Figure 2.13: Functions of a BOP
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2.3.1 The Blowout Preventer Systems
Figure 2.14: Subsea Blowout Preventer
Blowout preventers come in two varieties annular and ram.
Both are often used together in drilling rig BOP stacks, typically with at least one annular BOP capping a
stack of several ram BOPs.
2.3.2 Annular Blowout Preventer
Figure 2.15: Annular BOP
17
An annular-type blowout preventer can close around the drill string, casing or a non-cylindrical object,
such as the Kelly. Drill pipe, including the larger-diameter tool joints (threaded connectors), can be
stripped (i.e. moved vertically while pressure is contained below) through an annular preventer by
careful control of the hydraulic closing pressure. Annular blowout preventers are also effective at
maintaining a seal around the drillpipe even as it rotates during drilling. Regulations typically require
that an annular preventer be able to completely close a wellbore, but annular preventers are generally
not as effective as ram preventers in maintaining a seal on an open hole. Annular BOPs are typically
located at the top of a BOP stack, with one or two annular preventers positioned above a series of several
ram preventers.
Inside the cylindrical steel body of the annular preventer is a large ring of steel-reinforced rubber or
similar material, called the packing unit. Below this are pistons which are moved upwards by the forced
entry of hydraulic fluid into small ports. As the pistons push the packing unit upwards, the rubber-like
material is forced to expand in towards the centre of the hole, sealing tightly around the tubular running
through it, or, if no tubular is present, completely blocking the space. Annular preventers have only two
moving parts, piston and packing unit, making them simple and easy to maintain relative to ram
preventers. On high-pressure subsea stacks there are often two annular preventers, one above the
other, so that there is complete back-up, or redundancy of these vital elements.
2.3.3 Ram Blowout Preventer
Figure 2.16: BOP Ram Preventers
Below the annular preventers are three or very often four sets of ram-type preventers. These also
work under hydraulic pressure, which forces large steel rams to slide together horizontally to provide a
seal.
A ram-type BOP is similar in operation to a gate valve, but uses a pair of opposing steel plungers called
rams. The rams extend towards the centre of the wellbore to restrict flow or retract open in order to
permit flow. The inner and top faces of the rams are fitted with packers (elastomeric seals) that press
against each other, against the wellbore, and around tubing running through the wellbore. Outlets at the
sides of the BOP housing (body) are used for connection to choke and kill lines or valves.
18
Rams, or ram blocks, are of four common types: pipe, blind, shear, and blind shear.
Pipe rams close around a drill pipe, restricting flow in the annulus (ring-shaped space between
concentric objects) between the outside of the drill pipe and the wellbore, but do not obstruct flow within
the drill pipe. Variable-bore pipe rams can accommodate tubing in a wider range of outside diameters
than standard pipe rams, but typically with some loss of pressure capacity and longevity.
Blind rams (also known as sealing rams), which have no openings for tubing, can close off the well when
the well does not contain a drill string or other tubing, and seal it.
Shear rams cut through the drill string or casing with hardened steel shears. Shearing rams were
introduced in the 1960s.
Blind shear rams are intended to seal a wellbore, even when the bore is occupied by a drill string, by
cutting through the drill string as the rams close off the well. The upper portion of the severed drill string
is freed from the ram, while the lower portion may be crimped and the fish tail captured to hang the
drill string off the BOP.
Figure 2.17: Illustration of Ram Types
Source: Cameron Ltd.
Shear-type ram BOPs require the greatest closing force in order to cut through tubing occupying the
wellbore. Boosters (auxiliary hydraulic actuators) are frequently mounted to the outer ends of a BOPs
hydraulic actuators to provide additional shearing force for shear rams.
19
Figure 2.18: Shear Rams
Shear rams are specially designed blind rams. This type of ram will seal if pipe is in the hole by shearing,
or cutting, the pipe and sealing the open wellbore. Most shear rams require 3,000 psi to cut pipe. Since
this type of action drops the drillstring, a set of pipe rams may be installed below the shear rams and a
tool joint set on the pipe rams before the shear rams are activated. When the shear rams are installed in
conventional ram bodies, booster power units and larger bonnets may be necessary for efficient
operations.
Normally the annular preventers alone would be used to attempt to control the well pressure, and if they
were not enough, the pipe rams would be used, with the shear rams being operated only in the last
resort. The controls for all the preventers are in the doghouse, with miniature replica panels usually at
two other places on the rig, such as in the toolpushers office and at the forward lifeboat station.
20
Figure 2.19: Drilling Control System
2.4 Choke and Kill
While the preventers stop the surge of well fluids up to the rig, bubbles of gas which are responsible for
kicks (and ultimately blow-outs) can be circulated out of the drilling fluid system through narrow pipe
connected to the side of a cylindrical device called a drilling spool at the base of the tier of preventers.
This pipe is called the choke line and it is connected to a large manifold of valves on the drill floor called
the choke manifold. On the other side of the spool from the choke line is a fill line and this enables
heavy drilling fluid to be pumped into the well to quell, or kill a kick. Both lines are often duplicated for
full redundancy.
21
Figure 2.20: Subsea BOP Choke and Kill Lines
A well kill is the operation of placing a column of heavy fluid into a well bore in order to prevent the flow
of reservoir fluids without the need for pressure control equipment at the surface. It works on the
principle that the weight of the kill fluid or kill mud will be enough to suppress the pressure of the
formation fluids. Well kills may be planned in the case of advanced interventions such as workovers, or
be contingency operations. The situation calling for a well kill will dictate the method taken.
22
3. SUBSEA XMAS TREES
3.1 Xmas Trees
3.1.1 General
The name of Christmas tree derives from the appearance of older surface trees which, often painted
green, were thought to resemble the festive tree. Current subsea Xmas trees do not have this look but
the name is retained.
Figure 2.21: Christmas/Xmas Trees Surface and Subsea

The term CHRISTMAS or XMAS TREE originates from the term coined a long time ago when surface trees
were painted green and were an assembly of valves out to the side. It was suggested that they looked
like the festive season Christmas tree. The term remained even though current subsea trees bear no
visual resemblance to that image.
Source Wikimedia Commons and Fishsafe
23
Figure 2.22: Xmas Tree Relationships to other Equipment/Functions
Source Azur offshore Ltd
Figure 2.23: Subsea Tree Technologies

An illustration of the modern subsea Xmas tree
Source Courtesy of GE Oil & Gas
24
Directed Learning:
Use Google or other search engines to look up the background history on Christmas
trees on Wikipedia Christmas Trees.
The Xmas tree is the primary flow control system for fluid flow from or into the well. The flows which can
be considered include the following:
(a) Production produced fluids from the oil/gas/condensate bearing formation pass up through the
well tubing and the Xmas tree.
(b) Injection filtered and chemically inhibited seawater is pumped from the host facility into the
well to provide pressure support for the reservoir.
(c) Gas injection/disposal excess gas is pumped into an adjacent reservoir for temporary storage.
(d) Gas lift gas is pumped from the host facility, through the annulus to sub-surface injection
points in the tubing. The inclusion of gas into the produced fluid reduces the column density to
allow the reservoir pressure to flow the well. It is a flow boosting technique but with a low
efficiency.
The Xmas tree provides a link between the downhole components and the production equipment. Access
for downhole operations is provided through the tree (for example, wireline or other downhole
operations, such as acidising, downhole temperature and pressure measurement, coiled tubing, work
over and so on).
Figure 2.24: Subsea Xmas Tree Functions
The Xmas tree is the interface by which communication with and control of downhole equipment, such as
the surface controlled subsurface safety valve (SCSSV), can be achieved. This is done via porting
through the main valve block and tubing hanger. The monitoring functions downhole are for temperature
and pressure signals. However, in more recent designs, more penetrators are required for downhole
chemical injection for example.
There are two types of Xmas trees (provided by all the five main manufacturers) which are:
1. The CONVENTIONAL DUAL BORE TREE (also called a vertical tree).
2. The HORIZONTAL OR SPOOL TREE (also called a side valve tree).
25
Figure 2.25: Conventional and Horizontal Xmas Trees (Schematic)
Representation of the two types of Xmas trees. In the older design (conventional dual-bore tree) the
main valves are set in the vertical plane. In the newer spool or horizontal tree the main valves are
brought out to the side.
Source Courtesy of GE Oil & Gas
3.2 The Conventional Dual-bore Tree
Figure 2.26: Xmas Tree Valves

Valve arrangements for the two types of trees.
26
Figure 2.27: Conventional Dual-bore Tree Functions
Figure 2.28: Conventional Dual Bore Xmas Tree
27
Figure 2.29: Conventional Dual-bore Tree Schematic
Figure 2.30: Conventional Dual Bore Tree Function Schematic
Source Azur Offshore ltd
28
Figure 2.31: Conventional Tree Tubing Hanger
Production bore (5.5 inches) is offset in the hanger. Other penetrations include the Annulus (2 inches)
and others for hydraulic fluid to Down Hole Safety Valves, signal and power cables.
Source Cameron
29
Figure 2.32: Example of Dual-bore Xmas Tree (Aker Solutions and Dril-Quip)
For Drill-Quip tree note the protective framework and top cover (protection against lightweight dropped
objects). The view shows the interface panel with the location of each valve indicated (that is, PMW =
production master valve). Also yellow item inside the frame is the subsea control module, with small
stainless steel lines going round to the valve actuators.
On Dril-Quip Tree the Subsea Control Module (in Red-Orange) mounted on the tree at its side. Small
stainless steel tubes route the hydraulic control fluid to each valve actuator.
Source Aker Solutions and Lasmo Ltd
30
Figure 2.33 - GE O&G Conventional or Vertical Tree
Source - GE Oil & Gas Ltd
The conventional tree construction is based around the monolithic central valve block which is machined
to hold all the primary valves. These blocks are usually large forgings and are one of the critical path
components for the progression of the manufacture of completion equipment for a project. (The modular
approach does help to reduce the manufacturing time.)
The conventional subsea completions involve a subsea wellhead, a tubing hanger, a Xmas tree, a cap, a
flowline/umbilical interface and the completions protection structure. The equipment is installed using a
variety of dedicated tools, and in the case of the tubing hanger and Xmas tree, vertical access to the well
production tubing and annulus is typically achieved using a dual-string completion riser and a riser safety
package. To retrieve the equipment (as may be required for workovers and so on), the installation
process is reversed.
In a simple tree configuration there are four primary valves on the production flowline and three on the
annulus access line. The valves are used to shut down the well. In a shutdown of the well the first valve
to close is the wing valve, followed by the master and finally the sub-surface valve. The lower master
valve is generally manual in operation and the other valves are hydraulically operated. The valves do not
control or regulate flow, this function being taken care of by a choke which is usually placed downstream
of the wing valve. The choke is not used for an emergency shutdown of the wells.
The valves are the main components of the Xmas tree, and the basic operation of the hydraulic actuated
subsea gate valve is described later.
Other components within the Xmas tree and their functions are outlined below for the wellhead
connector, tree cap and crossover valving.
31
Wellhead Connector
The main connector is designed to lock down on to the wellhead housing with a degree of preload to
prevent wellhead and tree separation under all the foreseen wellhead pressures, and forces encountered
during operation.
The main seals of the tree to tubing hanger are at the stabs between tree and tubing hanger. The
connector is designed to produce a degree of preload to ensure that if leakage takes place from the
annulus or production bore stabs, then the seal integrity between the wellhead housing and the base of
the Xmas tree is maintained.
Tree Cap
The tree cap connects onto the tree top mandrel to provide a pressure barrier and to link the control line
function from the control system into the tree valves. On removal of the tree cap for workover the
control system is isolated from the host facility. On connection of the workover equipment the workover
system from the rig above is directly connected to the tree valves.
Crossover Assembly Annulus
The annulus/production line crossover assembly allows the facility for pressure bleed of the annulus,
especially if no separate service/annulus line is provided subsea. Where a service line is provided then
the crossover can facilitate service operations by allowing fluids to be transferred from the service line
back into the production line.
3.3 The Horizontal or Spool Tree
Figure 2.34: Spool or Horizontal Tree Functions
32
Figure 2.35: Horizontal Xmas Tree Design Principles
33
Figure 2.36: Horizontal Tree Schematic
Note includes a choke valve on the production side. Also tree includes a gas lift capability using
annulus tree valves, and includes a choke valve on the gas lift line.
34
Figure 2.37: Horizontal Xmas Tree Function/Schematic
Figure 2.38: Vetco Horizontal Tree
Source GE Oil & Gas
35
Figure 2.39: Cameron Shallow Water Spool Tree
Reproduced Wellhead on top of the Tree.
Source Cameron
Figure 2.40: GE O&G Horizontal Tree
Source - GE Oil & Gas Ltd
36
Figure 2.41: Control Functions Routed to Tree Valves Via the Tree Cap
When the tree cap is in place on the tree the control functions are routed from the production host, along
the umbilical to the tree via the cap. In this mode the tree can only be controlled from the production
host. For drilling or well workover activities the tree cap will be removed. In this state the tree cannot
be controlled from the host. The drilling or workover vessel will plug its control system into the tree, thus
taking over the control function.
First invented in 1990 and first installed in the North Sea in 1992, the spool tree or horizontal
completion involves some of the same equipment as described above, but with some very significant
differences. As in the conventional system, a subsea wellhead is installed first. However, the tree is
installed prior to drilling out for the 13 casing. The BOP is then installed on the tree and the well
drilled through, with suitable bore protectors.
The tubing hanger is actually positioned into the bore of the Xmas tree during the installation of the
tubing. The geometry of the tree is that of a spool and provides land/lock/seal profiles for the tubing
hanger. The tubing hanger allows vertical access to the production tubing, to satisfy
installation/workover requirements (annulus access is achieved in a different manner discussed below),
but is also configured to divert production and annulus flow laterally through the tree body to the
surrounding flow control valves provided. The name horizontal tree is derived from this unusual
configuration of a spool-shaped body, and horizontally arranged primary flow control valves; as opposed
to a solid block tree with, principally, vertically arranged flow control valves.
Following the installation of the tubing hanger and downhole completions, a plug is installed within the
tubing hanger, followed by the installation of an internal tree cap. These items are installed through the
marine riser and BOP, removing the need for a conventional dual-bore completion riser for the installation
of either the tubing hanger or the Xmas tree.
The Xmas tree may be run on a drill pipe, thereby simplifying greatly the running procedures and
equipment, since there is no requirement for a special riser safety package. The drilling BOP may be
connected directly onto the horizontal tree, to facilitate workover operations involving the tubing and its
hanger, without, as in conventional systems, first removing the Xmas tree from the wellhead. As with
37
the conventional system, retrieval of the equipment (as may be required for workovers and so on) is a
reversal of the installation process.
Because the tubing hanger lands in the body of the tree, there is no requirement for Xmas tree stabs.
Instead, annular tubing hanger/tree interface seals are provided for isolating fluid conduit galleries (well
annulus, production and downhole safety valve control function). Metal-to-metal and elastomeric seals
are provided between all functions.
The side annulus access below the tubing hanger is controlled by a metal sealing fail-closed actuated gate
valve (the annulus master valve). As with the production master valve, this valve is integral to the tree
spool body.
Figure 2.42: Exploaded View of Tree
3.4 Comparison of Tree Types
The wellhead adapter spool design incorporated into the horizontal tree provides certain advantages,
including the following:
Easy interface to wellhead equipment, not of completion equipment suppliers own make.
General insensitivity to the position of casing hangers in drilling wellhead.
Provision of new tubing hanger interface profiles (which will not have been subject to damage
during the drilling operations).
Provision of tubing hanger landing shoulder machined at a known position for positive tubing
hanger/Xmas tree interface.
38
In the incorporation of the tree into a spool, the features in comparison with a conventional tree which
give positive advantages are as follows:
The expensive completion riser and workover control system can be nearly eliminated.
The height of the tree assembly is reduced as the valves are not in the vertical bore of the tree.
This low profile is well suited to completions in shallow water and/or shipping lane applications.
This low profile reduces the size of any protective structure, hence cost of the same.
The essentially cylindrical shape of the horizontal tree presents opportunities for increased
flexibility and a reduction in machining time in the manufacturing cycle, when compared with
large conventional master valve blocks absorbing the capacity of relatively few large, heavy duty
machining centres.
The tree is required to be installed prior to completion of the well programme. This requires the
tree to be designed and built prior to completion operations, which could affect the overall
development schedules.
The well tubing can be retrieved through the tree without the need for tree removal, for example
to replace a downhole pump.
The drill-through spool tree seems to be the choice for ultra-deepwater shallow reservoir
production where simplified drilling/casing programmes can be used.
3.5 Materials
For non-critical service requirements the block can be made of AISI 4130 material or AISI 8630 material
(types of alloy steel), with only the seat pockets of the valve cavities inlaid with a corrosion resistant
material.
For potentially corrosive service the main components of the Xmas tree which are exposed to
production/injection fluids can, depending on service, either be made of low alloy steel overlaid with high
corrosion resistant alloys, such as Inconel 625, or alternatively the whole component may be made of
corrosion resistant alloys, such as Duplex or Super Duplex. The process of internal cladding has been
well developed and the standard design is to use low alloy steel overlaid with Inconel 625.
3.5.1 Specifications for Trees and Wellheads
The main specifications governing the design of subsea Xmas tree equipment are API 17D (API 6A for the
valves is referenced). Material corrosion requirements are generally covered in NACE MR-01-75.
3.6 Subsea Valves and Actuators
3.6.1 Valve Components
The seal of the standard gate is achieved against a seat immediately downstream of the gate. The seat
is located in valve seat pockets in which it seals. Metal sealing is typically provided for the gate/seat
interface the working seal and the seat-to-body seal is either resilient or metal-to-metal.
To provide a metal-to-metal seal between gate and seat both units are hardfaced: usually tungsten
carbide is used. The finished gate has a flatness as measured in lightbands. The most common type of
valve design is the slab gate, or the floating gate design. Other types of valves have included the split
gate designs.
The materials used within the valve and the block are dictated by the type of fluid in service. Where both
hydrogen sulphide and carbon dioxide are present (sour), exotic materials are used in order that
corrosion damage can be controlled, reduced or eliminated. Generally the standard is to use carbon steel
for the valve block and inlay the bores and valve pockets with Inconel 625 to provide corrosion and
erosion resistance.
In addition to the seal between gate/seat and body, the stem operating the valve has to provide sealing
of the internal valve. The stem passes through the valve bonnet and resilient seals, or stem packing
provides the seal. In subsea valves a secondary metal seal is provided on the stem-to-bonnet interface
when the valve is in the closed position.
39
3.6.2 Actuators
The valve is operated by a hydraulic actuator. These actuators, in a majority of cases, operate on a fail-
closed basis and require constant hydraulic pressure to keep the valve open. Thus, if there is a loss of
hydraulic communication with the valve (or the tree), the valve will automatically close. A standard
actuator design is shown in Figure 2.44 with the valve piston connected via the stem to the spring,
housed within the actuator can.
Figure 2.43: Examples of Spool/Horizontal Trees

Note that at the top of the tree the wellhead profile is reproduced. This allows landing of the BOP on top
of the tree for full bore workover activities.
Source Aker Solutions and Cameron
Figure 2.44: Fail-safe Valve Actuator
40
As the valve is remotely actuated, some form of position monitoring is required. Limit switches and
linear variable differential transmitters (LVDTs) have been used in the past but the accepted method of
valve position indication is through the control system. When the solenoid valve is actuated in the
control module, the feedback to the platform shows that the control fluid has been distributed to the
actuator.
An extension to the back of the stem provides visual indication of the actuator position, should divers or
an ROV (remote operated vehicle) be in the vicinity. In addition an override mechanism can be added to
the actuator to allow the valve to be opened by a diver or ROV. This allows an ROV to manually override
the valve and re-open it if hydraulic communication has been lost and the valve has fail-safe closed.
Actuators are currently designed to function at the correct water depth at 1,500 psi. The design of the
actuator is 3,000 psi to suit the control system pressures.
Much higher pressure systems are now available for high pressure reservoirs (up to 15,000 psi) and
ultra-deepwater (up to 3,000 m).
Figure 2.45: Details of Kristin Field Xmas Trees

Trees supplied by Aker Solutions for the Statoil Field Kristin.
Source Aker Solutions
41
3.7 Subsea Control System Interfaces
A subsea control module is shown in Figure 2.32 located on a conventional dual-bore tree.
Figure 2.46: Xmas Tree Scope of Supply

The full scope of supply for Xmas trees is illustrated. It is more than just the tree. It includes various
delivery frames, installation running tools, monitoring items and some spares.
Source Cameron Singapore
The hydraulic control lines from the control module to the individual valves are routed via the tree cap.
On removal of the tree cap the connection between the module and the valves is lost on purpose. When
the workover control system is connected, control of the tree valves is directly from the workover vessel.
The workover control system also provides for connection of the wellhead connector.
The subsea control system requirements may be categorised as follows:
(a) Installation and maintenance or workover phase:

Operation of primary bore valves.
Operation of connectors and latches.
(b) Production phase:
Operation of valves and chokes.
Flow path valves.
Subsea chokes (regulate flow).
Manifold valves.
(c) Provision of monitoring information:
Downhole conditions; temperature and pressure.
Wellhead temperature and pressure.
Choke position indication.
Control systems status.
42
3.8 Scope of Supply
As shown in Figure 2.47 when Xmas trees are ordered, they are complemented by a significant number
of other equipment such as:
Xmas tree running tool.

Xmas tree test and shipping skid.
Various other shipping skids (pup joint, adaptor and so on).
Tubing hanger running tool.
Tubing hanger jetting tool.
Wear bushing and running tool.
Tubing hanger emergency recovery tool.
Tubing hanger handling and test tool.
Wireline plug and wireline isolation sleeve.
3.9 Shallow Water Guideline and Deepwater Guideline Guidance Running

Systems
In shallow water depths (say up to 500 m) trees are normally run on a guideline system. Guidelines are
attached to the guide base posts (either by a diver or ROV) and brought up to the installation vessel.
The tree is run on these down to the guide base for connection to the wellhead.
Figure 2.47: Installing Xmas Trees (Shallow Water by Guidewires)

The guidewires are connected between the guide posts on the guide base up to the drilling vessel. These
cables are fed through the guides on the tree. The tree is run down using drill pipe sections with a
running tool connection attaching the tree to the drill pipe.
Source Courtesy of GE Oil & Gas and Azur Offshore Ltd
In deeper water (500 m or more) guidelines and guide posts cannot be used. Funnels (up or down) are
generally used.
43
Figure 2.48: Installing Xmas Trees (Deepwater by Guidelineless)
In deepwater (more than 400 m) the guidewire system does not work. The system deployed is a funnel
capture arrangement. Once within the capture section of the funnel, the funnel shape brings the
components into alignment as the tree is lowered further. The funnels may be upwards on the guide
base or downwards on the tree.
Source Cameron Singapore, Aker Solutions and Fishsafe
44
Figure 2.49: Running a Deepwater Tree
The Tree at the bottom, with the tree running tool connected above it. The combination is run to the
seabed, via the drilling vessel, using drill pipe.
Source - Total
3.10 Tree Protection
Where the trees are in a satellite or cluster arrangement the protection against dropped objects and
fishing gear is by a protective frame around the tree. In the past there were heavy structures but
nowadays lighter arrangements are also used. Various examples are illustrated in Figure 2.50.
45
Figure 2.50: Tree Protection Frames and Enclosures
In areas that are heavily fished the trees (and manifolds) are protected by covering structures. These
may be steel frames or concrete or GRP covers. They are often angled in shape so that the strike from a
trawl board rises and flies over the tree.
Source Fishsafe
Figure 2.51: Extendable Frame Protection System

The frame gives a pyramid cover shape.
Source - Fishsafe
46
3.11 All-electric Tree
Figure 2.52: All-electric Tree

In the electric tree the valves are actuated by DC motors rather than the normal hydraulic system. The
first all-electric tree was offered by Cameron.
Source Cameron
47
Two tree suppliers currently supply an all-electric tree. The first of these is Cameron (the tree called
CameronDC). The other is supplied by FMC Technology.
CameronDC represents a breakthrough solution to the risks of subsea production, and addresses the
challenges that can result in downtime, costly intervention, deferred production and lost revenue for
offshore operators. This all-electric system, powered by direct current, improves reliability, availability
and maintainability. The system has no batteries, hydraulics or accumulators and much of the
conventional electro-hydraulic equipment has been simplified or eliminated. The CameronDC design
translates to greater uptime performance and significant cost savings.
CameronDC is a unique all-electric system powered by direct current. It is claimed:
It increases reliability, availability and maintainability.
CameronDC is simpler.
Environmentally friendly.
Easier to install.
Fewer parts to maintain.
Better feedback and greater response time.
Improved System Availability and Reliability CameronDC provides 99% or better uptime
availability in deepwater and at long stepout distances.
OPEX/CAPEX Savings Operational savings are derived from fluids, reliability improvements, lower
intervention costs and increased total production. Capital expenditure savings include umbilicals,
hydraulic fluids, and installation and commissioning.
Deepwater and Long-distance Stepouts CameronDC delivers capability at virtually limitless water
depths and long-distance stepouts (beyond 100 miles) coupled with great response times.
Actuation Speed and Accuracy With the elimination of hydraulics for power and signal, control
system commands can be sent in rapid succession thus avoiding the lag time needed for accumulator
charging. Flow and control of the well are maintained with precision.
High-speed Communication and Real-time Condition Monitoring Without the need to transmit
hydraulic signals through the umbilical, communication with equipment is near instantaneous and
feedback on subsea conditions is instantaneous.
Environmentally Friendly Without dependence on conventional hydraulics, the system offers

significant health, safety and environmental advantages. The potential for hydraulic leaks is eliminated,
as is the issue of fluids disposal.
The first all-electric tree was installed in the Total Field K5F in The Netherlands waters in 2008. It has
been successfully operating since then.
48
Figure 2.53: First Electric Trees in K5F Gas Field
3.12 Drill Through Spool Tree
The Dalia Field (Angola) was the first to utilise the spool trees capability of the drill through method.
The drill through horizontal tree design was selected in conjunction with a light well architecture and a
simplified drilling programme (36, 14 and 10). The horizontal drill through Xmas tree also
permitted installation on cable from an intervention vessel as opposed to the usual drilling rig
installation, avoided BOP trips before running the completions, and offered the capability to suspend
the drilling process at several stages; for example, after the top hole drilling, after the 10
installation, after sand screen and lower completion installation etc. Thus providing a maximum of
flexibility during combined drilling and UFL installation operations.
The spool tree may be set in the permanent guide base, with the BOP above early in the drilling
programme and drilling carried out through it. This has significant time and hence cost savings.
Dalia Field typical drilling sequences for a light well are as follows:
Jetting and setting of 36 conductor (with the tree guidebase) down to 65m.
17 drilling down to 600m and set plus cement the 14casing with 18 well head.
Run Xmas tree on cable and test well head connection with ROV.
Run BOP stack with drilling riser (on top of horizontal tree with wear bushing) and test it.
Drill 12 section and set and cement 10 casing (variable length depending on well).
Drill 9 drain section before installing the lower completion.
Run the upper completion with the tubing hanger using the work-over/test string.
Clean up and test the well with the work-over/test string, then retrieve to surface.
49
Shut down the well by closing the down hole SCSSV and setting the dual plugs in the tree.
Recover the test string, the drilling riser and the BOP stack.
Install the tree cap by ROV and inspect, before operating the tree via the control system.
The method is illustrated in the following four figures.
DRILL THROUGH XMAS TREE (Dalia Field)
* JETTING THE OUTER CONDUCTOR AND DRILLING FOR

THE INNER CONDUCTOR
Figure 2.54: Drill through Spool Tree Method (A)
50
RUNNING WELLHEAD AND CEMENTING CASING
Figure 2.55: Drill through Spool Tree Method (B)
RUNNING THE XMAS TREE
Figure 2.56: Drill through Spool Tree Method (C)
51
FUTHER DRILLING TO
RUNNING BOP AND TESTING
RESERVOIR THROUGH BOP +
TREE
Figure 2.57: Drill through Spool Tree Method (D)
Figure 2.58: Historic trend of Trees Supplied
Source - Douglas Westwood Ltd
52
Directed Learning:
Use the Internet to look up further details of electric trees and the K5F Field. Also look
up the Shtokman Field in the Barents Sea. Why would this field be a good target use
for electric trees? Discuss your ideas on the online forum.
53
4. SUBSEA MANIFOLDS AND TEMPLATES
4.1 Introduction
Production from subsea wells may either flow along the wells own flowline to the processing host, or the
flow from a number of wells may be commingled together and flow to the host through a common
flowline. A subsea manifold is used to commingle the flows from a number of wells.
Figure 2.59: Possible Subsea Tie-back Options

Three options are illustrated. (i) Each well has its own flowline back to the host platform with a 6 line.
(ii) The wells are clustered about a manifold. In the manifold the flows from each well are commingled
and sent to the platform in a 10 to 14 line. (iii) The wells and manifold are located in the same
structure. This is called a template manifold.
54
Options for Multiple Well Systems
To host
To host
Daisy Chain
Individual Tie-Backs
To host To host
Cluster Manifold Template Manifold
Cluster Manifolds are the typical arrangement utilised on subsea developments in

Gulf of Guinea, with multiple manifolds daisy-chained on a dual flowline loop !!!
Figure 2.60: Manifolding Options
In outlining the design parameters for templates and manifolds the two system definitions should be
clarified:
A template is a structural support to provide guidance and location for drilling operations.
Template structures exist with no manifolding facility, such as those used for accurate positioning
of wells during drilling and prior to the installation of a processing facility directly above the
template. The individual wells can be directly tied-back into the facility through rigid risers or
flexible dynamic risers.
A manifold refers to the production equipment for commingling and regulation of production
and service fluid from and to the subsea facilities.
55
Figure 2.61: Templates and Manifolds
56
Figure 2.62: Well Testing of Cluster Wells
Older approaches used a separate test line to a small test separator on the host. Current methods place
the Subsea Multiphase Meters on the Manifold or Tree.
Source - J E & P Associates
Figure 2.63: Possible designs of Manifolds and Flowlines for Round Trip Pigging
Source - J E & P associates
57
The basis is illustrated in Figure 2.64 for a standard manifold system for:
Three production wells (plus one spare).
Two water injection wells (plus one spare).
The production wells require gas lift capabilities.
The illustration shows the following:
o The piping runs and valves to provide flow from each well into the main production line as
commingled flow, or to divert each well, one at a time into the test line.
o The flowlines of the water and gas, from the host, to the manifold and the direction of the
water to the water injection well and of the gas to the production well.
o The combination of all these flowlines and valves. In practice use is made of the main oil
production flowline and the water injection line to provide a pigging loop (where they are
sized equal) and to make a connection of the two lines (with appropriate valves) to permit
the pig to be pumped down the water line, to enter the oil line and then return through that
line to the host.
Figure 2.64: Example of Manifold Design and Valves

Design for three production wells and two water injection wells with a pigging loop. Also the wells are
gas lifted. The manifold incorporates a subsea multiphase meter.
58
Figure 2.65: Example of Malampaya Field Manifold P&ID
The manifold is designed for 10 wells (five each side). Each side has its own 16 flowline, which can be
used to form a pigging loop (launching and receiving from the platform host).
Source Cameron Singapore
SUBSEA WELL SYSTEM (MANIFOLDED) TIED BACK TO EXISTING

PLATFORM
Existing Production
Facilities Controls & Chemical
J Tube
Inj. Umbilical
EXTRA
ITEMS
Production
Cassion Well 1
Riser
System
Production Line
Test Line
Production
Gas Lift Line
Subsea Well 2
Water Inj. Line

Manifold
.
Production
Well 3
Flexible
Jumper
Spools Spare Slot
Production
Spare Water Water Inj.

Water Inj. Well Well 1
Inj. 2
Slot
EXISTING PLATFORM
Figure 2.66: Wellstem (Manifolded) Tied Back to Existing Platform
Source Azur Offshore
59
Directed Learning:
Study the drawing representations of the valve types (manually-activated valves,
hydraulically-actuated valves and choke valves, as shown in Figure 2.64). Without
using Figure 2.64 try to make your drawing of your manifold with two production gas
lifted wells, one water injection well and a pigging loop.
4.2 Drilling Templates
Drilling templates are either single-well drilling guides (where no subsequent flow manifolding is
envisaged) or a multi-well guide system. The latter is often the case with a pre-drilling template where
the drilling process is undertaken early in the field development and heads up any arrival on site of other
production facilities. This may be stand-alone or incorporated with other drilling slots.
Figure 2.67: Drilling Template

The nine-well drilling template is a basic plate used to guide the hole opening drill bit (36-inch) into the
hole. The template maintains the exact distance separating the wells on the seabed. The drilling
template has piling points (to hold it in location on the seabed) and locating guides so that the eventual
platform may be positioned over it.
4.3 Template Manifolds
These combine the function of the drilling template and manifolding in one structure. An example is the
BALMORAL Template Manifold which has well slots for 14 wells in the structure. This has a large
protection frame which surrounds the structure. The current trend is for simpler, modular template
manifold systems often with four well slots.
60
Figure 2.68: Template Functions
4.4 Well Clusters Around a Manifold
An alternative configuration is where the wells have been drilled as individual satellite wells. This has
allowed the early drilling of wells, without the need for any structural fabrication. Once drilled and
completed these satellite wells are tied into the manifold pipework by spool pieces or jumpers from the
well to the manifold. This arrangement is termed a cluster-type development. The distance from the
wells to the manifold will be up to a few tens of metres.
Figure 2.69: Manifold Functions
61
Figure 2.70: Manifold Functions (Continued)
A number of different cluster configurations are illustrated, together with field examples.
Figure 2.71: Illustration of Various Well Cluster Arrangements

Various configuration of cluster wells may be deployed.
62
The main emphasis of these notes will be on the manifold functions though some brief considerations for
each unit are given below.
A comparison between templates and manifolds is given in Figure 2.72.
Figure 2.72: Template Manifolds vs. Well Clusters

Advantages and disadvantages of the two options.
4.5 Design Considerations
In reviewing the options for the use of seabed equipment and facilities the key parameters can be
considered under the following:
1. Number and type of wells
2. Inspection, maintenance and repair
3. Water depth and seabed conditions
4. Flow and production considerations
5. Operational requirements
6. Protection
7. Installation.
63
Figure 2.73: List of Manifold Design Considerations
4.5.1 Number and Type of Wells
The main influence on the choice of subsea configuration is the number and type of wells, their
development programme, the distance of the wells from any host facility and the required downhole
location.
As an example, for a field with a small number of wells, possibly of one type, with the field relatively
close to the host facilities, there may not be a need for any fluid commingling. Individual satellite wells
can be tied-back directly to the host facility through individual flowlines.
As the number of wells and the distance from the host facility increase, the cost of individual flowlines
from each well to the host facility becomes prohibitive and manifolding of the functions at a suitable
seabed location is preferred. The location of the manifold on the seabed will be selected mainly with
reference to the major cost elements of the development, which are the costs for drilling, for the flowline
from the manifold to the host facility and the individual flowlines from the wells to the manifold.
The wells could be incorporated onto a single seabed structure, acting as a drilling template, or as
separate satellite wells, clustered about a manifold. The decision on the approach to be adopted will
depend mainly on the drilling schedule and how many wells are already in the location. If the template
option were considered the well drilling programme could not start until completion of the template
structure.
4.5.2 Inspection, Maintenance and Repair
There is no single answer to the inspection, maintenance and repair philosophies to be adopted in the
design of the subsea facilities and the manifolds. Reliability of equipment, and especially the perceived
reliability of components, will influence the need for access to the facilities for repair or replacement.
64
The philosophy adopted by the operator will dictate some of the components to be used, whether they be
diver installed or remotely installed, and the likely components to be recovered. This is a key aspect to
be determined in the design of the manifold.
Inspection
Inspection can normally only be undertaken by ROV, and most facilities are designed to allow access for
such visual inspection. As part of a works authorisation for the pipeline system annual inspection of the
facilities has historically been required. From 1996 inspection has still been required but on a more
selective basis, if proven by the operator, rather than the mandatory basis now in force.
Maintenance
Subsea components are designed to be maintenance free for the field lifetime. The maintenance
operations considered are those associated with intervention requirements, such as well servicing, that
may require valves to be closed. These can be operated by ROV or by diver, if the water depth is not
very large.
Repair
The majority of subsea installations have been based on replacement, not repair: that is, the
equipment, or component that has failed is retrieved to the surface and replaced by another identical
unit. Various philosophies have been adopted and manifolds have been designed where the following
components are retrievable:
The total valve assembly, body, internals and actuator, by diver with flanged connection.
The valve actuator only, by diver using bolted connections, or remote tooling.
The valve internal plus actuator, by diver or using remotely operated tools.
The total valve assembly plus flowloops in a module, using remote tooling.
The total valve assembly is fully welded into the manifold pipework, and not retrievable, the
bonnet and stem seals can be repaired in situ.
4.5.3 Water Depth and Seabed Conditions
The water depth principally affects the hook up of the flowlines and control system and whether divers
will be used or the systems hooked up remotely.
In shallow water depths (up to 200 m+) the option is for either diver assisted or diverless (ROV)
intervention. Beyond, say 250 m water depth all work must be designed for diverless operations.
Loads imposed on the structure include those from drilling for a template configuration, self-weight,
thermal expansion from pipeline spools, and any impact loads from dropped objects and fishing activities.
The structure will be fixed to the seabed to provide resistance to the vertical and horizontal loads.
Types of fixing detail of the structure are piled or of a gravity base design. Both designs are utilised and
the selection of the type of structure is usually made based on the installation method and vessel
availability.
65
Figure 2.74: Installation and Operational Loads on Manifolds
Figure 2.75: Manifold Foundations
The options for the attachment of manifolds to the seabed include: (a) gravity alone or cylindrical skirts
(not illustrated); (b) piles; (c) mudmats; and (d) suction piles.
Source GE Power
66
4.5.4 Flow and Production Considerations
The characteristics of the produced fluids will primarily affect the transportation system back to the host
facility, in terms of the pressure drive available. The size and complexity of the seabed facility will
depend on the systems required for the safe and efficient operation. The following factors are
considered:
Production flow rates and turndown.
Gas lift to the production wells.
Water injection facilities.
Additional service lines for well killing and well squeeze.
Chemical lines for wax inhibition, hydrate inhibition and de-emulsifier.
In the initial process work on the transportation system from the manifold to the host facility, the size of
the lines to limit pressure losses and velocities for erosion will be calculated. During the field lifetime the
volume flow rate is likely to decrease in a well with a high gas/oil ratio the volume flow rate may
increase as the pressure decreases. Depending on the oil composition the expected arrival
temperature at the host facility will thus decrease, increasing the fluid viscosity and potentially causing
wax deposition and hydrate formation, unless adequate insulation is provided. It may be more cost
effective to allow the temperature to drop in the latter years of the field life and utilise other methods to
control any wax and hydrates. This could include chemical injection or regular pigging of the seabed
lines.
The operational requirements are defined below in the next section. The well testing requirement will
have an effect on the flow calculations for the pipework.
4.5.5 Operational Requirements
Requirements to be considered include:
Well testing.
Pigging.
Well servicing methods:
o by workover vessels or remotely from the host facility
o for well squeeze operations and well kill, instrumentation for monitoring (such as pressure,
temperature, hydrocarbon detection)
Instrumentation.
Well testing
For monitoring of the wells during production of the field, over a period of years, individual flow from
each well directly to the host facility would be preferred. This would allow monitoring of each well to
enable accurate measurement of the well and field depletion. From an economic consideration this is not
viable and commingling of the flow is usually required. It will be necessary to estimate the flow
contribution from each well during the field life. If only a single flowline connects the manifold to the
host facility, this can be accomplished by shutting in all wells except for the one to be tested, or by
providing a separate test line.
Pigging
Pigging of the flowline from the manifold to the host facility may be required to clear the line of water, in
the case of a gas line, or remove the gradual build-up of wax deposits in an oil line. In the UK sector the
operator of a pipeline is required to show methods by which the line integrity can be proven during the
field lifetime. Methods used have included the provision of corrosion coupons in the line, monitored in
the process stream, ultrasonic wall thickness checks at key points in the system, and through the use of
calliper pigs or survey pigs. The same line diameter throughout the flowline has to be maintained.
67
For potential build-up of products in the line, pigging can be considered on a routine basis or as a
contingency if chemical treatments do not work.
For routine pigging operations permanent pigging facilities are generally provided.
The pig is transported to the manifold in one line, and returns in another. A pigging loop can be provided
by two lines, for example the test and production line, the water injection and production line or the
water injection and production line, if the paired lines are of a similar internal diameter.
For non-routine pigging, and where the provision of a second line would be expensive, a subsea pig
launcher may be deployed. This requires the mobilisation of a vessel to deploy the launcher.
Well Servicing
Well servicing operations for subsea wells have been conventionally carried out from a drilling vessel
moored above the well. Other, more recent methods have included the use of dynamic positioning (DP)
drilling vessels, specific workover vessels and the use of diving support vessels (DSVs) converted for
workover operations. Routine operations involve the use of wireline or coiled tubing techniques,
deployed from the floating vessel.
Mobilising a workover vessel is costly and it would be preferable to accomplish any routine service
operations remotely from the host facility. Chemicals can be bull-headed into the wells from host
platforms via a service line, as can well squeeze treatments. Should the need for well servicing be on a
regular planned basis and the service requirements adequately defined, this may be accomplished
remotely through the subsea facility. Typically, remote well kill can be considered and more recently,
remote squeeze operations have been used.
Where subsea facilities are located close to, or underneath the host facility, workover can be from the
production vessel facility.
Several cluster layouts developed for well configuration allow access to the subsea wells from one surface
location for drilling and workover activities, while production continues in all other operational wells.
Instrumentation
The subsea facilities are remote from the host platform. Interpretation of events is aided by the
provision of reliable monitoring data, such as pressures and temperatures.
Monitoring of the status of the equipment will also provide information on potential leaks and equipment
failures. The provision of equipment is based on its need, cost of its provision, and the reliability of the
information and the equipment itself.
4.5.6 Protection
Template manifolds and manifolds alone are key elements in subsea systems and hence they must be
designed with appropriate levels of protection frames. Potential causes of damage include the following:
Dragging anchors.
Fishing gear.
Impacts from dropped objects.
68
Figure 2.76: Manifold Protection Requirements
Requirements for protection against (a) dragging anchors, (b) fishing gear, and (c) dropped objects.
Source J E & P Associates and Fishsafe
Figure 2.77: List of Some Typical Dropped Objects
69
Dragging Anchors
The main risk of dragging anchors is from merchant shipping if the development area is in a known
shipping channel, and from construction vessels during the initial installation programme and drilling
activities. Most construction work in the North Sea is from dynamically positioned vessels which reduce
the risk.
Drilling activities are conducted from anchored semi-submersibles and the use of well-proven anchor
handling procedures reduces the risks from anchor damage.
Should an anchor drag across a pipeline it will damage the line and no protection can be given. For the
manifold system provision of protection to withstand anchor damage would be very costly and with
adequate procedures the risk of damage is minimal. Therefore, for many designs the protection from
anchor damage is not included.
Fishing Gear
The Norwegian Petroleum Directorate guidelines are specific all systems shall be protected from
damage from fishing gear, anchors, chains and lines as well as from falling objects. In applying for
certification in the Norwegian sector the emphasis is also on protection of the fishing gear by avoidance
of any snagging features. In the UK sector the emphasis is more on protection of the subsea equipment.
Fishing statistics are available for the type of trawler activity, midwater or bottom trawling, the size and
type of trawler vessels. Typical values for trawl impact and pull over forces are the following:
Impacts of 15 kJ for trawl board.
Snagging a force of between 35 and 60 tonnes, depending on the field area, applied horizontal to any
potential snagging feature.
The impacts and pullover forces will depend on the field area (that is, size and type of vessel and fishing
equipment).
Historic data can be used to estimate the type of fishing and the density of trawling activity in any one
area. This can provide the background to any impact and snagging value used in the design of
equipment.
When the fishing gear impacts on the seabed equipment the impact is associated with the momentum of
the trawl doors or beam. The warp or trawl door may then snag on the seabed equipment. When the
fishing skipper knows that he is snagged he will then head back to the obstruction and will heave and tow
until either the fishing gear becomes free or the warp breaks.
For North Sea operations, liaison with the relevant fishing representatives is beneficial (for example, the
Scottish Fishermens Federation in Aberdeen) prior to any development to assess the potential trawl
activity for manifold and pipeline configurations.
To assist in the protection of the facilities, the location of the wells and subsea development, and the
schedule for construction works, can be made known to the fishermen and marked by buoys. The
operator can apply for a 500-metre exclusion zone around any subsea development. The area has
historically been marked by a surface buoy but recent trends, supported by the Department of Transport,
have been not to buoy the development area.
Dropped Objects
There are five basic source vessels for dropped objects:
1. Drilling/completion workover.
2. Support and supply.
3. DSV/MSV (diving support vessel/multi-purpose supply vessel).
4. Anchor handling.
5. Merchant shipping.
70
The highest risk of damage to the subsea equipment is during drilling and completions phase work.
Initial drilling is usually done prior to subsea construction work, but then further drilling is planned during
production operations. The drilling vessel is permanently moored above the facilities for some months
and heavy objects are handled frequently on the vessel.
There is comparatively little risk from the support and supply, anchor handling and merchant shipping
vessels, due to their minimal time on location above the wells.
DSV/MSVs spend time above the wells but following initial construction activities the handling of any
equipment is limited.
Several design philosophies have been adopted and the following is an accepted approach to dropped
objects. This is based on the cost of providing the protection and the level of risk associated with the
type of object to be potentially dropped.
For any of the above cases, the most likely objects to be dropped from any of the above vessels are
those that can be hand carried about the deck and are typically in the range up to 20 to 30 kg.
Depending on the size of the objects the impact energies (typically up to 50 kJ) when dropped can be
withstood by relatively small members.
Protective grating can provide the coverage for the small size of the dropped objects. Sensitive
equipment can be located inside the main structural members to provide protection, bearing in mind the
requirement for access for inspection and maintenance.
For larger, heavier objects the structure will have to be substantially stronger to resist the impact
energies, typically in the range 50150 kJ. The use of proven handling procedures can reduce the risk of
dropping the object and the structure can be designed to provide sloping members to deflect the object.
Plastic design methods can also be adopted for low probability dropped objects.
A protective structure cannot be designed to resist the impact of very heavy objects, such as the bottom
assembly, or a BOP. To reduce the risk of these objects impacting the seabed equipment strict
procedures for handling are adopted and in many cases these objects (and indeed all objects) are
handled away from the location in safe handling areas.
A list of the potential dropped objects for a drilling operation is given in Figure 2.77. From the figure it is
worth noting that although the dry mass of some of the objects is relatively large the impact energy is
not proportional.
For example:
the impact energy of the full 7.5 tonne container is some 85 kJ.
the impact energy of the 30-inch conductor, of 5.6 tonne is some 1,735 kJ.
Directed Learning:
In your area of the world, what would be the main risks for subsea installations? What
are the fishing activities, if any? Please share your thoughts with other students.
4.5.7 Installation/Decommissioning
There is no direct correlation between the number of wells and the size and weight of the manifolds
installed to date. Each system designed has been for different production data and based on different
design parameters.
In considering the installation aspects there has generally been distinct ranges of size and weights that
can be accommodated by the existing installation vessels.
1. DSV installation of approximately 80200 tonne capacity. Crane capacities vary for the size of
the structure to be installed (that is, crane outreach), sea state and weather conditions.
2. Heavy lift vessel of up to 6,000/10,000 tonnes.
71
The selection of piled or gravity base type structures could be influenced by the above vessel availability.
For a particular manifold layout a piled structure would generally be lighter for installation than an
equivalent gravity base structure. If the structure weight was close to the limiting weight of one range of
vessels, the piled structure could allow its installation by several vessels.
This could provide a more cost efficient installation.
The aspect of removal of the manifold has to be considered in the initial design stages. The operator has
to provide funding in the budget for removal and an outline of the system to be adopted. In a recent
removal programme a protective structure of some 40 tonnes was removed. Breakout loads of up to 80
tonnes were seen and the lift weights through the water were up to 70 tonnes in the prevailing sea
states.
Figure 2.78: Steps in the Installation of a Manifold (with Suction Piles)
4.6 Manifold Components
The components considered as part of the manifold are the following:
Valves
Chokes
Control modules
Instrumentation
Pipework and materials
Connections
72
Figure 2.79: List of Typical Manifold Components
Illustrating gate and ball valves
In particular ball valves are used for closing larger manifold valves, say above 8.
4.6.1 Valves
Valves are required for operational and maintenance reasons. Operationally, they isolate flow or switch
to test lines. Operational valves are generally remotely actuated. Maintenance valves are used to
isolate, provide vent/bleed, and to test connections during intervention and maintenance activities.
Historically both ball and gate valves have been used for subsea manifolds and pipelines. The selection
of the valve type is usually dependent on the designers preference. Gate valves were initially restricted
in sizes up to eight inches but more recently large-diameter high-pressure gate valves have been
developed. The gate valve, being of a linear actuation is generally preferred for the fail-safe-type
designs, where the valve reverts to its closed position on the loss of hydraulic power in the control
system.
Subsea gate valves are designed in accordance with API 6A, to 3,000, 5,000 and 10,000 psi working
pressure design. The piping system will have to be strength tested to 1.5 times its design pressure, and
once tied into the manifold system the overall pipeline system subjected to a 1.1 times design pressure
leak test.
4.6.2 Chokes
Chokes regulate the flow and provide for pressure equalisation between wells. They can be located on
the manifold or on individual wells.
Typical choke designs are illustrated in Figure 2.79. The choke is the one component of the manifold
system most subject to wear and the development of retrievable chokes, or at least retrievable elements
of the chokes, has been undertaken.
73
Since the subsea choke is likely to be replaced every two or three years they are made easily retrievable
using insert approaches (illustrated in Figure 2.79).
Figure 2.80: Subsea Retrievable Choke

The choke mechanism is subject to high wear and so must be replaced frequently (say every three
years). The design illustrated is a barrel insert type. The whole unit (choke mechanism, actuator
device and control) is locked into the barrel frame. Often its release and removal is like that on a
bayonet-type light bulb with a push and twist action.
4.6.3 Control Modules
The control modules can be located on the manifold or on each of the separate wells for satellite-type
designs. The decision on the location of the control module will depend mainly on where the majority of
the control and signal functions exist. It will also depend on the required protection for the control
modules, the number of connections to be made at either location and the foreseen maintenance
requirements for the control system.
4.6.4 Instrumentation
Instrumentation will be provided on each of the well systems. The instrumentation on the manifold is
generally for the pressure and temperature readings on the commingled production and pressure
readings upstream of any water injection branches. Flow meters (orifice type) are also used in manifold
systems.
The control system will be configured to provide high pressure and low pressure alarms. The low
pressure alarms will be required as part of any pipeline integrity monitoring system.
Instrumentation is required within the choke to monitor the choke position. Linear Variable Differential
Transducers (LVDTs) provide the required indication.
74
Valve position indication is usually inferred from the control system and not directly on the valve stem.
Several systems have been installed with leak detection devices. These have been hydrocarbon-sensing
devices and the use of density sensitive devices located in a purpose-designed catchment area.
4.6.5 Pipework and Materials
The pipework is designed to conform to ANSI B 31.3 (a British standard steel grade). Aspects to consider
are the service requirements (i.e. fluid chemistry inclusion of hydrogen sulphide and carbon dioxide),
the temperature range for operation and pressure regime, fluid flow rates and velocities. These
parameters are to be considered throughout the life of the field.
For example, a hot crude with a high GOR (gas/oil ratio) may be transported by subsea pipeline to a host
facility. Under normal flow conditions the pipeline does not require insulation, for the first few years,
except during periods of well shut-in and cold start-up. In latter years insulation of the line is required.
If the pressures are high, then on well shut-in the temperature of the fluid in the manifold (mainly gas)
will decline towards seabed ambient. On opening the flow across the choke the temperature will
decrease and the steel downstream of any chokes will have to be suitable for low temperature operation.
In the layout of the pipework the number of bends and straight sections after the chokes and the
expansion allowances in the pipework support point are to be considered.
4.7 Future Developments and Trends
A modular approach can be adopted, with the emphasis placed on simplicity of construction and ease of
handling. A number of vendors supply compact four-well template manifolds. Diverless system
development will continue and layouts of manifolds will address the remote connection and retrieval of
equipment. A number of diverless connection systems are offered by other vendors. Structural and
protective developments will be made to reduce the overall weight of equipment for ease of installation
and decommissioning. Here lightweight composite materials can be used.
On-going development of components and equipment will address the reliability to improve the long-term
use without maintenance. A range of template manifolds are shown in Figures 2.812.84.
Figure 2.81: Examples of Template Manifold Examples

Examples are from the Kristin Field in the Norwegian part of the North Sea where there is a high fishing
activity.
75
Figure 2.82: Template Manifold Example
Four-well template manifold with foundation skirt and over-trawlable angled protection frame.
Figure 2.83: Template Manifold Example (Balmoral Field)

Large 14-well template manifold set below the production semi-floating production host.
76
Figure 2.84: Template Manifold Example (Otter Field)
The seabed system comprises:
(a) An existing exploration well used as a water injection well covered with its own protective frame;
(b) A separate new four-well template manifold with three production wells plus one water injection well.
Source Fishsafe
A range of wells clustered around a manifold are illustrated in Figures 2.852.91.
Figure 2.85: Well Cluster Example (Britannia Field)

The field has a subsea development tied-back to the main platform. The wells are arranged in a linear
cluster one side of the manifold. Further wells could be added at the other side of the manifold at a later
date if required.
Source Chevron UK
77
Figure 2.86: Well Cluster Example (Lyell Field)
The field has a subsea development tied-back to a third party platform (Ninian South Platform). The
wells are arranged in a circular cluster around the manifold.
The spacing between each well allows production from each well to continue even when the nearby well is
being drilled (minimum distance about 8 m). For safety the BOP would be lowered to the seabed away
from the wells (to the indicated landing zones) and then carefully moved across onto the wellhead.
The total diameter of the well cluster is well within the movement of the drilling semi (outlines above)
without the need to move the anchors.
Source Oryx
78
The large manifold at the centre of the well cluster is connected to various flowlines which travel to the
processing host platform. Note that the flowlines are layed away from the manifold, requiring flow
connecting spools with an almost 90 angle
Source Oryx

Because the trees are external to the manifold they are protected with extra covering on their tops. The
flow and jumper connections from the tree to the manifold are buried for protection.
Source Oryx
79
Conoco UK large manifold Lyell Field
North Sea
Figure 2.89: Lyell Manifold
Source Azur Offshore
Figure 2.90: Well Cluster Example (Strathspey Field)

The very large 14-well manifold has an extensive protection frame. Note the location markings on the
frame (face, corner and well bay) for divers or ROVs to navigate correctly.
80
Figure 2.91: Well Cluster Example (Gimboa Field)
Note in this illustration that the flow connecting spools from the tree to the manifold are held horizontally
by foam blocks along their length. This is designed to provide a smoother flow path than the previous
style of connectors which went down from the tree, along the seabed and then up to the manifold.
81
Figure 2.92: Flowline In-Line Sled
The Sled acts as a small manifold and allows connection direct from a Tree.
Source - Azur Offshore Ltd
The Gorgon gas project is a natural gas project in Western Australia, involving the development of the
Greater Gorgon gas fields, subsea gas-gathering infrastructure, and a liquefied natural gas (LNG) plant
on Barrow Island The project also includes a domestic gas component. It is currently under construction
and once completed, will become Australia's fourth LNG export development.
Upstream Offshore Wells & Facilities
The Upstream scope of the Project includes:
Drilling eight high-rate, big-bore development wells at the Gorgon field, and ten at the Jansz-Io field.
A subsea gas gathering system and subsea pipelines that will deliver gas from the Gorgon and Jansz-Io
fields, located between 65 and 130 kilometres respectively off the west coast of Barrow Island.
Pipelines that run from the shore crossing on the west coast of Barrow Island across to the east coast,
where they tie-in to the gas treatment plant.
A domestic gas pipeline that runs more than 90 kilometres from Barrow Island to the Western
Australian mainland where it will tie-in to the existing Dampier to Bunbury Natural Gas Pipeline.
The Gorgon Upstream scope includes the design and construction of all wells and facilities to source gas
from the Gorgon and Jansz-Io gas fields, transportation to the liquefied natural gas (LNG) plant on
Barrow Island and delivery of domestic gas via a pipeline to the Western Australian mainland. It also
includes the wells and facilities required for the Carbon Dioxide (CO2) Injection Project on Barrow Island.
82
Drilling & Completions
This includes 18 high-rate, big-bore development wells; eight at the Gorgon field and 10 at the Jansz-Io
field. Deepwater drilling rigs are being used to complete drilling activities. It also involves drilling 17 wells
for the CO2 Injection Project on Barrow Island.
Subsea Gas Gathering System

The subsea gas gathering system will be located on the ocean floor over the Gorgon and Jansz-Io gas
fields.
The Jansz-Io field is located approximately130 kilometres northwest of Barrow Island in 1,350 metres of
water and will be brought onstream first. The initial subsea development is a ten well, two manifold
system.
The Gorgon field is located approximately 65 kilometres to the west of Barrow Island in 200 metres of
water and will commence production approximately six months after the Jansz-Io field. The initial subsea
development is an eight well, three manifold system.
Subsea trees will contain and control the production wells at the both fields. The produced gas from the
wells will be gathered at several manifolds installed at each field, then transported via pipelines
to Barrow Island.
Pipelines & Umbilicals

Both field developments are supported by a feed gas pipeline, monoethylene glycol (MEG) injection
pipeline, utility pipeline and fibre optic, electro-hydraulic control umbilicals a total of six product
pipelines and two umbilical casings. The pipelines and umbilicals will come onshore on the west coast of
Barrow Island. Conduits for the pipelines and umbilicals were drilled beneath the beach via horizontal
directional drilling to minimise environmental impact. The pipelines and umbilicals will be buried and run
from the west coast of Barrow Island across to the east coast, where they tie-in to the gas treatment
plant.
Domestic Gas Pipeline

A 300 terajoule domestic gas plant is included in the Project. Domestic gas will be exported to the
mainland via a pipeline that is more than 90 kilometres long, connecting into the existing Dampier to
Bunbury Natural Gas Pipeline.
Carbon Dioxide Injection Project

CO removal and compression facilities will be located at the LNG plant site. Once the reservoir CO
has been compressed it will be transported by underground pipeline to one of three drill centres where it
will be injected into the Dupuy Formation beneath Barrow Island. This will reduce greenhouse gas
emission from the Project by approximately 40 percent.
83
Figure 2.93: Gorgon & Jansz Gas Field Development in Australia
Source - Chevron
Figure 2.94: Subsea Scope of Supply
Source - GE Oil & Gas
84
Figure 2.95: Land Based LNG Plant
Source - Chevron
Figure 2.96: Gorgon Manifold
Source - GE Oil & Gas
85
Directed Learning:
Look up further information on the Gorgon and Jansz Gas Fields Development using
Google. Collect further information about the Subsea Production equipment employed.
Online Assessment:
Log on to the Learning Management System to complete the online assessment for
this module. If you dont achieve at least 75%, you may revise the module and
attempt the test again to improve your score.
86

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FUNDAMENTALS OF SUBSEA

Wellheads, Xmas Trees and

John Preedy PhD

Copyright IIR Limited 2015. All rights reserved.

Source J E & P Associates and Azur Offshore Ltd

CAMERON (Now OneSubsea, combining Cameron and Slumberger) - USA

FMC Technologies - Norway

GE(Oil & Gas) VETCO - USA

AKER SOLUTIONS - Norway

Figure 2.3: Typical Subsea Wellhead

Source GE Power and Cameron

2.1 Subsea Wellhead and Guide Base

The three main functions of a wellhead can be considered as follows:

i. To provide a location for suspension of casing strings

ii. To provide sealing and pressure containment

Figure 2.4: Subsea Wellhead Functions

Source Azur Offshore Ltd

Source Azur Offshore Ltd

Source Azur Offshore Ltd

Figure 2.7: Shallow Waterguide Base with 4 Guide Posts

Source Azur Offshore Ltd

Source Azur Offshore Ltd

Source J E & P Associates

2.2 Tubing Hanger System (Conventional Dual-bore Trees)

2.2.1 Tubing Hanger

Assist in monitoring the well for pressure increases and losses.

Allow for cleaning fluid circulation.

Figure 2.11: Sub-surface Completions Schematic

Source J E & P Associates

2.2.2 Wellhead Conversion Assemblies

2.3 The Blowout Preventer (BOP)

Figure 2.12: Operation of a Subsea BOP

Source Wikimedia Commons

Figure 2.13: Functions of a BOP

Source J E & P Associates

Figure 2.14: Subsea Blowout Preventer

Source J E & P Associates

Blowout preventers come in two varieties annular and ram.

2.3.2 Annular Blowout Preventer

Figure 2.15: Annular BOP

Source J E & P Associates

2.3.3 Ram Blowout Preventer

Figure 2.16: BOP Ram Preventers

Source Azur Offshore Ltd

Figure 2.17: Illustration of Ram Types

Source: Cameron Ltd.

Source J E & P Associates

Source J E & P Associates

2.4 Choke and Kill

Source J E & P Associates

3.1 Xmas Trees

Figure 2.21: Christmas/Xmas Trees Surface and Subsea

Source Wikimedia Commons and Fishsafe

Source Azur offshore Ltd

Figure 2.23: Subsea Tree Technologies

Source Courtesy of GE Oil & Gas

Figure 2.24: Subsea Xmas Tree Functions

Source J E & P Associates

1. The CONVENTIONAL DUAL BORE TREE (also called a vertical tree).

2. The HORIZONTAL OR SPOOL TREE (also called a side valve tree).

Source Courtesy of GE Oil & Gas

3.2 The Conventional Dual-bore Tree

Figure 2.26: Xmas Tree Valves

Source J E & P Associates