Havbunnsproduksjon

NTNU 26. mars 2012

Sverre Corneliussen
Senior System Enginer, FMC Studies & Tenders
Contents
Subsea field layout & equipment
Subsea structures & X-mas trees
Subsea Wells
Subsea Control Systems
Safety systems
Well flow
Subsea Instrumentation, Vega example
Pressure protection
Pressure & temperature sensors
Sand sensors
Multiphase meters
Subsea separation
Subsea Applications
Topside Controls
Topside
Process
Umbilical/Flowline
Production Vessel
Floating production ship
Manifold
XT
Bijupira Saleema
Snorre Tension Leg Platform (TLP)
Snorre
UPA
Terra Nova iceberg protection
Owertrawl
protection
Subsea to beach (Ormen Lange)
8 Slot Template System. Ormen Lange
1100 ton
Suction
anchor
Basic reservoar and drilling
Horisontal Well
completion
Fishhook well
Wellhead system
13 3/8
Casing
Hanger
18 3/4
Wellhead
Housing
13 3/8
Production
tubing
Hanger
14
Smaller production bore (5 -7 )
Production tubing installed brfore XT
XT can be removed without removing
production tubing
X-mas tree
Weight 40 ton
Subsea Control
Module
X-mas tree
Horizontal X-mas tree
Subsea Production Control
Functions Production Control System
19
1. Safety
- Shuts in the subsea system in critical situations
2. Operator Interface during Daily Operation
- Operation of subsea valves and chokes
- Monitoring of production parameters and system
integrity
20
Electro Hydraulic Control System
Hydraulic
Actuators
Injection
Chemicals
Hydraulic
Power unit
Xmas
Tree
Subsea
Distribution
unit
Umbilical
Cross Section
Electric
Cables
Umbilical
Master
Control
Station
Electric
Power Unit
Topside
Gateway
Hydraulic and
Chemical Lines
SCM
Up to 200 km
Fluid lines
Electrical lines
Fluid lines: Super duplex
Electrical lines: HDPE
21
Subsea Control Umbilical - Typical
Topsides Termination Subsea Termination
Connects topsides control equipment to subsea field equipment
Routes hydraulic and electric power and chemicals to subsea field
Routes signals between topside and subsea equipment
Cross Section
22
Subsea Control Module (SCM)
Lifting Adapter
Anti-Rotation Guide Pin
Locking Mechanism
Hyd. Couplers
Elec. Connectors
Elec. Connectors
23
Subsea Electronic
Subsea Hydraulics &
Mechanics
Subsea Control Module: Components
SCM
without
outer can
SCM
Typical operator display picture
DHSV
PMV PWV
Choke
Manifold HIPPS
Flowline
Production Riser
Riser
EV
Utility Riser
CIV
EUC 1
EUC 2
Isolation of well from environment (OLF 070)
Subsea Control Safety Requirement
ESD of single well to SIL 3
PSD of single well to SIL 1
HIPPS to SIL 3
Workover to SIL 2
Flow assurance
Natural flow
Pressure balancing using chokes
Flow optimization in flow lines
Well testing
Flow boost
Gas lift, in riser, in well
Booster pumps
Flow assurance
Hydrates
ice created of gas, water and oil
Stable in cold, deep water
Methanol or MEG anti frost
Wax, asphalt, corrosion
Injection of wax, asphalt and corrosion inhibitor
Pigging
Scraping plug pumped through flowline
Conductor
interface
Hydrate formation in 1200 m water depth
Subsea Instrumentation
Vega as example
Vega is a gas & codensate field in the North Sea
Sofisticated instrumentation due to high pressure and split
of production between different owners
Vega subsea instrumentation
High Integrity Pressure Protection System (HIPPS)
2 + 1 HIPPS valves on manifold
6 voted pressure sensors
High accuracy pressure and temperature sensors
Quartz crystal sensor
Acoustic sand detector
Listen for sand pings
Multi phase meter for flow measurement of wet gas
Microwave sensors for 3 D model of flow
Nuclear density meter
P & T sensors for PVT calculation over Venturi
9 Nuclear density meter
Vega field
Vega template & manifold
High I ntegrity Pressure Protection System (S)HI PPS
PSD600
CU A
PSD A- B link

SV1

SV2

SV3
Flow
Line

BV1

BV2

BV3

MIV2
DCV
BV1
DCV
SV1
DCV
MIV2
DCV
SV2
DCV
BV2
DCV
SV3
DCV
BV3
PT6
A/B
PT7
A/B
PT4
A/B
PT5
A/B
PT10
A/B
PT8
A/B
PT9
A/B
PSD600
CU B
A B A B A B A B A B
A B
A B
A B
A B
Service/
/
Line
IV2 IV1
A B A B A B
From
wells
MAIN HIPPS VALVES
TEST VALVES
SI L 3 controller hardware architecture
PSD SYSTEM SIDE A PSD SYSTEM SIDE B
PSD600 Control Unit
Sensors
Output to final
elements
Top Side
Sub Sea
SC1
SC2
ETH
PSD600 Control Unit
Sensors
Output to final
elements
SC1
SC2
ETH
U
m
b
i
l
i
c
a
l
PSD600 Control Unit
Switches Output
SC1
SC2
ETH
PSD600 Control Unit
Switches Output
SC1
SC2
ETH CAN
From CAN
sensors
CAN CAN
From CAN
Sensors
CAN
From CAN
sensors
From CAN
Sensors
Comm.
Power
Comm.
Power
Direct
link
Direct
link
Direct
link
Direct
link
SCU
A
SCU
B
SI L 3 controller software architecture
PSD Safety Core A2
ETH Subsystem
PSD Safety Core A1
CSC01 Execution control
PSD Safety Application
PSD Control Unit
Triton PXA255 (T-ETH-400/64S/32F/ETN/EXT) with RedBoot Firmware
Sensor Reading
Linux Operating System
Linux kernel 2.6.x
FMC 722
Handler
Serial
Handler
Net
Handler
Maintenance
and
Diagnostics
ETH Router
RS 422 x 1
UART TTL x 2
Ethernet 100 Mbit PHY
SW
HW /
FW
RS 422 x 1
UART TTL x 2
DO x
32
AI 4-20
mA x 16
CAN
PHY
CSC01 CAN Safety Chip (M16C) 16 Bit Renesas Microcontroller
CAN
Open
Stack
Test
RAM,
CPU
Serial
Handler
DO control,
Monitoring and Test
Sensor
Reading and
Test
ADC
SPI
EEPROM
SPI
Config
Handler
SW
HW /
FW
ADC
(SPI)
WD
SPI
Kernel
Mod
WD
Int.
Lock
FSPS
PWR
MON &
CONTR.
PT/ TT FUNCTI ONAL COMPONENTS
FLOW LINE
HARNESS
ADAPTER
PENETRATOR
ADC BOARD
CONTROL
BOARD
ELECTRONICS
PROBE
TRANSDUCER
PT/ TT FUNCTI ONAL COMPONENTS
HOUSI NG MODULE:
The module is consisting of an flange
with a probe for process interface and
cylindrical housing for the containment
of the electronic boards.
The electronics is contained in
atmospheric pressure sealed with
glass-metal penetrator towards the
ambient pressure.
The jumper connection is done via an
adapter module.
QUARTZ CRYSTAL TECHNOLOGY
Total Error Band: 0.02 % FS
Pressure ranges: 0- 345Bara, 0-690Bara, 0-1035Bara
Standard Temperature ranges : -30 to 150 C
Temperature accuracy: 0.3 % CR
Product family : PT/TT
Drift: 0,02 %FS/year @25C
Electrical interface:
RS485, CANOPEN
Sand detector Working principle
The results of sand
ClampOn DSP Particle Monitor Subsea
DEEPWATER
Weight 18 kg
4500 Meter Water Depth
Intelligent DSP Processing = improved S/N ratio
ROV installable sensor
COMPACT SUBSEA
Weight 8 kg
3000 Meter Water Depth
Intelligent processing = improved S/N ratio
ROV installable sensor & clamp
ALL SYSTEMS
Fast economical installation
No drilling, welding or pressure drop
Digital communication between field and computer
ClampOns Subsea Philosophy!
Titanium body
J umper interface
High pressure chamber with silicon oil
Glass-metal penetrator
Atmospheric chamber
Electronic beam weldings
No o-rings, gaskets or mechanical seals!
Subsea multiphase meters on each well
Allows for accurate and continuous online well
allocation
Multi-rate testing to be performed whenever
desired
Reduced need for well testing by using topside test
separator; only needed for verification:
Represents redundant solution
Yearly or when indication of anomalies
Reduces host platform deferred production
Results in substantial well regularity improvement
Micro
wave
Gamma
ray
Venturi
Subsea seabed separation
Separate water and sand from oil
Produced fluid may contain 90 % water from old wells
Remove and re-inject water and sand close to well
Avoid transport of water long distance for separation on surface
Separate heavy oil from gas on deep fields
Pump heavy oil to surface, natural well pressure will not lift oil
Gas to surface by natural flow
Subsea Separation
Separator Module
Pazflor reservoir
Miocene: 65% of overall reserves
Heavy oil: 1722 API
High viscosity: 40 cP at 55C
Reservoir Pressure: 200 bar
Reservoir Temperature: 65C
Oligocene: 35% of overall reserves
Light oil: 35-38 API
Reservoir Pressure: 350 bar
Reservoir Temperature: 115C
Free flow is not possible
Solution - Subsea Processing
Gas / Liquid Separation and
Liquid Boosting:
Gas flows freely to the FPSO
Hydrate preventions of flow lines by
means of depressurization is possible
Reduced cost due to elimination of
circular flow line
Liquid out of separator with relative low
gas fracttion
Efficient pumps with high P can be used
Increased recovery & less power
consumption
Boosting of liquid
Stabilized flow regime in risers reduces
slugging
LC
Pumps
Sep gas
XV
Sep
inlet
XV
Separator
liquid XV
Sep
inlet
bypass
XV
Riser
top XV
Pump
outlet XV
Choke
valve
PMV
PWV
Riser
top XV
ROV
LAH
RO
PC
23bar
60C
LAL
SSU Process Principle
Separator I nternals
Internals:
Gas outlet pipe
EvenFlow
Liquid distributor plates
Singel helix
Sand cone
Swirl breaker
Liquid flushing arrangement
Level Measurement
Subsea Nucleonic Density Profiler:
Nucleonic source array (Cesium 137-50mCi)
Two detector arrays with Geiger Mller
tubes
Topside PLC
Source and detectors installed in dip pipes
Detectors are retrievable, whereas nucleonic
source is permanently installed
Primary function is to measure liquid level, but
provides also information about density
distribution between HH and LL
Test Overview
EFAT of:
Control System
Pump Systems
Interchangeability of modules
System Integration Test of all SSU
Shallow Water Test of SSU#2
Function Test of SSU#1
Snhvit
Ormen
Lange
Longest & deepest fields
Tormore-
Laggan
Shell
Perdido
FMC Kongsbergs Global Presence
Houston
Kongsberg
Singapore
Dunfermline
Rio De Janeiro
St. Johns
Macae
Lagos
Eq. Guinea
Luanda
Aberdeen
Bergen
Stavanger
Perth
Mossel Bay
Blow Out
Preventer
(BOP)
58
BP Macondo Shear ram failure
59
BOP
shear
RAM
60
Thank You for Your Attention!