2/27/2014

Subsea Field Development - Challenges and Solutions for Tie-In and Connection Systems

Session: Focus on Technology

Subsea Australasia Conference19-21 February 2014

Zahid Hasan

AOG 2014

Outline

• Subsea Field Development- Introduction, Top Down Approach and Options

• Tie-In and Connections Systems- Introduction and Options• Comparison and Selection of Tie-In and Connection Systems• Field Development with alternate Tie-In and Connection

systems• Available Connection Systems (New Generation )

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Subsea Field Development

• Custom configuration of Subsea equipment

providing a variety of system designs

• Develop field architecture

• Well design and placement

• Host facilities and specification

• Configuration and routing of flowlines, umbilicals

and risers

• Installation Options

• Reduce risk with credible and proven solutions

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Reservoir& Field

System Solution

Sub-system solution

Available Products

The proposed system solution will be based on

• Technical decision factors,

• Location and Geographical condition

• Regulatory and political factors

• Operator’s preference

• Contractor’s preference

• Individual supplier’s preferences

• Available products and competence

Subsea Field Development- Top Down Approach

AOG 2014

Subsea Field Development – Top Down Approach

Level Main Factors Tie-in & Connection topics

Reservoir, Field,location + Government and Company requirements (= Design Basis)

• Reservoir parameters (pressure, temperatures,gas/oil, size, water depth, well locations etc)

• Process requirements• Geographic location/Environmental conditions• Availability of vessels in region

• Connection parts qualified for parameters• Connection system meets installation and

operational requirements• Can be used/maintained from small vessels

in remote locations

System Solution • Flow assurance philosophy• Hydraulic and injection distribution philosophy• Pigging/commissioning requirements• Retrieval of modules without pulling

jumpers/spools

• Injection volumes, thermal insulation• Multibore vs Monobore System• Subsea Parking of jumpers/spools for

module • Pre-installation and/or batch setting of

jumpers/spools.

Sub-system solution

• Horizontal and/or vertical System• Simple, complex tooling or hydraulic connectors• Guiding, installation requirements• External forces (installation and operation)• Rigid- and/or flexible lines and umbilicals

• Qualified and preferably field proven solutions

• Injection and/or hydraulic distribution through connectors

• Swivel functionality to handle torsion in flexible lines

Available Products • Sizes and capabilities (pressure, temp, capacity, insulation etc)

• Qualification requirements, track record• Installation vessel, methods and procedures• Commissioning requirements• Contingency operations

• Qualified and preferably field proven System• Handling, installation, guiding • Connectors, seals, caps, tools• Procedures

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Typical Subsea Field Developments Options

• Satellite Tieback

• Cluster Manifold

• Cluster Manifold with Satellite Tieback

• Mixture of ManifoldCluster and remote/inline tiebacks

• Daisy Chained Tieback

• Integrated Template/Manifold

AOG 2014

Outline

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• Subsea Field Development- Introduction, Top Down Approach and Options

• Tie-In and Connections Systems- Introduction and Options• Comparison and Selection of Tie-In and Connection Systems• Field Development with alternate Tie-In and Connection

systems• Available Connection Systems (New Generation )

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What is a Tie-In and Connection System

In reference to Oil and Gas Industry the connection system:

• Joins two pieces of equipment (e.g. tree to wellhead, jumper to hub, etc.)

• Prevent fluid leakage to the environment• Establish and maintain a seal on a gasket• Withstand external loading (internal pressure,

bending, tension, torsion)

AOG 2014

Tie-in and Connection System Options

Orientation Application Connector type/actuation

Horizontal Pipe sizesNon insulatedInsulatedMono-boreMulti-bore

Mechanical w/”large” toolMechanical w/”small” toolsHydraulic w/contingency

Vertical Pipe sizesNon insulatedInsulatedMono-boreMulti-bore

Mechanical w/”large” toolMechanical w/”small” toolsHydraulic w/contingency

Small-bore Injection lines ROV installation, FLOT + Torque tool or hydraulic

Flying leads Hydraulic distribution and/or injection linesEl/FO jumpers

ROV installation, FLOT + Torque tool

Module connectors

SizesNon insulatedInsulatedMono-boreMulti-bore

Mechanical ”small” toolHydraulic w/contingency

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Outline

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• Subsea Field Development- Introduction, Top Down Approach and Options

• Tie-In and Connections Systems- Introduction and Options• Comparison and Selection of Tie-In and Connection Systems• Field Development with alternate Tie-In and Connection

systems• Available Connection Systems (New Generation )

AOG 2014

Selection of Connection System

Challenges:• Design Basis and Customer

Requirements• Many needs in one field• Intervention Strategy • Reuse of existing tooling• Cost evaluation criteria• Interfaces

– Internal interfaces in Subsea Production System

– Interfaces to pipeline/flowline

• External forces • Physical interfaces • Handling and installation • Installation procedures

• Knowledge and experience of involved personnel

• Personal and cultural preferences based on experience

Reservoir, Design Basis, Field layout

System, Flow assurance, Hydraulic

and injection fluid distribution

Pipe sizes

Horizontal

Multi-bore or Flying Leads+ small-bore

Insulated connectors

Not insulated

Vertical

Multi-bore or Flying Leads+ small-bore

Insulated connectors

Not insulated

Module

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Vertical vs Horizontal Tie-In Systems Selection• Regional preferences and customer preferences• Total installed cost• Field architecture (on-template wells, off-template well clusters

and wide area distribution wells)• Ease of fabrication (onshore/ offshore)• Lifting capacity of the installation vessel • Ease of performing jumper installation• Ease of Tree and / or Manifold retrieval• Regional requirement for overtrawlability and hence minimum

height protection structures (i.e. North Sea applications).• Avoidance of trapped water and potential hydrate formation• Multi-phase and Wet Gas meters location (Need to be in a vertical

leg for proper performance)

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Rigid Vs Flexible Jumpers

• Selection of Rigid or Flexible jumpers is dependant on– Field Layout– Design Requirement (Pressure, Temperature etc.)– Material Philosophy– Insulation Requirement– Fluid in bore– Total Installed Cost

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Outline

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• Subsea Field Development- Introduction, Top Down Approach and Options

• Tie-In and Connections Systems- Introduction and Options• Comparison and Selection of Tie-In and Connection Systems• Field Development with alternate Tie-In and Connection

systems• Available Connection Systems (New Generation )

Typical Production DC Layout – Vertical Mono-bore connections

SDU

SRM

UTH

EFL and HFL jumpers(elec, hyd, chem)

FCM

EHXT

SCM

M spools and vertical connections

10” PLET Jumpers(Vecon Connectors)

MCMManifold

10” Flowline (PIP)

10” Flowline (PIP)

UTH

Methanol 2” jumpersKC4-3 vertical connections

Umbilical(elec+fibre+hyd+chem+ 5x1.5” for methanol)

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Typical Production Drill Centre with vertical connections

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Drill Center with Vertical Rigid Spools

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Typical Production DC Layout withHorizontal multi-bore well jumpers/connectors

• No SDU (Distribution in manifold)• All horizontal connections• Multi-bore connections (XT to manifold)

Umbilical(elec+f ibre+hyd+chem+ 5 x1.5” for methanol)

SRM

FCMEHXT

SCM

XT Jumpers6” prod + 2” methanol + elec + hydUCON multi bore horizontal

10” PLET Jumpers(UCON mono bore horizontal)

MCM

Manifold

10” Flowline (PIP)

10” Flowline (PIP)

SCM

MCMManifold

Mono-bore DC

Multi-bore DC

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Typical Production Drill Centre with horizontal connections

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Drill Center with Horizontal Rigid Spools

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Drill Centre with Vertical Rigid Spools

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As Built Drill Centre

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Outline

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• Subsea Field Development- Introduction, Top Down Approach and Options

• Tie-In and Connections Systems- Introduction and Options• Comparison and Selection of Tie-In and Connection Systems• Field Development with alternate Tie-In and Connection

systems• Available Connection Systems (New Generation )

Different Connection SystemsHistorical - Integral Hydraulic

and Mechanical / CAT Tie-in Systems

UCON ROV-Tool

Mechanical Tie-in System

TORUS IV

ROVCON

STABCON

TORUS III MAX - CAT & CAT-Lite

UTIS

• Used Large tools• Longer installation time

UCON-H

UCON-V

Collet or Clamp

Clamp

Collet

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Standard Connection Systems

Connection Systems

Horizontal

UCON-H

UCON-H-12 UCON-H-12 INS UCON-H-18 UCON-H-18

INS UCON-H-22

Stabcon MK2 Rovcon MK2

Vertical

UCON-V-KC UCON-V--KL

KLV-8 (MAX) KLV-10 KLV-14 KLV-16

Torus-III

Smallbore Module Connectors

Manifold System

Well Completion

Systems (XTs)

Well Access Systems (Riser)

Process

• UCON Family – UCON-H, Horizontal– UCON-V, Vertical

• Based on the same family of standards– Collet Connectors (KC)– Clamp Connectors (KL)

• The core collet and clamp connectors use the same mono-bore and multi-bore hubs/connector bodies and Seals

• The design and qualification philosophy is that qualified seals can be used in all connectors.

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KC/KL connector family

KC4-10 KC4-12KC4-14

KC4-27

KL4-10 KL4-12

KL4-18

KL4-27

KC4-34KC4-18

KL4-16

Max pipe OD (Inches)

KC4-16

KL4-14

KC4-22

12.75” 14” 16” 18” 20” 24” 30” 36”

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UCON-H Product Family• 4 versions available today• UCON-H-22 is available Q1 2014

UCON-H-22

UCON-H-18

UCON-H-12, insulated

UCON-H-12UCON-H-18, insulated

• Basic ROV manipulator held tooling

• Mono-bore and Multi-bore

• Integral Insulated or non-insulated

• Horizontal or Vertical

• Guideline or guideline-less operations

• No interface with seabed during installation and connection

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UCON-H Multibore Connections

Umbilical Termination Head (UTH)

Insulated Multibore Welljumper Termination Head(6 + 2x1.5 + 8 HL)

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UCON-H Connection System

Multi-bore KC4 Connector

6” + 2x1.5” + Hyd + chem + EL

• Stroke-in and connect• Rigid Spools (mono/multi bore)• Flexible lines / umbilicals• Pig Launchers /Receivers• Pig Loops

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Connection System Installation

UCON-H SystemROVCON System

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UCON-H Video

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Installation/Parking of Connection System without Production Equipment

Tubing Head (U Loop) Flowbase System (Flexible Flowloop)

Tubing Head (Without U Loop) for UCON System

• Simpler Parking/pre-installation of well jumper

• Direct interface with Tree hub

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Installation of UCON System without Production Equipment

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Conclusions

• Tie-in and Connection system selection is fundamental to an

economic field development

• Vertical & or Horizontal tie-ins with rigid and or flexible pipe may be

selected – feature common connectors and hubs

• UCON Connection system reduces total installed cost

• Simplified ROV deployed Tooling reduces installation time

• Integral Thermal Insulation available vs. adding “dog houses”

improves thermal performance and reduces cost

• Subsea parking & pre-installation of jumpers without Subsea

production equipment is enabled

• Reduced personnel onboard vessels and simplified maintenance

• Wide Pipe range available

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Thank You