Liuhua 4 1 Subsea Tieback Project …Nanhai$Tiao$Zhan$ Liuhua 4-1 Subsea Tieback Project...
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FPS Nanhai Tiao Zhan Liuhua 4-1 Subsea Tieback Project Thermoplastic Production Control Umbilical ESP Power Umbilicals JDR’s Hartlepool facility recently delivered umbilicals and ESP power cables for the Liuhua LH41 subsea tieback project. The project is located in the South China Sea approximately 215km from Hong Kong and 240km from Shenzhen. The China National Offshore Oil Corporation (CNOOC) operates the subsea field in depths ranging from 260 to 300m. Host production facilities comprise the FPS Nanhai Tiao Zhan and the FPSO Nanhai Sheng Li. The development of the LH41 oil field includes one production manifold for eight production wells, jumpers and an 18” Subsea Pipeline. JDR supplied 3 x 14km ESP power umbilicals, 1 x 14km main production control umbilical and a bridging manifold control umbilical. LH111 FPS and LH111 FPSO were modified to meet LH41 production requirements. The development also allows for future expansion of the field with an additional manifold serving up to four additional wells. The ESP power umbilicals were produced on JDR’s stateof theart vertical layup machine (VLM). The VLM was commissioned for demanding projects such as LH 41. JDR Hartlepool UK Factory
Transcript of Liuhua 4 1 Subsea Tieback Project …Nanhai$Tiao$Zhan$ Liuhua 4-1 Subsea Tieback Project...
FPS Nanhai Tiao Zhan
Liuhua 4-1 Subsea Tieback Project Thermoplastic Production Control Umbilical ESP Power Umbilicals JDR’s Hartlepool facility recently delivered umbilicals and ESP power cables for the Liuhua LH4-‐1 subsea tieback project. The project is located in the South China Sea approximately 215km from Hong Kong and 240km from Shenzhen. The China National Offshore Oil Corporation (CNOOC) operates the subsea field in depths ranging from 260 to 300m. Host production facilities comprise the FPS Nanhai Tiao Zhan and the FPSO Nanhai Sheng Li.
The development of the LH4-‐1 oil field includes one production manifold for eight production wells, jumpers and an 18” Subsea Pipeline. JDR supplied 3 x 14km ESP power umbilicals, 1 x 14km main production control umbilical and a bridging manifold control umbilical.
LH11-‐1 FPS and LH11-‐1 FPSO were modified to meet LH4-‐1 production requirements. The development also allows for future expansion of the field with an additional manifold serving up to four additional wells.
The ESP power umbilicals were produced on JDR’s state-‐of-‐the-‐art vertical lay-‐up machine (VLM). The VLM was commissioned for demanding projects such as LH 4-‐1.
JDR Hartlepool UK Factory
Main Thermoplastic Umbilical – 1 x 14km
The LH 4-‐1 subsea tieback enabled utilisation of existing facilities with modifications to the FPS. The thermoplastic umbilical was optimized for hydraulic control system response and delivery of required injection chemicals. The cross section was designed with a drag diameter to apparent weight ratio necessary to meet dynamic mode requirements.
A thermoplastic umbilical solution was selected at FEED to minimize project cost and maximize system reliability.
Liuhua 4-1 Subsea Tieback Project ESP Power Umbilical Cross Section Main Umbilical Cross Section
3 x POWER TRIADS:-‐ 70 mm² IEC 60228 CLASS 2 COPPER CONDUCTOR-‐ EXTRUDED SEMI-‐CON XLPE CONDUCTOR SCREEN-‐ XLPE INSULATION-‐ EXTRUDED SEMI-‐CON XLPE INSULATION SCREEN-‐ WRAPPING OF SEMI-‐CON WATER BLOCK TAPE-‐ METALLIC SCREEN-‐ EXTRUDED OUTER JACKET (MDPE)-‐ Uo/U(Um) = 6/10(12)
EXTRUDED POLYPROPYLENE ROPE FILLERS
15 mm WIDE BLACK LONGITUDNAL STRIPE
POLYETHYLENE INNER SHEATH -‐ 4 mm NOMINAL THICKNESS
STRENGTH MEMBER -‐ 4.1 mm Ø GALVANISED STEEL WIRE -‐ TWO LAYERS (89 LAYER 1, 98 LAYER 2) -‐ CONTRA-‐HELICAL
POLYETHYLENE OUTER SHEATH-‐ 5 mm NOMINAL THICKNESS
POLYPROPYLENE ROPE FILLERS
EXTRUDED GSW ROPE BALLAST ELEMENTSESP POWER UMBILICAL
ESP Power Umbilical – 3 x 14km
Each ESP power umbilical contained three x 3 phase power circuits to service the eight wells and provide a complete spare circuit. The use of multi-‐triad power umbilicals reduced the number of risers thereby simplifying system complexity and minimizing project cost.
The umbilical bundles were laid up on JDR’s state-‐of-‐the-‐art vertical lay-‐up machine (VLM). The VLM has a capacity of 60 tonnes per bobbin, which reduced the number of core splices thus reducing risk to the project.
3 x QUAD CABLES: -‐ 16mm² COPPER CONDUCTORS (19 STRAND) -‐ XLPE INSULATION (600/1000V) -‐ BELTED HDPE INNER JACKET -‐ COPPER DRAIN WIRES -‐ OVER LAPPED COPPER / POLYESTER TAPE -‐ HDPE OUTER JACKET
7 x HYDRAULIC HOSES (SEE TABLE) -‐ NYLON 11 TLO LINER -‐ BRAIDED ARAMID BURST REINFORCEMENT -‐ POLYMER OUTER JACKET
12 mm WIDE BLACK LONGITUDNAL STRIPE
POLYETHYLENE INNER SHEATH -‐ 3 mm NOMINAL THICKNESS
EXTRUDED GSW ROPE FILLER ELEMENTS
STRENGTH MEMBER -‐ 4.0 mm Ø GALVANISED STEEL WIRE -‐ TWO LAYERS, -‐ CONTRA-‐HELICAL
POLYETHYLENE OUTER SHEATH-‐ 5 mm NOMINAL THICKNESS
POLYPROPYLENE ROPE FILLERSMAIN THERMOPLASTIC UMBILICAL
Liuhua 4-1 Subsea Tieback Project Dynamic Analysis Umbilical Hardware
Dynamic Analysis
A major part of the supply contract included dynamic riser design. JDR’s in-‐ house riser team performed the riser design and undertook extensive analysis using Orcaflex software. The JDR riser team was faced with challenges including the need to model FPS rig movements during workovers of existing LH 11-‐1 wells directly under it. The main umbilical and ESP power umbilical risers were optimized to provide fatigue resistance for the design life.
Riser engineering included: • Tension/angle plots for bend stiffener design
• Calculation of FPS hang-‐Off loads
• TDP location & arc-‐length
• Distribution of buoyancy modules • Specifying tension across entire length of riser • Specifying min/max sag/bend clearance
Umbilical Hardware
Hardware design is undertaken internally by JDR’s termination hardware design team. Subsea equipment was designed with stand alone CP for the design life. All hardware and ancillary equipment was designed using the latest 3D CAD software. Fabrication drawings were produced from 3D models.
Hardware delivered included: • Flexible pull-‐in heads • Hang-‐off bodies and split clamps • Dynamic bend stiffeners • Buoyancy modules • Riser base clamps • Subsea termination units
JDR Cable Systems Ltd
Littleport Innovation Park, Wisbech Road
Littleport, Cambridgeshire CB6 1RA
T +44 (0)1353 860022
Liuhua 4-1 Subsea Tieback Project Hartlepool, UK Factory Loadout
Hartlepool UK Factory
JDR produces umbilicals and cables from three principle manufacturing locations: 1) Hartlepool UK, 2) Littleport UK and 3) Sattahip Thailand. Hartlepool was chosen for the LH 4-‐1 project because of its twin thermoplastic umbilical and power cable production lines. Both products were made concurrently to reduce delivery lead time.
The Hartlepool factory assets are:
• Experienced labour force
• Horizontal lay-‐up machine (6 carrier)
• Vertical lay-‐up machine (3 / 6 / 12 carrier)
• SZ hydraulic umbilical line
• 2 x 2,200 tonne carousels
• 2 x 4,000 tonne carousels
• 2 x 100 bobbin armourers
• 220 mm OD extrusion Line
LH 4-‐1 – Complex Loadout
A heavy lift vessel fitted with a temporary 2,000 tonne carousel was used to ship the umbilicals to China. Once in country, the umbilicals will be transferred to an installation vessel. The loadout process was complex because the single carousel had to contain all four
umbilicals complete with topside hardware, dynamic bend stiffeners and subsea terminations. JDR engineering teams provided detailed packing design while JDR’s loadout team executed a safe and effective loadout. All lengths were packed on the carrousel.
JDR is a leading worldwide provider of custom
designed and manufactured subsea umbilicals and
power cables for a broad range of applications in the oil
and gas sector and the growing offshore renewable
energy industry.
JDR Cable Systems Ltd
Greenland Road, Hartlepool
Cleveland TS24 0RQ
T +44 (0)1429 851890
For more details on JDR’s capabilities and services please contact:
www.jdrcables .com UK USA THAILAND NORWAY SINGAPORE
