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 ControlsTopsideProcess

Umbilical/Flowline

Production Vessel

Floating production ship

ManifoldXT

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 Lange1100 ton

Suction anchor

Basic reservoar and drilling

Horisontal Well completion

Fishhook well

Wellhead system

13 3/8” CasingHanger

18 3/4” WellheadHousing

13 3/8” Production

tubingHanger

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

HydraulicActuators

InjectionChemicals

HydraulicPower unit

XmasTree

SubseaDistributionunit

Umbilical Cross Section

ElectricCables

Umbilical

MasterControlStation Electric

Power Unit

TopsideGateway

Hydraulic and Chemical Lines

SCM

Up to 200 kmFluid linesElectrical lines

Fluid lines: Super duplexElectrical 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 withoutouter can

SCM

Typical operator display picture

DHSV

PMV PWV

Choke

Manifold HIPPSFlowline

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 Integrity Pressure Protection System (S)HIPPS

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

PT6A/B

PT7A/B

PT4A/B

PT5A/B

PT10A/B

PT8A/B

PT9A/B

PSD600 CU B

A B A B A B A BA 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

SIL 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

SensorsOutput to final elements

SC1

SC2

ETH

Umbil

ical

PSD600 Control Unit

Switches Output

SC1

SC2

ETH

PSD600 Control Unit

SwitchesOutput

SC1

SC2

ETHCANFrom CAN

sensors

CAN CANFrom CAN Sensors

CAN

From CAN sensors

From CAN SensorsComm.

Power

Comm.

Power

Direct link

Direct link

Direct link

Direct link

SCUA

SCUB

SIL 3 controller software architecture

PSD Safety Core A2

ETH Subsystem

PSD Safety Core A1CSC01 Execution control

PSD Safety Application

PSD Control Unit

Triton PXA255 (T-ETH-400/64S/32F/ETN/EXT) with RedBoot Firmware

Sensor Reading

Linux Operating SystemLinux kernel 2.6.x

FMC 722 Handler

Serial Handler

Net Handler

Maintenance and

Diagnostics

ETH Router

RS 422 x 1UART TTL x 2 Ethernet 100 Mbit PHY

SW

HW /FW

RS 422 x 1UART 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

TestRAM, CPU

Serial Handler

DO control, Monitoring and Test

Sensor Reading and

Test

ADCSPI

EEPROMSPI

Config Handler

SW

HW /FW

ADC(SPI)

WD

SPIKernel Mod

WD Int. LockFSPS

PWR MON &

CONTR.

PT/TT FUNCTIONAL COMPONENTS

FLOW LINE

HARNESSADAPTER

PENETRATOR

ADC BOARD

CONTROLBOARD

ELECTRONICS

PROBE

TRANSDUCER

PT/TT FUNCTIONAL COMPONENTS

HOUSING 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 150º 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

DEEPWATERØ Weight 18 kgØ 4500 Meter Water DepthØ Intelligent DSP Processing = improved S/N ratioØ ROV installable sensor

COMPACT SUBSEAØ Weight 8 kgØ 3000 Meter Water DepthØ Intelligent processing = improved S/N ratioØ ROV installable sensor & clamp

ALL SYSTEMS•Fast economical installation•No drilling, welding or pressure drop•Digital communication between field and computer

ClampOn’s Subsea Philosophy!

Titanium body

Jumper 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: 17–22° API

− High viscosity: 40 cP at 55°C

− Reservoir Pressure: 200 bar

− Reservoir Temperature: 65°C

Oligocene: 35% of overall reserves

− Light oil: 35-38° API

− Reservoir Pressure: 350 bar

− Reservoir Temperature: 115°C

è 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 gasXV

SepinletXV

Separatorliquid XV

Sepinlet

bypassXV

Risertop XV

Pumpoutlet XV

Chokevalve

PMV

PWV

Risertop XV

ROV

LAH

RO

PC

23bar 60°C

LAL

SSU Process Principle

Separator Internals

• 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 Müller 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

Snøhvit

Ormen Lange

Longest & deepest fields

Tormore-Laggan

Shell Perdido

FMC Kongsberg’s Global Presence

Houston

Kongsberg

Singapore

Dunfermline

Rio De Janeiro

St. John’s

Macae

LagosEq. Guinea

Luanda

AberdeenBergen

Stavanger

PerthMossel Bay

Blow Out Preventer (BOP)

58

BP Macondo Shear ram failure

59

BOP shear RAM

60

Thank You for Your Attention!