NTNU 28. mars 2011 Sverre Corneliussen Senior System ...

1 HavbunnsproduksjonNTNU 28. mars 2011 Sverre CorneliussenSenior System enginer , FMC Studies & TendersContents 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 separationSubsea ApplicationsTopside ControlsTopsideProcessUmbilical/Flowline Production VesselFloating production shipManifoldXTBijupira SaleemaTerra Nova iceberg protectionSnorre Tension Leg Platform (TLP)Snorre UPAS ubsea to beach (Ormen Lange)8 Slot Template System . Ormen Lange1100 tonSuction anchorManifold. Ormen LangeManifold. Ormen LangeBasic reservoar and drillingHorisontalWell completionFishhook wellWellhead system13 3/8 CasingHanger18 3/4 WellheadHousing13 3/8 Production tubingHangerX- mas tree systemX-mas treeChoke moduleControl moduleRunning toolsX- mas treeWeight 40 tonSubsea Control ModuleX- mas treeHorizontal X-mas tree19XT valves and sensors, typical layout HXTWell flow outChemicals inSubsea Production ControlFunctions Production Control System211.

2 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 22 Electro Hydraulic Control SystemHydraulicActuatorsInjectionChemica lsHydraulicPower unitXmasTreeSubseaDistributionunitUmbili cal Cross SectionElectricCablesUmbilicalMasterCont rolStationElectricPower UnitTopsideGatewayHydraulic and Chemical LinesSCMUp to 200 kmFluid linesElectrical linesFluid lines: Super duplexElectrical lines: HDPE23 Subsea Control Module (SCM)Lifting AdapterAnti-Rotation Guide PinLocking MechanismHyd. CouplersElec. ConnectorsElec. Connectors24 Subsea ElectronicSubsea Hydraulics &MechanicsSubsea Control Module: ComponentsSCM withoutouter canSCMT ypical operator display pictureDHSVPMVPWVC hokeManifoldHIPPSF lowlineProduction RiserRiser EVUtility RiserCIVEUC 1 EUC 2 Isolation of well from environment (OLF 070)Subsea Control Safety FunctionsESD Node(redundant)HPUH ydraulicSupplySolenoidValves(redundant)

3 To riser EVUPSR elayXTPMVPWVDHSVDumpDCVPWVDCVPMVDCVDHSVD CVSCMP roduction FlowESD SignalsElectrical PowerHydraulic FluidPilot SupplyCIVCIVDCVI njection LineCIV= Chemical Injection ValveDCV= Directional Control ValveDHSV= Down Hole Safety ValveEPU= Electrical Power UnitESD= Emergency Shut DownHPU= Hydraulic Power UnitPMV= Production Master ValvePWV= Production Wing ValveSCM= Subsea Control ModuleUPS= Uninterruptible Power SupplyXT= X-mas TreeEPUS ubsea 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 pumpsFlow 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 flowlineSubsea InstrumentationVega as exampleVega is a gas & codensate field in the North SeaSofisticated instrumentation due to high pressure and split of production between different ownersVega 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 fieldVega template & manifoldHigh Integrity Pressure Protection System (S)HIPPS SIPPS SENSORSIPPS VALVESIPPS logic systemPSD logic systemSIPPSBase case: Vega SIPPS, including MEG9' Production TEST sensor production PT9 Mai n flow linePT8PT7 From wells Note.

4 XOV is normally forced closedNormal LP functionfrom MCMS afety critical LP functionfrom PSD 600 in MCMS afety critical LP functionFrom PSD600 in MCMN ormal LP functionfrom MCMN ormal LP functionfrom MCMS afety critical LP functionFrom PSD 600 in MCM TEST VALVE Bypass VALVE SV3SV2SV1BV3BV2BV1PT10 SIPPS functionality: SV 1, SV 2, BV 1, BV 2 and MEG valve are triggered by PT 4-7 BV 3 and SV 3 are test MEGFlow modulePT 4PT 3PT 2PT 1 Steady state MEGV-cone FlowlineV-cone MEGPT5PT 6 PT 11 SIL 3 controller hardware architectureSwitch/RouterSwitch/RouterSw itch/RouterSwitch/RouterPSD System SIDE APSD System SIDE BPSD600 Control UnitSensorsOutput to final elementsTop SideSub SeaA1A2 ETHPSD600 Control UnitSensorsOutput to final elementsA1A2 ETHU mbilicalPSD600 Control UnitSwitchesOutputA1A2 ETHPSD600 Control UnitSwitchesOutputA1A2 ETHFSK modemFSK modemPowerPowerSwitch/RouterSwitch/Route rFSK modemFSK modemPower PowerSwitch/RouterSwitch/RouterACACSIL 3 controller software architecturePSD Safety Core A2 ETH SubsystemPSD Safety Core A1 CSC01 Execution controlPSD Safety ApplicationPSD Control UnitTriton PXA255 (T-ETH-400/64S/32F/ETN/EXT)

5 With RedBoot FirmwareSensor ReadingLinux Operating SystemLinux kernel 722 Handler Serial Handler Net HandlerMaintenance and DiagnosticsETH RouterRS 422 x 1 UART TTL x 2 Ethernet 100 Mbit PHYSWHW /FWRS 422 x 1 UART TTL x 2DO x 32AI 4-20 mA x 16 CAN PHYCSC01 CAN Safety Chip (M16C) 16 Bit Renesas MicrocontrollerCAN Open StackTestRAM, CPUS erial Handler DO control, Monitoring and TestSensor Reading and TestADCSPIEEPROMSPIC onfig HandlerSWHW /FWADC(SPI)WDSPIK ernel ModWDInt. LockFSPSPWR MON & FUNCTIONAL COMPONENTSFLOW LINEHARNESSADAPTERPENETRATORADC BOARDCONTROLBOARDELECTRONICS PROBETRANSDUCERPT/TT FUNCTIONAL COMPONENTSHOUSING 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 CRYSTAL TECHNOLOGY Total Error Band: % FS Pressure ranges: 0-345 Bara, 0-690 Bara, 0-1035 Bara Standard Temperature ranges : -30 to 150 C Temperature accuracy: % CR Product family : PT/TT Drift: 0,02 %FS/year @25C Electrical interface: RS485, CANOPENSand detector Working principleThe results of module -a challenge!

6 clampon ultrasonic intelligent SensorsChokeThe subsea modules are more an more compact - more instrumentation and less space for optimum from choke to detector is less then 2 metersChokes generates high unwanted ultrasonic noise due to extreme velocities!How to overcome this? lets look at a real case! clampon DSP Particle Monitor SubseaDEEPWATER Weight 18 kg 4500 Meter Water Depth intelligent DSP Processing = improved S/N ratio ROV installable sensorCOMPACT SUBSEA Weight 8 kg 3000 Meter Water Depth intelligent processing = improved S/N ratio ROV installable sensor & clampALL SYSTEMS Fast economical installation No drilling, welding or pressure drop Digital communication between field and computerClampOn s Subsea Philosophy!Titanium bodyJumper interfaceHigh pressure chamber with silicon oilGlass-metal penetratorAtmospheric chamberElectronicbeam weldingsNo o-rings, gasketsor mechanicalseals!Subsea multiphase meters on each wellAllows for accurate and continuous online well allocation Multi-rate testing to be performed whenever desiredReduced need for well testing by using topside test separator.

7 Only needed for verification: Represents redundant solution Yearly or when indication of anomalies Reduces host platform deferred production Results in substantial well regularity improvementMicro waveGamma rayVenturiSubsea 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 flowSubsea SeparationSeparator ModuleChallenges with the Pazflor in West Africa Low energy reservoir Deep water ~ 800 1000m High viscosity and stable emulsion Large pressure drop in flowlines and risers High water productionfrom year 4 Large amounts of methanol needed for hydrate prevention Free flow is not possibleSolution - 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 reducessluggingLCPumpsSep gasXVSepinletXVSeparatorliquid XVSepinletbypassXVRisertop XVPumpoutlet XVChokevalvePMVPWVR isertop XVROVLAHROPC23bar 60 CLALSSU Process PrincipleSeparator Internals Internals: Gas outlet pipe EvenFlow Liquid distributor plates Singel helix Sand cone Swirl breaker Liquid flushing arrangementLevel Measurement Subsea Nucleonic Density Profiler.

8 Nucleonic source array (Cesium 137-50mCi) Two detector arrays with Geiger M ller 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 LLTest 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#1Sn hvitOrmen LangeLongest & deepest fieldsTormore-LagganFMC Kongsberg s Global PresenceHoustonKongsbergSingaporeDunferm lineRio De JaneiroSt. John sMacaeLagosEq. GuineaLuandaAberdeenBergenStavangerPerth Mossel BayThank You for Your Attention!Blow Out Preventer (BOP) BP Macondowell61 BOP shear RAM62