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Havbunnsproduksjon
NTNU 26. mars 2012
Sverre Corneliussen
Senior System Enginer, FMC Studies & Tenders
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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
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Subsea Applications
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Topside ControlsTopside
Process
Umbilical/Flowline
Production Vessel
Floating production ship
Manifold
XT
Bijupira Saleema
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Snorre Tension Leg Platform (TLP)
SnorreUPA
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Terra Nova iceberg protection
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Owertrawl
protection
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Subsea to beach (Ormen Lange)
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8 Slot Template System. Ormen Lange1100 ton
Suctionanchor
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Basic reservoar and drilling
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Horisontal Wellcompletion
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Fishhook well
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Wellhead system
13 3/8
CasingHanger
18 3/4
Wellhead
Housing
13 3/8
Productiontubing
Hanger
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Smaller production bore (5 -7 )Production tubing installed brfore XT
XT can be removed wi thout removing
production tubing
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X-mas tree
Weight 40 ton
Subsea Control
Module
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X-mas tree
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Horizontal X-mas tree
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Subsea Production Control
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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 systemintegrity
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Electro Hydraulic Control System
HydraulicActuators
InjectionChemicals
HydraulicPower unit
XmasTree
SubseaDistributionunit
UmbilicalCross Section
ElectricCables
Umbilical
MasterControlStation Electric
Power Unit
TopsideGateway
Hydraulic andChemical Lines
SCM
Up to 200 kmFluid linesElectrical lines
Fluid lines: Super duplex
Electrical lines: HDPE
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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
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Subsea Control Module (SCM)
Lifting Adapter
Anti -Rotation Guide Pin
Locking Mechanism
Hyd. Couplers
Elec. Connectors
Elec. Connectors
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23
Subsea Electronic
Subsea Hydraulics &
Mechanics
Subsea Control Module: Components
SCM
without
outer canSCM
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Typical operator display picture
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DHSV
PMV PWV
Choke
Manifold HIPPSFlowline
Production Riser
Riser
EV
Utility Riser
CIV
EUC 1
EUC 2
Isolation of well from environment (OLF 070)
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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
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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
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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
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Conductor
interface
Hydrate formation in 1200 m water depth
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Subsea Instrumentation
Vega as example
Vega is a gas & codensate field in the North Sea
Sofisticated instrumentation due to high pressure and splitof production between different owners
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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
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Vega field
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Vega template & manifold
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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
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 BA B
A B
A B
A B
A B
Serv ice/
/
Line
IV2 IV1
A B A B A B
From
wells
MAIN HIPPS VALVESTEST VALVES
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SIL 3 controller hardware architecture
PSD SYSTEM SIDE A PSD SYSTEM SIDE B
PSD600 Control Unit
SensorsOutput to final
elements
Top Side
Sub Sea
SC1
SC2
ETH
PSD600 Control Unit
SensorsOutput to final
elements
SC1
SC2
ETH
Umbilical
PSD600 Control Unit
Switches Output
SC1
SC2
ETH
PSD600 Control Unit
SwitchesOutput
SC1
SC2
ETHCAN
From CAN
sensors
CAN CAN
From CAN
Sensors
CAN
From CAN
sensors
From CAN
SensorsComm.
Power
Comm.
Power
Direct
link
Direct
link
Direct
link
Direct
link
SCU
A
SCU
B
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SIL 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 2Ethernet 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
SerialHandler
DO control,Monitoring and Test
Sensor
Reading and
Test
ADC
SPI
EEPROM
SPI
ConfigHandler
SW
HW /
FW
ADC
(SPI)
WD
SPIKernel
Mod
WDInt.
LockFSPS
PWR
MON &
CONTR.
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PT/TT FUNCTIONAL COMPONENTS
FLOW LINE
HARNESS
ADAPTER
PENETRATOR
ADC BOARD
CONTROL
BOARD
ELECTRONICS
PROBE
TRANSDUCER
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PT/TT FUNCTIONAL COMPONENTS
HOUSING MODULE:
The module is consisting of an flangewith a probe for process interface andcylindrical housing for the containmentof the electronic boards.
The electronics is contained inatmospheric pressure sealed withglass-metal penetrator towards theambient pressure.
The jumper connection is done via anadapter module.
QUARTZ CRYSTAL TECHNOLOGY
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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
S d d t t W ki i i l
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Sand detector Working principle
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The results of sand
Cl O DSP P ti l M it S b
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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 dropDigital communication between field and computer
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ClampOns 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!
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Subsea multiphase meters on each well
Allows for accurate and continuous online wellallocation
Multi-rate testing to be performed wheneverdesired
Reduced need for well testing by using topside testseparator; only needed for verification:
Represents redundant solution
Yearly or when indication of anomalies
Reduces host platform deferred production
Results in substantial well regularity improvement
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Micro
wave
Gamma
ray
Venturi
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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
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Subsea Separation
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Separator Module
Miocene: 65% of overall reserves
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Pazflor reservoir 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
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Solution - Subsea Processing
Gas / Liquid Separation andLiquid Boosting:
Gas flows freely to the FPSO
Hydrate preventions of flow lines bymeans of depressurization is possible
Reduced cost due to elimination ofcircular flow line
Liquid out of separator with relative lowgas fracttion
Efficient pumps with high P can be used Increased recovery & less power
consumption Boosting of liquid
Stabilized flow regime in risers reducesslugging
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LC
Pumps
Sep gas
XV
Sep
inlet
XV
Separatorliquid 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
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Separator Internals
Internals: Gas outlet pipe
EvenFlow
Liquid distributor plates
Singel helix
Sand cone
Swirl breaker
Liquid flushing arrangement
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Level Measurement
Subsea Nucleonic Density Profiler: Nucleonic source array (Cesium 137-50mCi)
Two detector arrays with Geiger Mllertubes
Topside PLC
Source and detectors installed in dip pipes
Detectors are retrievable, whereas nucleonicsource is permanently installed
Primary function is to measure liquid level, butprovides also information about densitydistribution between HH and LL
i
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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
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Snhvit
Ormen
Lange
Longest & deepest fields
Tormore-
Laggan
Shell
Perdido
b l b l
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FMC Kongsbergs Global Presence
Houston
Kongsberg
Singapore
Dunfermline
Rio De Janeiro
St. Johns
Macae
Lagos
Eq. Guinea
Luanda
AberdeenBergen
Stavanger
PerthMossel Bay
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Blow OutPreventer(BOP)
58
BP Macondo Shear ram failure
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BP Macondo Shear ram failure
59
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BOPshearRAM
60
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Thank You for Your Attention!