Havbunnsproduksjon

NTNU 28. mars 2011

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

Terra Nova iceberg protection

Snorre Tension Leg Platform (TLP)

Snorre UPA

Subsea to beach (Ormen Lange)

8 Slot Template System. Ormen Lange1100 ton

Suction anchor

Manifold. Ormen Lange

Manifold. Ormen Lange

Basic reservoar and drilling

Horisontal Well completion

Fishhook well

Wellhead system

13 3/8” CasingHanger

18 3/4” WellheadHousing

13 3/8” Production

tubingHanger

X-mas tree system

X-mas tree

Choke module

Control module

Running tools

X-mas tree

Weight 40 ton

Subsea Control Module

X-mas tree

Horizontal X-mas tree

19

XT valves and sensors, typical layout HXT

Well flow out

Chemicals in

Subsea Production Control

Functions – Production Control System

21

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

22

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

23

Subsea Control Module (SCM)

Lifting Adapter

Anti-Rotation Guide Pin

Locking Mechanism

Hyd. Couplers

Elec. Connectors

Elec. Connectors

24

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 Functions

ESD Node(redundant)

HPUHydraulicSupply

SolenoidValves

(redundant)

To riser EV

UPS

Relay

XT

PMV PWV

DHSV

DumpDCV

PWVDCV

PMVDCV

DHSVDCV

SCM

Production Flow

ESD Signals

Electrical Power

Hydraulic Fluid

Pilot Supply

CIV

CIVDCV

Injection Line

CIV = 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 Tree

EPU

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

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

SIPPS SENSORSIPPS VALVE SIPPS logic system

PSD logic system

SIPPS

Base case: Vega SIPPS, including MEG

9'’ Production

TEST SENSOR

production

PT9

Main flow

line

PT8 PT7

From wells

Note:XOV is

normally forced closed

Normal LP function

from MCM

Safety critical LP function

from PSD 600 in MCM

Safety critical LP function

From PSD600 in

MCM

Normal LP function

from MCM

Normal LP function

from MCM

Safety critical LP function

From PSD 600 in MCM

TEST VALVE

Bypass VALVE

SV3 SV2 SV1

BV3 BV2 BV1

PT10

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 valves.

Test/Batch MEG

Flow module

PT 4

PT 3

PT

2P

T 1

Steady state MEG

V-cone Flowline

V-cone MEG

PT5 PT 6

PT 11

SIL 3 controller hardware architecture

Switch/Router

Switch/Router

Switch/Router

Switch/Router

PSD SYSTEM SIDE A PSD SYSTEM SIDE B

PSD600 Control Unit

Sensors Output to final elements

Top Side

Sub Sea

A1

A2

ETH

PSD600 Control Unit

SensorsOutput to final elements

A1

A2

ETHU

mbi

lical

PSD600 Control Unit

Switches Output

A1

A2

ETH

PSD600 Control Unit

SwitchesOutput

A1

A2

ETH

FSK modem

FSK modem

Power Power

Switch/Router

Switch/Router

FSK modem

FSK modem

Power Power

Switch/Router

Switch/Router

AC AC

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…

Choke module -a challenge!

ClampOn Ultrasonic Intelligent Sensors

Choke

The subsea modules are more an more compact - more instrumentation and less space for “optimum” conditions.

Distance from choke to detector is less then 2 meters

Chokes generates high unwanted ultrasonic noise due to extreme velocities!

How to overcome this? – lets look at a real case!

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

Challenges 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 production from year 4– Large amounts of methanol needed for hydrate prevention

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

FMC Kongsberg’s Global Presence

Houston

Kongsberg

Singapore

Dunfermline

Rio De Janeiro

St. John’s

Macae

LagosEq. Guinea

Luanda

AberdeenBergen

Stavanger

PerthMossel Bay

Thank You for Your Attention!

Blow Out Preventer (BOP)

BP Macondo

well

61

BOP shear RAM

62