Templates and Manifold
Templates and Manifold
Cluster Applications
Cluster Applications
Subsea Clusters of wells are
Subsea Clusters of wells are basically single satellite wells arranged around a basically single satellite wells arranged around a subseasubsea manifold assembly that collects, commingles and exports flow to surface gathering manifold assembly that collects, commingles and exports flow to surface gathering facility. Each satellite well is not mechanically connected to the manifold except by facility. Each satellite well is not mechanically connected to the manifold except by flowlines and umbilical, and hence a flowline connection to each well and to the flowlines and umbilical, and hence a flowline connection to each well and to the manifold is normally required.
manifold is normally required.
Typically manifolds at the center of a
Typically manifolds at the center of a cluster development can accommodatecluster development can accommodate between 2 and 12 wells,
between 2 and 12 wells, allow for simultaneous oil, gas and aquifer allow for simultaneous oil, gas and aquifer production andproduction and handle gas or water injection. Manifold
handle gas or water injection. Manifold foundations can be piles, gravity or foundations can be piles, gravity or skirtsskirts depending on seabed conditions.
depending on seabed conditions.
Cluster-style developments were originally developed to counter-act the potential Cluster-style developments were originally developed to counter-act the potential for damage from dropped objects at surface. A falling 18-3/4 in.
for damage from dropped objects at surface. A falling 18-3/4 in. drilling BOP stackdrilling BOP stack could damage several wellheads and trees on a
could damage several wellheads and trees on a conventional production templateconventional production template layout for example, whereas in a
layout for example, whereas in a cluster-style development, one well completion atcluster-style development, one well completion at worst would be affected. A typical subsea
worst would be affected. A typical subsea manifold system includes:manifold system includes:
base framebase frame
manifold frame (which supports the valve blocks and headers)manifold frame (which supports the valve blocks and headers)
structure for supporting ROV interface pointsstructure for supporting ROV interface points
controls distribution unitscontrols distribution units
accumulator banksaccumulator banks
control modulescontrol modules
hydraulic trunkinghydraulic trunking
satellite interconnectionssatellite interconnections
pipeline connectionspipeline connections
pigging loopspigging loops
protective roof protective roof
The most recent deepwater manifold systems have included retrievable manifolds with remote diverless connections The most recent deepwater manifold systems have included retrievable manifolds with remote diverless connections of of intra-field flowlines, umbilicals and pipelines.
Daisy Chain Application
Daisy Chain Application
The
The Daisy Chain Daisy Chain subsea subsea wells wells consist consist of of two two or or more more subsea subsea satellite satellite wells wells joinedjoined together by a common flowline (and possibly
together by a common flowline (and possibly umbilical). Valving on theumbilical). Valving on the flowbases of the daisy-chained wells allows basic
flowbases of the daisy-chained wells allows basic manifolding to comminglemanifolding to commingle flowstreams. Each subsea tree may have a choke
flowstreams. Each subsea tree may have a choke installed to avoid pressureinstalled to avoid pressure imbalances in the flows.
imbalances in the flows. Using
Using daisy daisy chained chained wells wells allows allows combined combined use use of of infield infield flowlines flowlines by by more more than than oneone well,
well, and and may may provide provide a a continuous continuous loop loop for for round round trip trip pigging pigging if if needed.needed. The
The advantages of advantages of a a daisy daisy chain chain completion completion are:are:
Similar to a single satellite well, cost is only Similar to a single satellite well, cost is only incurred if and when aincurred if and when a
completion is purchased and installed, the
completion is purchased and installed, the operator doesn't have to purchaseoperator doesn't have to purchase significant infrastructure before he needs it.
significant infrastructure before he needs it.
Some sharing of flowlines may be Some sharing of flowlines may be possible.possible.
Round trip pigging is possibleRound trip pigging is possible
Wells are not mechanically linked and can therefore be located over a wideWells are not mechanically linked and can therefore be located over a wide
area, which is especially
area, which is especially important in oilfields where low permeability exists.important in oilfields where low permeability exists.
In-situ access to the installed equipment by Remote Operated Vehicle (orIn-situ access to the installed equipment by Remote Operated Vehicle (or
divers) is good because of
divers) is good because of the absence of adjacent equipment.the absence of adjacent equipment.
Potential damage from dropped objects is constrained to (at worst) a Potential damage from dropped objects is constrained to (at worst) a single completion.single completion.
Simultaneous production and drilling is not Simultaneous production and drilling is not a problema problem
Disadvantages of daisy chain wells are: Disadvantages of daisy chain wells are:
Subsea chokes are probably needed on each Subsea chokes are probably needed on each well.well.
Absence of a "common datum" for flowline connections and umbilical tAbsence of a "common datum" for flowline connections and umbilical t ie-in.ie-in.
Necessity for the drilling rig to move anchors in order to reach another well.Necessity for the drilling rig to move anchors in order to reach another well.
By daisy chaining pairs of wells together, operators can better utilize the flowlines to the two completions. Instead of a By daisy chaining pairs of wells together, operators can better utilize the flowlines to the two completions. Instead of a single function (production), the dual flowlines provide an ability to round-trip pig the lines, divert both production flows single function (production), the dual flowlines provide an ability to round-trip pig the lines, divert both production flows into a single flowline if the second is
into a single flowline if the second is damaged, and individually test the two wells whenever needed through independentdamaged, and individually test the two wells whenever needed through independent lines. As more subsea wells
lines. As more subsea wells are needed, the attraction of daisy are needed, the attraction of daisy chains disappears as a manifold becomes more feasible.chains disappears as a manifold becomes more feasible.
Free-Standing Riser System
In
In a a free-standing free-standing production production riser riser system system (FPRS), (FPRS), the the production production riserriser transports
transports fluids fluids from from the the seafloor seafloor to to a a surface surface production production facility facility which which can can be be eithereither a
a ffllooaattiinng g sseemmii-- ssuubbmmeerrssiibblle e ppllaattffoorrm m oor r a a ttaannkkeer r mmooddiiffiieed d tto o aaccccoommmmooddaattee production
production equipment equipment on on board. board. Frequently Frequently the the production production riser riser returnsreturns processed
processed fluids fluids back back down down to to the the sea sea floor floor via via the the sales sales line.line. Cameron
Cameron has has the the capability capability to to design design and and build build conventional conventional as as well well as as unique,unique, innovative
innovative risers risers for for any any subsea subsea completion completion or or production production requirement.requirement. One
One example example of of a a customized customized solution solution is is the the Cameron Cameron FPRS FPRS design design whichwhich represents
represents a a deepwater deepwater development development option. option. This This system system has has beenbeen successfully
successfully installed installed twice twice in in the the Gulf Gulf of of Mexico, Mexico, once once in in 1540 1540 feet feet of of water water andand again
again in in 2140 2140 feet feet of of water.water. The
The Cameron Cameron FPRS FPRS offers offers reduced reduced project project costs costs compared compared with with fixed fixed bottombottom supported
supported facilities facilities or or tension tension leg leg platform platform and and provides provides reduced reduced project project cycle cycle time,time, reusability,
reusability, along along with with low low maintenance maintenance as as the the main main areas areas for for reducing reducing overalloverall capital
capital and and operating operating costs.costs. The
The free-standing free-standing production riser production riser system system is is a a non-integral non-integral structural structural supportsupport column
column with with direct direct production and production and annulus annulus access access to to each each well well and and dedicated dedicated oiloil and
and gas gas sales sales lines. lines. The The riser riser column column is is free-standing free-standing with with no no tensioner tensioner support,support, installed
installed and and retrieved retrieved from from the the floating floating production production vessel vessel mooredmoored overhead.
overhead.
Internal air cans, external buoyancy from syntactic foam and several joints
Internal air cans, external buoyancy from syntactic foam and several joints with external air tanks all with external air tanks all combine to providecombine to provide the riser buoyancy required to make the riser free-stand from the ocean floor. Attaching the riser column to the template is the riser buoyancy required to make the riser free-stand from the ocean floor. Attaching the riser column to the template is a riser base and connector with a titanium stress joint.
a riser base and connector with a titanium stress joint. The system is designed to
The system is designed to use a variable air buoyancy riser use a variable air buoyancy riser capable of supporting multi-well free-standingcapable of supporting multi-well free-standing production/annulus tubing and export sales lines
production/annulus tubing and export sales lines directly underneath the bow or directly underneath the bow or stern of the floating production facility.stern of the floating production facility. Additionally, the system allows simultaneous drilling, completion and workover activities while
Additionally, the system allows simultaneous drilling, completion and workover activities while production is ongoing.production is ongoing. The riser is i
The riser is i nstrumented to measure riser response to various environmental conditions and nstrumented to measure riser response to various environmental conditions and to obtain actual fatigueto obtain actual fatigue information. The riser is wired with
information. The riser is wired with strain gauges, accelerometers and inclinometer to monitor riser stresses, motion andstrain gauges, accelerometers and inclinometer to monitor riser stresses, motion and positions during installation and operation.
positions during installation and operation.
The instrumentation is connected to the vessel using an electrical cable. The cable is i
The instrumentation is connected to the vessel using an electrical cable. The cable is i nstalled on the riser during actualnstalled on the riser during actual installation of the riser. The
installation of the riser. The other instrumentation equipment has been previously installed on other instrumentation equipment has been previously installed on the appropriate riser jointsthe appropriate riser joints prior to shipment to the vessel. The joint-mounted electronics are located in pressure vessels at the bottom of the
prior to shipment to the vessel. The joint-mounted electronics are located in pressure vessels at the bottom of the instrumented joints.
instrumented joints.
Subsea cables connect the riser equipment to the controls unit on the production facility. The production riser Subsea cables connect the riser equipment to the controls unit on the production facility. The production riser instrumentation desktop computer is located in the
instrumentation desktop computer is located in the production control room and is capable of storing data production control room and is capable of storing data during all rigduring all rig conditions including rig
conditions including rig abandonment.abandonment.
The riser instrumentation has two redundant systems connected to
The riser instrumentation has two redundant systems connected to the desktop computer. There are separate electronicthe desktop computer. There are separate electronic cables for each system attached to the production riser as it is installed.
cables for each system attached to the production riser as it is installed.
MOSAIC Distribution Elements
MOSAIC Distribution Elements
Distribution Elements in the
Distribution Elements in the MOSAIC system include flowbases, manifolds andMOSAIC system include flowbases, manifolds and umbilical termination assemblies. These assemblies are used to receive
umbilical termination assemblies. These assemblies are used to receive producedproduced fluids from multi-well templates or satellite wells
fluids from multi-well templates or satellite wells in order to control, commingle andin order to control, commingle and divert the flow to a production riser or pipeline.
divert the flow to a production riser or pipeline.
Pre-engineered MOSAIC flowbases are available for a variety of single Pre-engineered MOSAIC flowbases are available for a variety of single wellwell applications such as production satellite, water injector, gas
applications such as production satellite, water injector, gas lift production andlift production and intermediate daisy-chain base. For two wells or
intermediate daisy-chain base. For two wells or more, pre-engineered MOSAICmore, pre-engineered MOSAIC components can configured into manifolds to be used
components can configured into manifolds to be used with satellite producers, injectors, daisy-chains and combinations of with satellite producers, injectors, daisy-chains and combinations of these.
Cluster manifolds and daisy-chain solutions have been Cluster manifolds and daisy-chain solutions have been mademade attractive with development of field-proven flowline connection attractive with development of field-proven flowline connection systems which permit trees to be
systems which permit trees to be installed prior to the installed prior to the manifold,manifold, without the need for
without the need for integrated template structures. This allowsintegrated template structures. This allows field system construction to evolve as the field is developed, and field system construction to evolve as the field is developed, and its true scale determined.
its true scale determined.
Distribution Elements are rated for operating pressures matching Distribution Elements are rated for operating pressures matching the Christmas trees. Modularity is achieved through the use of the Christmas trees. Modularity is achieved through the use of common valve blocks, connectors, structures and porch
common valve blocks, connectors, structures and porch extensions. The design capacity of a
extensions. The design capacity of a manifold assembly maymanifold assembly may change by changing the number
change by changing the number of modules added to the structureof modules added to the structure and the size and/or quantities of the headers.
and the size and/or quantities of the headers. A typical subsea manifold system includes a
A typical subsea manifold system includes a base frame, abase frame, a manifold frame (which supports the valve blocks and
manifold frame (which supports the valve blocks and headers),headers), and a structure for supporting ROV i
and a structure for supporting ROV i nterface points, controlsnterface points, controls distribution units, accumulator banks, control modules, hydraulic distribution units, accumulator banks, control modules, hydraulic trunking, satellite interconnections, pipeline connections,
trunking, satellite interconnections, pipeline connections, piggingpigging loops and protective roof.
Satellite Applications
The Subsea Satellite Well consists of a subsea well and guidebase or flowbase, supporting a subsea tree, with individually connected flowlines and control umbilical. The guidebase/flowbase is not mechanically linked to another wellhead, and the flowlines and umbilicals are attached to each satellite tree one at a time.
Subsea Satellite wells feature independent foundations, not l inked or shared with other wells, each system is installed individually,
The advantages of a satellite completion are:
Cost is only incurred if and when a completion is purchased and installed,
the operator doesn't have to i nvest in significant infrastructure before he needs it.
Wells can be located over a wide area, which is especially important in
oilfields where low permeability exists.
Access limitations to the i nstalled equipment by Remote Operated Vehicle
(or divers) are avoided because of the absence of adjacent equipment.
Potential damage from dropped objects is constrained to (at worst) a single completion. Simultaneous production
and drilling is not a problem. Disadvantages of satellite wells are:
Absence of a "common datum" for flowline connections and umbilical t ie-in. Necessity for the drilling rig to move anchors in order to reach another well. Individual flowlines are needed for each well
Satellite wells can be completed in a number of different ways:
Tree on "dumb" guidebase - where the flowline is connected directly to the tree, and the guidebase can be a simple drilling guidebase. This requires removal of the connected flowline and umbilical should the tree be retrieved for any reason. Tree on flowbase - as the tree lands and locks to the wellhead, flowloops from the tree production, and possibly annulus valve blocks, stab into receptacles on the flowbase. Flowlines and umbilicals are made up to the flowbase, and the flowline does not need to be disturbed if the tree is removed.
Subsea template field layouts involve a structural frame that supports and protects a number of subsea wells together on the seabed. In areas of high fishing intensity, the template structure is ideal for deflecting trawl boards and dragged lines away from sensitive wellhead equipment.
A key advantage of templates over cluster or satellite completion systems is that the subsea tree normally connects directly to the flowline mandrel and template pipe work as it lands and locks onto the wellhead, this effectively eliminates one of the flowline connections needed between a subsea tree and cluster-style manifold. Subsea production templates fall into two broad categories:
Unitised templates Integrated templates
The unitized template is normally modular in concept, and involves initially installing a drilling template structure prior to spudding the wells. This drilling template acts as the "temporary" guidebase for the wells. This drilling template spaces out wells to the required position, may support conductor loads and provides the datum on
which the production equipment is based. Following drilling, the production parts of the system are installed, either as "flowbases" run with the wellhead high pressure housing, or as a separate structure with flowline connection mandrels and piping installed. Wells can have individual, dedicated flowlines back to a processing facility, or can be commingled in a manifold arrangement (usually retrievable) and exported together in a common flowline. Typically unitized templates are smaller than integrated templates, with capacity for between 2 and 8 wells.
The integrated template is typically more complete prior to load-out than the unitized template. An integrated template has well bay inserts or flowbases installed already, and requires only drilling out and completion before production can begin. Template size can be large, with up to 24 wells (or more), several thousand tons in weight, and a significant construction project needed to build, test and install the template. A large installation barge can be expected to be required. Although initial investment in the integrated template can be large, the "per well" cost falls rapidly as more wells are drilled and completed. In addition, the advanced state of completion of the template before load-out allows for extensive integration testing and proving prior to the template leaving the fabrication yard.
Template Production Systems
Subsea template field layouts involve a structural frame that supports and protects a number of subsea wells together on the seabed. In areas of high fishing intensity, the template structure is ideal for deflecting trawl boards and dragged lines away from sensitive wellhead equipment. A key advantage of templates over cluster or satellite completion systems is that the subsea tree normally connects directly to the flowline mandrel and template pipe work as it lands and locks onto the wellhead, this effectively eliminates one of the flowline connections needed between a subsea tree and cluster-style manifold.
Subsea production templates fall into two broad categories:
Unitised templates Integrated templates
The unitized template is normally modular in concept, and involves initially installing a drilling template structure prior to spudding the wells. This drilling template acts as the "temporary" guidebase for the wells. This drilling template spaces out wells to the required position, may support conductor loads and provides the datum on which the production
equipment is based. Following drilling, the production parts of the system
are installed, either as "flowbases" run with the wellhead high pressure housing, or as a separate structure with flowline connection mandrels and piping installed. Wells can have individual, dedicated flowlines back to a processing facility, or can be commingled in a manifold arrangement (usually retrievable) and exported together in a common flowline. Typically unitized templates are smaller than integrated templates, with capacity for between 2 and 8 wells.
well bay inserts or flowbases installed already, and requires only drilling out and completion before production can begin. Template size can be large, with up to 24 wells (or more), several thousand tons in weight, and a significant construction project needed to build, test and install the template. A large installation barge can be expected to be required. Although initial investment in the integrated template can be large, the "per well" cost falls rapidly as more wells are drilled and completed. In addition, the advanced state of completion of the template before load-out allows for extensive integration testing and proving prior to the template leaving the fabrication yard.
Mudline Wellhead
Using a mudline completion allows some significant benefits to the operator instead of a wellhead platform, such as:
All the external forces are transferred to the 30 in. conductor Lower tie-back seals can be tested,
360 ? orientation freedom
Direct access to production tubing annulus Positive lockdown of the 7 in. tubing hanger
Unitized tie-back adapter spool (eliminates the need for more than one nipple up)
Concentric tubing hanger
Control of SCSSV while running tubing hanger
Immediate production when flowlines and umbilicals have been pre-installed Easy removal after depletion of well
Re-usable on another completion
This Cameron stack-down mudline wellhead system has a number of important features:
Separate running/tie-back threads and seal areas High pressure and high l oad capacity
Hanger centralization during running
Optional Stack-down profile allows complete cement clean up between casing strings Special wash-out tool that avoids rotating large diameter casings
Low torque metal seals and dual resilient back-up seals External interface test port
Right hand release running tools
The STC-10 (Single-Trip Compact) wellhead is a premium subsea wellhead for applications to 10,000 psi WP, and is a favorite choice of operators worldwide. It is cost-effective for lower pressure wells where Cameron's CAMLAST metal-end-cap seals are adequate.
The economical STC-10 wellhead shares some of the same features and benefits as our STM wellhead. It is compact, runs casing hangers and seal assemblies in a single trip and features interchangeable weight-set, elastomeric parallel bore seal assemblies. STC-10 seals are Cameron's proprietary CAMLAST metal-end-cap seals. Design modifications incorporated over the years have improved first time seal assembly setting. Introduction of a dedicated seal assembly running tool has simplified running procedures where the casing hanger has already been installed. This running tool provides a straightforward stab, test and tool retrieval.
Five- or six-string casing options are available. The STC-10 wellhead system is available with either Cameron hub or mandrel profiles, and features a passive lockdown of the high-pressure housing into the 30" housing.
The STC-10 wellhead offers simple installation procedures. A five-string
configuration can be installed with just four cam-actuated running tools, all with right-hand release. STC-10 wellheads can be used in either guideline or
guidelineless operations.
Our primary subsea wellhead is the STM Wellhead System, which is offered in standard and enhanced deep-water, high-capacity versions. The STM (single trip, metal-seal) wellhead is an all-purpose product for applications to 15,000 psi. It will satisfy the vast majority of all subsea requirements, including corrosive
environments associated with deep-water exploratory, production or injection wells. STM wellheads are suitable for use with single wells, large multi-well templates or TLP operations.
A key feature of the STM wellhead is Cameron's exclusive hydraulically set parallel bore metal (PBM) seal assemblies for casing hangers in the 18-3/4" high-pressure housing. These radially engaged, bi-directional seals provide constant contact pressure on both inner and outer sealing surfaces. PBM metal seals set between parallel surfaces and, unlike competitive systems, are not forced down into tapered bowls. This means the same seal l oading exists if pressure comes from above or below. Competitive tapered bowl systems can lose seal l oading if pressure comes from below, as pressure forces those components up i nto ever widening seal surfaces.
STM wellheads feature a recessed seal surface machined in the housing bore below each primary seal surface, creating a protected, separate contingency sealing surface. Every STM wellhead has three seal assembly configurations for maximum sealing contingencies: standard all-metal seal, metal seal with CAMLAST insert, and a metal seal positioned to seal in the recessed bore. STM seal assemblies lock firmly to both casing hanger and wellhead housing. However, the housing lock ring can be
removed to lock the seal
assembly to the casing hanger if the casing hanger sets high. Interchangeable STM components help reduce inventory and tooling
requirements, and minimize rig time during installation and
workover. Seal assemblies on the 13-3/8", 10-3/4" (or 9-5/8"), and 7-5/8" (or 7") casing hangers are identical and interchangeable. Each assembly can be run in one trip using a single running tool. The tool used for retrieving the seal assembly is a dedicated tool, preventing inadvertent seal assembly retrieval.
Both five- and six-string configurations are offered to accommodate any drilling program. A 16" casing hanger and seal assembly allows drilling with a 17-1/2" bit and use of full-bore running equipment.
Three options are available for connecting STM wellheads to blowout preventers and Christmas trees: Cameron hub, mandrel, and Cameron's new deep-water, high-capacity (DWHC) profile which has been provided without charge to the i ndustry to promote standardization among deep-water producers and equipment suppliers.
Two lockdown options are offered for connecting the STM wellhead high-pressure housing to conductor housings: passively activated standard lockdown, and passively activated preloaded high capacity lockdown. The passively activated high pressure lockdown is achieved without a separate lockdown trip.
STM-15 Wellheads
The STM-15 (Single Trip Metal Sealing 15,000 psi) wellhead system incorporates Cameron reliability and a variety of versatile, time-saving features.
Applicable for 15,000 psi, 350 G F, sour service wells in any water depth,
for both 5-string and 6-string configurations.
Each casing hanger and seal assembly is run in a single trip.
All seal assemblies are identical allowing the used of one running tool for
all casing hangers.
Each seal assembly is completely retrievable as a unit.
The connection between the casing hanger and the casing hanger running
tool (and between housings and running tools) can be tested at surface to full rated working pressure.
The seal assembly utilises parallel bore metal sealing (PBM seal)
technology eliminating problems inherent to tapered bore designs.
The 18 3/4" housing is run with the bore protector in place. BOP testing is not dependent on wear bushing installation.
A retrievable, re-installable guidebase is the standard offering and features
shock absorbing guide posts. This is retrieved and replaced with a production guidebase prior to running the subsea tree.
All running tools are left hand make-up and right hand release.
The STM-15 wellhead can be supplied with either a Cameron hub or an
ABB-Vetco mandrel profile.
A key feature of the STM wellhead is Cameron's exclusive hydraulically set parallel bore metal (PBM) seal assemblies for casing hangers in the 18-3/4" high-pressure housing. These radially engaged, bi-directional seals provide constant contact pressure on both inner and outer sealing surfaces. PBM metal seals set between parallel surfaces and are not forced down i nto tapered bowls. This means the same seal loading exists if pressure comes from above or below, (tapered bowl systems can lose seal loading if pressure comes from below, as pressure forces those components up into ever widening seal surfaces).
Modular Subsea And Integrated Completions
The general expectation with modular equipment systems is that, while it might be possible to reduce initial capital costs, you'll have to give up something important in return. Like flexibility or expandability, or desirable product features and benefits, for example. You could say i t's a series of compromises in the name of cutting costs. In actual practice, however, the real savings in conventional modular systems are more likely to come from simplified installation procedures, reduced personnel training and faster delivery times. Yes, there are some manufacturing economies to be found, but precision machining processes rarely lend themselves to corner cutting. On the other hand, the compromises required by these systems can result in significant inefficiencies and hidden costs. Loss of flexibility in implementing future developmental phases can put you in some very expensive predicaments.
Smaller building blocks
That's why we designed MOSAIC TM (Modular Subsea And Integrated Completions) production systems to be modular at a much lower level than competitive systems. Because MOSAIC modules start with smaller, less expensive building blocks, equipment for initial development phases can be provided more efficiently, without having to invest in extra equipment or structure that may not be needed later. For more than thirty years, we have been observing which subsea equipment features work best and applying those features to other related products. Things like alignment methods, seals, connection devices, bolt-on peripherals...we've optimized every component down to the smallest pieces. Not only does this minimize manufacturing costs, but it also facilitates installation and operating requirements with user-friendly features that spell
reliability and versatility. The result is MOSAIC, a pre-engineered, cost-optimized product line that is worthy of the Cameron name.
For virtually any subsea job
Unlike conventional approaches, MOSAIC systems are not based on modular structures, but rather a combination of standardized components that fit together in a modular fashion. Modular systems that depend on structure as a starting point are simply not appropriate for many applications. MOSAIC systems, on the other hand, can be adapted for virtually any subsea job, and are more easily expanded as field development needs evolve. They fit your requirements better in the short term and the long term, too. (Think, for example, of modular office furniture that can only be purchased by the cubicle as opposed to being able to specify the work surfaces, drawer stacks, shelves, and other components you need to satisfy each workers personal requirements. Then think how difficult it i s to anticipate the needs of workers who haven't even been hired yet.)
The asset manager's choice
This critical difference makes MOSAIC systems especially appealing to asset managers whose job is to take a longer term view in developing oil and gas reserves. MOSAIC components are infinitely expandable and configurable to accommodate any asset management scheme. Many fields are developed in phases, with decisions on subsequent phases dependent upon economic results of initial efforts. The modular-element, building block approach of MOSAIC systems allows
producers to specify pre-engineered components having application-specific features without incurring the higher costs or extended lead times of custom systems. MOSAIC systems can be used for cluster wells or daisy chains. They can be provided with individual flowbases or as part of a large template/manifold combination. They can be rig-deployable or not. In effect, you can specify a system that fits your needs like custom-designed equipment, but with all the benefits of standardized, pre-engineered components.
Six MOSAIC elements
In the MOSAIC system, six basic elements or component families have been designed: Position, Pressure, Distribution, Access, Control and Connection. (These elements are described in more detail on the following pages.) Within each
element family, dozens and, in some cases, hundreds of product options are possible. Cameron engineers have focused on reliability, functionality and deliverability for each of the basic MOSAIC elements. We know faster delivery times are important in todays market, but we also know that reliability is key. Every pre-engineered MOSAIC component is based on field-proven Cameron product technology, and is backed by our global network of service centers and aftermarket
facilities. You wont have to be a guinea pig for some unproven engineering concept with MOSAIC.
Best subsea value
And, you'll have considerable flexibility in selecting the equipment package that's right for each job. There's even a choice of Christmas trees (see box). Our famous Dual Bore tree and innovative SpoolTree products have been re-designed as modular assemblies, so you can stay with the basic technology your people are most familiar with, while reaping the benefits of a pre-engineered, modular system. Since the dawn of the subsea era, Cameron has pioneered and refined many of the most important subsea product technologies. We have a well-deserved reputation for tackling the most difficult, exotic jobs the oil and gas industry can dish out. Now were proud to i ntroduce MOSAIC systems, the culmination of our experience and leadership i n producing reliable subsea production systems for the most reasonable cost (best value). In short, MOSAIC systems are the perfect fit for today's subsea economics.
MOSAIC systems are based on the two most reliable and cost-effective trees available in the world.
The heart of any subsea system is the Christmas tree, and Cameron offers producers a choice of two highly reliable and feature-rich trees in its MOSAIC system. Both trees, the innovative SpoolTreeTM Christmas tree and the famous Cameron Dual Bore tree, are proven performers the world over. Instead of devel- oping a totally new access element, Cameron has re-engineered these two well- accepted Christmas tree products to be offered in modular, pre-engineered versions. This provides cost saving standardization without the risk of unproven technology. Since its introduction in 1992, the patented SpoolTree Christmas tree has revolutionized the subsea industry. It is the number one tree in the Gulf of Mexico and other oil- producing regions, and has been widely copied by Cameron competitors. Its unique wellhead/tree/hanger configuration allows completion and workover operations to be performed with the t ree in place. Cameron's Dual Bore Christmas tree is the one many oilmen grew up with. It was the first to feature a dedicated annulus bore for troubleshooting, well servicing and well conversion operations, and is now the number one tree in the North Sea. As the company that introduced both of these pacesetting products, we've had plenty of opportunity to refine and simplify our designs. The result is two versatile, highly reliable MOSAIC trees that are now available as pre-engineered, modular assemblies.
MOSAIC Field Architecture
Factors Affecting Field Layout
The architecture of the field layout depends upon many factors. These factors are identified by considering all the operations that are carried out on the field throughout its life.
During project phase
Development drilling and well completions. Subsea equipment installation, hookup and
commissioning.
During the field operation phase
Normal operation.
Well workover operations.
Underwater I.M.R. activities (mostly with ROV). Additional drilling and subsea equipment installation.
During field decommissioning
Well abandonment and plugging.
Subsea equipment retrieval or abandonment. Final seabed survey.
The key factors driving the field seabed layout are as follows:
Reservoir configuration, bottom hole locations and subsea well seabed positions.
Drilling rig semi-submersible position, weather heading, mooring pattern and vessel characteristics (including
drilling riser/vessel maximum excursions).
Seabed condition and bathymetry.
Dominating weather conditions during drilling and workover operations but also during underwater operations with
various surface vessels.
Supply boat movements and vessel loading/offloading.
Optimum location of all subsea facilities in particular during pipelay/umbilical lay operations and eventual
retrieval.
Shipping lanes, fishing activities (if any) and other existing facilities on the seabed e.g. abandoned exploration
well.
The key factors listed above all have a number of secondary conditions affecting the design layout process. Each of them are examined in turn:
Reservoir and Wells Profiles
The reservoir configuration evaluated and simulated by reservoir engineers dictates the bottom hole location of the wells, which could be of various profiles, vertical, deviated, highly deviated, extended reach, or horizontal. The well profiles resulting from the selected drilling rig capabilities dictate the seabed location of the wells or position of the wellheads.
Drilling Rig and Mooring Pattern
In a typical field water depth, the anchor lines (between 8 and 12 lines) of t he semi-submersible drilling rig may need to be deployed and positioned in a large and equally distributed pattern over a length of 2000m or more.
The heading of the rig is dictated by the prevailing or dominant weather condition because the rig may be used for drilling operation and completion, and also installation of some subsea equipment with overboard craning. In addition, seabed corridors, in between mooring lines (dynamic mooring lines with an excursion envelope and touch down area) must be identified for the installation of future seabed facilities e.g., tie-back of additional fields.
Finally, the mooring of any drilling rig above a subsea cl uster needs to follow strict "mooring anchoring procedures" to eliminate as much as possible any risk to the subsea facilities. The dropping of anchors and chains and the dragging of anchors are the most significant risks. During drilling and well completion operations, as well as during well workover operations, the rig may need to move on its anchor lines away from the vertical of the cluster, to minimize the risk of dropping heavy objects. A safe handling area should be designated and included i n the "vessel anchoring procedure".
Seabed Bathymetry
The seabed condition and corridors for flowlines and umbilical laying need to be surveyed. Obstructions, soil condition (soft or hard etc), slope and possibility of spans must be identified.
Dominating Weather and Storm Conditions
The predominant weather pattern for winds and currents should be determined. The drilling rig is positioned heading accordingly.
Identically, during underwater operations (installation, IMR, etc.) surface vessels operated on D.P. are also be positioned inline with the above listed conditions.
During extreme storm conditions or typhoon, any vessel may be moved away, including the drilling rig.
Well Locations
The alternatives of directionally drilled wells from a central cluster location versus a satellite well configuration, where wells are drilled vertically is normally considered. Several long rigid flowlines may be required for the vertically drilled option, with a large number of subsea connections compared to the cluster option. The cost may quickly rise beyond that needed to make the solution cost effective, especially if the cluster wells can be tied-in by the drilling vessel.
The following factors have been used in setting the wellhead positions:
Cluster/template position, Bottom hole well positions,
Wellhead separation, center to center to allow a minimum separation between wellhead equipment Jumper lengths to be easily manageable from the drilling rig,
Approach angle to the North and South of the manifold to be maximized for flowlines and/or umbilicals Dropped object trajectories
Flexibility of jumpers for connection requirements
Protection From Dropped Objects
The major aspects of this philosophy are that structural protection provides against small dropped objects and procedure are imposed to avoid potential damage from large dropped objects as much as possible. However, the risk can never be totally eliminated.
The equipment design and the field layout may require that all heavy lifts be undertaken from a surface position that is not vertically above any subsea equipment. Potential drift angles on sinking dropped objects are considered in designating a safe handling area.
MOSAIC Project Management
Introduction:
Cameron recognizes the importance of the three central pillars of Project Management:
Cost Time Quality
No-one disputes the quality and workmanship of Cameron parts and products, and Cameron products are among the best value delivered, not only from the capital expenditure standpoint, but even more so when total life-cycle costs are
calculated. Cameron products are unquestionably the best investment a company can make. And for delivery, Cameron now offers the "30-day Tree," a revolution in delivery commitment. A very significant investment in modularization has been made by Cameron in recent years, to allow us to offer "customized trees" at "standardized" delivery terms. A short description of our Project Management techniques is given below:
Management:
The management of the project sets the project goals and provides direction for the project team in the execution of the work. In addition, day-to-day responsibilities of the management are to measure t he work as it proceeds and report
progress to the customer project team on a continuous basis. If the progress falls behind the agreed targets for any reason, the project management instigates recovery plans to bring the work back on schedule in a timely and efficient manner.
Quality Assurance:
The Quality Assurance department has the responsibility to ensure that the agreed procedures and standards are being adhered to in the course of executing the works to guarantee that the end product(s) fully meets the requirements of the contract and project scope. The well-proven Cameron quality systems form the basis of measurement, and regular internal and subcontract audits are used to verify that the work is being performed to the agreed system. Any inconsistencies and non-conformities identified in the project are identified as a part of operating the quality system, and a known procedure followed to quantify the problem and resolve it on a permanent basis. A process of continuous improvement is encouraged by the quality department, and past experience has shown that the exceptional attitude to quality improvement by its staff is a major reason for the pre-eminent position of Cameron in the supply industry and its outstanding success in the design technology field today.
Engineering:
The design and engineering team consists of qualified, capable experts in the field of subsea equipment design, with many years of experience behind them. The engineering team is responsible for the concept and detail design, drawing and 3-D modeling, developing bills of material and parts lists, requisition preparation and interfacing with other engineering contractors. Cameron have also had successful experience using the engineers responsible for design to follow up with manufacture, fabrication and testing to ensure the equipment performs to specification and to be on-hand to correct any unforeseen problems and changes.
Interface Control
A significant aspect of the engineering activities is interface control. The project team uses a system that has been tested in other projects in the past and is known to work. A full procedure forms part of the Quality System, but essentially each interface is identified and numbered, and a tracking sheet established with action dates to close-out the interface, in other words to fully define it. A simple database structure is normally used to log the interface numbers.
Cost Control:
The cost control function initially develops a ?code of accounts? by which to track costs expended on the project. This breakdown should correspond to the needs of both the customer and Cameron for cost control. The main project budget is assembled from the various elements of cost identified by the project team, and cost curves and cash flow predictions are prepared to explicitly track and report the project costs as and when they are incurred. A comprehensive procedure is used to describe the necessary activities and responsibilities of the cost control department, and this procedure forms a part of the quality system.
Schedule:
Schedule, together with cost control and quality assurance is one of the key drivers in ensuring that the project execution meets the requirements of the contract. Project planning involves virtually the whole project team to identify the tasks and activities needed to complete the work, assign resources to the tasks, determine the duration of the activity and resolve the interrelationships and logical sequence of activities. Cameron are fully cognizant of the critical path method of work
planning, and use sophisticated planning tools as a normal part of our work. Based on the work breakdown structure provided in the contract documents, a project plan is developed to cover the entire work scope, with a detailed look-ahead of approximately six months to give the detail necessary to accurately plan the work without swamping the project in distracting minutiae. A milestone plan is normally developed as part of the Contract Master Schedule (CMS), together with a Control Level (Network Schedule) and Detailed plan for implementing the work. The planning department use the Cost Time Resource (CTR) technique for projects to break the work down to the detailed level, with deliverables quantified as either documents or equipment/materials. To accurately measure the course of the work, the deliverables are ?weighted? or valued so that progress reports are biased to critical activities. A document register i s created by the engineering staff, and used by planning, to provide a tangible benchmark for judging engineering progress. Agreed percentage complete values are assigned to document completion stages ahead of the work, so that the engineering can be measured as objectively as possible.
Procurement:
Procurement of material and subcontracted services is a critical activity in the successful completion of the project. Cameron?s long experience in this area, and its excellent relationships with suppliers and subcontractors in this industry, gives it a significant edge in the execution of this project. The ongoing relationships with these suppliers and subcontractors is a major factor in problem resolution, and alleviating the often adversarial relationships seen i n other ?one-off? projects in the marine industry. Cameron has already pre-qualified the preferred subcontractors for elements of the work outside Cameron?s normal business activities, and the normal business relations with these parties avoid the chance of nasty surprises from working with an unknown subcontractor. The purchasing effort consists of a standard purchase order for companies providing simple materials or services, and involves a more encompassing contract for subcontractors providing both engineering and manufacturing/fabrication services. The project team are well-versed in project procurement including
requisition development, specification and scope of work creation.
Material Control:
The prime responsibility of the material control group (which is a part of the Procurement function in this project) is to track the flow of materials both into and out of the various construction facilities and to follow the path of the materials once inside the project boundaries, thus ensuring full traceability. Preservation and protection of equipment while in the Cameron facilities is also managed by the Material control group as a part of their normal activities.
Administration:
Administration includes secretarial and clerical functions for the project, (filing, word processing, travel, office facilities, and general services for the project. A project secretary to the Project Manager is responsible for the performance of these responsibilities and ensures they are available and sufficient.
Safety:
The safety plan is developed by the safety department in conjunction with the engineering and project management functions. Each design review on the equipment developed includes a safety review where potential hazards and unsafe aspects are identified and solutions found. The safety plan once implemented forms the basis of measurement and conformance to safety standards. Other requirements of the safety department, include verifying safe work practices, auditing conformance and leadership of formal safety studies, (FMECA, FTA, etc).
MOSAIC Project Summaries
Cameron has supplied critical products and systems to some of the most significant projects around the world. This list gives a small selection of projects, click on the links to download a pdf brochure describing the project, and Cameron's scope of supply in detail.
Note that if you are an authorized Cameron Transact User, you have access to our experience database containing hundreds of projects, which can be searched or sorted by product line, geographic region, customer etc. Contact your Cameron salesman if you need more information about registering as a Cameron Transact User.
TC1442 Typhoon Project (8 pages)
Details of Cameron's MOSAIC Systems for Chevron USA and BHP Petroleum's Typhoon project in the Gulf of Mexico.
TC1444 Malampaya Project (8 pages)
Details of Cameron's MOSAIC Systems for Shell's Malampaya project in the Philippines.
TC1448 Ceiba Field Early Production System (8 pages)
Details of Cameron's MOSAIC Systems for Triton's Ceiba field early production system off the coast of Equatorial Guinea.
TC1642 Ceiba Phase 1A Production System (8 pages)
Describes the second part of the successful Ceiba Field Development Project.
TC1478 Captain Expansion Project (12 pages)
Details of Cameron's MOSAIC Systems for Texaco's Captain field development in the North Sea.
TC1479 King Kong Field Development (8 pages)
Details of Cameron's MOSAIC Systems for Mariner Energy and Agip Petroleum's King Kong field development project in the Gulf of Mexico.
TC1483 B3 Expansion Project (8 pages)
Details of Cameron's MOSAIC Systems for the Petrobaltic-operated B3 field development in the Baltic Sea offshore Poland.
TC1640_B3 Petrobaltic B3 (1 page)
CAMTROL Production Controls project summary sheet.
TC1640_Captain Texaco Captain Expansion (1 page)
CAMTROL Production Controls project summary sheet.
TC1640_Ceiba_EPS Triton Ceiba Early Production System (1 page)
TC1640_Malampaya Shell Malampaya (1 page)
CAMTROL Production Controls project summary sheet.
TC1640_Pat_Baleen OMV Patricia Baleen (1 page)
CAMTROL Production Controls project summary sheet.
MOSAIC Summary Overview
For more than 35 years, Cameron engineers have been designing subsea drilling and production equipment for every conceivable situation, in every oil-producing region of the world.
Today's deep-water projects are among the most challenging ever.
And while Cameron's reputation for tackling the most exotic oil and gas assignments is well-known, our most important accomplishment may turn out to be something very different altogether.
Like in making subsea systems simpler and less costly, for example.
We're proud to introduce MOSAIC(tm) (Modular Subsea and Integrated Completions) production systems - the first pre-engineered subsea system that delivers the time and money-saving advantages of modular components, but with the flexibility of custom-made.
With MOSAIC systems, we've optimized and standardized every piece of equipment in our broad line of subsea products. And we've done it at the lowest component level, so you still have hundreds of choices to deliver the functionality you're looking for.
MOSAIC systems are divided into elements or component families: Wellhead, Tree,Manifold, Template, Controls and Connection. The product and component choices are described on thefollowing pages.
And the combinations are endless. MOSAIC systems can be used for cluster wells or daisy chains. They can be provided with individual flowbases or as part of a large template/manifold assembly. If needed, they can be rig-deployable.
You even have a choice of Christmas trees. The i nnovative SpoolTreen Christmas tree and the proven Cameron Dual Bore trees have both been re-engineered as modular assemblies for use in t he MOSAIC system.
In short, MOSAIC systems can be adapted for virtually any subsea job, and t hey're more easily expanded as field development needs evolve.
We like to think that MOSAIC systems are an asset manager's best friend, because they don't require early commitment to expensive structures when revenue streams are still uncertain.
Instead of designing new, unproven product approaches, Cameron engineers have focused on value-engineering the ones we already had. The result i s MOSAIC subsea production systems - the perfect fit for today's subsea economics.
Related Documents
TC 1784 Cameron Products and Services Overview
MOSAIC System Engineering
System Engineering takes the multitude of individual parts and components, and packages them into an integrated, working system. The objective is to execute a complex multi-supply project in the most effective manner possible. The principal fundamentals are discussed below:
Interface Control Interface engineering
Interface engineering consists of several specific activities:
Identify the interface and assign a number Define the interface
Assign responsibilities for closing out the interface Identify technical references
Formally close out the report
Interface management commences at contract award with the development of the interface plan. The i nterface plan identifies all external contractor interfaces ("key interfaces"), numbers them, defines information required and the agreed dates for interface data issue, as well as close out. Interface descriptions for each numbered item are listed on standard interface form.
System Integration Test Planning and Management
System Integration Testing (SIT) is the function and integrity testing of the complete system, (for example subsea trees, manifold, controls system and flowline connection system). SIT is strongly influenced by the interface engineering results to guarantee key interfaces are thoroughly tested. Interchangeability of all major sub-assemblies is also confirmed, and in so doing the operations staff are trained and service staff prepared for installation procedures. Initiation for this final test of the equipment prior to installation starts early in the project so that components can be scheduled to arrive at the test site at the appropriate time, and suitable test and handling facilities are available when required.
Design change control
In a "system" involving many components and multiple contractors, the impact of relatively minor design changes can be significant, and can have repercussions far beyond t he component itself. Design changes are therefore strictly controlled through use of a design change control procedure to prevent unexpected and unnecessary impact on affected parties, and to communicate approved changes in a timely manner.
Handling procedures
Drilling rig size and capabilities can limit equipment handing operations in some circumstances, and one aspect of system engineering is to ensure equipment is not designed beyond what the installation vessel can manage or manipulate. In particular, deck cranes often have a challenge picking up equipment from supply boats, and moonpool constraints limit handling operations under the rig floor. This phase of system engineering reviews the necessary operations of the installation vessel and checks that the subsea equipment fits within its working envelope.
Intervention and ROV (Remote Operated Vehicle)
Many of the subsea completions supplied by Cameron in the past have included an ROV interface of some description. The ROV is now such a common feature of subsea completions that provision for ROV intervention to subsea equipment is almost standard, (even in "diver depths"). Cameron assumes responsibility for ROV intervention interfaces including design, system integration testing, and technical support of offshore service work. The goal of the system engineering phase is to minimize the different types of i nterface between ROV and subsea equipment, and to optimize the interfaces to the least complex, working solution.
Tolerance and Weight Control
Weight control is coordinated through the System Engineering group to accurately define and report weights and centers of gravity/buoyancy. Procedures for weight control, and weight control reporting activities are project-specific, developed in conjunction with the customer in accordance with project requirements.
Tolerance studies may be required for interfacing subsystems to confirm proper engagement and function. Important tolerance data affecting external interface points are normally issued/required on specific interface documents. The validity of tolerance studies is often dependent on the i nformation received from other contractors, hence the interface control system, is a critical link in the tolerance study exercise.
Cameron utilizes proprietary 3-D modeling packages to enhance weight and tolerance control measures. Accurate weight data is now calculated early in the project, and is monitored closely as the design develops.
Document Control
Effective control of project documents is an important aspect of system management. Document control is managed by a Project Document Controller, who maintains a working system for identifying, coding, and transmittal of the project's documents and drawings.
Emphasis is placed on establishing consistent document and drawing content and format. Electronic Integrated Document Management Systems are used to exploit latest technology in document creation, filing/archiving and transmission.
Transmittals
Transmittals (electronic or paper) are used for outgoing documents and drawings (other than correspondence) to ensure a permanent record of the dispatch exists in the project file. This system benefits both Cameron and its clients by providing objective evidence during any later di scussions or disputes regarding receipt of important documentation. For a paper-based system, duplicate transmittals are attached to the outgoing document or drawing and the recipient signs and returns one copy, filing the other as their permanent record of receipt.
Filing
Maintenance of a comprehensive project file is a necessary discipline on complex projects. Normally all project correspondence is filed by originator and date, and each issue or revision of project documents and drawings are held electronically in a historical file for reference.
Numbering
Document numbering can be a complex and confusing process. Cameron add "intelligence" to the document number so that the originator, work package and type of document can be ascertained from the number.
Supplier document control
Purchase orders and contracts awarded to suppliers normally define the methods to be adopted for the registration, filing, distribution and transmittal of all documents and drawings submitted to the project. Suppliers to Cameron are normally contractually obliged to abide by the project procedures for document control.
Safety and Risk Management FMECA/FTA
Failure Mode and Effect Analysis (FMEA) is a method of establishing the effect of failure within systems. This analysis can be performed at any level of assembly. FMEA may also be done together with Criticality Analysis (CA). The combined exercise is then called a Failure Mode Effect and Criticality Analysis (FMECA). FMEA is a "bottom up" technique most suited to the stage of a project when detailed drawings at part and component level are available.
A fault tree analysis (FTA) provides a means of showing the logical relationship between a particular system failure mode and the basic failure causes. The technique can be applied between any levels, from system to assembly or component level. It is useful for assessing compliance with safety requirements, analyzing common cause failures and justifying design improvements or additions. FTA is a "top down" approach making the technique particularly suitable for starting reliability evaluations early in a project.
HAZOP
Hazard and Operability (HAZOP) studies are the formal, systematic, critical review of the process and engineering design in order to identify potential hazards and operability problems and their consequences. The formal review entails an
examination of all possible deviation from intended operation by the application of "guide words" to each element of the design.
Reliability, Availability, Maintainability
Reliability analysis is used to evaluate the potential events that could disrupt production from the subsea facility, and identify where a design change could improve overall availability of production. Factors such as the "quality of equipment", redundancy, spares on hand, module size and retrieve-ability, and early warning systems are reviewed to gauge the impact of system reliability.
It is anticipated that a target availability can be established early in the project, which governs the decisions on system design to reach the target. Cost analysis shows whether additional project investment to achieve the required availability is economically justified.
Risk Assessment
Risk is the combined effect (product) of the probability of occurrence of an (undesirable) event, and the magnitude (consequence) of the event.
A quantitative risk assessment identifies and quantifies the potential risks for the project. Using the comprehensive experience of Cameron, and its extensive database, the majority of hazards and potential impacts to availability can be classified and assessed. For any new equipment, or new applications a formal hazard review may be implemented, in order to systematically evaluate the potential hazards.
Design Basis
The Design Basis has two main stages:
Initially at the start of the project, to identify the known data and requirements from the customer influencing the
system design,
At the end of the system engineering phase, to incorporate the results and findings of the system engineering
activities into the project design basis used for the detail design and analysis.
The detail engineering activity uses this developed design basis as input to carry out the final design of the equipment and ensure all design basis requirements are met and updated as necessary. The "Design Basis" document then becomes a
'controlled' single point reference available to the whole design group. It is continuously reviewed and, (if necessary), updated throughout the project life.
System Engineering initially establishes the basis for all engineering work to follow and provides the necessary focus for progression to the final system design. It ensures the system linkage of the finished design engineering work to the initial system requirements, (established through contract specification documents and compliance with the applicable industry and governmental codes). The ultimate objective is to ensure the finished system design is fully functional, installable, operable, reliable, and maintainable as a `total' system. A comprehensive design basis is the most appropriate vehicle to communicate the design principals and decisions to the team.
Material selection
Material engineering for all hardware packages is carried out in the system engineering phase. The material selection, material specification, welding specification and procedures, corrosion protection and coating requirements are defined for each of the responsible engineering groups, both internal and subcontracted.
Flow assurance/analysis
The flow assurance activity can exploit the latest multi-phase process flow programs to accurately define liquid hold-up, slug size, hydrate formation tendency and erosion hot-spots, to confirm system design is adequate, or identify where design changes are needed.
Another aspect of flow assurance is the control system steady state and transient hydraulic and electrical analyses. It is common practice to analyze the hydraulic tubing of the control system both from the response time aspect as well as the fluid cleanliness levels, (flow regimes etc). Cameron's work during the system engineering ensures that the Control Systems have the necessary logical verification and e lectrical feedback loops built-in.
Structural & foundation analysis
Selection of the optimum foundation design is dependent upon the results of the studies commissioned for this project. When soil data and seabed conditions are fully known, the optimum foundation can be designed for review and approval.
Installation/operational analysis
Analysis work includes wellhead/casing system load analysis, dynamic riser analysis and load transfer,
manifold/wellhead/tree/running tool installation, and operation loads. Such analysis information is exchanged with the installation contractors via the Interface Plan.
Various mainframe and PC based computer analysis software is used by Cameron including FLEXCOM, DERP, COSMOS, PATRAN, CAESAR II, and ANSYS as considered necessary. Verification packages for any of the programs used can be provided as required. For example, Cameron would perform a preliminary riser analysis (if required) using the DERP and FLEXCOM software to assess the magnitude of the riser loading at each coupling and into the completion equipment. These results input into wellhead, tree, and running tool component load analyses to confirm design suitability and compliance with material allowable stress levels. Finite element modeling and analysis using PATRAN and ANSYS is run for critically loaded members in the system. The manifold piping arrangement is rigorously stress-analyzed using the program CAESAR II, which was successfully used on the Wanaea and Cossack Manifolds piping for example.
Field layout
The Subsea Wellhead, Tubing Hanger, Tree, Flowline Jumpers and Connections, and the Manifold subsystem layout drawings are used to identify critical tolerances, interface input requirements, equipment stack-up combinations, installed clearance requirements, preliminary weights, critical material selections, corrosion protection data, and ROV
intervention/access. This component of the system engineering phase is therefore critical to the success of the project, and is described in more detail in the "Field Architecture" section.
Optimization & Value Engineering
Optimization involves challenging the base case design and generating/evaluating alternatives that may be more cost-effective or safer than the base case. A formal system of evaluation (called SMART) is used to ensure consistency and completeness.
Using sophisticated modeling packages such as Pro/Engineer offers optimization benefits, including the enhanced image generated with three-dimensional graphics, the rapid design development of options possible through the parametric relations defined by the user, and the "virtual" assembly available prior to physical assembly. These design aids give a much improved design development phase, enabling each part and assembly to be clearly visualized and assembled to mating parts long before material is ordered.
Advanced Multiplex Electro-Hydraulic
Control Systems
PRODUCTION
CONTROLS
More than 30 years ago, Cameron installed the very first subsea production system. Shallow and simple by today's standards, it nonetheless marked the beginning of a new era in subsea oil and gas production. Today, all the knowledge and experience gained in production control technology is available to the industry in the CAMTROL Production Control System.
The industry spoke, and Cameron Controls listened. The CAMTROL system has been engineered and qualified as a completely integrated system from the ground up -starting with 30 years of subsea experience, combined with the latest control technology and system analysis tools. With i ts integrated approach and component-level modularity, the CAMTROL system offers unequaled advantages in cost savings, flexibility and expandability.
It's the first and only system available that incorporates all the advanced features the industry now demands, and it is the only system available with MOSAICTM
certified system components:
• Modular components
The reliability of pre-engineered components, the adaptability to handle any field scenario, plus the flexibility t o expand as development scenarios change.
• High-integrity materials
Robust, seawater-tolerant components, designed and qualified to 3000 meters (10,000 feet).
• Segregated, redundant electronics
Delivers maximum reliability against single-mode failures.
• Smaller and lighter
Compact Subsea Control Module weighs less than 1000 kg (2200 lbs.), allowing easy installation and intervention with standard work-class ROVs.
• The most functionality in the industry
Up to 32 control functions i n each standard subsea control module.
• Retrievability
Standard tooling and modular design - plus a systems-level approach to field development - enable critical subsea components to be easily retrieved.
Cameron provides a true systems approach for maximum efficiency.
Beyond field-proven reliability, the flexible, modular structure of the CAMTROL Production System allows Cameron to look at your field development from a systems level. Rather than designing new components, we can focus on analyzing the base case and options development scenarios, then re-configure our standard, pre-engineered equipment and components to meet the RAM analysis optimized solution to your project.
