Deepwater Subsea Test Tree & Intervention Riser System

Transcription

1 Deepwater Subsea Test Tree & Intervention Riser System Bill Parks DTC International, Inc. Ultra-Deepwater Drilling, Completions, and Interventions TAC Meeting May 29, 2013 Apache Corp HQ, Houston, TX 1 rpsea.org

2 Project Descriptions RPSEA Project Title: Deepwater Subsea Test Tree (SSTT) and Intervention Riser System (IRS) 2

3 Project Summary RPSEA Project # : Deepwater Subsea Test Tree (SSTT) & Intervention Riser System (IRS) o Subsea Test Tree (SSTT) o Intervention Riser System (IRS) o Surface Tree (ST) 3

4 Project Deliverables Certified, Ready-to-Fabricate Design for: 6 ⅜ 20 ksi Subsea Test Tree (SSTT) 6 ⅜ 20 ksi Intervention Riser System (IRS) 6 ⅜ 20 ksi Well Control Package (WCP) 6 ⅜ 20 ksi Emergency Disconnect Package (EDP) 6 ⅜ 20 ksi Surface Tree Intervention Control System (ICS) Standardized Interfaces (to be Donated to Industry) for: Subsea Test Tree (SSTT) - Tubing Hanger Running Tool (THRT) Well Control Package (WCP) Subsea Tree Intervention Control System (ICS) Production Control System (PCS) Cost Estimates for: Manufacture and Qualification of New Components Manufacture and Delivery of a Complete SWIS for 12,000 WD Commercialization Plan 4

5 SWIS Block Diagram X X 5

6 Basis of Design 63/8 Bore (was 5 1/8 Bore) 20,000 psi 350 deg F Temperature Rating 12,000 ft Water Depth Rating Full NACE MR Compatibility (H 2 S & CO 2 ) Applicable for use on both Vertical and Horizontal Trees Fully Integrated Subsea Well Intervention System 6 SSTT Full Bore Design for use with 18 3/4 BOP Stack & 21 Riser (was Slim Bore Design for use with 13 5/8 BOP Stack & 16 Riser) IRS Capable of both Thru Drilling Riser & Open Water Operations RIS Deferred (Future Upgrade) ICS EH/MUX w/ Acoustic/Wireless Back Up (was Acoustic w/wireless Back Up)

7 Current/Planned Activities o Identify Potential Suppliers for all Key Components Identified and obtain required information for detailed design of SWIS Assemblies o Select/Confirm Material Requirements for all components. o Complete Detailed Design of SSTT, WCP, EDP, IRS, Surface Tree and ICS. o Hold Operations Review and HAZOP/HAZID for all SWIS Operating Modes o Conduct FMECA of SWIS and submit for Review and Comment o Obtain Budgetary Cost and Schedule estimates for Manufacturing, Qualification and Delivery of Key Components 7

8 Project Status o o o o o RPSEA Project was the highest rated project in the entire RPSEA portfolio at time of award RPSEA Project and are the lowest rated projects in the entire RPSEA portfolio in terms of Cost Share participation (11.2%) after 6 rounds of solicitation DTC s initial proposal was selected from 7 proposals submitted because it was the only proposal that offered a forward looking solution, i.e. 20 ksi, 350 deg F, 12,000 water depth vs. 10 ksi, 250 deg F, 6,000 water depth. DTC s second proposal was selected because it enhanced and completed the system being developed under the initial contract Project has essentially been on hold since last summer due to insufficient funding to support the negative cash flow 8 o The lack of industry participation and support has made it extremely difficult for DTC to complete this work and may result in these two projects being cancelled and funds being re-allocated to other projects o All work must be completed by 30 June 2014

9 9 Project Cost Breakdown o RPSEA Project Total Contract Amount $1,939,049 Maximum RPSEA Contribution (80%) 1,551,239 Reserve for Technology Transfer (1%) 19,390 DTC Reimbursable Amount 1,531,849 Cost Share Amount 407,200 Total Amount Spent to Date $ 297,979 Total Cost Share to Date $ 76,507

10 RPSEA Cost Share Distribution o Total Cost Share for Both Projects $1,384,232 o Total Cost Share Contributions to Date $ 155, ,000 o Total Cost Share Incurred to Date $ 265,672 o Cost Share Absorbed by DTC to Date $ 110,672 1,229,232 o Total Cost Share Absorbed by DTC $ 1,229,232 o Amount of Cost Share being solicited $ 1,200,000 10

11 RPSEA Cash Flow Projections 1,500, $ 1,200,000 Cost Share Contribution Without Cost Share With Cost Share 1,000, , $ 275,741 CASH FLOW ($) 0.00 (500,000.00) ($ 396,659) (1,000,000.00) ($ 924,259) (1,500,000.00) ($ 896,534) 11 (2,000,000.00) ($ 1,596,659) CASH DISBURSEMENTS AND RECEIPTS OVER REMAINDER OF PROJECT (July '13 - Sep '14)

12 Thank You QUESTIONS? 12

13 Contacts PI: Bill Parks DTC International, Inc RPSEA PM: James Pappas

14 14 SWIS P & ID

15 Well Control Package (WCP) Well Control Package (WCP) WCP Connector (18 3/4 20 ksi SHD-H4 profile) Safety Shear Head (6 3/8 20 ksi) Triple Ram BOP (6 3/8 20 ksi) Production Isolation Valve (6 3/8 20 ksi Gate Valve w/ Shear Gate) WCP RE-Entry Hub (13 5/8 20 ksi Vetco DW-H4 profile) Crossover Valve (2 1/16 20 ksi Gate Valve) Annulus Access Valve ( 2 1/16 20 ksi Gate Valve) Circulation Valves (2 1/16 20 ksi Gate Valves) Circulation/Kill Valve (2 1/16 20 ksi Gate Valve) Chemical Injection Valves (1/2 20 ksi Gate Valves w/ Integral Check Valves) 15

16 Emergency Disconnect Package (EDP) EDP Connector (13 5/8 20 ksi Vetco DW-H4) Retainer Valve (6 3/8 20 ksi Gate Valve) Annular BOP (6 3/8 15 ksi) [Future Upgrade] Circulation Valves (2 1/16 20 ksi Gate Valves) Chemical Injection Valves(1/2 20 ksi Gate Valves w/ Integral Check Valves) 16

17 Subsea Test Tree (SSTT) 17 Full-Bore Design (18 ½ OD) Rated for 1 MM 20 ksi Dual Ball Valves (1 Cutting, 1 Sealing) 4 Chemical Injection Valves 2 Downhole 2 at SSTT Emergency Disconnect Module Shear Joint Retainer Valve Riser Circulation Valve Upper (Annular) Pack-Off Joint Accumulator Module(s) EH/MUX Control Module 32 Functions (26 Hyd, 4 Elec, 2 Chem Inj) Wireless Backup (thru wall of Drilling Riser) Riser Adapter

18 Valve Module 18 ½ OD 6 ⅜ Bore (6.35 Drift) 20,000 psi Pressure Rating 350 deg F Temperature Rating Fail Safe Closed w/ Pressure Assist Balanced Piston Design WL/CT Cutting Capability (TBD) 18

19 Lower Pack-Off Joint (Ported Slick Joint) 18 ½ OD 6 ⅜ Bore (6.35 Drift) 9 ⅝ Pack-Off Diameter 20,000 psi Pressure Rating 350 deg F Temperature Rating 1,000 million 20,000 psi Tensile Rating 16 Thru-Ports for THRT & Downhole 12 Hydraulic Lines 2 Chemical Lines 2 Electrical Cables 19

20 Accumulator Module 18 ½ OD x 150 (12 ½ Feet) Long 6 ⅜ Bore (6.35 Drift) 20,000 psi Pressure Rating 350 deg F Temperature Rating 1 Million 20,000 psi Tensile Rating 8 x 2.0 gallon LP Accumulators 2 x 1.3 gallon HP Accumulators Can be installed in series for additional volume 20

21 Intervention Riser System (IRS) Mono Bore Riser w/ DTC s Breech Loc Riser Connector Full Bore (6 1/2 ID) with Smooth ID Small Diameter (13 3/8 OD) High Strength (Rated for 1.0 MM 20,000 psi) Fast Make Up (1/12 turn), Pre Loaded Connection Titanium Riser Joints 45 ft Joints plus Pup Joints 75 lbs/ft in seawater (estimated) > 12,000 ft Water Depth Rating 21

22 Intervention Control System (ICS) E/H MUX Control System Based upon DTC s MODSYS Modular Control System Components Packaged into Small, ROV Retrievable Modules 12,000 ft Water Depth Rating Wire, Optical Fiber, Acoustic and Wireless Communication Wire and Battery Power 22

23 Wireline Tool Selector / Storage Rack Subsea Lubricator Package Variable Length Lubricator Wireline Tool Selector/Storage Rack Tool Trap & Tool Catcher Dual Wireline Pack Offs Multi Port Grease Injector Head Variable Pressure Wiper Seal Subsea Grease Injection System 3 Chemical Injection Valves Optional Tractor 23 Subsea Winch Package Battery Operated Winch (48v DC) Variable Speed Motor ROV Retrievable Battery Packs Remote Data Monitoring Slick Line and/or E Line

24 Wireline Tool Selector / Storage Rack 16 Individual Storage Tubes in two rotating racks (8 Tubes/ Rack) Tool Strings up to 90 Long Subsea Tool Change-Out w/o ROV Assistance Integrated Tool Trap & Tool Catcher 5 ⅛ Bore (5.09 Drift) 20 ksi Pressure Rating (Only one Tube pressurized at a time) Storage Tubes can be accessed in any order Currently evaluating similar design for lubricator 24