HANDBOOK SUBSEA ENGINEERING. ELSEVIER Gulf Professional Publishing is an imprint of Elsevier YONG BAI QIANG BAI

Transcription

1 SUBSEA ENGINEERING HANDBOOK YONG BAI QIANG BAI AMSTERDAM BOSTON HEIDELBERG LONDON NEW YORK OXFORD PARIS SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY TOKYO ELSEVIER Gulf Professional Publishing is an imprint of Elsevier

2 Preface About the Authors List of Abbreviations xxv xxvii xxix PART I SUBSEA PRODUCTION SYSTEMS 1. Overview of Subsea Engineering Introduction Subsea Production Systems Field Architecture Distribution Systems Subsea Surveys Installation and Vessels Cost Estimation Subsea Control Subsea Power Supply Project Execution and Interfaces Flow Assurance and System Engineering Subsea Operations Commissioning and Start-Up Production Processing Chemicals Injection Well Testing Inspection and Maintenance Subsea Structures and Equipment Subsea Manifolds Pipeline Ends and In-Line Structures Jumpers Subsea Wellheads Subsea Trees Umbilical Systems Production Risers Subsea Pipelines 24 References 25

3 vi Contents 2. Subsea Field Development Subsea Field Development Overview Deepwater or Shallow-Water Development 29 23, Wet Tree and Dry Tree Systems Wet Tree Systems Dry Tree Systems Systems Selection Subsea Tie-Back Development Tie-Back Field Design Tie-Back Selection and Challenges Stand-Alone Development Comparison between the Stand-Alone and Tie-Back Developments Classification of Stand-Alone Facilities Artificial Lift Methods and Constraints Basic Artificial Lift Methods Gas Lift Subsea Pressure Boosting Electric Submersible Pump (ESP) Subsea Processing Template, Clustered Well System, and Daisy Chain Satellite Well System Template and Clustered Well System Daisy Chain Subsea Field Development Assessment Basic Data Water-Cut Profile Process Simulations 61 References Subsea Distribution System Introduction System Architecture Design Parameters Hydraulic System Electrical Power System and Communication SDS Component Design Requirements Topside Umbilical Termination Assembly (TUTA) Subsea Umbilical Termination Assembly (SUTA) 68

4 Contents vii Umbilical Termination Head (UTH) Subsea Distribution Assembly (SDA) Hydraulic Distribution Manifold/Module (HDM) Electrical Distribution Manifold/Module (EDM) Multiple Quick Connects (MQCs) Hydraulic Flying Leads and Couplers Electrical Flying Leads and Connectors Logic Caps Subsea Accumulator Module (SAM) 88 References Subsea Surveying, Positioning, and Foundation Introduction Subsea Survey Subsea Survey Requirements Subsea Survey Equipment Requirements Sub-Bottom Profilers Magnetometer Core and Bottom Sampler Positioning Systems Subsea Metrology and Positioning Transducers Calibration Water Column Parameter Acoustic Long Baseline Acoustic Short Baseline and Ultra-Short Baseline Subsea Soil Investigation Offshore Soil Investigation Equipment Requirements Subsea Survey Equipment Interfaces Subsea Foundation Pile-or Skirt-Supported Structures Seabed-Supported Structures Pile and Plate Anchor Design and Installation Geotechnical Capacity of Suction Piles Geotechnical Capacity of Plate Anchors Structural Design of Suction Piles Installation of Suction Piles, Suction Caissons, and Plate Anchors Driven Pile Anchor 133 References 137

5 viii Contents 5. Installation and Vessels Introduction Typical Installation Vessels Transportation Barges and Tug Boats Drilling Vessels Pipe-Laying Vessels Umbilical-Laying Vessels Heavy Lift Vessels Offshore Support Vessels Vessel Requirements and Selection Basic Requirements for Vessels and Barges Functional Requirements Installation Positioning Surface Positioning Subsea Positioning Installation Analysis Subsea Structure Installation Analysis Pipeline/Riser Installation Analysis Umbilical Installation Analysis 155 References Subsea Cost Estimation Introduction Subsea Capital Expenditures (CAPEX) Cost Estimation Methodologies Cost-Capacity Estimation Factored Estimation Work Breakdown Structure Cost Estimation Process Subsea Equipment Costs Overview of Subsea Production System Subsea Trees Subsea Manifolds Flowlines Testing and Installation Costs Testing Costs Installation Costs Project Management and Engineering Costs 182

6 Contents ix 6.7. Subsea Operation Expenditures (OPEX) Life cycle Cost of Subsea System RISEX RAM EX Case Study: Subsea System CAPEX Estimation 188 References Subsea Control Introduction Types of Control Systems Direct Hydraulic Control System Piloted Hydraulic Control System Sequenced Hydraulic Control System Multiplexed Electrohydraulic Control System All-Electric Control System Topside Equipment Master Control Station (MCS) Electrical Power Unit (EPU) Hydraulic Power Unit (HPU) Subsea Control Module Mounting Base (SCMMB) Subsea Control Module (SCM) SCM Components SCM Control Mode Description Subsea Transducers/Sensors Pressure Transducer (PT) Temperature Transducer (TT) PressureATemperature Transducer (PTT) Sand Detector High-Integrity Pressure Protection System (HIPPS) Subsea Production Control System (SPCS) Installation and Workover Control System (IWOCS) 222 References Subsea Power Supply Introduction Electrical Power System Design Codes, Standards, and Specifications Electrical Load Calculation 228

7 x Contents Power Supply Selection Electrical Power Unit (EPU) Electrical Power Distribution Hydraulic Power System Hydraulic Power Unit (HPU) 239 References Project Execution and Interfaces Introduction Project Execution Project Execution Plan Schedule Versions and Baseline Updates Project Organization Project Management Contracting Strategy Quality Assurance Systems Integration Manufacturing and Testing Installation Process Management HSE Management Interfaces General Roles and Responsibilities Interface Matrix Interface Scheduling Interface Management Plan Interface Management Procedure Interface Register Internal Interface Management External Interface Management Interface Resolution Interface Deliveries 266 References Subsea Risk and Reliability Introduction Overview of Risk Management Risk in Subsea Projects 269

8 Contents xi Risk Assessment General Assessment Parameters Risk Assessment Methods Risk Acceptance Criteria Risk Identification Risk Management Plan Environmental Impact Assessment Calculate the Volume Released Estimate Final Liquid Volume Determine Cleanup Costs Ecological Impact Assessment Project Risk Management Risk Reduction Reliability Reliability Requirements Reliability Processes Proactive Reliability Techniques Reliability Modeling Reliability Block Diagrams (RBDs) Fault Tree Analysis (FTA) Concept Timing Input Data Requirements Strengths and Weaknesses Reliability Capability Maturity Model (RCMM) Levels Reliability-Centered Design Analysis (RCDA) Qualification to Reduce Subsea Failures 289 References Subsea Equipment RBI Introduction Objective Subsea Equipment RBI Methodology General Subsea RBI Inspection Management Risk Acceptance Criteria Subsea RBI Workflow Subsea Equipment Risk Determination 299

9 xii Contents Inspection Plan Offshore Equipment Reliability Data Pipeline RBI Pipeline Degradation Mechanisms Assessment of PoF Value Assessment of CoF Values Risk Identification and Criteria Subsea Tree RBI Subsea Tree RBI Process Subsea Tree Risk Assessment Inspection Plan Subsea Manifold RBI Degradation Mechanism Initial Assessment Detailed Assessment Example for a Manifold RBI RBI Output and Benefits 327 References 327 PART II FLOW ASSURANCE AND SYSTEM ENGINEERING 12. Subsea System Engineering Introduction Flow Assurance Challenges Flow Assurance Concerns Typical Flow Assurance Process Fluid Characterization and Property Assessments Steady-State Hydraulic and Thermal Performance Analyses Transient Flow Hydraulic and Thermal Performances Analyses System Design and Operability Well 5tart-Up and Shut-Down Flowline Blowdown 345 References 347 IE. Hydraulics Introduction Composition and Properties of Hydrocarbons 351

10 Contents xiii Hydrocarbon Composition Equation of State Hydrocarbon Properties Emulsion General Effect of Emulsion on Viscosity Prevention of Emulsion Phase Behavior Black Oils Volatile Oils Condensate Wet Gases Dry Gases Computer Models Hydrocarbon Flow General Single-Phase Flow Multiphase Flow Comparison of Two-Phase Flow Correlations Slugging and Liquid Handling General Hydrodynamic Slugging Terrain Slugging Start-up and Blowdown Slugging Rate Change Slugging Pigging Slugging Prediction Parameters for Slug Characteristics Slug Detection and Control Systems Equipment Design for Slug Flow Slug Catcher Sizing Slug Catcher Design Slug Catcher Design Process Slug Catcher Functions Pressure Surge Fundamentals of Pressure Surge Pressure Surge Analysis Line Sizing Hydraulic Calculations 392

11 xiv Contents Criteria Maximum Operating Velocities Minimum Operating Velocities Wells Gas Lift 397 References Heat Transfer and Thermal Insulation Introduction Heat Transfer Fundamentals Heat Conduction Convection Buried Pipeline Heat Transfer Soil Thermal Conductivity U-Value Overall Heat Transfer Coefficient Achievable U-Values U-Value for Buried Pipe Steady-State Heat Transfer Temperature Prediction along a Pipeline Steady-State Insulation Performance Transient Heat Transfer Cooldown Transient Insulation Performance Thermal Management Strategy and Insulation External Insulation Coating System Pipe-in-Pipe System Bundling Burial Direct Heating 439 References 443 Appendix: U-Value and Cooldown Time Calculation Sheet 445 Properties of Ambient Surroundings Hydrates Introduction Physics and Phase Behavior General Hydrate Formation and Dissociation 456

12 Contents xv Effects of Salt, MeOH, and Gas Composition , Mechanism of Hydrate Inhibition Hydrate Prevention Thermodynamic Inhibitors Low-Dosage Hydrate Inhibitors Low-Pressure Operation Water Removal Thermal Insulation Active Heating Hydrate Remediation Depressurization Thermodynamic Inhibitors Active Heating Mechanical Methods Safety Considerations Hydrate Control Design Philosophies Selection of Hydrate Control Cold Flow Technology Hydrate Control Design Process Hydrate Control Design and Operating Guidelines Recovery of Thermodynamic Hydrate Inhibitors 478 References Wax and Asphaltenes Introduction Wax General Pour Point Temperature Wax Formation Gel Strength Wax Deposition Wax Deposition Prediction Wax Management General Thermal Insulation Pigging Inhibitor Injection Wax Remediation Wax Remediation Methods 495

13 xvi Contents Assessment of Wax Problem Wax Control Design Philosophies Asphaltenes General Assessment of Asphaltene Problem Asphaltene Formation Asphaltene Deposition Asphaltene Control Design Philosophies 502 References Subsea Corrosion and Scale Introduction Pipeline Internal Corrosion Sweet Corrosion: Carbon Dioxide Sour Corrosion: Hydrogen Sulfide Internal Coatings Internal Corrosion Inhibitors Pipeline External Corrosion Fundamentals of Cathodic Protection External Coatings Cathodic Protection Galvanic Anode System Design Scales Oil Field Scales Operational Problems Due to Scales Scale Management Options Scale Inhibitors Scale Control in Subsea Field 539 References Erosion and Sand Management Introduction Erosion Mechanisms Sand Erosion Erosion-Corrosion Droplet Erosion Cavitation Erosion Prediction of Sand Erosion Rate 549

14 Contents xvii Huser and Kvernvold Model Salama and Venkatesh Model Salama Model Tulsa ECRC Model Threshold Velocity Salama and Venkatesh Model Svedeman and Arnold Model Shirazi et al. Model Particle Impact Velocity Erosion in Long Radius Elbows Erosion Management Erosion Monitoring Erosion Mitigating Methods Sand Management Sand Management Philosophy The Sand Life Cycle Sand Monitoring Sand Exclusion and Separation Sand Prevention Methods Calculating the Penetration Rate: Example Elbow Radius Factor Particle Impact Velocity Penetration Rate in Standard Elbow Penetration Rate in Long Radius Elbow 567 References 568 PART III SUBSEA STRUCTURES AND EQUIPMENTS 19. Subsea Manifolds Introduction Applications of Manifolds in Subsea Production Systems Trends in Subsea Manifold Design Manifold Components Subsea Valves Chokes Control System Subsea Modules Piping System Templates 583

15 xviii Contents Manifold Design and Analysis Steel Frame Structures Design Manifold Piping Design Pigging Loop Padeyes Control Systems CP Design Materials for HP/HT and Corrosion Coating Hydrate Prevention and Remediation Pile and Foundation Design Design Methodology Design Loads Geotechnical Design Parameters Suction Pile Sizing Geotechnical Design Suction Structural Design Installation of Subsea Manifold Installation Capability Installation Equipment and Installation Methods Installation Analysis 628 References Pipeline Ends and In-Line Structures Introduction PLEM General Layout Components of PLEMs PLEM Design and Analysis Design Codes and Regulations Design Steps Input Data Required Design Methodology Structure Mudmat PLEM Installation Foundation (Mudmat) Sizing and Design Load Conditions Mudmat Analysis PLEM Installation Analysis Second-End PLEM First-End PLEMs 657

16 Contents xix Stress Analysis for Both First- and Second-End PLEMs Analysis Example of Second End PLEM 659 References Subsea Connections and Jumpers Introduction Tie-in Systems Jumper Configurations Jumper Components and Functions Flexible Jumper Components Rigid Jumper Components Connector Assembly Jumper Pipe Spool Hub End Closure Fabrication/Testing Stands Subsea Connections Bolted Flange Clamp Hub Collet Connector Dog and Window Connector Connector Design Design and Analysis of Rigid Jumpers Design Loads Analysis Requirements Materials and Corrosion Protection Subsea Equipment Installation Tolerances Design and Analysis of a Flexible Jumper Flexible Jumper In-Place Analysis Flexible Jumper Installation 697 References Subsea Wellheads and Trees Introduction Subsea Completions Overview Subsea Wellhead System Function Requirements Operation Requirements Casing Design Program 709

17 xx Contents Wellhead Components Wellhead System Analysis Guidance System Subsea Xmas Trees Function Requirements Types and Configurations of Trees Design Process Service Conditions Main Components of Tree Tree-Mounted Controls Tree Running Tools Subsea Xmas Tree Design and Analysis Subsea Xmas Tree Installation 757 References ROV Intervention and Interface Introduction ROV Intervention Site Survey Drilling Assistance Installation Assistance Operation Assistance Inspection Maintenance and Repair ROV System ROV Intervention System ROV Machine ROV Interface Requirements Stabilization Tool Handles Torque Tool Hydraulic Connection Tool Linear Override Tool Component Change-Out Tool (CCO) Electrical and Hydraulic Jumper Handling Tool Remote-Operated Tool (ROT) ROT Configuration Pull-In and Connection Tool 790

18 Contents xxi Component Change-Out Tool 791 References 793 PART IV SUBSEA UMBILICAL, RISERS & FLOWLINES 24. Subsea Umbilical Systems Introduction Umbilical Components General Electrical Cable Fiber Optic Cable Steel Tube Thermoplastic Hose Umbilical Design Static and Dynamic Umbilicals Design Manufacture Verification Tests Factory Acceptance Tests Power and Control Umbilicals IPU Umbilicals Ancillary Equipment General Umbilical Termination Assembly Bend Restrictor/Limiter Pull-In Head Hang-Off Device BendStiffer Electrical Distribution Unit (EDU) Weak Link Splice/Repair Kit Carousel and Reel Joint Box Buoyancy Attachments System Integration Test Installation Requirements for Installation Interface Installation Procedures Fatigue Damage during Installation 816

19 xxii Contents Technological Challenges and Analysis Umbilical Technological Challenges and Solutions Extreme Wave Analysis Manufacturing Fatigue Analysis In-Place Fatigue Analysis Umbilical Industry Experience 824 References Drilling Risers Introduction Floating Drilling Equipment Completion and Workover (C/WO) Risers Diverter and Motion-Compensating Equipment Choke and Kill Lines and Drill String Key Components of Subsea Production Systems Subsea Wellhead Systems BOP Tree and Tubing Hanger System Riser Design Criteria Operability Limits Component Capacities Drilling Riser Analysis Model Drilling Riser Stack-Up Model Vessel Motion Data Environmental Conditions Cyclic p-y Curves for Soil Drilling Riser Analysis Methodology Running and Retrieve Analysis Operability Analysis Weak Point Analysis Drift-Off Analysis VIV Analysis Wave Fatigue Analysis Hang-Off Analysis Dual Operation Interference Analysis Contact Wear Analysis Recoil Analysis 850 References 851

20 Contents xxiii 26. Subsea Production Risers Introduction Steel Catenary Risers (SCRs) Top Tensioned Risers fttrs) Flexible Risers Hybrid Riser Steel Catenary Riser Systems Design Data Steel Catenary Riser Design Analysis Strength and Fatigue Analysis Construction, Installation, and Hook-Up Considerations Pipe-in-Pipe (PIP) System Line-End Attachments Top Tensioned Riser Systems Top Tensioned Riser Configurations Top Tensioned Riser Components Design Phase Analysis Flexible Risers Flexible Pipe Cross Section Flexible Riser Design Analysis End Fitting and Annulus Venting Design Integrity Management Hybrid Risers General Description Sizing of Hybrid Risers Sizing of Flexible Jumpers Preliminary Analysis Strength Analysis Fatigue Analysis Riser Hydrostatic Pressure Test 887 References Subsea Pipelines Introduction Design Stages and Process Design Stages Design Process Subsea Pipeline FEED Design 897

21 xxiv Contents Subsea Pipeline Design Basis Development Subsea Pipeline Route Selection Steady-State Hydraulic Analysis Pipeline Strength Analysis Pipeline Vertical and Lateral On-Bottom Stability Assessment Installation Method Selection and Feasibility Demonstration Material Take-Off (MTO) Cost Estimation Subsea Pipeline Detailed Design Pipeline Spanning Assessment Pipeline Global Buckling Analysis Installation Methods Selection and Feasibility Demonstration Pipeline Quantitative Risk Assessment Pipeline Engineering Drawings Pipeline Design Analysis Wall-Thickness Sizing On-Bottom Stability Analysis Free-Span Analysis Global Buckling Analysis Pipeline Installation Challenges of HP/HT Pipelines in Deep Water Flow Assurance Global Buckling Installation in Deep Water 913 References 914 Index 915