How To Build A Kingkong Production System

Transcription

1 MOSAIC Certified Mariner Energy, Inc./Agip Petroleum King Kong Development Cameron MOSAIC Systems for the King Kong Field Development

2 King Kong Development The King Kong Deepwater Gulf of Mexico Development Project is located in approximately 3900 feet (1189 meters) of water in Green Canyon Blocks 472, 473 and 516. The development is approximately 150 miles (241kilometers) south of New Orleans, Louisiana. T he Mariner Energy, Inc./Agip Petroleum King Kong Development Project consists of three Cameron SpoolTree Production Systems each tied back to a central, four-slot, piggable, subsearetrievable manifold. From the manifold, two flowlines extend 16 miles (26 kilometers) to the Agip Petroleum Allegheny Tension Leg Platform (TLP). The development also incorporates six Pipeline End Termination Skids (PLETS) including four infield production PLETS and and two flowline PLETS. These skids are positioned across the ocean floor to link the SpoolTree systems to the central manifold, and the manifold to the TLP. The Cameron subsea system for the King Kong development incorporates a wide range of KING KONG DEEPWATER PROJECT T he Cameron components for the King Kong field are fieldproven, modular components that are part of Cameron s MOSAIC product line. The subsea production trees are 4 10,000 psi WP Cameron SpoolTree Systems. Each tree incorporates modular components such as Cameron FLS and FLS-R Gate Valves, Cameron Compact Modular (CM) Actuators, Cameron Willis Subsea Retrievable Chokes and Cameron Vertical Connection (CVC) Systems. flexibility and several unique features including: the four-slot subsea retrievable manifold is moon pool deployable; the retrievable pigging loop on the manifold allows for future expansion of subsea field(s); the SpoolTree system can be operated at control pressures of 3000 or 5000 psi and in water depths up to 5000 feet (1524 meters); simple conversion from guideline to guidelineless tree installation by replacement of the upper guide funnel with guide posts; accommodation in the SpoolTree body and tubing hanger for up to six hydraulic and one electrical downhole lines; and the choice of several wellhead hub configurations. 2 3

3 Cameron MOSAIC Systems and Subsystems for the King Kong Development Cameron MOSAIC Components for the King Kong Field Development The King Kong field uses field-proven components from the Cameron MOSAIC product line. The Cameron SpoolTree Subsea Trees - proven over and over in field applications around the world. Subsea Retrievable Insert Chokes - with a selection of actuator assemblies and trim cartridges, and other field-proven MOSAIC components. MOSAIC provides flexible modularity to create nearly endless system combinations with reliable and economical subsea equipment. MOSAIC systems are all based upon a combination of standard components. This modular, or building block approach, allows producers to specify pre-engineered components with application-specific features. The Cameron MOSAIC solution for the King Kong field is one of the myriad of combinations available. Contact us and we will design one for you. Subsea Manifold FLS Gate Valves CM Actuators Hydraulic FLS-R Gate Valves Manual FLS-R Gate Valves CVC Production Hubs CVC Flowline Hubs Retrievable Pigging Loop Dual Header Piping Manifold Pile Top Pressure Caps SpoolTree Christmas Tree Systems Subsea Retrievable Guidelineless Funnel Extended Length Spool Body FLS Gate Valves CM Actuators DWH Tree Connectors CC40 Subsea Retrievable Chokes Hydraulic Chemical Injection Valves with Manual Back-Up Removable Choke and Control Pod Porches ROV Panels Hydraulic Tubing Hangers and Running Tools Isolation Sleeves Tree Hang-Off Frames Debris Caps High Pressure Caps All Related Running and Testing Tools Pipeline End Terminals (PLETS) Manual Gate Valves Infield Production and Flowline CVC Hubs Skid and Frame Structure Cameron Vertical Connection (CVC) Systems CVC Hubs and Connectors on Manifold, Trees and PLETS CVC Test Skid Fabricated Rigid Jumpers Spreader Beams Shipping Skids Slings 4 5

4 King Kong Production System Components The King Kong project utilizes Cameron MOSAIC Production Systems for the Christmas tree and related to match the pigging valve bores. Two of the flowline hubs are used as export flowline tie-ins and two are used for (Cameron hub profile) without disassembling the spool body from the tree frame. Hydraulic Tubing Hanger The Cameron Tubing Hanger is a x wireline plug system. Like the tree Cameron Willis CC40 Subsea Chokes The Cameron Willis CC40 SR Subsea Retrievable Insert Control Choke is hydraulically locked. A mechanical secondary unlock, actuated by ROV, is also provided with each CVC connector. systems. Several key elements include: landing and locking the pigging loop or Additional flexibility in the SpoolTree extended spool body, the hanger has utilized to regulate flow during A spherical AX gasket provides Subsea Manifold The King Kong four-slot, piggable subsea-retrievable manifold is used to tie the three Cameron SpoolTree production systems to two export flowlines via the PLETS. The manifold can be run and retrieved through the moon pool and is supported by a single jetted pile housing. The manifold is rated for water depths of 4500 feet (1372 meters). Valves, hubs and connectors are rated to 10,000 psi WP. Design parameters include PSL-3, Material Class EE and Temperature Class V. Main manifold components include the manifold pile top and structural frame, retrievable pigging loop, header piping, manifold valves, and the hubs for the infield production and flowline tie-ins. The manifold valves are configured in four dual-cavity blocks with two outlets on each end and one outlet located between the valves on the bottom of the block. A total of eight Cameron 5-1/8 10,000 psi WP FLS Gate Valves are located on the manifold. The valves are actuated by Cameron Compact Modular (CM) Actuators (fail close) with ROV overrides. The manifold contains two 7 10,000 psi WP FLS-R Gate Valves for pigging service. Both FLS-R valves provide a full 6-5/8 flow bore. One FLS-R is ROV operated, the other is hydraulically actuated with an ROV override. The King Kong manifold also incorporates four 6 10,000 psi WP CVC infield production tie-in hubs with 5-1/2 flow bores; and four 6-3/8 10,000 psi WP with 6-3/8 flow bores. The header pipes are 8-5/8 OD by 6-5/8 ID to match the pigging valve bores. The infield production piping is 7 OD by 5-1/8 ID for field expansion flow loops. The manifold includes four upstream and four downstream pressure and temperature transducers. A control pod is located on the pigging loop side. SpoolTree Christmas Trees The King Kong trees are 4" x 2" 10,000 psi WP Cameron SpoolTree systems. The trees are designed to operate in water depths up to 5000 feet (1524 meters) at control pressures of 3000 or 5000 psi. Design parameters include PSL-3, Temperature Class V and Material Class EE. The trees are designed for flexibility and versatility and include a number of modular options: The extended length spool body is designed to accept an HD-H-4 or H-4 profile. The spool body in the tree and the Cameron tubing hanger are ported to allow up to six downhole hydraulic lines and one electrical downhole line. Although current plans call only for use of three hydraulic and one electrical lines (two SCSSVs, one downhole chemical injection line and one downhole pressure/temperature gauge), the system allows for the addition of downhole chemical lines or smart well technology. The tree upper funnel is subsea retrievable and installable to allow for conversion from guidelineless to guideline installation before or after tree installation. Choke and pod porches are removable to allow for versatility. The Cameron DWH tree connector (H-4 profile) can be removed and replaced with a DWC connector system allows the second wing valve to be used as an orifice valve (start-up choke) if set prior to deployment. This eliminates the requirement for a subsea retrievable choke. The Cameron SpoolTree Production System spool body is central to the tree assembly. It acts as a tubing spool during completion, and as a tree block manifold when the tubing hanger is landed. The spool incorporates 4-1/16" 10,000 psi WP production valves (master, primary wing, secondary wing) and 2-1/16" 10,000 psi WP annulus valves (master, workover, crossover). Both production and annulus valves are Cameron FLS Gate Valves with Cameron CM Actuators. All CM Actuators include extended linear ROV override capabilities and position indication features. The tree also includes pressure and temperature sensors at the production valve block and downstream of the choke. A pressure sensor is also located at the annulus wing block. Test lines are provided for the wellhead AX gasket. Isolation valves are 1/2" 15,000 psi WP three-quarter turn, ROV-activated isolation needle valves. Subsea Production Manifold penetrations for up to six downhole fluid lines and and one electrical line The Cameron tubing hanger system allows the use of a smaller riser system. The oversized tubing thread connection reduces critical stresses at the pup joint thread root. The tubing hanger is installed with the Cameron Hydraulic Tubing Hanger Running Tool which features a soft-land function. The tubing hanger lands in the SpoolTree bore and is oriented via an orientation sleeve. A unique Cameron feature allows for full control of downhole hydraulic functions while the tubing hanger is being run. Internal Tree Cap The SpoolTree Internal Tree Cap is installed into the tree above the tubing hanger to provide a secondary barrier from production fluids and incorporates the wireline plug. A field-proven Cameron Metal End-Cap seal provides 10,000 psi WP isolation to the plugged tubing hanger. The cap is run and retrieved through the BOP stack using a mechanical or hydraulic running tool. Tree Debris Cap The SpoolTree completion system includes a weight-set, non pressure containing debris cap which latches to the top of the spool body to protect the tree during production. The cap allows the top of the spool and the inside of the cap to be filled with corrosion inhibitor and is retrieved with an overpull of approximately 100 lb. production. This choke is 4-1/16 10,000 psi WP with studded inlet and flanged outlet. It is designed to PSL-3 and incorporates a unitized plug and cage trim cartridge that is suitable for the full life of the well. The linear hydraulic stepping actuator and trim assembly can be retrieved, leaving the choke body subsea. The assembly latches to the choke body via a crown connector. The connector s locking fingers provide a secure connection and require minimal clearance for installing and retrieving the insert. CVC Jumper System The King Kong jumper system incorporates the CVC hubs on the manifold, trees and PLETS along with a rigid pipe jumper system which contains the CVC connectors. There are a total of seven jumpers in the King Kong field. These consist of two flowline jumpers and five infield production jumpers. Of the five infield production jumpers, the three production tree jumpers have the capacity to incorporate multi-phase flow meters. Each of the rigid jumpers is made up of an M-style fabricated pipe with a CVC connector on each end. The connectors are lowered onto the corresponding hub on either the manifold, tree or PLETS. The jumper systems are installed vertically from a construction vessel. The CVC collet-type connectors and hydraulic running tools are attached to each end of the fabricated jumper. The assembly is lowered into position on a spreader beam (using either guidelines or dynamic positioning). Once in position, the collet connectors are lowered directly onto the fixed CVC hubs and are metal-to-metal sealing between the manifold hub and the connector. The gasket seal is tested by ROV via the ROV panel located on the connector gooseneck. Once the connection is made and tested, the running tools and spreader beam are retrieved. CVC installation tools are retrievable and reusable so multiple connections can be made with the same running tool. All hydraulic systems for connection installation are incorporated into the running tool - no hydraulics are left subsea. CVC connection systems are available in sizes from 4 10,000 psi WP to psi WP using the same CVC running tool. Pipeline End Termination Skids Four infield Pipeline Termination Skids (PLETS) include 6 10,000 psi WP (5-1/2 bore) CVC hubs and 5-1/8 10,000 psi WP ROV-operated FLS Gate Valves. Two flowline PLETS include 6-3/8 10,000 psi WP (6-3/8 bore) CVC hubs with 7 10,000 psi WP ROV-operated FLS-R Gate Valves with 6-5/8 through bores. SpoolTree Subsea Production System 6 7

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