Ceiba Field Early Production System. Cameron MOSAIC Systems

Transcription

1 MOSAIC Certified Ceiba Field Early Production System Cameron MOSAIC Systems for the Ceiba Field Early Production System

2 The Ceiba Field Early Production System

3 Nigeria KM Niger Delta C B D E Malabo A Bioko Island Douala H Cameroon Gulf of Guinea Principe Rio Muni Basin Ceiba Field Block G Block F Bata Equitorial Guinea The Ceiba Field is located in Gabon Block G of the Rio Muni Basin, 35 kilometers (22 miles) off the continental coast of Equatorial The Ceiba Field Early Production System consists of four Cameron SpoolTree Production Systems each tied back to individual, retrievable subsea manifolds. Each manifold ties one tree to two export flowlines via a fabricated well jumper Cameron Vertical Connector (CVC) system. The flowlines Guinea, approximately 241 kilometers (150 miles) south of the country s capital, Malabo. The water depth is approximately 730 meters (2400 feet). are then tied back to the Floating Production Storage Offloading (FPSO) vessel. The FPSO is moored in approximately 91 meters (300 feet) of water, 29 kilometers (18 miles) offshore and has a crude oil storage capacity of 2 million barrels. The wells in the Ceiba Field have been completed using field-proven, modular components that are part of Cameron s MOSAIC product line. The subsea production trees are 5000 psi WP Cameron SpoolTree Systems. Each tree incorporates modular components such as Cameron FLS Gate Valves, Cameron Compact Modular (CM) Actuators, and Cameron Vertical Connection (CVC) Systems. The control system is the Cameron CAMTROL Advanced Multiplexed Electro-Hydraulic Control System which features standardized, modular components, open electronics architecture and highly flexible hydraulics.

4 TM The Ceiba Field Early Production System set a deepwater industry record, with a discovery to first oil time of less than 14 months. The following indicates the fast pace of this project and the successful use of Cameron MOSAIC systems to provide pre-engineered components with application-specific components within a tight delivery schedule: Start Triton Energy announces Ceiba Field discovery. Month 8 Cameron delivers fourth SpoolTree Christmas tree; Month 1 Triton Energy confirms Ceiba Field discovery. Cameron delivers first manifold. Month 2 Cameron submits proposal for MOSAIC system. Month 9 Cameron delivers two more manifolds; Month 3 Cameron is awarded contract for MOSAIC system. Cameron delivers CAMTROL topsides equipment; Month 4 Cameron delivers STM wellheads and tools; First tree is installed. Triton Energy signs contract with FPSO manufacturer. Month 10 Second and third trees and four manifolds are installed. Month 6 Cameron delivers first SpoolTree Christmas tree. Month 13 FPSO arrives in Ceiba Field. Month 7 Cameron delivers two more SpoolTree Christmas trees. Month 14 First oil achieved.

5 Cameron MOSAIC Systems and Subsystems for the Ceiba Field Early Production System Subsea Manifolds Retrievable Pigging Loops CVC Connectors FLS Hydraulically Actuated Gate Valves Piping as Required Dual Header Piping Manifold Support Structure Manifold Running Tool Debris Cap Production Well Jumper Systems CVC Running Tools CVC Connectors Adjustable Well Spreader Beams Fabricated Piping STM Wellhead Systems Completion Guide Bases Casing Hangers, Seal Assemblies, Wear Bushings Running and Testing Tools SpoolTree Christmas Tree Systems FLS Gate Valves CM Actuators DWH Tree Connectors Hydraulic Tubing Hanger and Running Tool Isolation Sleeve Electro-Hydraulic Umbilical Junction Hubs Running Tools Debris Caps High Pressure Caps Integral Spool Bodies and Protective Structures All Related Running and Testing Tools CAMTROL Production Control System Surface Components Master Control Station (MCS) Electrical Power Unit (EPU) Uninterruptible Power Supply (UPS) Hydraulic Power Unit (HPU) Return Reservoir Unit (RRU) Topside Umbilical Termination Unit (TUTU) Manifold-Mounted Subsea Components Umbilical Termination Assembly (UTA) Subsea Distribution Unit (SDU) Subsea Control Module (SCM) Subsea Accumulator Module (SAM) UTA-to-SDU Umbilical Jumper SDU-to-Tree Control and Monitoring Jumper SDU-to-Manifold Pigging Jumper Tree-Mounted Subsea Components Fixed Junction Plate Production Pressure/Temperature Transmitter Annulus Pressure Transmitter Downhole Pressure/Temperature Transmitter Jumper Intervention Equipment Deepwater Liftline Running Tool (DLRT) System Analyses Reliability Availability Maintainability Analysis Hydraulic Analysis Electrical Communication Analysis Electrical Power Analysis

6 Ceiba Field Early Production System Components The Ceiba Field project utilizes Cameron MOSAIC Production Systems for the Christmas tree and related systems. Several of the key elements are described in detail below. CAMERON MOSAIC COMPONENTS Subsea Manifolds Each Ceiba Field manifold is used to tie one Cameron SpoolTree production system to two export flowlines. All Manifold Being Installed manifold pressure-containing components are rated for 5000 psi WP. The support structure is designed so that neither snag loads nor loads from thermal expansion of flowlines are induced into the manifold. Main components of each manifold include the manifold frame, pigging loop, dual header piping, and the CAMTROL Subsea Distribution Unit (SDU) and Umbilical Termination Assembly (UTA). The manifold contains interfaces for subsea installation of the the flowline connections, production jumper, UTA, SDU, and the pigging loop. The manifold is supported on a single pile which includes a 30" conductor housing profile for use with the STM running tool. The pigging loops are fully retrievable and feature two 8" CVC connectors and a double-acting Cameron hydraulic 8" gate valve with ROV manual override. The loop provides a dual-port hot stab for flying-lead connection of the gate valve to the SDU. Insulation is applied to the loop pipe and insulated enclosures are provided for the CVC connectors. The dual header piping includes two 8" CVC connectors hubs, one for the pigging loop, one for the export line. One header also includes a branch tie-in to the Manifold Isolation Valve (MIV), a Cameron 6" manual gate valve with ROV interface. The second header also incorporates two CVC hubs along with a Cameron 1/2" manual gate valve for the annulus bleed line. The header lines are fully piggable and the branch tie-inline has a pig-excluding device. Each manifold contains four ROVinstalled flying leads: UTA-to-SDU, SDU-to-tree, SDU-to-pigging valve, and manifold-to-tree. Production Well Jumper System The Ceiba Field production well jumper system is an M-style fabricated jumper made of 6-5/6" OD pipe with two 6" Cameron Vertical Connectors (CVC) on the ends. The system is 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 the spreader beam (either using guidelines or dynamic positioning). Once in position, the collet connectors are lowered directly onto fixed CVC hubs and are hydraulically locked. Once the CVC Running Tool connection is made and tested, the running tools and spreader beam are retrieved. STM Wellhead System The Ceiba Field wellhead system is a Cameron Single Trip Metal Sealing (STM) Type S Wellhead rated for 10,000 psi WP. The 18-3/4" housing hub incorporates a profile designed to accommodate the Cameron tree connector. SpoolTree Christmas Trees The Ceiba Field Christmas Trees are 5" x 2" 5000 psi WP Cameron SpoolTree systems. Although primarily intended for guidelineless installation, guideline capability is also incorporated into the design. SpoolTree System Ready for Installation The tree spool body is central to the tree assembly and acts as a tubing spool during completion, and as a tree block manifold as the tubing hanger is landed. The spool incorporates 5-1/8" 10,000 psi WP production valves (master, wing, choke isolation) 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 Compact Modular (CM) Actuators. All CM actuators include extended linear ROV override capabilities. and position indication features.

7 The tree also includes a pressure and temperature sensor at the production wing valve and a pressure sensor at the annulus SpoolTree Christmas Tree Being Installed wing block. Test lines are provided for the wellhead AX gasket, electrical connectors and high pressure cap. Isolation valves are 1/2" 10,000 psi WP ROV-activated isolation needle valves. The SpoolTree system latches to the wellhead via a Cameron DWH Connector. Hydraulic Tubing Hangers The Cameron 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. The hanger has three downhole lines, two for the surface-controlled subsea safety lines, and one downhole chemical injection line. The hanger also incorporates an electrical line for the downhole pressure and temperature gauge. CAMTROL Production Controls The CAMTROL Advanced Multiplexed Subsea Production Control System for the Ceiba Field EPS project is designed to control and monitor four oil production trees, with the standard CAMTROL system providing expansion capability to accommodate all envisioned full field development (FFD) wells. Components of the CAMTROL system are installed on the subsea trees at distances ranging from 4.5 to 8.0 kilometers (3 to 5 miles) from the host (FPSO). The CAMTROL system is a standalone system linked to the FPSO DCS via the Master Control Station (MCS) dual redundant 100-megabit fast Ethernet data pathways. The subsea system is controlled by electronic signals sent to Subsea Control Modules (SCMs). Data gathered and monitored by the SCMs is displayed on graphic well-screen displays at the MCS in an air-conditioned, purged control room located on the FPSO. A Hydraulic Power Unit (HPU) and Electrical Power Unit (EPU) provide hydraulic fluid and electric power via hoses and cables within the four umbilicals. A Return Reservoir Unit (RRU) provides sufficient safe volume to accept Emergency Shut Down (ESD) returns from the potential FFD system. An Uninterruptible Power Supply (UPS) guarantees up to three-hours electrical power should FPSO power not be available. Four umbilicals, one for each EPS well, supply redundant services from the FPSO. Each umbilical is connected to a Topside Umbilical Termination Unit (TUTU) at the surface and ends subsea at a hinge-over-lock type Umbilical Termination Assembly (UTA), which docks at a subsea manifold. CAMTROL Subsea Distribution Unit From the UTA, an ROV-installed flyto-place jumper connects the UTA and a Subsea Distribution Unit (SDU). Uniquely, each SDU is retrievable from the manifold and serves as the control point for its tree, as well as the distribution center for field expansion via three FFD junction points with long-term protective covers. A Subsea Accumulator Module (SAM) and Subsea Control Module (SCM) are located within the SDU, each capable of being run and retrieved with the ROV-guided Deepwater Liftline Running Tool (DLRT). The DLRT is purpose designed to operate as an integral part of the CAMTROL system in remote locations, where infrastructure is limited, and in water depths of up to 3000 meters (10,000 feet). A hot-stab type pigging jumper enables the SCM to control the manifold pigging valve, without requiring control equipment permanently fixed to the manifold. An ROV-installed, fly-to-place jumper connects the SDU and its tree. The SCMs provide true dual redundancy; dual Subsea Electronic Modules (SEMs), dual electrical and hydraulic supplies, and a second set of Valve Electronic Modules (VEMs) provide the extra availability required of remote systems. The SCMs also feature Cameron HydraQuad couplers and standard interfaces; they control hydraulic and associated tree and manifold functions, and acquire data for transmission to the FPSO. The modules are pressure compensated to 3000 meters (10,000 feet), lightweight (1200 kilograms or 2645 pounds), compact, and have been systematically designed and qualified for deepwater applications. CAMTROL Subsea Control Module

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