Professional Documents
Culture Documents
Cluster Applications
Subsea Clusters of wells are basically single satellite wells arranged around a subsea
manifold assembly that collects, commingles and exports flow to surface gathering
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
manifold is normally required.
Typically manifolds at the center of a cluster development can accommodate
between 2 and 12 wells, allow for simultaneous oil, gas and aquifer production and
handle gas or water injection. Manifold foundations can be piles, gravity or skirts
depending on seabed conditions.
Cluster-style developments were originally developed to counter-act the potential
for damage from dropped objects at surface. A falling 18-3/4 in. drilling BOP stack
could damage several wellheads and trees on a conventional production template
layout for example, whereas in a cluster-style development, one well completion at
worst would be affected. A typical subsea manifold system includes:
base frame
manifold frame (which supports the valve blocks and headers)
structure for supporting ROV interface points
controls distribution units
accumulator banks
control modules
hydraulic trunking
satellite interconnections
pipeline connections
pigging loops
protective roof
The most recent deepwater manifold systems have included retrievable manifolds with remote diverless connections of
intra-field flowlines, umbilicals and pipelines.
Daisy Chain subsea wells consist of two or more subsea satellite wells joined
together by a common flowline (and possibly umbilical). Valving on the
flowbases of the daisy-chained wells allows basic manifolding to commingle
flowstreams. Each subsea tree may have a choke installed to avoid pressure
imbalances in the flows.
Using
well,
daisy chained wells allows combined use of infield flowlines by more than one
and may provide a continuous loop for round trip pigging if needed.
The
Potential damage from dropped objects is constrained to (at worst) a single completion.
Simultaneous production and drilling is not a problem
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
into a single flowline if the second is damaged, and individually test the two wells whenever needed through independent
lines. As more subsea wells are needed, the attraction of daisy chains disappears as a manifold becomes more feasible.
In a free-standing
transports fluids from
a floating semiproduction
processed fluids back
One example of a
represents a
successfully installed
again in 2140 feet of
The free-standing
column with direct
and gas sales lines.
installed and
overhead.
Internal air cans, external buoyancy from syntactic foam and several joints with external air tanks all combine to provide
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.
The system is designed to use a variable air buoyancy riser capable of supporting multi-well free-standing
production/annulus tubing and export sales lines directly underneath the bow or stern of the floating production facility.
Additionally, the system allows simultaneous drilling, completion and workover activities while production is ongoing.
The riser is instrumented to measure riser response to various environmental conditions and to obtain actual fatigue
information. The riser is wired with strain gauges, accelerometers and inclinometer to monitor riser stresses, motion and
positions during installation and operation.
The instrumentation is connected to the vessel using an electrical cable. The cable is installed on the riser during actual
installation of the riser. The other instrumentation equipment has been previously installed on the appropriate riser joints
prior to shipment to the vessel. The joint-mounted electronics are located in pressure vessels at the bottom of the
instrumented joints.
Subsea cables connect the riser equipment to the controls unit on the production facility. The production riser
instrumentation desktop computer is located in the production control room and is capable of storing data during all rig
conditions including rig abandonment.
The riser instrumentation has two redundant systems connected to the desktop computer. There are separate electronic
cables for each system attached to the production riser as it is installed.
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 linked or shared with
other wells, each system is installed individually,
The advantages of a satellite completion are:
Potential damage from dropped objects is constrained to (at worst) a single completion. Simultaneous production
and drilling is not a problem.
Template Applications
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.
Unitised templates
Integrated templates
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.
SUBSEA WELLHEAD
Mudline Wellhead
Using a mudline completion allows some significant benefits to the operator instead of a
wellhead platform, such as:
This Cameron stack-down mudline wellhead system has a number of important features:
STC-10 Wellheads
STM Wellheads
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 loading exists if pressure comes from above or
below. Competitive tapered bowl systems can lose seal loading if pressure comes
from below, as pressure forces those components up into 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 75/8" (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 industry to promote standardization among deepwater producers and equipment suppliers.
Two lockdown options are offered for connecting the STM wellhead highpressure 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.
The seal assembly utilises parallel bore metal sealing (PBM seal)
technology eliminating problems inherent to tapered bore designs.
All running tools are left hand make-up and right hand release.
All seal assemblies are identical allowing the used of one running tool for
all casing hangers.
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.
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 into 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).
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 it'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 is 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 introduce MOSAIC systems, the culmination
of our experience and leadership in 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 tree 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.
Normal operation.
Well workover operations.
Underwater I.M.R. activities (mostly with ROV).
Additional drilling and subsea equipment installation.
The key factors driving the field seabed layout are as follows:
Reservoir configuration, bottom hole locations and subsea well seabed positions.
Shipping lanes, fishing activities (if any) and other existing facilities on the seabed e.g. abandoned exploration
well.
Drilling rig semi-submersible position, weather heading, mooring pattern and vessel characteristics (including
drilling riser/vessel maximum excursions).
Dominating weather conditions during drilling and workover operations but also during underwater operations with
various surface vessels.
Optimum location of all subsea facilities in particular during pipelay/umbilical lay operations and eventual
retrieval.
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 the 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 cluster 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 in 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
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 the 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 is 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 in 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
Interface management commences at contract award with the development of the interface plan. The interface 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 the 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 interface 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 information 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 discussions or disputes regarding receipt of important documentation. For a paperbased 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 electrical 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 costeffective 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.
PRODUCTION
CONTROLS
Advanced Multiplex Electro-Hydraulic
Control Systems
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 its integrated approach and componentlevel 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 to expand as development scenarios change.
High-integrity materials
Robust, seawater-tolerant components, designed and qualified to 3000 meters (10,000 feet).
Retrievability
Standard tooling and modular design - plus a systems-level approach to field development - enable critical subsea
components to be easily retrieved.
The Electrical Power Unit (EPU) provides conditioned electrical power to the topside
and subsea system components. The EPU supplies dual, isolated, single-phase
power for the subsea system through the composite service umbilical, together with
power supply modules for the MCS and HPU.
The Master Control Station (MCS) provides control and monitoring of the complete
system, including surface and subsea installed equipment. Two complete and
segregated MCS channel networks incorporating high reliability GE Fanuc 9070
PLC's simultaneously monitor data functions to and from each other, surface and
subsea. In the event of a channel network failure, the other continues to seamlessly
operate the control system. This dual redundant architecture eliminates single mode
failure points and the requirement for bumpless transfer from the failed to the
healthy channel network.
The MCS features open-architecture electronics with dual Fast Ethernet (or serial
RS-485 and choice of topside communication protocol including MODBUS and
Profibus) links to the host control system. It is OPC v.2 compliant for compatibility
with all other OPC v.2 compliant equipment. The MCS standard modems are
qualified to control up to 10 Subsea Control Modules at 40 km (24.9 miles) offset,
and the standard MCS can accommodate up to eight modems per channel.
The standard design of the MMRT allows these operations to be performed using
common intervention methods - diver-assisted, conventional guideline, guidelineless
or with an ROV - in water depths to 3000 meters (10,000 feet).
The MMRT is designed for efficient operation with a work-class ROV and is interfacecompliant with API 17H using weight transfer systems for neutral buoyancy.
Oil-filled, pressure-compensated construction designed for -10aC to +50aC (14YF to 122 YF); controlledenvironment electrical connections; seawater-tolerant materials available throughout hydraulic system
Dual SEMs with single valve electronics modules standard; dual valve electronics modules are available to
increase system total availability
HydraQuad Couplers feature pressure-balanced shear seals which, when combined with Cameron directional
control valves, provide virtually leak-free operation for lower Opex and less non-productive time.
Nominal supply pressures of 207 bar or 345 bar (3000 psi or 5000 psi) for tree and manifold valves; 345 bar, 517
bar or 690 bar (5000 psi, 7500 psi or 10,000 psi) supply pressure for SCSSV and other HP needs
INSTALLATION /
WORKOVER CONTROLS
Cameron Installation/Workover
Controls Systems (IWOCS)
Installation / Workover Control Systems (IWOCS)
Cameron provides a comprehensive range of IWOCS to meet the requirements of
vertical and horizontal completions in all water depths. Systems are available for
rental and outright purchase, as well as re-purchase after initial large-development
demand.
This diverse offering allows Cameron to provide cost-effective solutions from single
well satellites to large deepwater, multi-well developments in the most remote
corners of the globe.
High-reliability IWOCS operate hydraulic functions during installation, intervention
and workover of subsea completion equipment and provide facilities for monitoring
and testing various subsea functions.
Most developments use one of four field-proven standard system configurations to
minimize the cost and duration of subsea interventions and workovers throughout the whole life of the field. Custom design
solutions are available to meet specific requirements and applications.
Shallow Water Vertical Completions
IWOCS for shallow water, vertical completions provide DH control of tree functions and a failsafe pilot control system for
the LMRP. DH control is provided for THRT functions. Options are available to provide simple hydraulic interlocking of LMRP
and tree functions to ensure correct sequencing of the valves in the vertical flow path and prevent inadvertent closure of
tree valves on coiled tubing or wire line. DH control of SSTT functions and related control panel functions are additional
options.
Major system elements typically include:
Test System
IWATS Tree-to-BOP Connector
Description
Blowout Preventer
Direct Hydraulic
Downhole Pressure/Temperature Transmitter
Emergency Disconnect Package
Emergency Disconnect Unit
Electro-Hydraulic Multiplex
Emergency Shutdown System
High Pressure
Hydraulic Power Unit
Installation Workover Autonomous Test System
Installation Workover Control System
Lower Marine Riser Package
Low Pressure
Mobile Drilling Unit
Master Telemetry Unit
Portable Electronic Test Unit
Programmable Logic Controller
Remotely Operated Vehicle
Remote Telemetry Unit
Subsea Accumulator Module
Subsea Control Module
Simultaneous Workover and Production Operation Scenarios
Subsea Test Tree
Tubing Hanger Running Tool
Tree Running Tool
Workover Hydraulic Power Unit
Workover Subsea Control Module
Workover Control System
within SAP-R3, CAMSERV offers a broad range of quality services, as well as reconditioned products and OEM replacement
parts to keep projects running smoothly. CAMSERV brings you more ways to minimize your Total Cost of Ownership. And
only CAMSERV offers the worldwide resources of Cameron, with the 24/7 convenience and personal, responsive service of a
local supplier - anywhere you are. CAMSERV services include:
Consignment programs
Jumper Basket
The offshore/lift certified jumper basket provides for the transportation and storage of deck jumpers and sheaves.
disconnection at the end of the Tree running sequence prior to recovery of the TRT.
Umbilical Sheaves
The umbilical sheaves assist deployment of the workover/TRT and THRT control umbilicals and are sized to ensure that an
umbilical cannot be bent beyond recommended minimum bend radius. Sheave rollers are made from corrosion-resistant
material and provide smooth, abrasive free movement of an umbilical.
The WOCS radio link system provides a highly secure, line-of-sight, dual channel ESD communications link between a MDU
and a fixed platform or floating production system. The system is intended for use under SimOps and provides the ability to
initiate a fully automated shutdown of the subsea production facility from the MDU or other workover/intervention vessel.
Major components of the system include an MTU located on the production facility, and a RTU and ESD panels located on
the MDU. Alarms are raised at both ends of the link in the event of any communication errors or system failures.
The EDU enables safe disconnect of the surface, rig-mounted, equipment from the
fixed subsea equipment during drilling unit drift, drive-off or other emergency
situations. The unit consists of a multi-way remotely operated hydraulic and
electrical stab plate at the LMRP/BOP stack interface, allowing the workover
functions to be disconnected between the tree and the workover umbilical in the
event that the drilling riser is disconnected from the BOP.
The integrated local control panel provides control of tree functions, TRT/ workover umbilical reel and the THRT umbilical
reel.
FLOWLINE
CONNECTION
Cameron Vertical Connection (CVC)
System
Definition:
Flowline tie-in connection of a flowline to a subsea facility. This includes
Trees
Manifolds
Templates
FLETs (FlowLine End Terminations)
Installation Methods:
(Pipeline and Flowline Installation)
o
o
o
Towed-in-Place Bundle
o MC 441, Satellite Wells
Towed-in-Place Pipeline
o Troika Export Lines, Rigid Jumpers
Design Features:
Vertical Connection
Tool Make-up
Guidelineless
ROV Operated
Subsea Seal Replacement
The pipe-to-hub seal is verified at full pipeline test pressure before the
CAMFORGE forging tool is removed from the pipe bore.
The hub does not require pressure-relief vent ports which could form leak
paths.
The CAMFORGE forging tool is simple with a minimum number of moving parts.
The CAMFORGE system can be thoroughly inspected on the surface prior to subsea deployment.
Simple
Cost-effective
Well proven
Diver assisted installation
Remote Stab
Diverless make-up
Collet Connector
Pre-loaded connections
Gasket (metal) seal connection
Excellent for high separation forces
Pull-In
Lay-Away
Connection
Remote flowline cap removal and seal plate installation is available if required
Two methods of remote, diverless flowline connection are the "pull-in" method where the flowline is attached to a sled and
pulled to the well by cables, and the "lay-away" method where the flowline is lowered vertically on guidewires and then laid
away from the well. (A variation of the lay-away technique is the "spool piece tie-in" where a pre-fabricated spool with
connectors on either end is lowered vertically and stabs a receptacle at the wellhead and the pipeline end simultaneously).
Factors such as the water depth, the practicality of using divers and the requirement for either wellhead to platform (first
end) connection or platform to wellhead (second end) connection determine which method is to be used.
Cameron offers a variety of flowline connection systems, from a simple flange or swivel flange with an AX or BX gasket to a
totally remote hydraulic connection system. The broad range of products available and years of previous experience place
Cameron in a position to provide the optimum flowline tie-in and connection solution for any subsea field.
The length compensating joint can be hydraulically extended or retracted during installation of the spool piece and
After spool piece installation, metal-to-metal seals are energized in the joint.
The system provides single wire rope pull-in of one or two major diameter
hubs to the subsea template, subsea manifold or satellite tree. Each hub
features metal-to-metal seals and can accommodate a grouping of
flowlines, control lines and electrical cables.
MOSAIC Connection Elements utilize common interfaces which allow a variety of different types of connection systems to be
attached. For example, modular Christmas trees are designed to allow whatever type of connection system is required
(vertical, horizontal, diver-assist or ROV-driven).
This modularity leads to reduced engineering cycle times by minimizing the engineering required for modifications, and
reduces or eliminates errors found during assembly or offshore installation. By utilizing the systemic view, all connection
requirements in a field development, such as well jumpers, pipeline jumpers, and umbilical terminations, can use the same
connection technology. This simplifies tool requirements, reduces the number of running procedures to be accommodated,
and also reduces spare parts inventories.
Larger hub arrangement accepts large bore flowline, multi-bore lines &
umbilicals
First & second end connections of flowline/hydraulic control bundles,
electrical cables and pipelines.
HSAS
Email |
Print |
Bookmark
Cameron swivels are used as tie-in components for subsea pipelines and can be
used for land and offshore applications to accommodate the following conditions:
These conditions may occur due to land settling, platform movement, pipeline
expansion and contraction dye to thermal changes, crossing of an earth fault,
seafloor scouring due to ocean currents, or a future need to bury a pipeline.
Features of Cameron swivels include:
Swivels seals tightly against sand and abrasive materials to ensure long
subsea service life.
Single Swivels
The single swivel consists of forged components which are assembled and welded
together to form a low profile, high strength unit consisting of three basic parts; the
body, swivel cup and cup retainer. Single swivels allow 10 angular movement of
the pipeline in any direction to accommodate a wide variance in pipe approach
angles. The full bore of the single swivel does not restrict normal pipeline pigging
operations including intelligent pigs.
Double Swivels
The double swivel consists of two single swivel designs mounted back-to-back with a single forged body. This allows for a
maximum 20 deviation in the angle of approaching pipeline sections.
CHRISTMAS TREE
CameronDC Subsea Electric Tree
hydraulic signals through the umbilical, communication with equipment is near instantaneous and
feedback on subsea conditions is instantaneous.
Environmentally Friendly - Without dependence on conventional hydraulics, the system offers
significant health, safety and environmental advantages. The potential for hydraulic leaks is eliminated,
as is the issue of fluids disposal.
CameronDC is a unique all-electric system powered by direct current. Suddenly reliability, availability
and maintainability take a giant leap forward. CameronDC is simpler. Environmentally friendly. Easier
to install. Fewer parts to maintain. Better feedback and greater response time. Is it game-changing
technology? Absolutely.
Modular SpoolTree
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.
The SpoolTree system's unique wellhead/tree/hanger arrangement lands the tubing
hanger on a dedicated load shoulder in the tree. This stack-up configuration saves
significant rig time (see below) by allowing completion and workover operations to
be performed with the tree in place and flowlines undisturbed.
The SpoolTree system's horizontal valve assembly allows an unobstructed vertical
path to the tubing completion. SpoolTree valves are external to the vertical bore.
Therefore, wireline tools no longer are run through gate valves, greatly reducing the
risk of damaging tree components. Production and annulus valves are contained on
the exterior of the spool in mini-blocks. Connected to the blocks are flowloops which
provide production, cross-over and circulation functionality.
All SpoolTree system valves are the field-proven Cameron FLS Gate Valves. A
typical valve cluster would include: production and annulus master valve, production
and annulus wing (isolation) valve, cross-over valve, workover valve and isolation
valves for SCSSV, CIV and other requirements. Because the SpoolTree tubing
hanger is a concentric bore design, completions can be installed with a single work
string. This eliminates the need for expensive workover/completion riser systems,
which translates to significant capital equipment savings.
The SpoolTree system provides numerous safety advantages, too. Its body is machined with an 18-3/4" hub profile on top
to allow installation of a standard 18-3/4" drilling blowout preventer. In fact, all completion activities can be performed
under full BOP control.
Even if the well is live under the tubing hanger due to production tubing failure, safe full-bore access can still be achieved
using the drilling BOP. In a conventional system, wireline plugs would be installed in the tubing hanger so the tree could be
removed for installation of a BOP for tubing hanger access. This potentially dangerous situation is eliminated by the
SpoolTree design.
Mudline Tree
The Modular Mudline Subsea Tree has been developed as a simple production
system that can be economically installed on a mudline well from a jack-up rig. This
system uses diver assistance to minimize cost and complexities and is very suitable
for shallow water production projects.
The Modular Mudline Tree offers the following features:
Tree design offers the option of completing inside 9-5/8 in. or 7 in. casing.