cameron mosaic systems for the malampaya projectƒ³n de pemex... · 16” 2500 lb ansi cameron...
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Each of the wells will be completed using field-proven, modular components that are
part of Cameron’s MOSAIC product line.
The production manifold is retrievable and incorporates the capacity to connect up to ten
producing wells, two control umbilicals and two flowlines. It integrates two production
headers and a pigging loop. The subsea production trees are 10,000 psi WP Cameron
SpoolTree Systems which are installed guidelineless on drill pipe. Each tree incorporates
modular components such as Cameron FLS Gate Valves, Cameron Compact Modular (CM)
Actuators, Cameron Willis CC40 Subsea Retrievable Insert Chokes, Cameron McPac
Flowline Connection Systems, and Cameron DWH Mechanical Dog and Window Collet
Connectors. The subsea production control system is the Cameron CAMTROL Advanced
Multiplexed Electro-Hydraulic Control System which features standardized, modular
components.
The Malampaya Project
The Malampaya field is located
in Block SC38 of the South China
Sea in 750 to 1150 meters of
water. The subsea production
system is located at a water depth
of 820 meters. The field is approx-
imately 80 kilometers off the coast
of Palawan Island in the Republic
of the Philippines. The goal of the
project is to supply natural gas
to power plants within the
Philippines.
32
DOWNSTREAM
UPSTREAM
CALMLoading Buoy
ElectricityPowerStations
Alternative Fuel
Onshore Gas Plant
CondensateStorage
24" Dry Gas Export
16" CRA Flowlines
Future 16" Flowline
Subsea Manifold
850 m
30 kmManifoldTo Platform
500 kmPlatformTo Land
Initially five Malampayawells will be drilled.
The Malampaya subsea gas production system consists of a
cluster well development with initially five Cameron SpoolTree
Systems producing to a central subsea production manifold.
From the manifold, two 30-kilometer flowlines carry the gas
to the platform where it is processed. The dry compressed
gas is transported through a 500-kilometer pipeline onshore
to the power generation facilities. Condensate is stored in
the concrete gravity structure at the base of the production
platform and is exported to shuttle tankers through a catenary
anchored leg mooring (CALM) offloading system 3 kilometers
from the production platform.
C H I N A
TAIWAN
PHILIPPINES
PHILIPPINES
Malampaya
Hong Kong
T'aipei
Bangkok
VIETNAM
THAILAND
CAMBODIA
LAOS
BURMA
ManilaQuezon City
Manila
Quezon City
NEWGUINEA
A U S T R A L I A
I N D O N E S I A
M A L A Y S I A
JAPAN
BORNEOSingapore
L U Z O N
MINDORO
Batangas
Pacific
Ocean
Indian
Ocean
East China
Sea
SOUTH
China
Sea
SOUTH
China
Sea
Shell Philippines Exploration B.V. chose Cameron
Modular Subsea and Integrated Completions (MOSAIC)
Systems for their Malampaya project.
Cameron’s Malampaya Project Subsea Components
The Malampaya field will be completed using field-proven components from the Cameron MOSAICproduct 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. CAMTROL Production Control System - standard components which adapt to a variety of field configurations. 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 Malampaya field is one of the myriad of combinations available. Contact us and we will design one for you.
TM
4
Cameron MOSAIC Systems and Subsystems for
the Malampaya Project
Production Manifold System
Pile Assemblies and Pile Spacer Template
Manifold Support Structure
Retrievable Production Manifold
Dual Production Headers
Pigging Loop
Modular Valve Blocks with Jumper Hubs
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
CC40 Subsea Retrievable Chokes and
Aqua-Torq Choke 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
McPac Well and Flowline Connection Systems
Jumper Hubs
Hub Support and Alignment Structures
McPac Clamp and Seal Assemblies
Jumper Pipe Assemblies
PLES Tie-In Porches
McPac Hub Connection Tools
CAMTROL Production Control System
Surface Components
Hydraulic Power Unit
Electrical Power unit
Topside Umbilical Termination Unit
Portable Electronic Test Unit
Test and Flushing Hydraulic Power Unit
Subsea Components
Subsea Control Modules
Electro-Hydraulic Jumper Umbilicals
Subsea Accumulator Units
Tree and Manifold Mounted Instrumentation
Subsea Distribution Unit
Installation/Workover Control System
Hydraulic Power Unit with Control Panel
Radio Telemetry Link
Workover/Tubing Hanger Running Tool
Hose Reel and Umbilical
Tubing Hanger Reel and Umbilical
Diverless Intervention Tooling
5
The Malampaya 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
Production Manifold System
The Malampaya production manifold
is supported with a three-pile foundation
and includes a fixed support structure
and retrievable manifold.
The manifold has the capacity to
connect up to 10 production wells, two
control umbilicals and two flowlines.
Contingency is provided for a third
flowline connection and third injection
umbilical as needed later in the life of
the field.
The manifold is configured with two
main pipe headers and a pigging loop.
Each header includes an ROV-operated
16” 2500 lb ANSI Cameron Welded Body
Ball Valve in an Inconel™ material trim. A
hydraulically actuated Cameron Welded
Body Ball Valve is positioned on the
pigging loop.
Ten modular valve blocks with
integral jumper connection hubs are
positioned five on each side of the
manifold. Each block incorporates
hydraulically actuated 5” 5000 psi WP
Cameron FLS Gate Valves and McPac
clamp connection hubs. The McPac hub
faces on the well jumpers provide connec-
tion points for the 5” production bore and
two additional 1” bores (one for methanol
injection, the other for annulus access).
The manifold and jumper system pro-
vide a fully welded , super duplex tubing
distribution system from the umbilical to
the trees for methanol and annulus fluids.
All production-exposed surfaces within
the subsea system are either inlaid or slid
corrosion-resistant materials.
STM™ Wellhead System
The Malampaya wellhead system is a
Cameron Single Trip Metal Sealing (STM)
Type S Wellhead rated for 10,000psi WP.
The 18-3/4” housing hub incorporates
a profile designed to accommodate the
Cameron DWHC tree connector.
SpoolTree™ Christmas Tree
The Malampaya Christmas Trees are
5” x 2” 10,000 psi WP guidelineless
Cameron SpoolTree systems.
The tree spool body is central
to the tree assembly and
acts as a tubing spool
during
comple-
tion, and
as a tree
block
manifold
as the
tubing
hanger is landed. The spool incorporates
5” 10,000 psi WP production valves
(master, wing, choke isolation) and
2” 5000 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
ROV override capabilities. 1/2” 10,000
psi WP needle valves serve as annuls vent
valves and provide methanol injection.
The SpoolTree system also integrates a
4-1/16” 10,000 psi WP Cameron Willis
CC40 Subsea Retrievable Insert Choke
to regulate production flow.
The SpoolTree system latches to the
wellhead via a Cameron DWH Mechanical
Dog and Window Connector. This con-
nector is designed to meet the bending
loads encountered in deepwater.
CC40 Retrievable
Insert Choke
The 4-1/16” 10,000
psi WP Cameron
Willis CC40
Retrievable Insert
Control Choke is
utilized to regulate
flow during produc-
tion operations. The choke incorporates a
fixed body and a unitized plug and cage
trim cartridge and actuator assembly.
This assembly is latched to the body with
an internal crown connector. It can be
retrieved to the surface, leaving the choke
body subsea. The choke actuator is an
Aqua-Torq™ stepping actuator which
provides precise, incremental steps from
open to closed.
Hydraulic Tubing Hanger
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 orient-
ed via an orientation sleeve in the hanger.
The hanger has a 5” concentric bore
with a 5” side production outlet, one
downhole hydraulic line and one down-
hole electrical line. All lines are capable
of continuous monitoring during
installation. The production seals
are field-proven Cameron RLH
metal-to-metal seals with Cameron
Metal End-Cap Seal back-up. The
tubing hanger body is prepped to
receive the metal-to-metal sealing SSR
wireline plug with elastomer back-up.
McPac™ Flowline Connection System
All jumper connections to the wells, the
pipeline end modules, and the umbilical
termination unit are made with the field-
proven Cameron McPac™ Flowline
Connection System.
The McPac System is a compact,
horizontal clamp-type connection system
which can be used for everything from
large bore pipelines to small flowlines
and umbilicals. The system uses the
hydraulically powered McPac Hub
Connection Tool to mate the seal plate to
the hubs which are mounted on the trees,
manifold and pipeline end structure.
The tool is also used to pressure test the
metal-to-metal seals. An ROV powers and
operates the tool. The tool is retrieved for
use on the next connection, leaving only
the clamp and seal plate subsea.
CAMTROL™ Production Control
System
The CAMTROL Advanced Multiplexed
Hydraulic Control System for the
Malampaya project is designed to
control and monitor ten gas production
trees and the manifold. Components of
the CAMTROL system are installed on the
subsea trees and manifolds at a distance
of 30 kilometers from
the platform.
The CAMTROL
system is fully
integrated with
the platform
automation sys-
tem. It is controlled by
means of electronic sig-
nals sent to the Subsea
Control Modules (SCMs). Data monitored
by the SCMs is displayed on graphic
displays on the platform.
A Hydraulic Power Unit (HPU) and
Electrical Power Unit (EPU) provide
hydraulic and electrical power via hoses
and cables within
the umbilicals.
Two umbilicals
supply redundant
services from
the plaform.
Each umbilical
supplies the
entire manifold.
ROV-installed,
fly-to-place
jumpers connect
between the mani-
fold and Christmas trees for all supply
and control functions.
Each Subsea Distribution Unit (SDU)
is equipped with ROV-retrievable Subsea
Accumulator Modules (SAM). The SAMs
can be run and retrieved with the SCM
running tool.
The Subsea Control Modules (SCMs)
feature dual redundancy, Cameron
HydraQuad™ couplers and standard
interfaces. They control hydraulic and
associated functions on the trees and man-
ifolds, and acquire data for transmission
to the platform. The modules are pres-
sure-compensated. They are light weight,
compact and have been specifically
designed for deepwater applications.
The Cameron Installation/Workover
Control System uses multiplex technology
for rapid response. It is fully integrated
with the CAMTROL control system.
76
Subsea Production Manifold
SpoolTree Subsea Production System McPac Hub Connection Tool
Subsea Control Module
Malampaya System Components
Pile Spacer Template Installation
McPac Well Jumper Connection Hubs
Western Hemisphere
Cameron
PO Box 1212
Houston, Texas 77251-1212
Tel 713 939 2211
Fax 713 939 2620
Eastern Hemisphere
Cooper Cameron (U.K.) Ltd.
5 Mondial Way
Harlington
Hayes, UB3 5AR
England
Tel 011 44 181 990 1800
Fax 011 44 181 990 1888
Asia Pacific/Middle East
Cooper Cameron (Singapore) Pte, Ltd.
Subsidiary Of Cooper Cameron Corporation
2 Gul Circle, Jurong Industrial Est
Singapore 629560
Republic Of Singapore
Tel 65 861 3355
Fax 65 861 6197
Visit our website at:
www.camerondiv.com
Cameron, MOSAIC, McPac, Aqua-Torq, CAMTROL HydraQuad, STM and SpoolTree are trademarks of Cooper Cameron Corporation.Inconel is a trademark of Inco Alloys International, Inc.
@ Cooper Cameron Corporation, Cameron Division, Printed in USA, 9/00, PAH/5M, TC1444
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