the design and installation of the buchan field subsea equipment

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  • 8/9/2019 The Design and Installation of the Buchan Field Subsea Equipment

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    EUR

     7

    THE DESIGN

     ND INST LL TION OF THE  UCH N

    FIELD

    SU SE EQUIPMENT

    by

    D.B.L.

    Walker

    P Trading

    Limited

    EUROPE n

    OFFSHORE

    PETROLEUM

    conFEREnCE

     

    EHHI ITIOn

    ©

    Copyright 198 European Offshore Petroleum Conference and Exhibition

    This paper was presented at the European Offshore Petroleum Conference

    and

    Exhibition held In London England October21·24 1980 The material Is subject tocorrection by the author

    Permission to copy isrestricted to

    an

    abstract

     

    not more than 300 words

    ABSTRACT

    This paper cover s

    th e d es ign and

    installation of

    the Buohan Field subsea equipment

    inoluding:

    template, trees and completions, wireline

    r iser

    and BOP staok, subsea manifold, flowlines and

    umbilioals, produotion

    riser

    and oontrol system.

    A brief desoription

    of th e

    rig modifioat ions to

    enable

    i t

    to

    handle

    t he produot ion

    riser is also

    inoluded.

    INTRODUCTION

    The

    Buohan Field l ies in

    b look 21/1 of

    the

    North

    Sea, 160 km

    eas t-north-east of

    Aberdeen.

    The

    water

    depth is between 112 and 118 m and environmental

    oonditions

    are similar

    to those exper ienoed

    in

    the

    Forties

    Field whioh l ies

    55 km further to

    the

    east.

    With estimated

    reooverable

    reserves of

    only

    50 million bar re ls o f

    oil ,

    however, Buohan is a

    twentieth

    of

    the

    size of i ts

    giant

    neighbour.

    An eoonomio evaluation indioated

    that

    the

    Field

    was too sma ll to be

    exploited

    along oonvent ional

    l ines,

    suoh

    as

    a

    fixed

    platform

    tied in to

    the

    Forties

    pipeline.

    The development had

    to

    be on a

    relatively

    short

    time

    soale requ iring

    low

    oapital

    investment.

    The reader

    is

    d ireo ted to Referenoe 1

    fo r a review of

    the

    alternative

    sohemes oonsidered

    by

    th e Company.

    Field

    development is based on

    produotion

    from

    subsea wells

    to

    a oentral underwater

    manifold.

    A semi-submersible drilling

    rig,

    oonverted to

    oarry produotion

    equipment, is

    permanently

    anohored ove r t he manifo ld to whioh i t

    oonneots

    by

    a produotion

    riser.

    Multiple

    lines in

    the

    riser bundle

    oarry the

    oil

    up to

    the rig for

    prooessing and baok

    down

    to the

    seabed fo r

    export.

    A pipeline t ies th e manifold into a C LM tanker

    loading buoy.

    When

    bad weather

    fo ro es th e

    tanker

    to

    stop

    loading,

    produotion

    oeases.  f oonditions

    oontinue

    to

    worsen,

    then

    th e

    produotion

    ris er is

    designed to be reoovered and staoked on

    board

    th e

    rig until

    the

    weather improves.

    275

    With this basio oonoept, BP farmed

    into

    the

    Buohan

    Field in July 1977 and with a 54 interest beoame

    th e

    operator.

    Plans were

    developed fo r

    a peak

    produotion

    from 8

    subsea

    wells of 72,000

    bbls

    pe r

    day

    with

    an expeo ted f ield

    l i fe of

    5 years. Based

    on a oomputer simulation

    of

    f ield operation, i t was

    estimated that produotion oould be maintained for

    65

    of

    the yea r, g iv in g an average annual

    produotion

    rate of 48,000

    bbls per day. The

    rig

    has 3 ,500

    bbls

    of

    storage

    whioh

    improves

    th e

    system

    performanoe.

    With a

    gas/oil

    ratio

    of 56

     310

    sof/bbl

    exoess

    gas

    will

    be flared

    on

    th e

    r ig.

    Provision has

    been

    made

    to introduoe a gas l i f t

    system

    to boost

    produotion

    as reservoir

    pressure

    deolines.

    Figure 1 i l lustrates th e Buohan

    Field.

    Five

    of

    th e

    wel ls a re o lu st er ed t og et he r direotly under th e

    rig to faoil i tate workover  s ee F igure 2 . Two

    s te l l i te wells

    l ie

    1. 7 km to

    the south

    and

    provision

    has

    been made

    fo r

    a

    third.

    Preliminary

    field development

    plans were based on

    an

    18 month rig oonversion programme November

    1977

    to

    May

    1979 and a

    oonourrent

    19 month

    drilling and

    well oompletion

    pha se . F lowline

    construotion was soheduled for summer 1979

    with

    produotion

    star ting in th e autumn of that

    year.

    THE SUBSEA TEMPLATE

    To

    meet

    t hi s t ar ge t i t

    was

    obviously essential

    to

    build and insta l l

    the dr i l l ing template

    for

    the

    cluster

    of

    subsea wells as rapidly as possible

    during

    the

    summer

    of

    1977, to

    enable produot ion

    dr i l l ing to

    prooeed

    over

    th e following

    months.

    References and

    i l lustrat ions

    at end of paper.

  • 8/9/2019 The Design and Installation of the Buchan Field Subsea Equipment

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    The

    template therefore had to be simple and

    easily

    fabricated. Since

    th e

    layout of

    th e

    wells had no t

    been d ec ide d, t he t em pl at e had to provide a number

    of d r il li n g s lo t s with th e facili ty to

    support

    th e

    flowlines.

    An 8 s l o t t em pl at e w it h a 5. 2 m spacing between

    well

    centres

    was chosen as shown in Figure

    3.

    With

    th e

    underwater manifold occupying one

    slo t, . th ere

    was p ro vi si on f or 5 template wells with 2 spare

    slots in case drilling was abandoned on any

    location. The template rested on th e seabed on

    aO.65 mwide

    s k i r t

    round t he base Of each

    1.22 m diameter conductor

    guide.

    The

    structure

    was held in place by four 12 inch  300 mm

    pi n

    piles. Provision was made to jack t he t em pl at e

    up on i ts

    piles to

    maintain i t level

    in

    t he e ve nt

    of

    a sloping or uneven seabed.

    The

    90

    tonne template was taken ou t

    to

    th e field

    on

    a

    flat

    top barge and

    lif ted

    into

    th e

    water

    by

    a

    crawler

    crane

    on

    th e deck

    of

    a large supply

    vessel.   t was winched down to

    th e

    seabed where

    divers confirms i ts orientation and position,

    some 7 m from an existing exploration

    well, later

    to be tied in as a

    producer.

    The

    piles

    were

    driven

    using a small underwater v i b r o ~ h m m e r

    No

    levelling

    was reqUired and

    th e

    template was

    secured to th e piles by th e inflation of

    annular

    packers. Installation

    time

    was

    4 days.

    Design, fabrication and

    installation

    of th e

    template took a to tal 01 4 months. SUbsequent

    d rill in g and construction work has

    validated

    th e

    basically

    simple concept and i f

    th e structure

    were redesigned today, very few modifications

    would be

    introduced.

    COMPLETIONS   ND

    TREES

    Immediately following template installation in

    August 1977, drilling commenced·on th e 4 template

    wells. This extended

    over the next 14

    months,

    which also

    included

    th e

    setting of 90

    m of 30

    inch (760 mm conductor to

    ac t

    as a foundat ion

    for the underwater manifold.

    The

    wells were

    temporarily

    suspended pending delivery

    of

    th e

    subsea trees.

    Simultaneously two satell i te wells were drilled

    by a second r ig during 4 months in th e summer

    of 1978. By mOdifying th e original programme

    of

    5

    template

    w el ls p lu s

    one

    southern

    s a t e l l i t e

    to

    become

    4 template plus

    two

    satellites (one

    of which

    was drilled

    back

    into

    th e central

    formation) th e d rill in g schedule was maintained.

    The layout of t he t em pl at e

    wells,

    manifold and

    th e off-template well is

    shown

    in

    Figure

    2.

    C on tr ac ts f or

    th e

    trees, hangers and

    associated

    downhole equipment were placed in February 1978

    and f irs t

    deliveries

    were made to

    th e

    rig in

    December of

    th e same

    year. With a

    closed in

    wellhead pressure close to 5,000 ps i

     34 MPa ,

    10,000 psi (68 MPa rated equipment was specified.

    The completion had to

    provide

    fo r

    th e

    introduction

    of

    gas l i f t a t some future date by wireline

    intervention only and had to be capable of being

    used

    in

    both

    perforated

      i.e.

    previously

    tested)

    276

    and unperforated wells. A nominal 4 x 2 inch

    (100

    mm

    x 50 mm dual completion was

    specified

    with each string carrying a

    su rf a ce c o nt r ol l ed

    down-

    hole

    safety

    valve  In the case of

    th e

    4

    production

    string, this

    is

    a

    tubing

    retrievable

    valve, with the facili ty in case o f f ai lu re to

    be permanently locked ou t and replaced by a

    wireline

    retrievable unit. For the operation

    of

    th e

    gas l i f t

    t he t ub ing string

    has been provided

    wi th side pocket mandrels

    into

    which gas

    l i f t

    valves can be

    introduced

    by wireline. In

    th e

    case of satell i te w el ls , t he se gas l i f t valves

    ar e already in place. This, i t is hoped, will

    avoid th e need to bring in a workover rig to

    install them d ur in g t he commissioning of th e gas

    l i f t system.

    Two types

    of

    subsea dual tUbing hangers were used.

    A hydraulically se t hanger was used on the converted

    production well, p ro vi di ng t he

    facilities fo r

    hanger

    setting

    and simUltaneous

    wireline

    access

    to both bores with one

    multi-purpose

    hydraulic

    setting tool. The hangers used on

    th e

    other wells

    relied on

    being mechanically set with

    d r i l l

    pipe,

    using a second purpose-built aCCess

    tool

    fo r

    wire-

    line and testing purposes.  

    Dual bore split trees were used, shown schematically

    in Fi gu re 4. Each tree weighs 52 tonnes and was

    installed

    as a single

    unit. The

    lower

    tree contains

    a dual manual master

    v al ve b lo ck ;

    th e upper

    carries

    a six valve block - 2

    master,

    2 wing, and 2 swab

    all hydraulically operated and fit ted with

    e x te r na l p o si t io n

    indicators. A by-pass loop

    carrying

    a further 3 valves i s mounted on th e

    lower tree and provides

    th e

    link between

    th e

    dual

    4

    inch

    flowlines

    back

    to the

    manifold

    and the

    upper

    tree.

    Prior

    to introducing gas l i f t t he by- pas s val ve

    can be

    lef t

    open to all ow b ot h flOWlines to carry

    o il and

    to

    p er mi t p ig gi ng to remove wax

    deposits.

    In

    th e

    event

    of major equipment failure, th e upper

    tree

    can be recovered leaVing th e lower half in

    place.

    This would r eq u ir e d iv er

    intervention

    to

    break th e connector, flow loop flanges and.

    control

    circu its.

    As each tree became available, th e wells were

    re-entered, th e completions run and t he w el ls

    perforated, using

    one

    .rig

    a t

    th e

    template

    location

    and one

    over

    th e

    satell i te

    wells.

    Total

    time

    spent on t he se o p er a ti on s fo r

    th e

    4 template and

    1

    off-template

    wells amounted to 9 months and 3

    months

    fo r

    th e

    two

    satell i te

    wells.

    WIRELINE

    BOP ST CK

    Following t he r un ni ng of th e

    tree, a ll

    further

    wireline

    work

    was

    conducted through a custom

    b u ilt

    wireline BOP

    stack

    mounted above

    th e

    tree.

    This

    carries

    both a set o f b li nd rams, designed

    to seal with or without a

    wireline

    in p la ce , and

    a set of shear rams.

    By altering

    th e

    position

    of

    a spool beneath th e rams, i t can be run

    to

    provide

    wire line access

    to

    e it he r s tr in g .

    The stack

    is

    used with

    th e

    dual 4 x 2 inch wireline riser and

    is

    operated

    from a

    se lf - co n ta i ne d se rv i ce control

  • 8/9/2019 The Design and Installation of the Buchan Field Subsea Equipment

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    system, designed to be moved with i t from one

    rig

    to

    another.

    During normal operations the tree and

    down

    hole

    safety valves ar e

    controlled

    from the production

    platform

    through a

    10 line

    hydraulic umbilical.

    For reasons

    of

    safety, however,

    i t is desirable

    during

    a workover

    to control

    both

     OP

    stack

    and tree from a

    single control

    panel

    on the

    workover

    rig.

    This

    is achieved

    by

    routing the

    incoming

    10

    line

    tree

    umbilical through a control

    stab on the high pressure cap which seals off

    the

    top

    of

    the tree.

    When the

    cap is removed

    to

    permit t he

     OP to

    be run,

    the circuit is

    broken and a

    stab

    on the

     OP stack

    takes

    the

    place of

    the one

    on th e

    cap.

    The

    stack functions

    and tree valves ar e then controlled from a

    single panel via twin 28 line

    umbil ical s to

    the

    service control

    unit on

    the

    workover rig.

    THE SUBSEA M NIFOLD

    The biggest

    piece

    of

    subsea equipment

    in

    the

    Field

    is

    the

    underwater manifold which weighs

    110

    tonnes

     See

    Figure

    5 . This assembly of valves and

    connectors is

    mounted on

    the template directly

    under the platform. The valves and pipework

    ar e

    mounted between

    two

    horizontal frames, th e upper

    being supported 5 m above the lower

    by

    4

    corner

    posts

    and a

    central 30

    inch column.

    Passing vertically through the manifold

    ar e

    a

    12

    inch line to

    carry the exported crude,

    eight

    4 inch  production and

    eight

    2 inch lines

    fo r

    gas l i f t

    11

    female

    riser connectors ar e

    mounted

    face up on

    the

    top frame

    to

    receive

    the production

    riser

    and

    projecting

    below the lower frame ar e 17

    stabs

    and two connectors.

    The

    main centrally mounted

    inch wellhead connector connects

    on

    to a

    dummy

    wellhead and

    is the principal

    means

    of

    securing the manifold to the

    seabed.

    The connector

    is welded to the 30 inch column which runs

    up

    through the middle

    of

    the manifold and transmits

    the

    riser loads

    imposed on

    the

    top frame down

    to

    the

    foundation.

    The second connector

    is

    mounted

    on the 12

    inch export

    line.

    A third horizontal frame

    of

    similar dimensions

    and

    known

    as the manifold base, is mounted on the

    30 inch

    conductor below th e manifold i t sel f . Apart

    from a

    12

    inch manually

    operated

    valve

    in the

    export line, there ar e no

    other

    valves on t he base;

    i t

    merely s erv es t o support the short spools

    of

    pipe

    linking the

    template

    pipework

    to

    the female

    receptacles which

    receive the

    manifold stabs.

    By using this means i t was possible to insta l l

    the manifold base

    in

    advance of the manifold and

    to

    make

    up

    and

    install the

    flanged pipework spools

    between i t and

    the

    trees.

    The

    base

    is

    no t

    designed to

    be recovered

    to the

    surface. Components in the manifold can be

    recovered fo r maintenance  and in t he event of

    major problems, the ent ire s tructure can be

    lif ted into

    th e moonpool

    of

    the

    production platform.

    As

    in

    the

    case

    of

    the

    trees,

    this

    would

    require

    diver intervention.

     

    To understand

    the

    uses

    of

    the manifold i t should

    be

    considered in

    the

    l ight of the

    19

    separate risers

    which

    make up the riser

    bundle  see Table

    1 .

    By

    opening

    or c losing

    valves

    in the

    manifold i t

    provides the

    means

    to:-

     a Shut in

    the

    flow subsea when

    the risers

    ar e

    disconnected.

     b Manifold th e

    production or

    gas

    l i f t

    flows

    subsea

    in the event that some of the risers

    ar e not run.

     c Cross connect the

    service

    risers

    to the

    crude carrying

    risers to

    allow flushing

    with water

    prior to

    disconnect.

     d Provide the

    return

    path fo r pigging the

    flowlines

    via the high pressure service

    r iser .

     e

    Provide

    a

    link

    between

    the

    high

    pressure

    r iser and the

    flowlines

    to create a f lowpath

    fo r well

    killing.

    This

    is

    an

    alternative

    route

    to

    the normal means of

    killing

    a

    well

    through

    the wireline riser.

      t should be noted

    that

    the manifold contains

    no

    subsea chokes.

    INSTALLATION  ND HOOK UP

    The manifold

    base

    was installed in June 1979. Prior

    to

    that

    the

    divers had jetted

    out the

    drill ing spoil

    and installed pipe supports

    on

    th e template

    fo r the

    pipe spools which would run between the trees and

    the

    base. The operation was

    conducted from a

    semi

    submersible

    diving vesse l

    anchored

    over

    the template.

    Spools of pipe were fa:bricated on the deck

    of

    the rig

    to

    measurements taken. by

    the

    divers

    using

    special

    j igs.

    The

    spools were then lowered

    on

    winches

    over

    the side to

    th e seabed.

    Hydraulic

    bolt tensioners

    were used fo r making

    up

    the f langed and clamped

    connections

    subsea. 25 m spool p ieces were laid

    on the seabed at

    the

    edge of the template to act as

    expansion

    loops fo r the

    incoming flowlines from th e

    sate l l i te wells.

    A combination of good weather and

    careful

    planning

    by the contractors, SUb

    Sea International, and th e

    BP

    construction

    team

    r esul te d i n

    an exceptionally

    successful

    diving

    operation.

    This

    included 22

    spoolpieces

    being

    measured up,

    fabricated, installed

    and pressure tes ted in 45

    days,

    during which t ime

    the average time in

    the

    water was 22 hours pe r day.

    FLOWLINES

     ND UMBILICALS

    The second major construction job in the Field during

    the 1979 summer was

    the

    laying and connecting

    of

    the

    pipelines

    and

    the

    umbilicals. Each of

    the two

    southern satell i te wellS had

    to

    be tied

    in

    back

    to

    the

    manifold

    by

    twin 4

    inch flowlines

    and a

    control

    umbilical,

    and

    the 12 inch export line

    had

    to

    be

    laid to the loading buoy.

    Originally

    i t had been

    intended

    to

    lay a ll the lines from the new Santa Fe

    reel ship, Apache,

    bu t

    due

    to

    delays

    in

    he r

    construction

    programme, the

    12

    inch line

    was laid

    f irs t

    from

    the

    semi-SUbmersible, Choctaw 2,

    with the

    Apache arriving la ter in the

    Field

    to la y the

    flowlines

    and

    umbilicals.

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    The

    4 inch

    flowlines

    were epoxy powder coated and

    welded up

    into 300m strings at

    the

    Santa Fe

    base

    at Leith.

    Tests earlier

    in the year had demonstrated

    the ability

    of the coating to

    survive the

    reeling

    and unreeling process. th e

    pipe

    was welded up into

    a

    continuous

    7 500 m

    le ng th as

      t

    was

    spooled

    on

    to

    the 25 m diameter drum vertically mounted midships

    on Apache.

    During

    the reeling process

    a

    supply boat was

    installing dead

    man

    anchors

    in

    the

    v ic in it y o f the

    satelli te wells to prepare for the initiation

    of

    pipelaying. A submersible was

    also

    present during

    the laying

    operation

    to assist in surveying the

    l ine.

    A  pull- in technique developed by BP

    was

    used to

    connect

    the flowlines to the satel l i te trees.

    After

    the lines were laid, the ends of

    the

    flowlines

    were held

    off

    the seabed

    by

    buoyancy

    tanks

    and

    drag

    chains

    and were p Ul le d

    in to

    the lower trees

    by

    a

    hydraulic

    winch clamped

    to

    the

    30

    inch

    conductor. Di ve rs t he n installed the short make-up

    spool

    to

    complete the connection. At the template

    end th e

    pre-installed spoolpieces

    served as

    the

    target

    fo r the lay down operation and using

    manipulator frames th e f langes

    on

    the spoolpieces

    and pipeline were

    brought

    into

    alignment. The

    laying rate reached 440

    m

    pe r hour

    including

    the

    ti me t ak en

    to

      t an anode

    every

    70

    m The

    best

    total time

    recorded

    fOr initiating from the

    dead

    man anchor,

    laying

    1.7 kmof

    flowline and

    laying down·the

    line at the template

      recovering

    and.adjusting

    to length

     

    required) was 14 hours.

    The two control umbilicals were laid simultaneously

    from reels on the stern of the Apache. Each

    umbilical consists

    of

    ten inch

     6

    mm

    hydraulic

    hoses packed round a central 1s

    inch  29

    mm

    steel

    cable which provides

    both strength

    and weight.

    Adequate tension was no t maintained, however during

    the

    abandonment of

    the

    two ends at the template and

    entanglement

    resulted.

    This was picked by

    the

    submersible

    s ur ve y and subsequently straightened

    out by divers.

    MANIFOLD

    INSTALLATION

    Only

    the

    manifold remained to be installed during

    September. 1979 after Apache had

    cleared the Field.

    The

    semi-submersible

    rig Dundee Kingsnorth was

    brought in

    to

    the shelter of Largo

    Bay

    in th e Firth

    of Forth

    where

    the

    flat

    t op barge

    carrying

    the

    manifold

    was

    manoeuvred between

    her

    twin

    hulls.

    Using the draw works and a string of dri l l pipe,

    the

    manifold was

    l i fted up

    into

    the moonpool where

    i t was secured during

    the

    tow

    to the

    Field.

    After

    a long wait

    on

    w ea th er a nd

    delays

    caused

    by

    last

    minute equipment problems the

    actual running of

    the

    manifold

    was completed

    in

    6 hours. Extreme

    care was

    required

    during

    the

    landing of

    the

    manifold

    on

    the base

    to

    avoid  damage to the

    stabs

    and

    connector s. A ll

    went well except for the connector

    on th e

    export

    line which would not c lo se and

    has

    sUbsequently had to be

    replaced.

    Although

    in

    theory

    the repair could have been

    carried

    ou t by

    recovering the

    manifold

    to

    the

    surface, in practice

    subsea

    replacement

    of

    components

    is

    very much

    simpler

    because

    of

    the

    size

    and w ei gh t

    of th e

    structure

    which makes

    handling

    extremely

    weather

    dependent.

    TH

    PRODUCTION RISER

    Like

    the

    Argyll

    design, the Buchan production r iser

    i s no t designed to stay connected in all

    weathers,

    but

    must be recovered and stacked. in the derrick in

    severe

    conditions. I t

    was

    designed

    to survive

    12

    m

    maximum

    waves with

    the

    associa

    ted

    rig

    offset

    and

    current,

    bu t recovery

    of

    the r iser will have to be

    initiated at a considerably lower threshold.

    Nevertheless i t is

    the ability

    of the

    t anker to

    stay

    connected to

    the

    loading

    buoy

    rather

    than

    the

    r iser

    which

    will

    determine

    the

    production from

    the Field.

    The

    r iser is shown

    in

    cross-section in Figure 6 and

    in elevation in Figure 7. Prior to the introduction

    of gas

    l i f t the

    bundle consi st s o f a central 12

    inch

    export r iser

    surrounded

    by ten

    4

    inch risers

    one production r iser from each

    of wel l s

    and two

    service risers

      see Table 1).

    The risers ar e

    independent

    of

    each

    other

    and are run

    and

    tensioned

    separately.

    The

    4

    inch

    r isers

    are,

    however constrained to deflect

    with

    the 12

    inch

    r iser by being spaced ou t from

      t by

    passing through

    guide funnels. These ar e

    supported

    on arms mounted

    every

    7.6 m

    along

    t he l ength

    of t he expor t

    r iser .

    Hence although each r iser

    in the

    bundle is independent

    in the axial

    direction, horizontally

    the bundle tends

    to

    deflect

    as

    a single composite beam.

    To reduce bending stresses at the b as e . of the r isers,

    a universal joint is mounted in t he expor t r iser

    directly

    above the manifold. Fo r th e

    same

    reason,

    the bottom 15 m joint

    on

    each production r iser is

    made

    from

    extra

    heavy

    tubular.

    With the introduction of gas l i f t

    facilities

    exist

    to

    cIampa 2 .inch gas

    l i f t

    r iser

    to

    each

    production

    riser

    and

    the

    guide

    funnels are

    sized to accommodate

    the

    pair.

    This r iser

    concept

    offers the advantage of operational

    f lexibili ty. Only SUfficient risers need

    to

    be run

    to

    accommodate flow and   required, individual

    r isers can be p Ul le d and

    replaced without

    haVing to

    recover the entire

    bundle.

    On

    tpe other

    hand r iser

    handling time

    during

    the

    running or

    recovering

    operation is increased

    by

    the need to

    handle

    individual lines sequentially.

    The

    r iser was th e

    subject

    of an immense amount

    of

    design analysis.

    Model tests were conducted on the

    bundle to establish drag and inertial coefficients

    on

    individual

    r isers.

    This

    data

    was

    then

    used

    in

    the

    stress analysis

    programme to

    predict th e

    bending

    behaviour

    of

    individual

    risers

    as

    well

    as the gross

    behaviour of the bundle. A

    spectral

    fatigue analysis

    was conducted

    to

    determine fatigue l ife and

    this

    was

    supported by

    fatigue t es ti ng o f

    a threaded

    r iser

    connector. In

    addition,

    during operation r iser

    behaviour

    will be continually monitored

    by

    instrumentation measuring parameters such

    as

    the

    deflection

    of the

    universal join

    and the pipe wal l

    strain

    at

    two locations on

    the r iser .

      8

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    RIG MOUNTED

    EQUIPMENT

    As well

    as

    the

    installation

    of

    production

    equipment

    the

    rig conversion

    programme incorporates several

    modifications

    in

    t he r eg ion

    of th e moonpool. These

    include:-

    enlargement of

    the

    moonpool

    to

    accommodate

    both

    production and wireline riser

    provision of

    four new

    36

    tonne

    r iser tensioners

     i n addition to the

    eight existing 27 tonne units

    installation

    of

    four

    hose reels

    to

    carry the

    main control umbilicals

     see

    below

    modifications

    to the

    derrick

    t o permi t handl ing

    the

    wireline

    riser

    through

    a second

    opening

    in

    the dril l deck floor

    proVlslon

    in

    the

    derrick fo r stacking

    30

    m

    lengths

    of

    riser

    provision of addi tional sheaves fo r tensioning

    lines

    and guide

    wires. All

    systems ar e

    designed

    to accommodate 5 m of

    rig heave.

    Flexible

    rubber hoses ar e used to connect the

    top

    of the

    risers

    into

    the moonpool pipework.

     ONTROL SYSTEM

    All the

    subsea equipment is

    controlled hydraul ical ly

    via 4 hydraulic umbilicals deployed from the

    production platforms.

    Two

    65 function umbilicals

    ar e run to twin control pods mounted

    on

    the base

    to

    control

    the

    trees

    and downhole

    safety

    valves

    and two 62 function umbilicals

    control

    the

    manifold

    operation

    through pods mounted

    on

    the

    upper manifold

    frame

     see Figure

    5 . Total duplication of

     ll

    key

    subsea functions

    is

    provided between rig and control

    pods.

    A 10 line hydraulic umbilical

    is

    run to each tree

    from the subsea tree pods.

    inch

    hydraulic lines

    ar e used throughout.

    The main umbilicals ar e deployed from 4 hose reels

    situated

    at

    the edge of the moonpool. A guide line

    system is used

    to

    run and recover the control pods.

      9

    In addition to the main control

    panel

    on the

    r ig,

    a

    second smaller unit on the   rill deck floor

    provides

    fo r

    local control of the riser

    connectors

    on top of

    the manifold.

    This is

    used

    during running

    and

    recovering the production riser.

    All

    subsea valves ar e fail safe closed.

    In

    addition

    the

    subsea control system is ti ed in to the main rig

    control panel

    t o ensure

    that in the

    event of

    a

    shutdown subsea valves will be

    closed.

    CONCLUSIONS

    The Buchan Field development can be

    seen

    as

    the

    natural successor

    to

    Argyll. While s im il ar i n

    concept, i t

    represents the extension

    of

    the

    floating

    production

    principle to a field

    with

    more

    subsea

    completions,

    bu t no radical departures in new

    technology. In

    terms of

    field

    size, however, i t

    comes

    close

    to

    the

    l imit of

    what can be

    achieved

    by

    the

    conversion

    of a standard

    dril l ing rig.

    The next

    step is

    l ikely to

    be custom

    buil t f10ating production

    platforms.

      KNOWLEDGEMENTS

    The author wishes

    to

    acknowledge BP

    Trading Limited,

    BP Petroleum Development

    Limited

    and

    their

    Partners

    in the Buchan Development, namely St.

    Joe Petroleum

    Corporation, CanDel

    Petroleum Limited,

    Natomas

    International, Gas and

    Oil

    Acreage

    Limited,

    Charterhall

    Oil Limit ed, Loch ie l

    Exploration  UK

    Limited, CCP

    North Sea Associates and

    City Petroleum

    Corporation

    fo r

    permission to

    produce

    this

    paper.

    REFERENCES

    1.

    Darnborough

    E. .

     The Buchan

    Field

    Development . Europec Paper No.

    230.

    October, 1980.

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    TABLE  

    The

    production r s r bundle

    Risers

    Number

    Nominal

    Operating Pressure

    Size

    Uns

    psi

    MFa

    Produotion 8

    4

    5

    34

    Low

    Pressure Servioe

    4

      5

    1 5

    High Pressure

    Servioe

    4

    75

    5

    Gas Lift

    8

    2

    325

    Export

     

    225

    1 5

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    FUTURE

    NORTHERN

    S TELLITE

    W

    FLO TING

    PRODUCTION

    PL TFORM

    SUBSE

    TEMPL TE

      WELLS

    C LM

    BUOY

    SOUTHERN

    S TELLITE

    WELLS

    Fig

    Layout of the Buchan

    Field

    SPIDER SU RT-

    PRODUCTION

    RISERS

    SUB SE

    H R I S T M S ~ · ·

    TREES

    S T

    W LL

    FLOWLINES

    SE BED

    T E M P L T E ~

    CONTROL

    UMBILIC LS

    UMBILIC LS

    CENTR L EXPORT

    RISER

    M NIFOLD

    Fig 2

    Layout of

    the template wel ls and

    manifold

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    Fig

    The template

    PRODUCTION

    STRING

      NOM

    UPPER

    T I

      I

     

    LOWER

    TREE

     

    L PRODUCTION

     

    PROPOSED

    GAS

    INJECTION

    Fig

    Schematic

    of

    a

    subsea

    tree

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    M NIFOLD

    CONTROL

    PODS

    TREE

    CONTROL

    PODS

    RISER

    CONNECTORS

    M NIFOLD

    UPPER

    FR ME

    I I I E  PORT

    LINE

    M NIFOLD

    LOWER

    FR ME

    ~ M N I F O L D

      SE

    Fig The subsea manifold

    GUIDE

    FUNN LS

    ~ E X P O R T

    RIS R

    S RVI

    RISER

    G S LIFT

    RISER

    PRODUCTION

    RISER

    Fig

    6 Cross section of

    th e production r is r

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      TENSIONERS

    12 EXPORT RISER

      4 RISERS 1

    OFF

    2

    RISERS  

    OFF

     

    GUI E

    FUNNELS

    UNIVERSAL

    JOINT

    MANIFOLD

    TEMPLATE

    Fig levation

    of

    the product ion r i s r