subsea (surf) installation · pdf filewhat is surf? • s –subsea • u...
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Subsea (SURF) Installation
Engineering A Contractor’s Perspective from Shallow to Deep
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Agenda
• An Introduction to SURF
• What is SURF?
• Why SURF?
• What makes SURF different?
• Design Considerations
• Installation Methods
• Advances in SURF
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What is SURF?
• S – Subsea
• U – Umbilicals
• R – Risers, and;
• F – Flowlines
• All the components required to produce hydrocarbons from reservoirs located under water without the well being directly connected to a host facility
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Why SURF?• Economics
• CAPEX is generally lower for a SURF development in deeper water than an equivalent directly connected host facility
• A SURF development will generally provide earlier first hydrocarbons
• SURF is better suited to phased developments
• Delays commitment to full CAPEX expenditure
• Offers the opportunity to stop further expenditure if field performs poorly
• Host costs are often already committed and only small incremental cost to make subsea tie-backs
• Offers flexibility to cater for reservoir uncertainty and nearby new discoveries
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What makes SURF different?
• There is not normally any technical problem seen in a SURF development that is not seen in conventional or onshore oil & gas
• The key difference is in the magnitude of those problems and where they occur.
• SURF developments typically;
• Are in deeper waters
• Have more complex reservoirs and fluid properties
• Experience more extreme environmental conditions
• Are in more remote locations
• Have more diverse supply chains
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Design Considerations
• Pipeline Systems
• Route Selection
• Flow Assurance
• Pipeline Material Selection
• Thermal Expansion & On-Bottom Stability
• Umbilical's & Control Systems
• Control Methodology & Umbilical Make-up
• Route Selection
• On-Bottom Stability
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Route Selection• Pipeline route should be selected based on:
• Lowest total cost – direct and shortest route vs cost of avoiding hazards and installation complications
• Seabed topography and avoiding slopes, unstable areas, faults etc
• Obstructions & debris
• Marine activities – fishing and shipping
• Existing assets
• Installability
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Pipeline Materials
• Typical subsea developments don’t have facilities to remove contaminants close to the wellhead
• More corrosion problems
• Leads to higher incidence of Corrosion Resistant Alloys (CRA) being used
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Flow Assurance
• Ensures production fluid gets from reservoir to point of sale by addressing;
• Why is it more important for subsea or SURF developments?
• Operational nuisances elsewhere become challenges in deep water
• Environmental factors increase the frequency of problems and amplify the consequences
• Lower temperatures, higher pressures
• Limited access to intervene & high cost of failure
• Hydraulic performance
• Pressure drop
• Multiphase flow issues
• Potential pipeline blockages
• Production fluid & chemistry issues
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Control Methodology & Umbilicals
• Unlike surface production facilities process intervention and control must be done remotely in a subsea development
• Control signals
• Monitoring & measurement of the production process
• Power
• Chemicals to be injected into the production system
• Typically by umbilical
• Hydraulic
• Electrical
• Fibre Optic
• Combination
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Thermal Expansion & Stability
• Similar issues to that seen in pipelines and cables anywhere
• Amplified subsea because of
• Greater temperature differentials
• Deepwater current phenomena
• Added difficulties in burial or installing components
• Load bearing limitations of diver-less connectors
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Installation Methods
• Rigid Pipeline Lay Methods
• S-lay
• J-lay
• Reel Lay
• Tie-ins
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S-Lay
• Pipeline is assembled on board the installation vessel from pipe joints
• Assembled pipeline lays horizontally across the installation vessel and is supported into an S shape down to the seabed
• Fast provided enough stations are available in the “factory” on board
• Better suited to shallow waters or lighter pipelines where stresses in the S can be managed
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J-Lay
• Pipeline is pre-assembled onshore and then completed on board the installation vessel
• Assembled pipeline hangs vertically from the installation vessel
• Best suited for deep waters with heavy pipe and accessories
• Slow & requires expensive equipment
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Reel Lay• Pipeline is assembled onshore in a Spoolbase and reeled onto the installation vessel
• Pipeline is then reeled off the vessel onto the seabed
• Moves most of the slow assembly task onshore, reducing offshore time and cost
• Best suited to locations where a Spoolbase is close or developments where the pipelines fit within the installation vessel reel capacity
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Tie-ins
• Provide the connections
between installed components
of the development
• Most engineered of all the
components of a Subsea
development
• Most prone to not working or
failing during installation
• Typically contain proprietary
connection systems
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Pipeline Tie-ins
• Various configurations each with their own installation benefits and drawbacks
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Control System Tie-ins• Various configurations each with their own installation benefits and drawbacks
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Design Advances• More challenging reservoirs are being developed
• Subsea pumps & power distribution
• Downhole & seabed pumps
• Subsea transformers
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Installation Advances• Components to be installed continue to get larger and heavier
• Deep water lowering systems
• Use of winches instead of cranes
• PLET handling frames
• Modularisation
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SURF Developments
• Continue to offer more economic access to hydrocarbons in deeper water
than directly connected host facilities
• Have their own unique difficulties due to where they are located
• Often take existing technologies and make them work in the subsea
environment
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