Subsea production system

Abstract: This invention refers to a subsea system for oil or gas production and water injection which operates without divers' assistance and with guide-cables, said system consisting of a template (50) equipped with 10 drilling mouths (53) arranged in two rows of 5, each said drilling mouth (53) consisting of a guide-pipe (54) whose upper end presents an external section for locking purposes and a guide-base (55) provided with four posts (56) removable by ROV; a central space for the setting of a manifold (60) through four posts (63) to guide the installation and means to ensure the final positioning of the manifold (6) within the established tolerances; bases of the export-line terminals (64) located at one of the ends of the template (50), each said base (64) being provided with two guide-posts removable by ROV; in addition to reaction posts (66) which orient the lowering of the pulling and connection tools and transfer the stresses to the structure of the template, receptacles (67) to lock the export-line terminals; analogous bases located in the other end of the template for the control umbilical units; guides (69) for piles arranged at each one of the four vertices of the structure (68) of the template; and a manifold (60) including a base-structure (70) where are attached the pipes, the hydraulic and electric control lines, the terminals (73) for connection to the WCTs (74) and to the MSTs (75), and terminals (76, 77) for connection to the export lines and to the hydraulic and electric umbilical units, as well as to the WCTs (74), MSTs (75) and their control system.

Description: This invention refers to a subsea system for petroleum production, consisting of a template-manifold structure, wet christmas trees and modules of satellite trees, which can also be equipped with a multiplexed electro-hydraulic type of control system which was specifically developed to be utilized in producing areas in water depths allowing for the use of guide-cables. For economic reasons, the development of petroleum fields in deep waters (water depth in excess of 400 m) requires the producing wells to be subsea, which implies that the well-head and the christmas tree be installed at the sea bottom, just above the marine ground (sea bed). For economic reasons, the usual practice for that development has been to group various wells in one single structure, which is set at the sea bottom. This structure is internationally known as a template. It usually includes a structure of a varied shape, often rectangular, in which there is provision for a given number of wells, which are spaced between each other according to a pattern established by the American Petroleum Institute (API), which determines that the minimum distance between well centers shall be equal to 2.28 m (7.5 ft). In the 1970's the petroleum industry started adopting the production of subsea wells, and wet christmas trees were developed. In the beginning, the production of various satellite wells was collected in a central manifold, usually installed on a platform, being thereafter transported to floating production storage units or to fixed platforms. With the discovery of major oil fields at great water depths, the petroleum industry started adopting subsea completions as an option which is economically more feasible for the production development of those fields. As a function of the specific characteristics of the producing reservoirs, the industry started developing new designs of template, so as to make possible the existence of various producing wells in one single area and to facilitate the collecting of the production in one single manifold, which could optionally be incorporated in the template. Hence the expression "template-manifold" is used to identify the structures which have the manifold associated with the template. Known subsea template-manifolds include structures containing the guide-bases, on which the well-heads and the christmas trees are installed. Bearing in mind that the distance between wells meets international standards and that this is not great in relation to the dimensions of the equipment units to be installed, it is easy to foresee the operational and safety difficulties which are to be faced for the wells to be put in a condition to produce. The impracticability or difficulty of human diving in deep waters leads to the necessity of operation by means of a remote-operated vehicle (ROV), both for the rendering of services, such as valve operation, and for inspection. Thus, the subsea equipment for use in deep waters must provide spaces for passage, area for landing, points for dockage and interfaces in the equipment for ROV operation. Contingency mouths are usually provided in the structure for casing wells lost during the work, which leads to larger dimensions for the structure. If the system were to allow for the utilization of any lost mouth for the interconnection of a contingency well located out of the template-manifold, the structure would be more compact, as it would not need contingency mouths. The systems are usually provided with resident pipes, that is pipes linked to the structure, so that their removal for maintenance purposes is not feasible. The use of modules with retrievable pipes is advantageous under this aspect, but requires a connection system avoiding the need for manufacturing and assembly tolerances or large-size structures. It is important that the flexibility for the connection be in retrievable modules, which is not usual. Similarly, it is important that the elements with high possibility of failure be in retrievable modules, which can be obtained through the use of the christmas trees themselves or modules of satellite trees, which is not usual either. Another problem which usually occurs is the deposition of cuttings originating from well drilling around the heads of wells already completed, which may require expensive and difficult cleaning operations, particularly in the case of deep-water operations, so that the structures must allow for the carriage of those cuttings and the accumulation of part of them without interfering with the operations. It is an object of this invention to provide a subsea production system including a subsea template structure, to be utilized in deep waters, and which may offer a higher operational flexibility than hitherto. Another object of this invention is to provide a subsea production system including a template structure which promotes a larger spacing between wells, thus increasing the safety in the performance of the operations and facilitating ROV-operations. The main object of the invention is the provision of a subsea production system including a template structure, a manifold structure, wet christmas trees, and modules of satellite trees, which may also be equipped with a multiplexed electro-hydraulic type of control, and in which the active components, such as manoeuvre valves, chokes and control modules, are located in the christmas trees and in the modules of satellite trees, instead of being in the manifold. This difference in relation to the prior art allows the maintenance to be effected at the surface, since those christmas trees and those modules of satellite trees are retrievable modules. Similarly, the inclusion of those active components in the christmas trees implies only minimum modifications in the dimensions of those christmas trees in relation to the wet christmas trees of the satellite wells. In addition, a higher manifold reliability is obtained. The subsea system according to this invention, is characterized by the features of claim 1. The preamble of claim 1 is based on GB-A-2226063 which discloses a subsea production system including a template structure, a manifold structure, and wet christmas trees, wherein the active components comprising manoeuvre valves and chokes are located in the wet christmas trees. The system can operate without divers' assistance and with guide-cables, said template structure may be equipped with 10 drilling mouths arranged in two rows of 5, each mouth consisting of a guide-pipe whose upper end presents an external section for locking purposes; a guide-base may be provided with four posts which are removable by ROV; a central space may remain for the setting of the manifold by means of four posts to orient the installation and devices to ensure the final positioning of the manifold within the established tolerances; bases of the export line terminals may be located in one of the ends of the template, each base being provided with two guide-posts which are remable by ROV, and also there may be reaction posts which guide the lowering of the pulling and connection tools and transfer the stresses to the template structure; receptacles may lock the export line terminals; analogous bases may be located in the other end of the template for the umbilical control units; guides for piles may be arranged in each of the four vertices of the template structure; and the manifold structure may include a base structure where are attached the pipes, the hydraulic and electric control lines, the terminals for connection to the wet christmas trees (WCTs), and/or to the modules of satellite trees (MSTs), and terminals for connection to the export lines and to the hydraulic and electric umbilical units. In order that the present invention may more readily be understood the following description is given, merely by way of example, with reference to the accompanying drawings, in which:- FIGURE 1 is an overhead perspective view of one form of the subsea production system according to this invention; FIGURE 2 is a perspective view of the manifold; FIGURE 3 is an exploded view of the well equipment; FIGURE 4 is a perspective view of the wet christmas tree; and FIGURE 5 is a perspective view of the module of satellite trees used with the apparatus of this invention. As can be inferred from the Figures, the subsea production system of this invention consists of a template 50 of rectangular shape, equipped with 10 drilling mouths 53 arranged in two rows of five. Each drilling mouth 53 consists of a guide-pipe 54 whose upper end presents an external section for locking purposes and a guide-base 55 provided with four posts 56 which are removable by ROV, the distance between the wells 57 being approximately 5.0 m. The guide-base 55 and its central guide-pipe 54 are intended for drilling the wells 57 and for the installation of the sub-surface equipment. In this case, the head of the conductor pipe 58 (Figure 3) is locked directly to the guide-pipe 54, without the use of a gimbal, so as to reduce angular deviations of the well-head. The central space of the template 50 is prepared for the setting of the manifold 60 (Figure 2) which is therefore provided with four posts 63 to guide the installation, and with means to ensure the final positioning of the manifold 60 within the established tolerances. In one of the ends of the template 50 are located the two bases of the export line terminals 64 each of which is provided with two guide-posts removable by ROV, in addition to reaction posts 66 which are intended to act as guides during the lowering of the pulling and connection tools and to transfer the stresses to the template structure. The bases 64 are also provided with receptacles 67 to lock the export line terminals, so that any accidental stresses, such as those caused by anchor dragging, are not transferred to the manifold 60. Any such stresses applied to the template 50 are limited through the use of mechanical fuses (breaking joints) installed in the lines. In the other end of the template 50 are located three bases, identical to those for the export lines, the central one being intended for the connection of the electric umbilical unit and the others being intended for the hydraulic umbilical units. The template 50 also presents, in each one of the four vertices of the structure 68, a guide 69 for piles; the piles can be driven and the template 50, after being levelled, can be attached to them through elastic deformation of their walls. The manifold 60 of Figures 1 and 2 contains a base-structure 70 to which are attached the pipes, the hydraulic and electric control lines, the terminals 73 for connection to the WCTs 74 and to the MSTs 75, and the terminals 76, 77 for connection to the export lines and to the electric and hydraulic umbilical units 78. The pipes are rigid, in four collectors (production, production testing, gas lift and, optionally, water). In addition to their branches, the terminal 73 of each well 57 presents the production line, production testing line, gas lift line, hydraulic supply line, and the operation line of the secondary control system and sub-surface safety valve (SCSSV), said terminals being rigidly attached to the structure 70 of the manifold, the flexibility required for connection being provided by loops 79 in the WCTs 74 and MSTs 75 (Figures 3, 4 and 5) in one case, and by the flexibility of the export lines and umbilical units in another case. The manifold 60 is provided in each branch with gate-type check valves 80, preferably welded, so as to isolate any of the wells during interventions, thus allowing the manifold 60 to be maintained in production. The valves 80 will be operated by ROV which, during the operation, shall remain set on a grid-type floor 83 which covers the manifold. Similarly, the collectors are provided with check valves 84 also operated by ROV and located near the connection to the delivery lines, such connection being achieved through two terminals of which one terminal 76 is for the production line, gas lift line and production testing line, and another terminal 77 is for the water injection line, said valves 84 allowing for the hydrostatic testing of the delivery lines and their connectors from the surface after the laying of those lines. The collectors are interconnected by means of valves 85, so as to allow for circulation operations or even for the temporary use of one of the lines in place of another which may have been temporarily impeded from performing its function. Two hydraulic umbilical units arrive at the manifold 60, each one being intended to serve five wells with eleven lines of which five are for the SCSSV, five are for hydraulic back-up and one is for supply. The supply shuttle valve can be both isolated and replaced by ROV in case of failure, the supply being maintained from one of the umbilical units. The electric umbilical unit is connected to the manifold by means of an electric distribution module 86 (EDM), it being through this module that the two cables (power and signal) branch out into ten pairs of cables. In spite of being installed together with the manifold, the EDM 86 can be retrieved independently, its connection to the umbilical unit being achieved by means of a terminal identical to that of the flow lines, and the connection to the manifold being achieved through ROV-operated connectors. With only minor modifications, the system of this invention allows for the installation of the manifold together with the template, so as to put the wells in production as they are being drilled. This concept removes from the manifold the active components, such as manoeuvre valves, chokes, control modules 87 and transducers, incorporating them in the arrangement of the WCT 74, and on the one hand allowing them to be a retrievable module the maintenance of which can be carried out at the surface, and on the other hand achieving a higher manifold reliability, the inclusion of these components implying minimum modifications in the dimensions of the WCT 74 as compared with the WCTs of satellite wells. As a function of the manoeuvre valves being incorporated at the WCT, its connector to the manifold presents three flow lines: production line, production testing line and annulus line, in addition to the hydraulic lines. The flexibility for connection to the manifold is obtained through loops located in those lines of the WCT. The valves of the WCT have their operating means turned to the external face of the template-manifold and equipped with an interface for secondary operation by ROV. Similarly, the chokes have their position indicators turned to the outside of the template-manifold, allowing for an easy visualization. The WCT 74 is equipped with an anchoring system for ROV-operation of not only the block and line valves, but also the small-diameter valves. The WCT 74 is equipped with a re-entry post 88 which allows, through one single guide-cable connected by ROV, the installation or retrieval of the control module 78, and the tree cap 89 of the WCT, as well as the connection of the installation tool for the performance of wireline operations. Another characteristic of this WCT is that it avails itself of a system of secondary unlocking of the well-head connector, by means of a tool similarly oriented by the re-entry post. The production WCT may be converted to a water injection WCT, on board the completion rig, through the mere inversion of the production choke. The subsea production system was conceived so as to allow for the interconnection of satellite wells; for this, any of the ten guide-bases 55 may be utilized, even in the presence of an installed well-head. This flexibility is obtained through the installation of an intermediate structure, the flow-line structure 90, locked externally to the guide-pipe 54. The flow-line structure 90 consists of a mechanical connector 93 operated by a specific tool to be locked to the external section of the guide-pipe 54 of the template and with an internal section in its upper portion designed to lock the MST 75. On beams branching out from the connector there is welded a cradle-structure 94 identical to those utilized in the template for the connection of the delivery lines and umbilical units, except for the absence of guide-posts, since in this case the pulling tool and the connection tool 95 are oriented by the external posts of the guide-base. Similarly, the lines originating from the satellite wells will be equipped with terminals similar to those of the delivery lines and umbilical units. The cradle-structure 94 allows for the setting of the pull-in tool, which pulls and locks the lines of the satellite well. Then the connection tool 95 is lowered, for releasing the terminal from the lines and then moving it towards the terminal 96 of the flow-line structure 90, inserting among them a plate containing the sealing rings. At last, two clamps are fastened against the terminals by means of bolts operated by the tool. From the terminal 96 of the flow-line structure there branch out pipes (annulus and production), as well as eight hydraulic lines and an electric cable for a pressure and temperature transducer (DPTT), ending in two vertical connectors 97, one for the flow lines and another for control, the flow-line structure 90 being installed with a drill pipe through the moonpool of the completion rig. The MST 75 allows for flow control between the satellite well and the manifold, transmitting also the functions of control and supervision. The MST consists of a connector 98 which is locked internally to the mechanical connector 93 of the flowline structure 90. This connector is hydraulically operated and provided with secondary mechanical unlocking, with extension up to the top of the MST 75 for operation by a tool run with drill pipe, incorporating the manoeuvre valves, chokes, control modules and transducers. The MST 75 has two vertical connectors for connection to the connectors 97 of the flow-line structure 90, and the terminal for horizontal connection to the manifold is identical to that of the WCT. The valves of the MST have their operating means turned towards the external face of the template-manifold and equipped with an interface for secondary operation by ROV. Similarly, the chokes has their position indicators turned towards the outside of the template-manifold. The MST is provided also with an anchoring system for ROV-operation of manoeuvre valves and small-diameter valves, and is equipped with a re-entry post 88 with functions identically to that of the WCT. The MST 75 can be similarly converted from production to water injection through the mere inversion of the production choke. The template-manifold may be equipped with a control system of the multiplexed electro-hydraulic type, with control modules 87 located in the WCTs 74 and MSTs 75.

Claims: A subsea production system, including a template structure (50), a manifold structure (60) containing pipes, control lines, check valves for said pipes, and connectors, and wet christmas trees (74) wherein the active components comprising manoeuvre valves and chokes are located in the wet christmas trees (74), characterized in that the system also includes control modules (87) as active components in the wet christmas trees (74), satellite tree interconnection modules (75), which may optionally be equipped also with a control of multiplexed electro-hydraulic type, wherein said template structure comprises means for detachably mounting said plurality of wet christmas trees and said plurality of satellite tree interconnection modules, in that the active components, comprising manoeuvre valves, chokes and control modules (87) are located in said satellite tree interconnection modules (75); and in that said wet christmas trees (74) and satellite tree interconnection modules (75) are located on the template structure (50). A subsea production system, according to claim 1, characterized in that the template (50) includes:-drilling mouths (53), each consisting of a guide-pipe (54) and a guide-base (55) provided with four posts (56) which are removable by means of a remotely operated vehicle; a central space provided with posts (63) for the setting of said manifold (60); bases of the delivery line terminals (64) located at one of its ends; bases identical to the bases (64) of said delivery lines located in the other end; and a guide (69) for a pile, positioned in each of the four vertices of the structure (68). A subsea production system according to claim 2, characterized in that each said base of the delivery line terminals (64) is provided with two guide-posts removable by means of a remotely operated vehicle, in addition to reaction posts (66) to guide the lowering of the pulling and connection tools and to transfer the stresses to the structure (68) of said template (50). A subsea production system according to claim 2 or 3, characterized in that each said base (64) presents receptacles (67) to lock the delivery line terminals. A subsea production system, according to claim 2, 3 or 4, characterized in that, of the three said bases identical to the bases (64) of the delivery lines, the central base is intended for the connection of the electric umbilical unit, and the lateral bases are intended for the connection of the hydraulic umbilical units. A subsea production system, according to any one of claims 2 to 5, characterized in that said guide-pipes (54) are provided with external sections to lock guide-funnels or the flow-line structure (90) as an intermediate structure. A subsea production system, according to claim 6, characterized by including the flow-line structure (90) as an intermediate structure locked externally to said guide-pipe (54). A subsea production system, according to claim 6 or 7, characterized in that said flow-line structure (90) consists of a mechanical connector (93), from which branch out guides on which is welded a cradle-structure (94) and a terminal (96). A subsea production system, according to claim 8, characterized in that, of the said terminals (96) of said flow-line structure (90), there branch out tubing and casing pipes, hydraulic lines and electric cable for pressure and temperature transducer, and ending in two vertical connectors (97). A subsea production system, according to any one of claims 1 to 9, characterized in that the manifold (60) includes:- a base-structure (70) for attachment of the pipes, the hydraulic and electrical control lines, the terminals (73) for connection to said wet christmas trees (74) and to said satellite tree interconnection modules (75), and the terminals (76, 77) for connection to the delivery lines and to the electric and hydraulic umbilical units (78); gate-type check valves (80) arranged in each branch; check valves (84) provided in the collectors and located near the connection to the delivery lines; valves (85) for interconnection of the collectors; electric cables and hydraulic lines; and electric distribution module (86) for connection of the electric umbilical unit to said manifold (60); pipes for production, production testing, water injection and gas lift; and connectors for the wet christmas trees (74), satellite tree interconnection modules (75), export lines and control umbilical units. A subsea production system, according to claim 10, characterized in that said terminal (73) of each well (57) presents the production lines, production testing lines, gas lift lines, hydraulic supply lines, and operation lines of the secondary system and sub-surface safety valve. A subsea production system, according to claim 10 or 11, characterized in that said terminals (73) are rigidly attached to said base-structure (70), the flexibility required for the connection being provided by means of loops (79) in the wet christmas trees (74) and satellite tree interconnection modules (75) and by the flexibility of the export lines and umbilical units. A subsea production system, according to any one of claims 10 to 12, characterized in that the valves of said wet christmas tree (74) and/or those of said satellite tree interconnection module (75) have their operating means turned to the external face of the assembly of template (50) and manifold (60) and are equipped with an interface for secondary operation by means of a remotely operated vehicle. A subsea production system, according to any one of claims 10 to 13, characterized in that said wet christmas tree (74) contains a re-entry post (88) to install or to retrieve the control module (87) and/or the tree cap (89) of the wet christmas tree (74), as well as to connect the installation tool for the performance of wireline operations. A subsea production system, according to claim 14, characterized in that said production wet christmas tree (74) and/or said production satellite tree interconnection module (75) may be converted for water injection through the mere inversion of the production choke. A subsea production system, according to any one of the preceding claim 14 or 15, characterized in that said satellite tree interconnection module (75) includes a re-entry post (88) with functions identical to that of said wet christmas tree (74). A subsea production system, according to any one of claims 10 to 16, characterized in that said satellite tree interconnection module (75) includes a connector (98) able to be locked internally to said mechanical connector (93) of said flow-line structure (90), said connector (98) being hydraulically operated and provided with secondary mechanical unlocking, with extension up to the top of said satellite tree interconnection module (75). A subsea production system, according to claim 2 alone or in combination with any one of claims 3 to 17, characterized in that the intermediate structure (90) and the satellite tree interconnection module (75) may be installed in any well mouth (53), so as to interconnect satellite wells; and in that this system may operate as a manifold, provided all mouths are equipped with flow-line structures and satellite tree interconnection modules.

Inventors: CAPPLONCH RICARDO WAGNER, COELHO EDUARDO JOSE DE JESUS, PAULO CEZAR AUGUSTO SILVA, SANTOS FILHO AMAURY GARCIA DOS, SILVA JOSE EDUARDO MENDONCA DA, CAPPLONCH, RICARDO WAGNER, COELHO, EDUARDO JOSE DE JESUS, PAULO, CEZAR AUGUSTO SILVA, SANTOS FILHO, AMAURY GARCIA DOS, SILVA, JOSE EDUARDO MENDONCA DA, Coelho, Eduardo José de Jesus, Silva, José Eduardo Mendonça da
Applicants: PETROLEO BRASILEIRO SA, PETROLEO BRASILEIRO S.A. - PETROBRAS
Application year: 1991
Main classification: E21B43
IPC codes: E21B43, E21B41