Subsea production system and method for line connection between a manifold and adjacent satellite wells

Abstract: This invention relates to a subsea production system in which the radial distance between each well (37) and the manifold (38) shall be reduced to an operational minimum, provided with connection terminals (45) which include:- at the lower portion a connector (47) of hydraulic type, and at the upper portion a re-entry mandrel (50) and a supporting structure (53) consisting of, at the lower portion a mud mat (54), centrally a waiting mandrel (55), laterally a structure (56) provided at the upper portion with eyelets (57), and at the upper portion a re-entry funnel (58). This invention also relates to methods for line connection between a manifold (38) and adjacent satellite wells (37).

Description: This invention relates to a subsea petroleum system in which the production from various wells is grouped in one single unit (manifold) and in which the distance between each well and the manifold is reduced to an operational minimum; the invention includes also the methods for line connection between the manifold and the adjacent wells. In the 1970′s, the petroleum industry started adopting the production of subsea wells and, as a consequence, wet christmas trees were developed. In the beginning, the production from various satellite wells was collected into a central manifold, usually installed on a platform, and transported from there to floating production storage units or to fixed platforms. With the discovery of large fields in deep waters, the petroleum industry started adopting central systems for subsea production collecting, as an economically more feasible option for the production development of those fields. For economic reasons, the usual practice has been to group the production from various wells through two main systems: (a) the manifold and (b) the manifold-template. (a) In the manifold system the wells are drilled from independent bases and located at minimum distances of nearly 300 m from the manifold; between the wells and the manifold independent subsea lines are used. The lines from the manifold to the surface production unit are common, which provides an economic advantage. (b) In the manifold-template system the wells are drilled from one single structure, offering as a main advantage economy in subsea lines between wells and manifold, as well as in the operations of connecting those lines. In this case the manifold is coupled to the drilling guide structure, known as the template. However, the advantages of the manifold-template are accompanied by various limitations, aggravated as the water depths become greater and greater, where floating vessels equipped with dynamic positioning systems are utilized in place of anchored platforms. In these cases, it is of fundamental importance to increase the distance between wells in order to reduce the risk of collision between equipment units, which could have serious environmental and economic consequences. With the purpose of assisting the exploitation of deep-water reservoirs, the prior art discloses the use of manifolds with wells located at large spacings, that is, in the range of 300 m or more, in which the christmas trees are preferably of the lay-away type, that is, they are installed already connected to the flow lines, so as to reduce the line-connection operations which would be performed in the other extreme, i.e. in the manifold. However, this technical solution, presents a disadvantage of an economic nature as a function of the line lengths utilized and of operational safety, since the long line section leads to the simultaneous utilization of two dynamic-positioning vessels: the rig and the lay barge. The prior art such as GB-A-2226063 also discloses a manifold-template which branches off radially from a central foundation on which said structure is set so as to remain out of contact with the marine ground and on which is located the central manifold for well production control. Each arm of the central structure has in its extremity an opening for adaptation of a guide-base to allow for well drilling and structure attachment, one of the structure arms being intended to receive the connectors of the export lines and of the well-control lines. However, structures of the above-mentioned type present as major disadvantages the fact that the manifold-template incorporates structures of large dimensions, such as arms to define the distances in an attempt to make feasible the operation with dynamic-positioning vessels and to minimize the large risk involved in those operations. As compared with the manifold-templates which incorporate structures of large dimensions, such as arms, the system hereinafter proposed according to this invention offers as advantages, in relation to the manifold-template mentioned above:- (a) the full flexibility in relation to the slope of the sea bottom, without the need for the provision of alignment means to correct deviations in well drilling, such as universal joints, loops and active connectors between the wet christmas tree (WCT) and the manifold-template; (b) the ability to be free from problems caused by drilling cuttings, without the need for the provision of equipment for debris dispersion, or space for the accumulation of debris which imply the separation of the manifold-templates from the ground; (c) the possibility of allowing for early drilling in relation to template installation, which renders the system advantageous even in water depths allowing for the use of guide- cables; (d) dispensing with the provision of contingency mouths, since the wells do not integrate the structure; (e) allowing for easy access of an ROV for inspection and operation of valves in the manifold and in the WCTs as a function of the distance between them; (f) allowing for a higher operational safety, as a function of the larger distance between the WCTs and the manifold, thereby drastically reducing the risk of damage caused by collision and dropping objects, particularly in operations without guide-cables; (g) the ability to present a simpler structure, not requiring arms, nor suffering the influence of stresses originating from the wells; (h) allowance for simpler operation, since it makes it feasible to lower the operating costs, and even the cost of the drilling rig itself; (i) in certain cases the avoidance of piling or levelling, the ability to be set on the sea bottom which in contrast to the use of templates allows its retrieval at the end of the project, leaving the sea bottom clear and enabling its reinstallation in another location as well as its retrieval for maintenance; (j) the independence of the connection between the satellite wells and the manifold of the height of the manifold structure in relation to the marine ground, since the traditional methods of connection, such as pull-in, are significantly impaired by the structure height; (k) the fact that the connection between the satellite wells and the manifold is not greatly affected by the configuration of the marine ground; (l) the fact that a larger number of wells may be interconnected to the system for identical dimensions of a manifold-template with arms, since the area required for connecting a satellite well to the manifold by the methods hereinafter proposed is much less than the area occupied by a well of the template; (m) the utilization of cheaper flexible lines due to the expectation of much smaller stresses than those of the traditional lay-away methods which involve long line lengths; and (n) the utilization of christmas trees used in satellite wells and already tested at great water depths, etc. In comparison with a manifold with satellite wells located at large distances, the system hereinafter proposed offers the major advantage of economy in lines and installation costs, as well as reducing drastically the risks of paraffin deposition in the lines as a function of the reduced line length exposed to the low sea bottom temperatures at great water depths. It is, therefore, an object of this invention to provide a subsea production system in which the radial distance between each well and the manifold shall be reduced to an operational minimum, possibly less than 50 m, offering the previously mentioned advantages, including a base-structure which can be directly set on the marine ground; the lines of the adjacent satellite wells connected to the base-structure which may or not contain the manifold; a manifold consisting of structures, pipes, check valves, modules and lines of the control system, connectors for the modules and valves and chokes, as well as terminals for interconnection to the modules of valves, containing manoeuvre valves, chokes and pressure transducers; a system for connection of the lines of the satellite wells promoting the interconnection of the satellite wells to the manifold containing christmas trees of the satellite wells preferably of the usual lay-away type; and interconnection lines of the satellite wells to the manifold of flexible or rigid type provided with flexible extremities, as well as connecting terminals. The subsea production system of the present invention is as defined in claim 1. The preamble of claim 1 is based on GB-A-2226063. The method of the present invention is defined in claim 6. The above-mentioned connecting terminals utilized in the system of this invention may in a first embodiment consist of a connector of hydraulic type presenting laterally a plate for connection to the lines of the satellite well which will be equipped with bending restrictors and optionally with shearing devices and, at the top, with a re-entry mandrel; said terminal may also be provided with a supporting structure consisting of a mud mat, a waiting mandrel, a lateral structure, eyelets for structure retrieval, and a re-entry funnel. A second embodiment of connection terminal utilized in the system of this invention may include a hydraulic type of connector presenting (i) laterally a plate for the satellite well connection lines which will be equipped with bending restrictors and optionally with a shearing device, and (ii) at the top a re-entry mandrel and upper and lower re-entry funnels to facilitate the retrieval and the installation of the terminal, said terminal being provided also with a supporting structure consisting of a mud mat, a waiting mandrel and eyelets for structure retrieval. This invention also relates to methods for line connection between the manifold and the adjacent satellite wells of that system. These and other objects and advantages will become more apparent from the following detailed description taken together with the accompanying drawings, in which:- FIGURES 1A and 1B are illustrative plan views of the manifold-template with arms and manifolds with distant satellite wells, according to the prior art; FIGURE 2 is an enlarged illustrative view of the subsea production system in accordance with this invention; FIGURE 3 is a sectional view of a first embodiment of the connection terminal and its supporting structure utilized in the subsea production system shown in Figure 2; FIGURE 4 is a sectional view of a second embodiment of the connection terminal and its supporting structure utilized in the subsea production system shown in Figure 2; FIGURES 5A to 5H are illustrative views showing various stages of the method for line connection between a manifold and an adjacent satellite well; FIGURES 6A and 6B are illustrative views showing the various stages of a first alternative of the method for line connection between a manifold and an adjacent satellite well; FIGURES 7A to 7D are illustrative views showing the various stages of a second alternative of the connection method; FIGURES 8A to 8H are illustrative views showing the stages of a third alternative of the connection method; and FIGURES 9A and 9B are illustrative views showing the various stages of a fourth alternative of the connection method. Figures 1A and 1B illustrate a prior art manifold-template 30 incorporating structures of large dimensions, such as arms 33 to provide spacers trying to make feasible the safe operation with dynamic-positioning vessels and with the manifolds 34 already connected to the satellite wells 35 at large distances. As can be inferred from Figure 2, the subsea production system, according to this invention, includes:- a base-structure 36 which can be piled or directly set on the marine ground, which may contain a manifold 38, and which may also be removed, in case of damage, for maintenance; a manifold 38 consisting of structure, pipes, check valves, modules and lines of a control system, in addition to terminals 39 for interconnection of the modules of valves and chokes 40 and also of connection bases 46; adjacent satellite wells 37 equipped with wet christmas trees 43 preferably of the lay-away type; connection terminal 45; and a connection system allowing for the interconnection of said satellite wells 37 to said manifold 38 by means of flexible or rigid lines 44 provided with flexible ends. It must be pointed out that in the case of severe damage the base-structure 36 may be removed for maintenance, and that it makes it possible to leave the sea bottom clear at the end of the life of the project. The manifold 38 may or may not be retrievable; if it is retrievable then the pipes, control lines, check valves, connectors, etc., may be brought back to the surface for maintenance purposes; if it is not retrievable then those components will be integrated in the base-structure 36. The modules of valves 40 contain manoeuvre valves, chokes and pressure transducers, each serving at least one well, so that the removal of one of the modules for maintenance does not imply a full halt in production. Their dimensions are preferably limited to the handling capacity of the drilling rig. Alternatively, the manoeuvre valves, chokes and transducers may integrate the WCTs, largely simplifying the manifold. all the operations are performed without the use of guide-cables. As it may be seen from Figure 3, the connection terminal 45 utilized in a first embodiment of the subsea production system, includes at the lower portion a connector 47 of hydraulic type with hydraulic secondary unlocking and mechanical tertiary unlocking, provided with accesses for the production and annulus lines, hydraulic control lines and electric cable for connection to the terminal of the manifold, and provided laterally with a swivel 48 for connection to the lines 44 of the satellite well 37. These connection lines will be equipped with bending restrictors 49 and optionally with shearing pieces, and at the upper portion with a re-entry mandrel 50, a supporting protection structure 53 for access to the connection terminal 45 which consists of, at the lower portion a mud mat 54 for setting on the marine ground, centrally a waiting mandrel 55 for support of the terminal 45 which shall also prevent cuttings from entering the terminal 45, a lateral structure 56 provided at the top with eyelets 57 for retrieval of the supporting structure 53 after the installation of the terminal at the connection base 46 of the manifold, and at the top a re-entry funnel 58 to facilitate the retrieval of the connection terminal 45. Therefore, the subsea production system of this invention includes:- a base-structure 36 which may be piled or directly set on the marine ground, may contain a manifold 38, and may in case of damage also be removed for maintenance purposes; a manifold 38 consisting of structure, pipes, check valves, modules and lines of a control system, in addition to terminals 39 for interconnection of valves and chokes 40, and also of connection bases 46; adjacent satellite wells 37 preferably equipped with wet christmas trees 43, of the lay-away type, which may contain manoeuvre valves, chokes and transducers; connection terminals 45 consisting of, in their lower portion a connector 47 of hydraulic type provided laterally with a swivel 48 for connection to the lines 44 of the satellite wells 37, said lines 44 being equipped with bending restrictors 49, and in their upper part a re-entry mandrel 50; supporting structure 53 of the connection terminals 45, said structure consisting of a lower mud mat 54, a central waiting mandrel 55, and a lateral structure 56, said structure being provided with eyelets 57 and re-entry funnel 58; and a connection system provided with flexible ends and allowing for the interconnection of said satellite wells 37 to said manifold 38 by means of lines 44 of flexible or rigid type. Moreover, in a second embodiment shown in Figure 4 the connection terminal 45 includes a connector 47 of hydraulic type with hydraulic secondary and mechanical tertiary unlocking, provided with:- accesses for the production line and annulus line, hydraulic control lines and electric cable, for connection to the terminal of the manifold; laterally with a swivel 48 for connection to the lines 44 of the satellite well 37, which will be equipped with bending restrictors 49 and optionally with shearing pieces; at the top, a re-entry mandrel 50 and an upper 59 and a lower re-entry funnel 60, as well as a supporting structure 63 for protection and access to the connection terminal 45. This connection terminal 45 consists, at the lower portion, of a mud mat 54 for setting on the sea bottom, presenting, at the top and laterally, eyelets 57 for retrieval of the supporting structure 63 after the installation of the terminal 45 at the connection base 46 of the manifold. The re-entry funnel 58 and the upper re-entry funnel 59 are preferably identical to the top of WCT 43, and the connection terminals 45 have re-entry mandrels 50 identical to the top of WCT 43 (Figure 2) so as to allow for the use of the WCT installation tool. The method for connecting the lines between a manifold 38 and adjacent satellite wells 37 is illustrated on Figures 5A to 5H. It must be pointed out that either embodiment of the connection terminal 45 may be utilized, it being necessary only to alter the connection base of the manifold. For purposes of illustration, in the connection method hereinafter described only the connection terminal of the first embodiment of the invention will be utilized. As can be inferred from Figures 5A to 5H, after the installation of the WCT 43 by rig 64 at the satellite well 37, the supply boat 65 lays the interconnection lines 66 between the well and manifold towards the manifold 38, abandoning them with a connection terminal 45 and their supporting structure 53 at their end. There are also illustrated an auxiliary cable 67 and a completion riser 68 (Figure 5A). After the laying of the lines 66 with the connection terminal 45 at the end, the supply boat 65 moves away and the rig 64 remains operating on the WCT 45 (Figure 5B). Once the completion is finished, the rig 64 moves towards the manifold 38 to fish the connection terminal 45 using the completion riser 68 and the WCT installation tool 69 itself (Figure 5C). Then the WCT installation tool 69 and the completion riser 68 (Figure 5D) are coupled to the connection terminal 45. The connection terminal 45 is then hoisted without the supporting structure 53 (retrievable a posteriori , with ROV assistance) and coupled to one of the terminals of the manifold 38, the connection being thereafter tested (Figure 5E). The supporting structure 53 is retrieved by the rig 64 using the cables 70 and with the assistance of ROV 71 (Figure 5F). The retrieval of the supporting structure 53 by the rig 64, illustrated on Figure 5G, is then completed to finish the interconnection of the adjacent well 37 to the manifold 38 (Figure 5H). It must be pointed out that the supply boat 65 (lay barge) is preferably a DP (dynamic positioning) vessel provided with A-frame since, in view of the short line section to be handled, there is no need for vessels of larger dimension. A first alternative of the connection method described above is illustrated in Figures 6A and 6B where, in contrast to the supply boat 65, a second rig 72 is utilized; in this case the WCT 43 will be lowered at the head of the well 37 simultaneous with the connection terminal 45, which therefore dispense with the supporting structure 53. A second alternative of the connection method is illustrated on Figures 7A to 7D, in which the installation of the connection terminal 45 is achieved with assistance of an operation tool equipped with thrusters. As can be seen from these Figures, the rig 64 installs the WCT 43, and the connection terminal is hoisted by the tool 73 equipped with thrusters 74, by remote-operation from a supply boat 65 (Figure 7A). After the installation of the WCT 43, the rig 64 works on the well 37 and the section 66 of lines is laid during the movement of the supply boat 65 towards the manifold 38 with the connection terminal 45 hanging from the remote-operation tool 73 (Figure 7B). The connection terminal 45 is coupled to the manifold 38, with the final adjustment facilitated by the thrusters 74 of the remote-operation tool 73 (Figure 7C), thus completing the interconnection of the adjacent well 37 to the manifold 38. The rig 64 is shown on the WCT 43 (Figure 7D). A third alternative of the connection method is illustrated on Figures 8A to 8H, in which the connection terminal 45 and the supporting structure 53 are hoisted from the rig 64 which installs the WCT 43. As can be seen from these Figures, the connection terminal 45 and the supporting structure 53 are hoisted from the rig 64 which installs the WCT 43, by means of an auxiliary cable 75 (or attached to the riser) originating from an auxiliary winch 76 installed on board or at the moonpool of the rig 64 (Figure 8A). The WCT 43 is installed on the well 37 with the connection terminal 45 and the supporting structure 53 still hanging from the rig 64 (Figure 8B). Once the installation of the WCT 43 has been completed, the rig 64 lays the connection terminal 45 with the supporting structure 53 (Figure 8C). Thereafter the installation is used to couple the WCT installation tool 69 to the connection terminal 45 to complete the riser 68 (Figure 8D). The connection terminal 45 is then hoisted without the supporting structure 53 and is coupled to one of the terminals of the manifold 38, the connection being thereafter tested (Figure 8E). The supporting structure 53 is then retrieved by the rig 64 using cables 70 and with the assistance of the ROV 71 (Figure 8F). After the retrieval of the supporting structure 53 by the rig 64, illustrated on Figure 8G, the interconnection of the adjacent well 37 to the manifold 38 is then completed (Figure 8H). A fourth alternative of the connection method of this invention is illustrated on Figures 9A and 9B in which, after the laying of the connection terminal 45, as shown in Figures 8C and 8D of the third alternative of the connection method, the connection terminal 45 is fished by the remote-operation tool 73 controlled from the supply boat 65, thus releasing the rig 64 (Figure 9A). The connection terminal 45 is thereafter coupled to the manifold 38, the final adjustment being facilitated by the thrusters 74 of the remote-operation tool 73 (Figure 9B), and the supporting structure 53 then retrieved, (a step which is not shown in the Figures) thus completing the interconnection of the adjacent well 37 to the manifold 38, as in Figure 8H. It must also be pointed out that there are possible variations of the method above, to lay the lines in the direction the manifold 38 to the WCT 43 using the same method and equipment units. The system here proposed may be embodied alternatively by the proven traditional pull-in methods, in which the connection terminal becomes a pull-in head and the approach of the pull-in head and the connection to the manifold 38 are achieved by the use of standard tools and techniques.

Claims: A subsea production system, including:- a base-structure (36) which can be either piled or directly set on the marine ground, may contain a manifold (38), and may be removed for maintenance in case of damage; a manifold (38) consisting of structure, pipes, check valves, modules and lines of a control system, in addition to terminals (39) for interconnection of modules of valves and chokes (40) and of connection bases (46); adjacent satellite wells (37) preferably equipped with wet christmas trees - WCTs - (43) of the lay-away type; characterized by connection terminals (45) consisting of, (i) in their lower portion a connector (47) of hydraulic type, (ii) laterally a swivel (48) for connection to the lines (44) of the satellite wells (37), said lines (44) being equipped with bending restrictors (49), and (iii) in their upper portion a re-entry mandrel (50); a supporting structure (53) of the connection terminals (45), said structure consisting of a lower mud mat (54), a central waiting mandrel (55) and a lateral structure (56), and said structure (56) being equipped with eyelets (57) and re-entry funnel (58); and a connection system provided with flexible ends allowing for the interconnection of said satellite wells (37) to said manifold (38) by means of the lines (44) of flexible or rigid type. A subsea production system according to claim 1, characterized in that the manoeuvre valves, chokes and transducers are installed in the WCTs (43) instead of in the modules of valves and chokes, thereby considerably simplifying the manifold (38), and rendering it more reliable; and in that all the operations are performed without guide-cables. A subsea production system, according to claim 1 or 2, characterized in that said connection terminal (45) includes a connector (47) of hydraulic type provided with, laterally:- (i) a swivel (48) for connection to the satellite well lines (44) which are equipped with bending restrictors (49), (ii) centrally and at the top a re-entry mandrel (50) and upper (59) and lower (60) re-entry funnels, and (iii) a supporting structure (63) which includes at the lower portion a mud mat (54), at the upper portion and centrally a waiting mandrel (55) and at the upper portion and laterally eyelets (57). A subsea production system according to claim 1, 2 or 3, characterized in that the connection terminals (45) are pull-in heads and in that after the abandonment of the terminal on the marine ground, the pull-in head is pulled by methods which utilize pull-in tools. A subsea production system according to any one of claims 1 to 4, characterized in that the re-entry funnel (58) and the upper re-entry funnel (59) are preferably identical to the top of the WCT (43); and in that said connection terminals (45) present re-entry mandrels (50) identical to that of the top of the WCT (43). A method for line connection between a manifold (38) and adjacent satellite wells (37), characterized by including the following steps:- laying the well manifold interconnection lines (66) using a supply boat (65) which moves towards the manifold (38), abandoning said interconnection lines (66) with a connection terminal (45) and its supporting structure (53) on their ends, after installation of the WCT (43) using the rig (64) at the satellite well (37); removing the supply boat (65) after laying the interconnection lines (66) with the connection terminal (45) and its supporting structure (53) on their ends, while the rig (64) remains operating on the WCT (43); once the completion has been finished, moving the rig (64) away towards the manifold (38) to fish the connection terminal (45) through the completion riser (68) and the WCT installation tool (69) itself; coupling the WCT installation tool (69) and the completion riser (68) to the connection terminal (45); hoisting the connection terminal (45) without the supporting structure (53) and coupling it to one of the terminals of the manifold (38); testing the connection of the connection terminal to the manifold; and retrieving the supporting structure (53) by means of the rig (64) using cables (70) and with the assistance of ROV (71), thus completing the interconnection of the adjacent well (37) to the manifold (38). A method according to claim 6, characterized by using a second rig (72) instead of said supply boat (65), and lowering the WCT (43) at the head of the well (37) simultaneously with lowering of said connection terminal (45). A method according to claim 6, characterized by including the following steps: installing the WCT (43) at the satellite well (37) by means of the rig (64) and hoisting the connection terminal (45) by means of a remote-operation tool (73) equipped with thrusters (74), controlled from a supply boat (65); after installation of the WCT (43), using the rig (64) to operate on the well (37) while the section (66) of lines is laid during movement of the supply boat (65) towards the manifold (38) with the connection terminal (45) hanging from the remote-operation tool (73); and coupling the terminal (45) to the manifold (38), thus completing the interconnection of the adjacent well (37) to the manifold (38). A method according to claim 6, characterized by including the following steps:- hoisting the connection terminal (45) and the supporting structure (53) by means of the rig (64) which installs the WCT (43), using an auxiliary cable (75) originating from an auxiliary winch (76) installed on board or in the moonpool of the rig (64) itself; installing the WCT (43) on the well (37) with the connection terminal (45) and the supporting structure (53) hanging from the rig (64); once the installation of the WCT (43) has been completed, using the rig (64) to lay the connection terminal (45) with the supporting structure (53); coupling the WCT installation tool (69) and the completion riser (68) to the connection terminal (45); hoisting the connection terminal (45) without the supporting structure (53) and coupling said terminal (45) to one of the terminals of the manifold (38), and then testing the connection; and retrieving the supporting structure (53) by means of the rig (64) with cables (70) and with the assistance of an ROV (71), thus completing the interconnection of the adjacent well (37) to the manifold (38). A method according to claim 9, characterized by including the following steps: after laying the connection terminal (45), fishing said connection terminal (45) by means of the remote-operation tool (73) controlled from the supply boat (65), thus releasing the rig (64); coupling the connection terminal (45) to the manifold (38) by means of the remote-operation tool (73); and retrieving the supporting structure (53), thus completing the interconnection of the adjacent well (37) to the manifold (38). A method according to claim 8 or 10, characterized in that, in the step of coupling the connection terminal (45) to the manifold (38) by means of the remote-operation tool (73), the final adjustment of said coupling is facilitated by the thrusters (74) of said remote-operation tool.

Inventors: SILVA JOSE EDUARDO MENDONCA DA, SILVA, JOSE EDUARDO MENDONCA DA, Silva, José Eduardo Mendonça da
Applicants: PETROLEO BRASILEIRO SA, PETROLEO BRASILEIRO S.A. - PETROBRAS
Application year: 1991
Main classification: E21B43
IPC codes: E21B43