Deep water slim hole drilling system

Abstract: The present invention relates to an arrangement to be used when drilling oil/gas wells, especially deep water wells, and the invention gives instructions for how to utilise the riser pipe as part of a high pressure system together with the drilling pipe, namely in that the arrangement comprises a surface blowout preventer (SURBOP) which is connected to a high pressure riser pipe (SR) which in turn is connected to a well blowout preventer (SUBBOP), and a circulation/kill line (TL) communicating between said blowout preventers (SURBOP, SUBBOP), all of which being arranged as a high pressure system for deep water slim hole drilling.

Description: Field of the invention The present invention relates to a deep water slim hole drilling system, and more specifically to such an arrangement designed to be installed on the seafloor to conduct a high pressure connection between an oilwell and a floating drilling vessel. Prior art From US 4.046.191 there are known different types of subsea blowout preventers including annulus shut off rams, share rams, etc. From US 3.424.253 there is known a method for drilling and working in offshore wells, in which method a blowout preventer has been located at the platform, i.e. at the top of the riser pipe. U.S. Patent No. 4 193 455 discloses a bottom-supported offshore structure including drilling equipment for use in drilling a well bore. The drilling equipment includes a surface blowout preventer (BOP) which is connected to a riser which in turn is connected to a well which comprises means for controlling flow of fluid into and out of the well and a well blowout preventer positioned at the well head. A drill string can be passed into the well through the assembly comprising the riser and the two blowout preventers. U.S. Patent No. 4 046 191 discloses a system for offshore drilling from a floating drilling structure. This system comprises a blowout preventer assembly at the lower end of a riser. The blowout preventer assembly is provided with bypass lines for relieving pressure. Summary of the invention The object of the present invention is to give instruction for utilizing the riser pipe as part of a high pressure system together with the drilling pipe. More specifically the present invention gives instructions for an arrangement comprising a surface blowout preventer or BOP-stack which will form the main pressure control barrier, a high pressure riser pipe which is adapted for housing the drilling string, as well as a subsea blowout preventer adapted to disconnect the riser pipe system and secure the well at the sea bed, especially in connection with slim hole drilling. Further, the subsea blowout preventer stack should allow for pressure control through a separate high pressure circulation and test hose included in the control umbilical. More specifically the present invention is characterized in that the arrangement comprises a surface blowout preventer which is connected to a high pressure riser pipe which in turn is connected to a well blowout preventer, and a circulation/kill line communicating between said blowout preventers, all of which being arranged as a high pressure system for deep water slim hole drilling. Further features and advantages offered by the present invention will appear from the following description taken in connection with the appended drawings, as well as from the appended patent claims. Brief disclosure of the drawings Fig. 1 is the arrangement drawing, showing valves and lines for the system. Fig. 2 is the arrangement drawing showing the double wellhead design. Fig. 3 is the general arrangement system showing the overall system components. Fig. 4 shows the deep water BOP system. Description of embodiments In the following embodiments of an arrangement according to the invention will be described. 3.0 DEEPWATER SYSTEM DESCRIPTION 3.1 General To be able to fully understand the new deepwater technology with operations from a small dynamic positioned drilling vessel, this section will combine description and requirements to equipment with operational considerations and activities. For the deepwater subsea coiled tubing drilling operation, a new 7.06"( 345 bar or 690 bar) CTBOP shall be built to allow for a multiple section well. The CTBOP system for the deepwater application will have a configuration where a Subsea CTBOP-stack is attached to the well head on the sea bed. A Surface Coiled Tubing BOP-stack formes the upper termination point of a high pressure riser system suspended by the Tensioning System. The Surface Coiled Tubing BOP-stack will form the main pressure control barrier while the subsea CTBOP-stack will have the ability to disconnect the riser system and secure the well at the sea bed. The Subsea CTBOP-stack allows for pressure control through a separate high pressure circulation and test hose included in the control umbilical. The control system will feature a deepwater electrohydraulic Multiplex system. As all the functions are hydraulic " failsafe ", one control system is sufficient ( ref, xmas tree wo systems). As of 1994, most of the conventional rigs are anchored so that they have a water depth capacity of 80-500m. Such semisubmersible drilling units and drillships takes use of guidelines for fast and reliable guiding operations. Experience has shown that under certain circumstances such as drilling in exposed arctic areas with icebergs or drilling in deep water, it may be necessary to use drilling units which can, at short notice, safeguard the the well and sail away so as not to endanger the rig and its crew. Systems based on dynamic positioning have now been developed to make it possible to drill effectivly without guide lines even under difficult conditions. The drilling unit approches the drilling location on a course determined by the wind and weather conditions. About 50-100m from the location an offset beacon is launched for reference and its signal is coded into the computer. When the ship is correctly positioned, a tautline position system is launched to the seabed. Tautline positioning is a secondary positioning device and will normally only be used as a primary system until the Guidelineless Permanent Guide Base (GPGB) with its reflectors and two positioning beacons has been installed. For deepwater applications where a ROV is not-feasible, a TV inspection system based on lowering the camera inside the drilling assebly is run to inspect the seabed prior to installation of the Guidelineless Temporary Guide Base (GTGB) This inside TV inspection system which also will be able to send and read sonar signals, will be used for all reentry operations of subsea equipment and drilling assemblies. There will be special drillbits prepared which will allow the camera/sonar head to protrude clear of the bit. The positioning signals will be taken from the beacon. To be able to find the GTGB after a drive off, sonar reflectors will aid in finding the final location. To be able to turn the ship into prevailing winds and currents the CTBOP,high pressure riser system and the surface coiled tubing equipment must be able to allow for rotation of the vessel. A rotational high pressure swivel joint integrated in the upper section of the riser assembly will allow the vessel to turn around the drilling vertical. As the circulation/test line and control umbilical are fitted to the riser and the rigs piping system, the rig can only turn 270 degrees one way before it must turn all the way back to cover the last sector of prevailing weather. The Subsea CTBOP/EQDP Assembly must include safe methods of orienting, alignment and docking of the individual components. To safeguard the riser from uncontrolled loads, a riser angle indicator is fitted, thus to give the driller an eary warning signal to prepare for emergency disconnection. When operating on dynamic positioning in shallow water (150-500m ), it must be possible to interrupt drilling, secure the hole and disconnect from the Subsea CTBOP , all within 30 seconds. To be able to perform a fast and reliable operation of the Deepwater Subsea CTBOP stack, conventional control systems can not be used. The response time for operation of functions will be excessive of the requirements. An electro-hydraulic MULTIPLEX control system will be used for this operation. As one will learn a deepwater DP operation differs a long way from conventional guidelineoperations from anchored drilling vessels. 3.2 Guidestructures and conductors. The Guidestructure shall provide an important interface to the new Coiled Tubing Wellhead System (CTWH) and to existing drilling rigs.Anticipated loads for the CT drilling operation do not require the use of a 30" Conductor as currently used in subsea drilling. But, a 30" Conductor may be used if an interface to an 18 3/4" BOP Stack system is required. As the CTWH is designed and developed, confidence may allow the elimination of the 18 3/4" Wellhead interface. This would allow running of the 20" Conductor on the Guidelineless Permanent Guide Base. (GPGB) The Guidebase and 20" Conductor shall act together and provide a stable structure for the CTWH System during all operations. All vertical and bending loads shall be effectively transferred through the Guidebase. External loads are estimated to be: Max. Vertical Load + : 91.000 kg Max. Vertical Load - :341.000 kg Max. Horizontal Load : 9.000 kg Max. Total Moment : 677.910 Nm 3.2.1 Interface to 18 3/4" BOP Stacks During development of the CTWH System, a special 18 3/4" Wellhead Housing Adapter will allow an interface to standard 18 3/4" Subsea BOP Stack systems. The same requirements of an 18 3/4" Wellhead Housing are to be met. Additional requirements are: 1. Land and lock inside the Guidelineless Permanent Guide Base (GPGB). 2. Transfer all applied loads to the 30" Conductor Housing (optional). 3. To be run with the 20" Conductor casing string. 4. Provide a landing support shoulder for the CTWH. 5. Provide a sealing profile for an 18 3/4" x CTWH pack-off ( Seal Assembly). 6 Allow CTWH Housing to be locked into the 18 3/4" Wellhead System.( A mechanical latch/unlatch locking ring would be preferable as this would allow the CTWH to be retrievable.) 3.2.2 Optional 30" Conductor A 30" Conductor may be used to support loads from a conventional drilling rig. The CT Drilling Vessel may install the 30" Conductor using standard pipe handling equipment. As interface to conventional drilling rigs is not required the 30" Conductor will not be used. 3.2.3 20" Conductor Casing The 20" Conductor Casing will provide the support required for the CTWH System. The 20" Conductor will be run on the 18 3/4" Wellhead Housing Adapter, initially, to maintain a structural interface to existing rigs. As the 18 3/4" Wellhead Adapter is not needed, it will be replaced by a 20" Conductor Housing. The 20" Conductor Housing will serve the same purpose as a 30" Conductor Housing in current Subsea Wellhead Systems. The 20" Conductor Housing will land and lock onto the GPGB. The 20" Conductor Housing shall transfer all loads from the CT drilling system into the 20"Conductor Casing. 3.2.4 The Guidelineless Temporary Guide Base (GTGB) In deep water it will be essential to install a "Well Locator". Due to currents and a guidelineless operation, the well location must be well defined. To allow for this, a specially equipped guide base, which is a development of an ordinary TGB, shall be used. It is equipped with three sonar reflectors set at 120° to each other. Two transmitters and two slope indicators are also fitted. Onboard the CT Drilling Vessel, a diagram recording all measurements and the placing of the transmitters and reflectors is completed for reference. The GTGB is to be lowered using a pre-assembled drillstring for a 26" (optionally 36") hole , and a special double action J-slot running tool. Before landing on the seabed, a special sonar/TV instrument is lowered down through the drill string and landed on a shoulder in the drill bit. The ocean bed is inspected minutely in order to determine the most suitable location to set down the GTGB. The signals from the transmitters on the GTGB are plotted together with the signals from the offset beacon and in this way the position will be defined. The sonar/TV instrument is drawn into the drillstring and the GTGB is landed. An external "Bluebird Camera" is now run to check the angle of the GTGB. The incline is similary controlled before the drilling equipment is pulled up on completion of drilling. The positioning computer is calibrated once more and the position of the hole is finally defined. The double action J-slot running tool is freed and the mudpumps are started. They flush the drill bit down into the formation until the penetration rate is reduced down to 10m/h . Then the rotation starts. The Double action J-slot running tool will eliminate the need for a separate trip to land the GTGB. Using this tool, operations can be carried out in deep water without having to re-enter the GTGB. It will be possible to land the GTGB and drill the 26" (optional 36") hole in one operation. The running tool is fitted to the GTGB by righthand rotation. After landing on the seabed, the weight will be neutralised and a further righthand rotation will release the inner body to allow for lowering and rotation. 3.2.5 Guidelineless Permanent Guide Base (GPGB) The GPGB is used to support the 30" Conductor Housing prior to cementing the 30"-20" annulus. As the 30" Conductor is phased out the 20" conductor casing will be supported into the GPGB. Additional requirements: 1. Provide slopeindicators for "Bluebird" or ROV observation 2. Transfere temporary loads to the GTGB while drilling out for the 20" (optional 30") Conductor. 3. To be run on a hydraulically operated running tool which latches inside the 20"(optionally 30") Conductor Housing. 4. Provide guidance for 18 3/4" Wellhead Adapter, Drilling BOP Stack, and the Subsea CTBOP System. When the drilling of the 26"(optionally 36") hole is completed and found to be in order, the GPGB is lowered using a preassembled drillstring for drilling of a 2-6 joints of 20" (optionally 30") casingsection using drill pipe. This section can also be jetted in place. The GPGB has already been prepared with two adjusted slope indicators and placed to the side of the ship's moonpool. The 20"(optionally 30") Conductors with the Conductor Housing is lowered down through the GPGB and locked into it. Due to the deepwater operation a hydraulic camactuated running tool must be used. By the camactuated hydraulic running tool and drill pipe, the GPGS is lowered to the seabed. With the conductor shoe 10m above the seabed/GTGB, the sonar/TV instruments are lowered and landed on a special cement shoe. The hole is located and the Conductor and GPGB is entered into the GTGB and landed in the correct location. An external underwater"Bluebird" camera is lowered down along the drillstring in order to check the angle of the GPGB before it is cemented in place. If the 20" (optionally 30") Conductor is to be jetted in place in the formation, a double action running tool for the 20" (30") Conductor Housing is used. In this way an un-nescessary trip can be avoided. The GPGB is to be equipped with a shock absorbing framework to receive the heavy BOP and Subsea CTBOP safely. 3.2.6 Guidance System. For the operational case where a conventional semi submersible shall make an emergency intervention the rig must be able to run guideline systems. To cater for this requirement the guide structure for the guidelineless system will be pulled and replaced with a guideline guiding structure. This can be achieved by using retrievable structures. Both systems are commonly used world wide, and interchangeability will make the operation easy without introducing any new technology. 3.3 Well casing alternatives The CTWH system is based on a "slimhole" well design as used on land type coiled tubing drilling operations. Typical slimhole well programs have used a 9 5/8" casing string as the surface conductor string. This size will not provide the support needed for the CTWH system. A 20" conductor ( or alternatively 30" )is proposed for the CTWH system. The 20" conductor can provide a minimum of 677.910 Nm bending resistance. It is estimated that the bending loads from a 4% offset will be approximately 406.746 Nm for a 7.06" bore wellhead system. A primary concern for the CTWH system is the ability of existing rigs to interface with the CTWH. In this case a 30" conductor string is required to resist the bending loads from an 18 3/4" subsea BOP stack. Another advantage of the proposed system is the ability of existing drilling rigs to drill and install the guide base, 30" conductor, 20" conductor and CTWH housing. The rig may leave, allowing the CT drilling vessel to complete the drilling programme. 3.3.1 Shallow Depth Drilling, 5000 psi (345bar) The shallow depth drilling system proposed would use the following casing program for drilling with only the CT drilling vessel: Casing size: Approx. depth: Type of drilling 20" 150 m open hole 7" 1200 m open hole 5" 2500 m 5000 psi (345 bar)/CTBOP The following is the casing program for drilling with both an 18 3/4" subsea BOP stack or the CTWH system: Casing size: Approx. depth: Type of drilling: 30" 50 m open hole 20" 150 m open hole 7"-9.5/8" 1200 m open hole or 18.3/4" BOP 5" 2500 m 5000 psi (345 bar)/CTBOP 3.3.2 Medium Depth Drilling, 10000 psi (690 bar). The medium depth drilling system would be rated to 10000 psi (690 bar) W.P. This system would require an additional casing string to be included in the drilling program. The proposed CTWH system would be rated to a full 690 bar. The BOP stack, H.P. riser and surface equipment would be rated to 345 or 690 bar W.P. For the 690 bar system two options exist for adding an additional casing string: A: A standard drilling rig would install the 30" and 20" casing strings (18 3/4" housing). An additional casing string, i.e. 13 3/8" or 10 3/4", would be run and set inside the 18 3/4" wellhead housing. This would be similar to normal subsea drilling procedure. The CTWH housing would be run and landed in the 18 3/4" housing. The 7" casing string on the CTWH housing would be a 345 bar rated string. The drilling rig could then leave and the CT drilling vessel would connect onto the CTWH and drill out for the 5" casing string. The CT drilling system would be rated for 690 bar. The casing program for this type of operation: Casing size: Approx. depth: Type of drilling: 30" 50 m open hole 20" 150 m open hole 13.3/8"-10.3/4" 1200 m 18.3/4" BOP 7" 2500 m 18.3/4" BOP 5" 4000 m 690 bar CTBOP B: If the CT drilling vessel performs the complete program, an additional casing string is required. This string would be run inside the 5" casing and landed/locked inside the CTWH. This could be a 3" or 3 1/2" casing string. Further study is required to determine the feasability of running this casing string and the problems associated with slimhole casing programs as stated in section 2.0 The casing program for drilling with the CT drilling vessel: Casing size: Approx. depth: Type of drilling: 20" 150 m open hole 7" 1200 m open hole 5" 2500 m 690 bar CTBOP 3" or 3.1/2" 4000 m 690 bar CTBOP 3.3.3 Production Tubing Requirements The coiled tubing drilling system is well center for production operations. A production string utilizing coiled tubing has several advantages over traditional threaded tubing strings. 1. No threaded connections reduces run time. 2. A continuos string has fewer places for potential leak points. 3. No upsets or couplings are required, which reduces running time of string and increases the circulation annulus area. 4.The CT drilling system would utilize conventional 3 1/2" drill pipe or coiled tubing up to 2" in diameter. The 5" casing string would have an I.O. of 4.276" (108.6) or greater for the 5000 psi 345 bar) rated system. 3.4 Proposed Wellhead System Design. The proposed system is designed to provide an interface to existing 18 3/4" subsea BOP stacks. An 18 3/4" Wellhead Adapter with 20" casing is landed in a 30" housing. The CTWH housing is landed inside the 18 3/4" Wellhead Adapter. At this point the CT drilling vessel would continue the drilling program upon connection to the CTWH. The CT drilling vessel will also be designed to run the same equipment as above. During the initial development of the CTWH system, the ability to have conventional rig back-up should problems occur, is highly recommended. As the CTWH system becomes field proven the 30" conductor housing and 18 3/4" wellhead adapter could be removed and replaced by a 20" conductor housing which would lock onto the Guidelineless Guide Base. An 18 3/4" Wellhead housing could also be used in conjunction with the CTWH system for high pressure applications. Additional casing strings could be run inside the 18 3/4" housing prior to running the CTWH housing. In this application a conventional drilling rig would install the 30", 20", and additional strings. The CTWH housing would then be landed in the 18 3/4" housing. 3.4.1 18.3/4" Housing Adapter Interface The 18 3/4" Wellhead Housing Adapter would provide the the interface to conventional drilling rigs using 18 3/4" - 10/15 m BOP stacks. The 18 3/4" Wellhead Adapter would provide the following: 1. Land and lock inside a standard 30" conductor housing. 2. Effectively transfer all static and dynamic loads to the 30" conductor 3. Designed to prevent fatigue of the 20" casing. 4. Hang off and support the 20" conductor string. 5. Provide a pressure interface (Hub or mandrel provide) with a metal gasket seal (AX or VX). This would be standard subsea housing profiles for 18 3/4" drilling systems. 6. Provide an internal latching profile for a cam actuated hyd. running tool. 7. Contain a landing shoulder to support test loads, casing hangers and CTWH housing. 8. Provide a seal area and lockdown for the CTWH housing when landed inside the 18 3/4" Wellhead Adaptor. 9. To be retrieveable and re-usable for exploration drilling activities. 3.4.2 Coiled Tubing Wellhead (CTWH) Housing. The CTWH Housing will be installed in either of 2 ways: A: Run through an 18 3/4" BOP stack, landed and sealed off inside the 18 3/4" Wellhead Housing Adapter. B: Run in open water by the CT drilling vessel on 3 1/2" drill pipe. The initial WH housing design will be designed as a standard CTWH interface. The connection will be preloaded to prevent full face to face separation for all working rated loads. It is recommended that the connection must be designed, analyzed and tested by a third party other than wellhead equipment manufacturer. The accepted hub profile, gasket seal area and connector interface could then be given to the industry for standardization of the CTWH interface. The standard interface would be provided to wellhead suppliers, allowing standard interfaces to subsea connectors for the BOP stack. Basic requirements for the CTWH housing: 1. Land and lock inside the 18 3/4" housing adapter. 2. To be run inside an 18 3/4" BOP stack. 3. Have an external packoff seal and lockdown seals off the 20" x 7" casing annulus. 4. Allow cement returns from the 20" x 7" annulus to pass prior to setting the 20" x 7" annulus seal. 5. Effectively transfer all static and dynamic loads from the CT drilling operation to the 18 3/4" wellhead adapter. 6. Prevent any fatigue loading from acting on the 7" or 5" casing strings. 7. Provide a metal seal barrier which can take the external pressure from 1500 m water depth and 690 bar internal W.P. 8. Provide a preloaded hub profile to resist hub separation and fatigue loads to the working envelope of the CT drilling system. 9. To have a maximum seal bore of 7.06" (179,3). 10. To have a maximum I.D. bore landing shoulder of 6.19" (157,23) to allow passage of a 6-1/8" bit. 11. Provide a landing shoulder for support of the 5" casing hanger and an addiiitional casing or tubing string. 12. Provide a sealing area and landing area for a BOP test plug. 13. Provide a method to test the 20" x 7" annulus seal without the 18 3/4" BOP stack. 14. Provide a secondary hanger seal area and lockdown above the 5" casing hanger. 15. Provide a support groove internally for running with a cam actuated hyd. running tool. 16. To resist external loads as stated in section 3.2. 17. To withstand a working pressure of 10000 psi (690 bar) and a Body test pressure of 15000 psi. 18. Provide a transition to the 7" casing threaded bottom connection. 3.4.3 Optional 18 3/4" Housing to CTWH Annulus Seal. The 20" x 7" casing annulus will be sealed by an optional externally energized packoff. This is required for the 18 3/4" BOP stack interface only. It is required only for pressure integrity into the CTWH housing when using an 18 3/4" BOP stack. 3.4.4 Casing Hanger Profile The proposed CTWH design has provisions for a reduced bore landing shoulder for the primary casing hanger. The largest casing size would be 5" for landing into the CTWH housing. The casing hanger profile shall provide: 1. A seal area for the annulus seal packoff to seal against after cementing the 7" x 5" annulus. 2. A lock groove for allowing a lock for the 5" casing hanger to resist full pressure loading below the hanger. 3. To have a maximum bore of 7.06" 3.4.5 Secondary Hanger Profile. A secondary hanger profile will be located directly above the 5" casing hanger. This will be used for a production tubing hanger or a secondary hanger string to run inside the 5" casing. The requirements of the primary casing hanger profile will be met by the secondary casing hanger. 3.4.6 Running/Test Tool Requirements The running tools required for the CTWH system will be similar to those used in standard subsea drilling systems, such as: Casing hanger running tool Seal assembly running tool BOP tester Seal assembly retrieval tool Wear bushing run/retrieval tool These tools shall be furnished with 3 1/2" IF (NC 38) connections. Adapters may be used to run tools on the coiled tubing string. The running/test tool requirements are: 1. To be run into the 7.06" bore BOP stack. 2. To support any combination of static and impact type loads which could happen during standard CT operations. 3. To be reusable after each run/retrieval operation. 4. To resist all external pressure loads up to the rated pressure of the system. 5. Actuated by weight or hydraulic pressure. 3.5 Subsea Coiled Tubing BOP (SCTBOP) and EQDP System The SCTBOP will be required to interface with the CTWH housing and maintain a rigid, preloaded connection during all CT drilling operations. The system will consist of a lower hydraulic connector, the modular or block type BOP unit, integral or individual isolation gate valves, an upper EQD hub or mandrel interface, and associated piping, controls etc. A primary concern for the BOP system is to maintain the minimum weight and envelope size to perform the CT drilling system functions. The SCTBOP will perform similar in function to the SWIB type systems used in previous Norwegian projects. A forged cavity BOP Block will provide the failsafe operation of a well control emergency shutdown, should any problems arise at the surface. The Subsea CTBOP system shall contain the hydraulic capacity to ensure a failsafe operation in a controlled disconnect or loss of control line pressure to the Subsea CTBOP control system. The system shall also allow for a comprehensive method for tubing bore or annulus circulation upon reconnection of the CT drilling vessel. A diagram of the intended circulation paths is shown in the drawing section of this report. Basic requirements of the Subsea CTBOP system: 1. Designed to interface the CTWH profile 2. Available in a 345 bar rated and a 690 bar rated system. 3. A minimum bore of 7.06" (179.3) 4. Effectively transfer all loads from the riser system through its upper connection to the CTWH housing. 5. Provide all hydraulic fluids needed to provide a failsafe operation of the control system. 6. Provide an external frame protection system for guidelineless operation. 7. Operate in a seawater depth range of 500 m - 1500 m. 3.5.1 Coiled Tubing Wellhead Connector. The CTWH Connector will lock onto the CTWH housing and produce a preloaded connection. Cyclic loads through the connection will be neglegible. The connector shall be able to align and connect to the wellhead under all operating conditions without guidelines. A secondary release accessible by ROV shall be provided. The connector shall maintain preload without hydraulic locking pressure under all expected operating conditions including disconnect and reconnection of the EQDP and riser system Basic requirements of the CTWH connector are: 1. Preload connection to resist all applied external and internal loads during normal drilling operations. 2. Provide a primary lock and unlock function with 104 bar max. hydraulic pressure. 3. Provide secondary unlock function accessible by ROV. 4. A visual indicator to show a fully locked and unlocked connection. 5. Provide a minimum 5° connection misalignment and connection without external or rig assistance. 6. Maintain preload without locking pressure under all operating conditions. 7. An upper connection to the CTBOP's or a preferred integral connection to the BOP block assembly. 8. Retain a metal sealing gasket for sealing into the CTWH housing. 9. Resist the external pressure from the 1500 m water depth. 10. Be designed in a 345 bar or 690 bar rated working pressure. 3.5.2 Deepwater Requirements for the Subsea CTBOP System. The 1500 m waterdepth rating for the SCTBOP system must be considered during the design of the BOP's isolation valves and control system. As we now have a high pressure system, we should not introduce an automatic riser fill up system to allow for filling of the riser in the case of lost circulation. All components must be designed for an external seawater pressure gradient. BOP's, by nature of their design, are greatly affected by external pressures exerted by the seawater. Opening pressures must be maintained to keep rams retracted during normal operation. The traditional AX, VX, and CX type gaskets used to seal the bores of subsea equipment are not designed to take high external pressures. These types of gaskets are tall in height and hydrostatic seawater pressures acting over this height try to collapse the seal away from the mating seal surface. New seal designs which are shorter in height are less sensitive to external pressure and also reduce the separation load in the connection when under internal pressure. All equipment seal systems should be bi-directional to prevent seawater ingress under high external pressures. Basic considerations of the deepwater system: 1. Reduce height of metal gasket seals 2. Use bi-directional seals with seal internal pressure and external seawater pressures. 3. Equipment must be designed to the control system configuration to ensure balanced pressure operation. 4. Perform external pressure testing to system components to ensure proper operation when used subsea. 3.5.3 Subsea CTBOP Requirements The new Subsea CTBOP stack will consist of a four ram cavity block or a two-double unit consisting of the following cavities: Subsea Casing/drillpipe shear/sealing ram BOP (SCDSR) Subsea coiled tubing/shear/sealing ram BOP (SCTSSR) Subsea variable bore drillpipe ram BOP (SVDPR) Subsea coiled tubing grip/seal ram BOP (SCTGSR) A general configuration of the Subsea CTBOP is shown in the drawing section of this report. The Subsea CTBOP can be a 345 bar or 690 bar rated system. It is recommended that the 345 bar system must be designed for a test pressure of-520 bar and not 690 bar as stated in API specifications 6A and 16A for 7 1/16" bore equipment. This will allow for a lighter weight 345 bar system for optimum comparison to the 690 bar system. A circulation/kill line from the surface will connect to the Subsea CTBOP system and access to an outlet between the two shear/sealing ram BOP's. The same line also has access to the BOP bore below the lower CT grip/seal ram BOP cavity. A bypass line will access the BOP bore above the upper Casing/Drill pipe Shear Ram BOP and reconnect below the lower CT grip/seal ram BOP cavity. 3.5.3.1 Isolation/Drillpipe/Shear/Sealing Ram BOP (SCDSR) This ram cavity shall have rams which are bi-directional sealing to allow testing of the riser during a reconnection. They must also seal below when the rams are used to shear and seal off after shearing 3.50" dia. drill pipe or 5" L-80 casing. Basic Requirements of the SCDSR BOP: 1. To shear 3.50" dia. drill pipe and seal off the well bore. 2. Shear 5" casing as specified by the drilling program. 3. To seal off the bore when pressure is applied above the Subsea CTBOP stack. 3.5.3.2 Subsea Coiled Tubing/Shear/Sealing Ram BOP (SCTSSR) This ram BOP will be designed to shear and seal off the coiled tubing string during a disconnect. The special ram will shear the pipe leaving a circular cut top for attachment of an overshot and an unobstructed flow path to the tubing bore. This ram BOP is only required to hold pressure from beneath the ram cavity. 3.5.3.3 Subsea Variable Bore Drillpipe Ram BOP (SVDPR) This ram BOP will be for sealing onto the drillpipe or alternate tubing string used on the Subsea CTBOP system. The variable bore range may also include the coiled tubing string. The ram design should also allow for hang-off of a 3 1/2" drill pipe connection if a controlled disconnect is required with drillpipe in the hole. A gripping ram is not required for this ram cavity. 3.5.3.4 Subsea Coiled Tubing Grip/Seal Ram BOP. ( SCTGSR) The primary coiled tubing to be used will be used by this ram for gripping the tubing string and maintaining a pressure seal on the coiled tubing during a disconnect operation. This ram will not be used for any normal drilling functions. If a variable bore grip and seal ram can be made available for small ranges of tubing, i.e. 2.00" - 2.375" dia., it would have a preference for use in this cavity. The drillpipe variable bore rams may provide limited gripping onto secondary coiled tubing strings during a disconnect. This would make it easier to accept a single sized grip/seal ram. 3.5.4 Bore Access Requirements The vertical bore in the BOP will have access to 2 separate access lines. These are to have a min. bore of 1" (25). Hydraulically operated failsafe gate valves, 1" bore, will be used to isolate the bore pressure. Special 1" bore bolted flanges will be designed for this purpose to reduce weight and height of the Subsea CTBOP stack. The two access lines are: CIRCULATION/KILL LINE The circulation/kill line will be directly linked to the CT drilling vessel by a 1" bore flexible hose. This line will provide access to the vertical bore between the (SCDSR) and the subsea CT shear seal ram (SCTSSR) BOP and connect to the vertical bore below the CT grip and seal ram (SCTGSR). Two isolation valves will be fitted at each entry to the BOP bore. BYPASS LINE The bypass line will connect to the vertical bore above the SCDSR. The flowloop will re-connect below the SCTGSR as the kill line, two failsafe hydraulic gate valves are used to isolate the bore pressure. 3.5.5 Isolation Gate Valve Requirements Failsafe operated, hydraulic gate valves will be used to seal off the Kill and Bypass Lines. These valves shall be depth-insensitive to the external water pressure. The control system shall be defined to aid in the design of the valve operator. The basic requirements of the gate valve: 1. 25 mm minimum bore through the valve. 2. Rated to 690 bar W.P. 3. Designed in modular block form to reduce weight and space. 4. To be depth insensitive to the control system and external seawater head. 5. Operate in a depth range of 500 - 1500 m. 6. Use metal seal bonnet and end connection gaskets. 7. Use metal sealing for body to gate seals. 8. A vented relief between the stem seal and the hydrualic operator seal. 9. Metal seal surfaces in the body are to be inlayed with Monel 625 CRA. 10. ROV override to be provided. 11. The actuator shall maintain the valve closed under the following possible design conditions: Water based control fluid, SG=1.05 Oil based control fluid, SG =.827 Local dumping of return fluid for water based fluids. 3.5.6 Upper Subsea CTBOP Connection The upper Subsea CTBOP connection will be mated to the EQDP connector. The connection must allow for a high angle release and re-entry. It is desireable that the connection be the same as that of the CTWH upper hub connection. A metal sealing pressure energized gasket shall seal the connection. Preload shall be sufficient to maintain hub face to face contact during all CT drilling operations. Basic requirements of the connection: 1. Minimum bore of 7.06" 2. Allow for high angle release and re-connection 3. Provide alignment and protection of sealing gasket during release and connection operations. 4. Provide guidance for guidelineless operation. 5. Preloaded connection for all operating conditions. 3.5.7 EQDP Connector Interface. The EQDP connector shall interface to the upper Subsea CTBOP connection. The requirements of section 3.5.6 also applies to the EQDP connector. In addition to the requirements of 3.5.6, the following apply: 1. Normal operating pressure of 104 bar. 2. Available in a 345 bar and 690 bar pressure rating. 3. Withstand all external loads from the CT drilling system with full pressure rating. 4. Provide a visual indication of a fully locked and unlocked connection. 5. Provide a ROV operated secondary release. 6. Fully aligned and connection make-up without guidelines. 7. Maintain full contact of mating hub surfaces during all operating conditions. 3.5.8 Riser Environmental Shut-off Valve A 7.06" bore annular BOP shall be fitted in the EQDP. It shall be used to test against as riser joints are being run and also to contain the riser fluid column when a disconnect is made. Basic requirements of the Annular BOP: 1. Normal operating pressure of 345 bar. 2. Primary bore pressure to be applied from the surface. 3. Available in 345 and 690 bar W.P. 4. To operate in the 500-1500 m water depth range. 3.5.9 Break-away Joint or Weak Link A break-away joint is to be positioned above the Riser Environmental Shut-off Valve. In the event of an excessive rig movement the break-away joint will shear prior to any damage occurring to the EQDP, Subsea CTBOP, or riser equipment. The break-away joint shall be able to be re-dressed and put back into operation at the vessel. 3.5.10 Riser Stress Joint Connection. Above the break-away joint a studded flange connection will be used for attachment of the riser stress joint. This connection will maintain a preloaded connection through all operating conditions 3.5.11 Installation of the Deepwater CTBOP Underwater equipment intended for use in extreme ocean depths such as 1500m differs on several points from the conventional versions used at lesser depths. So do the new CTBOP. In order to ensure safe positioning, the small DP vessel must be capable of turning to the prevalent weather and currents. The CTBOP will be designed to make that possible. The CTBOP system must also be designed to allow the EQDP to align/orient stabs etc during reentry of the EQDP after a disconnect operation. The retractable control stabs and the circulation line stab must be included in the automatic disconnect sequence. To allow for this, the CTBOP (lower assy.) has been equipped with an orienting guideframe which ensures that the EQDP and the (lower) CTBOP are correctly positioned in relation to each other. The CTBOP is lowered against the 9" wellhead until the bottom of the CTBOP is 5m above the wellhead. The weight of the submerged equipment is held in tension by the Snubbing Unit. By the observation of the ROV, the CTBOP will be landed and locked to the wellhead. 3.6 Riser System The CT drilling system riser will be a 7.06" min. bore high pressure riser system rated to the 345 bar or 690 bar pressure of the Subsea CTBOP system. The riser connections will be single joint Pin x Box external upset connections. A tapered torque set joint similar to and made up in the same manner as API standard drill pipe connections. A lower tapered stress joint will allow a transition of the stresses created by riser tension and the environmental forces. A high pressure swivel connection will allow rotation of the surface BOP and coiled tubing equipment relative to the riser. 3.6.1 High Pressure Riser Design. The design of the riser will take into account all static and dynamic loads applied by the CT drilling system and D.P. vessel. These will include: Rig offset Maximum heave and vertical rotation of the CT vessel Full pressure rating of the riser Controlled disconnect of the SCTBOP and EQDP. Selection of the high pressure riser tube material shall be of special concern. The riser must meet the requirements of NACE MR-0175. Special materials should be tested for use at higher strength levels so that a higher strength/weight rates can be utilized. Tube materials with a yield strength in the 85000 - 90000 psi minimum should be available. Special testing to ensure resistance to H 2 S cracking per NACE MR-0175 may be required. 3.6.2 Riser Stress Joint. The riser stress joint provides a transition of the peak stresses in the riser to EQDP connection over a tapered tubular section. A stress joint also provides a transition from a rigid EQDP and Subsea CTBOP unit and the more flexible riser system. This serves to reduce the stress in the lower riser section and produce a stable bottom for the tensioned riser system. The same requirements for the riser joints apply to the tapered stress joint. A detailed analysis shall be performed to determine the exact length of taper and size to give the most favourable response to the riser loads. 3.6.3 Riser Connections. The riser connection shall be designed to be made up and torqued to an amount needed to ensure a preloaded connection. Interresting proven threaded connections such as API Spec. 7, Rotary Drilling Equipment, type threads are preferred. Basic requirements of the riser connection are: 1. To be preloaded by torque to the max. load anticipated during all riser operational loads. 2. To be able to make and re-make up connections simular to API Spec.7, Drill Pipe Connections. 3. Designed to prevent cross-threading during running operations. 4. Have a joint strength specter greater than that of the riser tubular. 5. Have adequate material for re-surfacing outside dia and sealing surface if damaged during usage. 6. External upset connection. 7. To be welded to riser tubular. 8. To have a minimum bore of 7.06". 3.6.4 Circulation/Kill Line. A 25 mm bore circulation/kill line will be used for circulating out the riser, testing the Subsea CTBOP stack and verifying the well during a reconnection of the EQDP to the Subsea CTBOP. This line will be attached to the riser during running of the riser. The line will be rated to the same pressure as the CTBOP and riser system. A control stab connection made up when the EQDP mates to the Subsea CTBOP will allow communication from the surface to the Subsea CTBOP system. A steel protective covering shall be used as an outer covering for the flexible line. 3.6.5 Umbilical Attachment. Umbilical clamps will attach the control umbilical and circulation/kill line to the riser. The clamps shall maintain a rigid connection to the riser. 3.6.6 Surface Swivel Connection. A swivel connection shall be used below the surface BOP's and above the upper riser termination. This will allow rotation of the CT vessel and CT surface equipment relative to the riser. This connection shall have a primary seal and a secondary seal which can be externally energized upon verification that the primary seal is leaking. The swivel shall rotate under all operational cases of the CT drilling system. An external lubrication system will be used to maintain proper operation of the swivel connection. 3.6.7 Surface Flexible Connection. A flexible connection may be used below the upper riser connection to allow for excessive vessel side movement. The location shall be determined by a move advanced study of the predicted vessel movement and moonpool configuration. The flexible connection would allow a vertical positioning of the upper surface equipment and coiled tubing injector during all rig movements. 3.7 The Surface Equipment. 3.7.1 General description The Surface Equipment will form the main pressure control system to be used for well control during the drilling operations. The Subsea CTBOP will only act as a pressure barrier in case of an uncontrolled drive-off situation. The Surface Equipment comprizes the following main components which shall be integrated to the drilling vessel: Surface CTBOP latched to the top of the High Pressure Riser System by a hydraulic connector. Injector and Stuffing Box Assembly latched to the Surface CTBOP by a Quick-latch hydraulic connector. Coiled Tubing Reel Assembly Coiled Tubing Control Cabin 4" Flow line outlet from the CTBOP, connecting the CTBOP with the Active Mud System. 2" Choke outlet below the Upper Seal Grip Ram (USGSR), connecting the CTBOP with the Choke and Kill Manifold. 2" Kill inlet below the Shear/seal Ram to connect the CTBOP with the Mud Pumping System. 4" Downstream Isolation Valve , isolating the Active Mud System from the Choke and Kill Manifold. Remote operated gate valves shall be installed as: Inner Choke Valve Inner Kill Valve Inner Flow-line Valve Downstream Isolation Valve 3.7.2 Surface Coiled Tubing Equipment The coiled tubing equipment will be attached to the Mandrel for the Hydraulic Connector on top of the BOP Stack. The major components of the Coiled Tubing System are: 1. Tubing injector head assembly: The tubing injector head is designed to provide the thrust required, through a friction drive system, to snub the tubing into the well against pressure. It can also control the rate of lowering the tubing into the well if no well pressure exists, and pulling it out of the hole, to lift the full tubing weight and accelerate it to operating speed. 2. Tubing Reel Assembly: The tubing reel assembly is a fabricated steel spool capable of handling up to 8.000 meter of coiled tubing. The inboard end of the tubing is connected through the hollow end of the reel shaft to a rotating joint, which is mounted to the reel shaft. The rotating joint stationary section is connected to the fluid or gas circulation pump system, thus circulation can be maintained continuously as the tubing is reeled on and retrieved from the well. A shutoff valve is provided between the tubing and the reel shaft for emergency use. 3. Control Cabin Assembly: The control cabin houses the control panel which contains all the necessary controls and gauges for the operation of the coiled tubing unit once it is rigged up on the wellhead. 4. Power Assembly: The hydraulic power assembly is used as a prime mover for the tubing injection system. It is powered by a diesel engine/transmission assembly. It consists of pumps, valves, tanks and associated hardware to power the coiled tubing unit once it is rigged up on the upper safety block (for subsea workover systems). 5. BOP and Tubing Stripper System: A blowout preventor assembly is a device where the design provides positive protection against blowouts when operating coil tubing in well service work. BOPs can close around the tubing, close off an open hole, shear the tubing, grip and suspend the tubing, controlling the well pressure during all coiled tubing operations.A tubing Stripper is a hydraulic actuated tubing packoff device designed to seal tubing against well pressure as the tubing is being run into or withdrawn from the well.The seal is achieved by energizing the Stripper sealing inserts, thereby forcing the inserts against the coiled tubing. The Stripper sealing elements may be replaced with the well under pressure and must be regarded as consumables. 6. Monitoring System Assembly: Companies with the best technology have designed and integrated an advanced monitoring system that will compile and graphically display all pertinent job data including well pressure, circulating pressure, pump flowrates, densities, temperatures, and coiled tubing rate of speed, depth and weight. The instantaneous values of data will display on a computer screen while trends will display on a plot. Being computer based, tubing stress data is calculated along with warnings that are displayed, if required. The system also will retain information relating to tubing stress determining the life of a tubing string instead of selecting an arbitrary string life.The coiled tubing is plastically deformed during its reeling operation. The amount of cycles put into the tubing string of the plastic deformation is required to predict the service life. Inspection of the tubing is required to locate defects or cracks initiated during the coiling operation. The monitoring system can be the most important part of the coiled tubing system. A failure of the tubing string can result in an unsafe situation and loss of rig time required to retrieve the dropped tubing section. 3.7.3 The Surface CTBOP The coiled tubing BOP assembly is a single bore Blowout Preventer Stack which will be attached directly to the high pressure-riser and circulation line connections. The BOP assembly consists of three BOPs stacked in a single block. The BOPs are hydraulically operated with manual locking screw attachments. The rams can be positioned in any order from top to bottom. The Surface CTBOP must be designed with a shear ram capacity for both 2" coiled tubing and 3 1/2" Drill Pipe. The ram must also be capable of cutting 5" L-80 casing and maintain a seal there after. For practical reasons, the Surface CTBOP must allow a field dressing of two Shear/seal Ram designs i.e. blocks for 2"CT and blocks for 3 1/2" Tubulars. The Surface CTBOP must also allow for field replacement of the Seal/Grip Rams. Variable Seal Grip Rams to allow for both 3 1/2" DP and 2" CT is yet to be developed. The System must then be designed with two sets of ram blocks i.e. 2" CT and 3 1/2" DP The surface BOP to be used in conjunction with the subsea CTBOP will be: (from top to bottom) 1. Hydraulic Connector Mandrel 2. Upper Surface Annular 7 1/16" x 345 Bar(USA) 3. T-Spool 7 1/16" Bore x 345/690 Bar 4. CT Shear Rams 7 1/16" Bore x 345/690 Bar(USSSR) 5. Upper CTPipe Ram 7 1/16" Borex345/690 Bar(USGSR) 6. Lower CTPipe Ram 7 1/16" Borex345/690 Bar(LSGSR) 7. Hydraulic Connector 7 1/16" x 345/690 Bar The surface BOPs will provide the normal well control during subsea coiled tubing drilling operations. The most important consideration used in the design of the surface BOPs has been the ability to quickly change out rams in the stack arrangement. Many quick latch designs are used to retain the BOP actuators to the main body of the BOP. The surface BOPs will provide the normal well control during coiled tubing operations with either the well pressure acting to the surface through the completion riser or while the well has been killed. The important design features of the Surface CTBOP stack are listed: 1. Fast ram change or replacement to the individual BOP cavities. 2. Reduced size and weight to reduce stack-up height 3. Manually operated locking screws to close the BOPs with a loss of hydraulic supply and as a safety lock when the BOPs are closed. 4. Interchangeability of the rams to any of the ram bores in the stack. 5. Side outlets to allow circulation into a sheared and suspended tubing string. 6. Hydraulic Connector for fast installation to the Riser and the coiled tubing Injector and Stripping equipment. 7. Visual ram position indicators. 8. Equalizing valves to allow venting of pressure between ram bores. 3.8 The Control System 3.8.1 General To control the Well Pressure Control system for drilling with coiled tubing or small drill pipe, a common control system to operate all functions shall be established. The control system shall control both the surface BOP stack and assosiated equipment as well as the Subsea Coiled Tubing BOP with associated equipment. Since the most strignent requirement from rules and regulations conserns the subsea part of the system, this part will be the main guiding part of the study to choose type of control system. Bearing in mind that this control system shall be operated in 1500 meter of water, an electro hydraulic control system will be required. To cater for this it is recommended that a MULTIPLEXED control system is used. To operate the surface equipment, an electro hydraulic control system will be required to enable a common control system. The surface control system will also be manual operated. This study has only considered water based control fluid as hydraulic control fluid due to the water depth of up to 1500 meters. The Maximum hydraulic control working pressure is set to 3.000 psi or 210 bar to ensure quick response and to allow for control of all components in the system. In order to provide redundancy of the sub sea control system, fail safe to close position technology has been used. This means that all functions subsea will fail to closed position if the pilot signal is lost. Accumulators on the Subsea CTBOP has a check valve in the supply line to avoid ventilation of the accumulated fluid to the sea. The control of the system will be through a Multiplex Surface Control Unit controlling the the Subsea Coiled Tubing BOP stack through a subsea multiplexed electrohydraulic system and the Surface Coiled Tubing BOP stack through an electrohydraulic control system. The surface BOP is manually controlled as well as controlled through the multiplexed control unit. The well pressure control system can be operated from the Multiplex Surface Control Unit, Drillers Remote Panel and Toolpushers Panel. In addition the surface equipment can be manually operated from the surface BOP control unit. 3.8.2 Control System components. The Control System shall contain the following main components: Multiplex Surface Control Unit Electric Supply Skid with battery back up. Accumulator Skid Power Unit Hydraulic Surface BOP Control System. Drillers Remote Panel Toolpushers Panel Cable Reel Control Umbilical Subsea Electrohydraulic Control Module (POD) Subsea Multiplex Unit (POD) Control Stab/pod 3.8.2.1 Multiplex Surface Control Unit This unit is the main control unit for the system. The system is controlling all functions and is electrically operated. No hydraulic is part of this unit. Each function for the Subsea CTBOP stack has been given a code or address which is coded on surface and sent subsea to the control the POD where it is decoded and executing the function. Normally this would be to power electrical operated solenoid valves which in turns hydraulically operates a pilot hydraulic valve carrying out the function by directing hydraulic fluid. The hydraulic surface BOP control system is connected to and controlled through the Multiplex Surface Control Unit. The communication between the two units are however not multiplexed as for the subsea unit, but electrically controlled. Connected to the main control panel are the two external control panels, one located on the rig flor, and one in the toolpushers office. These panels may operate all functions in the Well Pressure Control System and associated equipment controlled through the multiplex control system. 3.8.2.2 Electric Supply Skid The Electric supply skid consists of power supply for the Multiplex Surface Control unit and the surface control unit. A battery back-up with power supply is part of the skid. 3.8.2.3 Accumulator Skid The Accumulator Skid cover the hydraulic accumulator capacity required for the well pressure control system explained by rules and regulations. The accumulator capacity cater for the complete well pressure control system, both subsea and surface. The accumulated volume shall be designed for 3.000 psi or 210 bar. 3.8.2.4 Hydraulic Power Unit The power unit consists of hydraulic pumps and associated equipment for the pumps such as starters, start and stop switches, gauges etc. The unit produces the hydraulic control fluid of 3.000 psi or 210 bar, and supplies both the subsea and surface systems via the accumulator skid. The unit utilizes water based control fluid which will be mixed by a mixing system on the unit. The mixing system should also allow for anti freeze mixture. 3.8.2.5 Hydraulic Surface BOP Control System. The hydraulic surface BOP control system controls all hydraulic operated componets included in the well pressure control system. The control system is an electro hydraulic system. The system only caters for control valves and is hydraulically supplied from the hydraulic power unit and accumulator skid. The electro part of the system is controlled from the Multiplex Surface Control Unit. The unit is based on hydraulically operated valves combined with manual operation for all functions. The functions can therefore be operated through the multiplexed system via solenoid valves which is electrically operated. The signal from the multiplex control system engages a solenoide which allows hydraulic pressure to switch the operating valve. The hydraulic pressure from the solenoide is kept as long as the push button on the control panel is pressed. When the button is released the pressure vents off. The correct working pressure for each function is controlled by hydraulic regulators which regulats the pressure down from 3.000 psi or 210 bar which is the maximum working pressure for the system. As several functions cater for the same working pressure it is estimated use of maximum 4 regulators. The system shall be a closed system allowing for full return of the hydraulic fluid. Care should therefore be taken to select correct hose size for the different functions between the unit and the function. 3.8.2.6 Drillers Remote Panel To enable control of the well pressure control system during the drilling operation a remote panel is located on the rig floor close to the driller. All functions can be operated from this panel and a mimic panel with lightbowls indicates position of all functions. In addition all working pressures for the system is monitored and may be adjusted from this panel. Consumption of hydraulic fluid is displayed on a flowmeter. The construction of the panel shall allow for hazardious area operation. 3.8.2.7 Toolpushers Panel The tool pushers panel is similar to the Drillers panel, but smaller with fewer functions to operate. The monitoring of the functions and working pressures are the same as for the drillers panel. 3.8.2.8 Cable Reel To enable comunication between the Multiplex Surface Control Unit and the Subsea Control Module, an electrical cable is required. The cable runs from the rig all the way down to the Subsea CTBOP clamped to the riser. To eaze handling and wear the cable is stored and handled by a powered reel. 3.8.2.9 Control Umbilical To operate the Subsea CTBOPs, hydraulic fluid and electrical connection between the Multiplex Surface Control Unit and Subsea Control Module is required. The hydraulic control fluid is run through a hose from the hydraulic power unit to the Subsea Control Module. Normally both these functions are catered for in one hose with electric conduits enclosed in the hose. The Subsea Control Module only requires hydraulic fluid for the control POD and does not require any individual control lines. To enable control of the kill/test line on the Subsea CTBOP stack, a special high pressure hose is required. This hose runs in parallel with the hydraulic control hose and the possibility to combine both in one common umbilical should be evaluated. 3.8.2.10 Subsea Electrohydraulic Control Module One subsea electro-hydraulic control module shall be provided. The module shall contain all solenoids and operating valves, pressure transmitters, flowmeter etc as required for the operation of the Subsea CTBOP Assembly. The main operating principles shall be : The hydraulic pilot valves shall be operated by a pilot signal triggered by an electric solenoid valve within the control module. The signal time is therefore reduced, so that even with lengthy distances such as 1500m between the CTBOP Assembly and the drillship, the functions can operate very fast. The solenoid valve may be a shear/seal type valve. This is a 3-way/2 position 210 Bar pilot valve with a solenoid coil on top. The solenoid coil is fitted in an oil filled hydraulic compensated chamber. The coil is 120v DC and will draw 0.4A when activated. The solenoidvalves shall be used to control and regulate the main operational fluid from the surface power unit. The pressure transmitter in the control pod will transform the operational and pilot pressures to electric signals. These are sent up to the Surface Control Unit onboard the Drilling Vessel. A bourdon tube transmitter may be used for this purpose. The signal from the transmitter must be amplified before it is sent up to the Drilling Vessel. The transmitter shall have a working range-of 0-4v and shall measure the differential pressure ranges of 0-70 Bar, 0-210 Bar (or 0-345 Bar). The hydrostatic pressure from the seawater shall be used as a reference so that the measuring signals from the transmitter will show a true value, which is independent of the gravity of seawater. A solenoid valve shall be used TO REDUCE PRESSURE to the operating functions of the Subsea CTBOP. Its inlet port shall be connected to the inletport for the regulator while the outlet port is vented to the sea. A solenoid valve to INCREASE PRESSURE shall be connected to the inlet port from the pilot fluid supply.A 5 liter accumulator shall be fitted in the circuit in order to attain an even regulation. A paddle type flowmeter shall be provided to measure the control fluid consumption to the individual functions of the Subsea CTBOP. It will induce a voltage from the movement of the paddles and these impulses shall be calibrated to give the number of litres which will pass through the flowmeter. The power supply shall be 24v DC and the meter will consume 10w. 3.8.2.11 Subsea Multiplex Unit The Subsea Multiplex Unit will receive an electrical command signal from the Surface Multiplex Control Unit. The command code is checked to ascertain that it is correct. The code is then relayed up to the Surface Multiplex Control Unit, Where it is checked to ensure that the return signal is identical to the signal which was originally sent. If the signal is correct, it will be reversed and a line will open and send the command down for the second time. The signal is decoded by the Subsea Multiplex Unit and if it is found to be correct, a signal will be given which activates the solenoid valve for that particular Subsea CTBOP function. The whole process shall be carried out in less than 0.6 sec.(1500m cable) The hydraulic pilot pressure will now flow through the solenoid valve and operates a hydraulic pilot valve. This opens and releases regulated pressure forward to activate its special function. 3.8.2.12 Subsea Control POD The control POD is the distribution central for all functions subsea. It shall be made such that all hydraulic functions are routed directly through the POD to either the EQDP or the CTBOP stack. All hydraulic control valves shall be located in the POD. However, some valves are required to be located close to the function on the Subsea CTBOP 3.8.2.13 Hydraulic Components on the CT BOP Stack. Connections between the EQDP and CTBOP stack shall utilize stingers, couplers or packers. The connections shall allow for a disconnect and reentry with maximum hydraulic control pressure in the connections. If retractable stingers are to be used, the numbers of stingers shall be reduced to a minimum. All hydraulic routing on the EQDP and CTBOP stack shall be hard piping with a minimum of connections to avoid possible leak paths. To comply for "Fail safe to close philosophy", pilot operated valves are required on the CTBOP stack. Each ram type BOP shall have one valve for open and closing function. Two of the rams will additionally have shut off valves for hydraulic supply. The supply line to the accumulators shall have a check valve between the accumulators and connection to the EQDP to prevent hydraulic fluid to escape to the sea. Further subsea accumulators are required. Accumulators located on the CTBOP stack shall have sufficient capacity to enable: 1. Closing of all rams and valves. 2. Opening all rams and valves. 3. Closing all rams and valves, pluss 25% without recharging the accumulators. Further the accumulators shall comply with NPD rules as a minimum. 3.8.2.14 Hydraulic Components on the EQDP. The same requirements for connections and hydraulic routing shall apply for the EQDP. The control valve for the EQDP Connector may be located on the EQDP or in the POD. This shall also apply to all control valves for the Riser Environmental Shut-off valve. 3.8.3 Hydraulic Operation Requirements The hydraulic control system operate and function on maximum working pressure of 3000 psi or 207 bar. All functions controlled from the control system and all components in the system shall comply with 207 bar as maximum working pressure. 3.8.3.1 Surface BOP Control System. The surface control system controls following functions and components: a: Quick Latches LQL; Lower Quick Latch UQL; Upper Quick Latch b: Ram type BOPs: LSGSR; Lower Surface Grip and Seal Ram USGSR; Upper Surface Grip and Seal Ram USSSR; Upper Surface Shear and Seal Ram c: Annular Type BOP: USA; Upper Surface Annular d: Valves: SIK; Surface Inner Kill IFV; Inner Flow-line Valve SIC; Surface Inner Choke OSV; Outer Shaker Valve e: In addition the side door stuffing box is controlled through the control system. If required the swivel will be pressure controlled from this unit as well. Below is given a short description of hydraulically control requirement for the different functions: a: The latches require only open close functions, but interlocks will be recommended to avoid unintentional opening of the latches. Regulated pressure in a range of 1500 psi or 100 bar will be required. The pressure must be easy to regulate between 500 psi (34,5 bar) and 3000 psi (207 bar). b: The ram type BOPs require open, close and block function. The requirement for hydraulic pressure is the same as for the latches. c: The annular preventer requires a separate regulator for controlling the hydraulic pressure between 34 bar and 207 bar. This regulator shall not be connected to other components. The reason for this is to enable adjustment of the hydraulic pressure at any time independent of other compnents. In addition an accumulator bottle shall be present in the closing circuit for easy movement of the packer element in stripping operations with drill pipe. d: The valves have the same requirements as the rams. e: The stuffing box requires a separate hydraulic regulator to operate the packer element similar to the annular preventer. No accumulators are required for this function. f: If the swivel requires any hydraulic pressure assistance, this will need to be highlighted by the supplier. Present no requirement is made. 3.8.3.2 Subsea CTBOP Stack Control System. The control system shall control all functions on the CTBOP stack. Following functions are present: A: Well Head Connector; WHC B: Ram type BOPs: SCTGSR; Subsea Coiled Tubing Grip and Seal Ram SVDPR; Subsea Variable bore Drill Pipe Ram SCDDSR; Subsea Casing and Drill pipe Shear Ram. C: Valves: LBV; Lower Bypass Valve UBV; Upper Bypass Valve LOKV; Lower Outer Kill Valve LIKV; Lower Inner Kill Valve UOKV; Upper Outer Kill Valve UIKV; Upper Inner Kill Valve The Emergency Quick Disconnect Package, EQDP, has following hydraulically operated functions: D: EQDC; Emergency Quick Disconnect Connector E: RESV; Riser Environmental Shut-off Valve A: Well Head Connector The well head connector shall feature primary latch and unlatch. In addition a secondary unlatch function shall be available in case of primary circuit failure. The secondary unlatch may be operational through the control system or operated by ROV only. If passive actuation cylinders are present, an "open-to-sea" accumulator with corrosion inhibitor to prevent corrosion of the cylinders shall be present. B: Ram type BOPs. The rams shall fail to closed position if pilot pressure is lost. The rams require return of exhaust fluid direct to sea without any common return line that can effect other rams or components. The rams shall have automatic locking device in closed position, in open position the rams are controlled by hydraulic opening pressure. The operating pressure for the rams is minimum 1500 psi (100 bar).. The rams only require one pilot line for opening. This is part of the "Fail to close position" philosophy. C: Valves. All gate valves shall fail to closed position as the rams if pilot pressure is lost. In addition to mechanical spring return, hydraulic control pressure shall be applied to ensure closure of the valves. If the valves have chambers or rooms that can be affected by the hydrostatic head, these shall be ventilated to special accumulators with corrosion inhibitors. D: EQDC. The EQDC shall have the same configuration and be controlled similar to the well head connector. For emergency quick disconnects accumulators shall be installed to allow for a fast unlatch operation of the connector. The connector shall be fail as is and requires a positive pilot pressure for both opening and closing operation of the connector. E: RESV. The RESV has the same operational requirements as an annular preventer. It requires a separate easy adjustable hydraulic pressure for operations. This is achieved by a separate regulator for this function in the control POD. 3.8.3.3 Additional Requirements for the Control System. 3.8.3.3.1 Selection of Modes: The control system shall cater for two modes, 1 - Coiled Tubing Mode 2 - Drill Pipe Mode In order to enable use of both coiled tubing and drill pipe, two different modes are required, The reason for this is to prevent damages to drill pipe in case of shutting in the well by use of the subsea coiled tubing ram. The rams cater for a nominal size of coiled tubing and present no variable coiled tubing grip/seal rams are available. If drill pipe is in use and one of the CT rams should close, damages on the drill pipe and possible on the ram blocks will be experienced. If the variable drill pipe rams are closed onto coiled tubing, no damage will occur. The SCDPSR will shear the coiled tubing, but this is allowed for and controlled by the control system. The SSCTSSR is only capable of shearing coiled tubing and component with smaller diameter. Accordingly a shear ram to allow for bigger sizes must be established which is the SCDPSR. Accordingly the coiled tubing rams must be controlled to open positions at all time drill pipe or any other components with larger diameter than the coiled tubing rams are dressed for, is present in the subsea BOP stack. Drill Pipe Mode will accordingly cater for following operation: Excluding SCTGSR and SCTSSR from functioning i.e. being locked in open position. Coiled Tubing Mode will include all functions for the subsea Coiled tubing BOP stack. The same option should also apply for the surface BOP stack, but this stack is located in an easy accessible area and the rams could easily be redressed to allow for either coiled tubing or drill pipe. The blockage of the subsea CT BOP rams shall be controlled by remote operated valves on the BOP stack. Two hydraulic operated control valves shall be connected to the supply-line for these rams. The selection of mode shall be through push buttons on both remote control panels, The Multiplex Control Unit and Surface BOP Control System. To explain the active mode, indicator lights shall be used. To change between modes shall be carried out such that none of the functionssubsea or surface shall shift or move except the control valves that the mode selection affects. 3.8.3.3.2 Emergency Quick Disconnect. To allow for emergency situation where the rig or vessel is in a drive-off situation, an Emergency Quick Disconnect function is required. The function shall be sequence controlled by the control system and only involve the subsea CT BOP stack and EQDP. Due to the two modes, two different EQD commands are required. The EQD for Coiled Tubing mode shall be as follows: Step 1 Following functions shall be carried out: SCTGSR Close SVDPR Close All valves on the CTBOP stack Close Riser Environm. Shut-off Valve Close Well Head Connector Vent. Step 2 SCTSSR Close Step 3 Emergency Quick Disconnect Open This sequence shall be executed in a minimum of time. It will therefore be recommended that the time delays between the steps are tested with the actual components and adjusted to minimize the disconnect time. The disconnect shall be carried out in the range of 30 seconds as maximum. As can be seen from the set up for CT mode the SCDPSR will close after disconnect by itself. This is done in order to prevent a double cut of the coiled tubing, which may cause problems in a re-entry operation To cater for an EQD function in Drill pipe mode following functions shall be executed: Step 1 SVDPR, Close All valves on the CTBOP stack, Close Riser Environm. Shut-off Valve, Close Well Head Connector: Vent. Step 2 SCDPSR, Close Step 3 Emergency Quick Disconnect Connector, Open The EQD function shall be available on the same locations as for the mode selection. To execute the EQD function only one button at each location shall be activated. The control system itself shall decide which sequence to be executed pending on which mode selected. One EQD button for each mode is not acceptable. 3.8.4 Operational Criterias of the DP Operation In order to operate safely when using the dynamic positioning system it is vital that the rig's positioning computer gets instant and precise signals regarding details such as an alternation in the angle of the high pressure riser. An electrically transformed signal from two riser angle sensors is continually fed into the computer and is compared with signals from the transmitters on the ocean bed.

Claims: Arrangement for use in drilling of deep water oil/ gas wells, which arrangement comprises a surface blowout preventer (SURBOP) which is connected to a riser (SR) which in turn is connected to a well comprising means for controlling fluid into and out of the well and a well blowout preventer (SUBBOP), characterised in that said riser is a high pressure riser (SR) and in that the arrangement further comprises a circulation/kill line (TL) communicating between said.blowout preventers (SURBOP, SUBBOP), all of which being arranged as a high pressure system for deepwater slimhole drilling, said well blowout preventer comprises pipe rams for casing pipe and coiling pipe, respectively, with the possibility of two-ways sealing (SCDSR, SCTSSR, SVDPR, SCTGSR), said pipe rams being connected with said circulation/kill line (TL) and encompassed by a bypass line (TL'), and said circulation/kill line (TL) in the well blowout preventer has a first branch (TL1) connected to an outlet between two upper pipe rams (SCDSR, SCTSSR) and a second branch (TL2)connected to an outlet below the lowermost pipe ram (SCTGSR) and having access to a drilling hole below said latter pipe ram and the top of the well (WH). Arrangement as claimed in claim 1, characterised in that said bypass line (TL') runs from the top of the well (WH) and from the lower side of the annulus of the lower pipe ram (SCTGSR) and to the uppermost pipe ram (SCDSR). Arrangement as claimed in claim 2, characterised in that in each branch (TL1, TL2)of the circulation/kill line (TL) to the well blowout preventer of the drilling hole, there are provided two isolating valves (U0KV, U1KV respectively L0KV, L1KV), whereas in the bypass line (TL') there are provided two bypass valves (UBV, LBV). Arrangement as claimed in claim 1, characterised in that the arrangement comprises means for injection of gas through said circulation/kill line for thereby allowing under balanced deep water drilling. Arrangement as claimed in claim 1, characterised in that the arrangement comprises a shut-off valve (RESV) which is connected to the riser pipe (SR), and which serves for preventing liquid in the riser pipe (SR) to leak out to the surrounding water when disconnecting the high pressure riser pipe (SR). Arrangement as claimed in claim 1, characterised in that the arrangement comprises fail safe control circuits for the operation of a multiplex deep water slim hole drilling system comprising electrically controlled and/or hydraulically controlled components. Arrangement as claimed in claim 1, characterised in that the arrangement comprises a high pressure swivel (HPS) below the surface blowout preventer (SURBOP) and above the upper pipe ram. Arrangement as claimed in claim 1, characterised in that it comprises an assembled blowout preventer (USSSR, USGSR, LSGSR) in said surface (SURBOP), which is directly connected to said high pressure riser pipe (SR) and associated circulation/kill line (TL), comprising three blowout preventers. Arrangement as claimed in claim 1, characterised in that the arrangement comprises means to adapt a slim hole wellhead for attachment to a wellhead of standard size. Arrangement as claimed in claim 1, comprising a flexible connection located below the upper pipe ram for thereby allowing large sideways movements of an associated vessel.

Inventors: GLEDITSCH SVEIN, GLEDITSCH, SVEIN
Applicants: MERCUR SLIMHOLE DRILLING AND I, MERCUR SLIMHOLE DRILLING AND INTERVENTION AS
Application year: 1995
Main classification: E21B33
IPC codes: E21B33, E21B43