USB - Ole Gjerstad - SUT - Manifolds and Connections May 2014

Subsea Manifold & Connection Systems
SUT
Subsea Awareness Course
Ole Gjerstad
27th May 2014
Agenda
Subsea Manifold Systems

– Manifold System Overview
– Cluster Manifolds
– Template Manifolds
– Foundations
– Project References (Photos)
– Valves
– ‘Key’ issues
Agenda
Subsea Connection Systems

– Where are connections used
– Metrology and tolerances for flowlines and
spools/jumpers
– Connector Types
– Pressure containing equipment
– Bore configurations
– Laydown connections
– GE Connection/tie-in systems:
VCCS,HCCS, SHO, ICARUS
Subsea Manifold Systems
4
GE Confidential and Proprietary Information
GE2014 All Rights Reserved
Manifolds / foundation structures
5
Manifold System Overview
Why Use Manifolds?

Single gathering point
Reduces number of flowlines
Single tie-back to production facility
Base for control of multiple wells
Selective production
Convenient for pigging
Field Expansion
Provide protection
Flow control sub-station
Power house
6
Subsea Production Systems
7
Major
Items
Manifold
8
Manifold Components
Manifold Module
- Support Structure
- Branch Piping, Isolation Valves
- Flowline / Spool Connection Interfaces
- Header piping
- ROV / Diver Interfaces
Foundation Structure
Protection Structure
- Dropped objects
- Fishing Friendly (Overtrawlable)
Optional Items
- Sand Detectors, Pig Detectors
- Pressure / Temperature Sensors / Flow Meters
- Control Modules
- Chokes
- Pigging Loops
9
Manifold System – Basic Principles
XT
Jumper
Header XT
Branch
SCM
SDU Header
EDU valve
Flowline
Branch
Isolation
valve
XT XT
10
Manifold-Piping
11
Types of Manifolds
Cluster Manifolds
Template Manifolds
12
Cluster Manifolds
Principle – Cluster Manifold
Wells are located away from the manifold
XT XT
Manifold
XT
XT
14
Chevron Kuito Project
15
Kuito 1A Manifold
16
Typical 4-well cluster manifold
Manifold with satellite jumper

connections
Integrated or separate header
module
Satellite trees
Jumpers
In-line configuration
17
Template manifolds
Principle – Template Manifold
Wells are located on the manifold-structure
MM
19
Production Templates
Wellheads and manifold located Cost effective; infield jumpers not

on one common foundation required, connection between
structure. tree and manifold normally
through a Choke Bridge Module.
20
Subsea Templates
Trees located directly on subsea structure

Share common header
Generally fixed number of trees but can also be configured
for expansion
Larger structure compared to cluster manifold
No flexibility in location of wells
Usually require large installation vessels
21
8-Slot Template
Integral skirt foundation

Integral headers
Integral PGBs
Standard 4-slot manifolds
Standard trees
Standard intervention
22
Foundations
Foundation Types
Mudmat
– Shallow Skirted
– Gravity Based
Pile
– Driven Pile
– Drilled & Grouted
Suction Anchor
– Single Can (Caisson)
– Multiple Can (Caisson)
24
Foundation Examples
Drilled Pile Foundation
Skirt Foundation
25
Foundation Examples
Driven Pile Foundation

(4-Corners)
Suction Anchor Foundation
(Single Caisson)
26
Template - Foundation
27
Snøhvit – Foundation GE Confidential and Proprietary Information
+ Protection Structure
Project References
Kuito 1a Manifold on Transport Barge
29
Snorre B: 8-slot Production template
Kizomba C: Production and W.I
manifolds during loadout.
31
Kizomba C: Production and W.I
manifolds during loadout.
32
Gorgon manifold stack-up onto
foundation
33
Subsea Valves
Valves
• Can drive size of manifold
• 20 to 30 years of operation
•Actuated Valves
•ROV operated Valves
• Long delivery time
• Expensive
35
Subsea Valves
• Ball or gate valves
• Produced by SSEV or by specialist suppliers
– Bel
– Petrovalve
– Cameron
• Specific subsea design
• Actuation by hydraulics and/or ROV
• Double acting or spring return fail modes
• Visual or electronic position indication
• Forged pressure containing parts
• Tungsten-Carbide coated friction areas
• Nickel alloy weld overlay on internals
• Manufactured according to API 6A (ISO
10423) Snøhvit 28” BV
• Qualified to API 6A (ISO10423) PR2
36
Kuito 1a Manifold: Valve Interfaces
37
Key Issues
Manifold- ‘Key’ Issues
• Valves and connections (Long Lead Items, high cost)
• Piping (Spec., Code, MTO)
• Materials (Impact on valves, piping, hubs/flanges)
• Foundation (Dependent on soil conditions)
• Interfaces ( Manifold is ‘frontrunner’)
• Engineering (High no of documents / drawings)
39
Agenda

–Where are connections used
–Metrology and tolerances for flowlines and
spools/jumpers
–Connector Types
–Pressure containing equipment
–Bore configurations
–Laydown connections
–GE Connection/tie-in systems:
VCCS,HCCS, SHO, ICARUS
Where can subsea connections be found?
42
Connection Systems
Typical connection applications include:
• PLET connection between flowline and spool/jumper (typically infield or export flowlines)
• Connection between spool/jumper (rigid or flexible) and template/manifold
• Connection between X-tree and spool/jumper (rigid or flexible)
• Connection at end of production riser
• Internal connections on templates and manifolds (pigging loop, choke bridge, valve modules)
• Internal connections on X-tree (choke module)
• Pressure and installation caps
• Pipeline initiation/laydown head connections
• Umbilical connections
• Riser connections
• Pig launchers/receiver connections
VERTICAL OR HORIZONTAL!
43
How to Connect?
Diver ROV
44
Metrology and tolerances
Typical layout: PLET, manifold, spools
45
Jumpers
Bonga Jumper spools prior to
final fabrication in Nigeria
Bonga final Jumper (M-

shape) at shipping stand on
Barge
46
HCCS – Snohvit
47
What is a Connection?
A connection is, in general, a joint consisting of:
Industry names Subsea names
• 2 Flanges = Hubs (Male & Female)
• Gasket = Seal
• Connection device or screws = Connector
The connector forces the two hubs together and creates a preload on the
seal positioned in between. The seal makes a high pressure proof joint.
Guiding structures are used to align the hubs prior to make-up.
48
Three main types of Connectors
Collet VH, MCV, CH-4
Dog or Mandrel DG, DG-4
VCCS, HCCS, SHO,

Clamp
Icarus, V-mec
All types do the same job: Mate hubs, preload seal, resist separation forces
49
Clamp connection assembly
Simple and robust
50
Concentric dualbore connection
Dualbore Seal
Annulus Bore
Main Bore
Cross Section of a Dualbore Connection
51
Pressure containing equipment
High level of complexity:
- Tight machining tolerances
- Loads: Preload, pressure, bending moments, axial load, torsion
- Structural integrity, pressure integrity
- Documentation and qualification per Client expectations
52
Multibore Connection
53
Laydown connections
F
M
Critical Loads:
- Bending moment
- Axial Force
- External pressure
54
Laydown connections
Installation with laydown head on a PLET structure
55
GE types of Connection Systems
VCCS - Vertical Clamp Connection System
For singlebore/dualbore rigid and flexible jumpers
HCCS - Horizontal Clamp Connection System

For singlebore/dualbore/multibore rigid and flexible spools
Suitable for large singlebore rigid export pipeline connections
HCCS S&HO - Stab & hinge-over

For singlebore/dualbore/multibore flexible jumpers and umbilicals
56
VCCS – System Components
Vertical Clamp Connector System (VCCS)

• Flexible jumper with goose-neck assembly
• Rigid jumper
Downfacing Connector
Assembly
Connection Tool
Upfacing Hub Assembly
57
Vertical Clamp Connection System, VCCS
PUP-PIECE
CLAMP
INDICATOR
BACK SEAL TEST
RECEPTACLE
TORQUE
BUCKET SEAL REPLACEMENT FEMALE HUB
INSULATION TOOL (VSRT) CLEANING TOOL
PLUG (VFCT)
PRESSURE CAP
DOWNFACING
HUB
INSULATED
DOWNFACING
ASSEMBLY UPFACING
PLASTIC DEBRIS CAP
TOOL BASKET STROKING TOOL (VCCT)
BUCKET
INSULATION
HOT STAB
TORQUE TOOL & 58

CALIBRATION GE Confidential and Proprietary Information
INSULATION RING PIG LAUNCHER HANDLING TOOL GE2014 All Rights Reserved
UNIT
FOR DOWNFACING
Vertical Clamp Connection System
System Test
Flexible Jumpers - Testing

59
Vertical Clamp Connection System
w/flexible flowlines and rigid jumpers
Kizomba - C
60
VCCS – Exxon Kizomba Development
61
Horizontal Clamp Connection System
HCCS Clamp Connector
Porch Guide Post
Female Hub
Termination Seal
O-Ring
Male Hub
Landing Beam 62
62
GE2014Connection Systems
All Rights Reserved
20.05.2014
HCCS – System Components
63
63
GE2014 All RightsSystems
Connection Reserved
20.05.2014
HCCS 30 – Stroking Tool being deployed
64
SHO & UTA and Porch
Lifting Yoke
UTA
SHO
Lock Barrel- Porch
In Lock Position
Guiding Post
(optional)
Landing structure
65
SHO & UTA UTA at 1st end
MB UTA Installation
Lowering of Umbilical from vessel
66
ICARUS - Horizontal connection system
Porch
Female Hub
Termination
Male Hub
Seal Clamp Connector
67
Connection Systems
ICARUS
• ROV Based Tie-in System
• VG Clamp Connector
• Connection size up to 18”
68
Project References
HCCS – Snohvit
70
North Bardawil: Inline Tee Connections
71
BP Valhall
72
Statoil Gjøa
28” PLET
73
Chevron – Lobito Tomboco: EFAT
• 5” x 2” Dual-bore flexible jumper

• approx. 50m lengths
74
Questions?
75
76

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Subsea Manifold & Connection Systems

Subsea Manifold Systems

Subsea Connection Systems

Why Use Manifolds?

Wells are located away from the manifold

Manifold with satellite jumper

Wellheads and manifold located Cost effective; infield jumpers not

Trees located directly on subsea structure

Integral skirt foundation

Drilled Pile Foundation

Driven Pile Foundation

Subsea Connection Systems

Bonga final Jumper (M-

Dog or Mandrel DG, DG-4

VCCS, HCCS, SHO,

Simple and robust

HCCS - Horizontal Clamp Connection System

HCCS S&HO - Stab & hinge-over

Vertical Clamp Connector System (VCCS)

Upfacing Hub Assembly

TOOL BASKET STROKING TOOL (VCCT)

TORQUE TOOL & 58

Flexible Jumpers - Testing

Seal Clamp Connector

• 5” x 2” Dual-bore flexible jumper

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