02 Vetco - Marine Raiser Systems [PDF]

Zitiervorschau

Marine Riser Systems

ChevronTexaco ChevronTexaco –– BP BP Training Training Alliance Alliance Floating Floating Drilling Drilling

Integrating … Wellhead, BOP and Riser Design

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The design of casing and wellhead systems should be performed with the complete wellhead system – including the riser.

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Guideline Type Drilling System

Guidelineless Drilling Systems Connector to Housing Interface

Guidebase/GRA Interface

Housing Interface

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Mudmat Interface

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MS-700 Family of Wellhead Systems

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H-4 Family of Wellhead Connectors

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BOP and Lower Marine Package

Courtesy of Hydril Company

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Lower BOP w/ Frame

Courtesy of Hydril Company

Lower BOP

LMRP Mandrel

w/o Frame

Annular

Choke Line

Blind -Shear Rams Kill Line

Super Shear Rams

Upper Pipe Rams Accumulators (x4) Middle Pipe Rams (Varible) Lower Pipe Rams

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(Varible Bore)

Wellhead Connector Courtesy of Hydril Company

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Lower Marine Riser Package (LMRP)

Courtesy of Hydril Company

Lower Marine Riser Package (LMRP) Riser Adapter

Mud Boost Line Control Pod (1 of 2) Single Flexjoint

Annular

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Choke Line Stab

LMRP Connector (H4) Courtesy of Hydril Company

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Funnel Down (Optional)

Hydrate Protection Hydrates must be prevented from entering the bottom of the connector. Ice formed from hydrates will prevent the connector from releasing

Fiber Reinforcement PN H12025-2 (16-3/4" Wellhead) PN H12025-3 (Super Wellhead) Rubber

Groove

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Groove

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Hydrate Protection (Methane Gas)

Hydrate Protection Plum H4 To Inject Freezing Inhibitor

Glycol Inhibitor

Outlet Thru Wash Ports ROV Hot Stab Inlet Thru Wash Ports

SHD H-4 Wellhead Connector

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Cavity Capacity 32 Gallon

Type of Well

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Exploratory Wells ™

Disposal

™

Non-Disposal

Developmental

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Wellhead Re–Entry Systems

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DP

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Moored

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Subsea Wellhead Angle

Riser Deployment and Retrieval

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Environmental conditions ™ Location ™ Season ™ Vessel

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Deployment / Retrieval ™ Riser fatigue life

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™ Currents

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Riser Handling and Lifting Gear Capacity ‹

Substructure

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Derrick

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Drawworks

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Hook block

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Handling gear

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Riser Running Tool

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Riser Gimble Shock Absorber

API Riser Coupling Class

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API RP 2R establishes riser coupling classes based on the tensile capacity of the coupling. These are; API Riser Coupling Class

Tensile Capacity in millions of pounds

A

.5

B

1.0

C

1.25

D

1.5

E

2.0

F

2.5

G

3.0

H

3.5

J (Proposed)

4.0

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MR-6E Riser Coupling ‹

Easy stabbing, fast makeup, and positive alignment

‹

Suitable for operating in water depths up to 7,500 ft depending on environmental and well control conditions; MR-10 designs can operate in depths to 10,000 ft.

‹

Preloaded connection significantly reduces the range of alternating stresses induced by cyclic loading to improve fatigue life

‹

Primary load path for tensile and bending loads through the dogs and into the body, does not impact actuating screws

MR Riser Running Tool 4-1/2” IF API Connection

18o Tapered Drill pipe Connection

Lift / Handling Eye

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Choke, Kill & Auxillary Test Caps

MR Box Connection Profile

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HMF Riser Coupling ‹

Ideal for deep water applications where high load operating conditions exist

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Stepped diameter design of pin and box simplifies engagement, even with severe vessel movement

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No loose parts preventing bolt loss and potential thread damage

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Field removable and replaceable nose piece

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Locking bolts preloaded in excess of rated coupling loads to extend fatigue load of riser system

HMF Riser Running Tools

Casing Elevator Lift Shoulder

Handling Lift Eye

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HMF Male Connection Profile

Mechanical Running Tool

Hydraulic Running Tool

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Riser Handling Tool

Spider

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MR-style riser handling spider supports the riser string on manual or hydraulically operated sliding dogs.

Hydraulic-gate riser spider is used when running or retrieving HMF riser joints through the rotary table.

Gimbal

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Gimbal shock absorber supports up to 2,000,000 lb and gimbals when the riser is positioned in the spider.

Reduces impact loads when running and landing marine riser joints.

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Single Flex Joint with Mud Boost Line

Flex Joints

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Single Flex Joint & Intermediate Flex Joint

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Riser Extension

Key Riser Components and Inspection

Drilling Riser

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Prepped for Buoyancy

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Installation of Syntactic Foam Buoyancy Modules on a Riser Joint

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90’ (27.4m) Riser Joint (w/ Spreader Bar)

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Telescopic Joint

Telescopic Joint

‹ Available for both multiple riser systems ‹ Compensates for heave and offset of the vessel ‹ Maximum rated riser tensile load capacity in

locked position ‹ Hydraulic latch release for inner and outer barrels

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‹ Dual split/solid packer elements ‹ Fixed or rotating integral/non-integral tensioner

rings ‹ SDL, SLS, KT and SDC tensioning rings

Primary Components of Telescopic Joint The outer barrel sub assembly has several functions: ‹

Providing a means to apply tension to the Marine Riser / BOP

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Fluid assist bearing to allow rig rotation

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Tension ring to eliminate the tensioner wire removal

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Dual packer assembly

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Kill, choke and Auxiliary line supply assembly

The inner barrel sub assembly functions: ‹

Providing communication between the vessel and the BOP during drilling

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Contains an Auto latch system to lock inner/outer

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barrel ‹

Split lock nut for easy servicing

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Cross-over flange to riser connection and diverter

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Fully extended can support 1.5m lbs

Crossover to Riser Connector

Split Lock Nut

Hydraulic Latch

Dual Packer Inner Barrel Latch

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Inner Barrel

Slipjoint / Telescopic Joint

Slipjoint / Telescopic Joint

Options Options

SDL Tension Ring

Fluid Assist Bearing

Kill & Choke & Hydraulic Supply Terminations

SLS Tension Ring

Options

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KT Tension Ring

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Type SDL Riser Support Ring

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Saves rig time by eliminating tensioner wire removal

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Stored below diverter and allows the rest of the riser to be pulled through

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Contains two sets of hydraulic dogs ƒ One to latch to diverter for storage ƒ The other to latch to outer barrel while drilling

Diverter System

In Floater Operations

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The primary function of a diverter is to divert shallow gas through overboard piping before the installation of the BOP stack. This vents the well and protects the formation before it is capable of handling closed-in pressure from the installed BOP. After the BOP is installed it is used to vent gas in the riser, above the BOP.

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There are two primary models of Vetco Gray diverters used on floaters: ƒ KFDS – using an expandable rubber packer ƒ KFDS- CSO – using a collapsible rubber element

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There is one primary model of diverter used on Jack-ups and Platform rigs : ƒ KFDJ – using an expandable rubber packer

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Diverters are available in 39-1/2”, 49-1/2” and 60” nominal sizes

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Pressure ratings range from 500 to 1000 psi

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Hang-off capacities range 500 kips – 2000 kips

KFDS Diverter System ‹

Pressure Rating (Wellbore): 500 PSI

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Diverter Operating Pressure:

Rotary Table

Control Lines/Block

ƒ Normal 750 psi ( 52 bar) ƒ Maximum 1500 psi (103 bar)

Insert Packer

Diverter Assembly

DiverterLocking Dogs

Diverter Housing Flowline

Flowline Seals (x2)

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Flex Joint

Crossover to Riser Connector

KFDS Diverter System ‹

Pressure Rating (Well bore): 500 PSI

‹

Diverter Operating Pressure: ƒNormal 750 psi ( 52 bar)

Control Lines/Block

ƒMaximum 1500 psi (103 bar)

Insert Packer

Diverter Assembly DiverterLocking Dogs

Diverter Housing

Flowline Seals (x2)

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Flowline

Diverter Assembly Packer Element

CSO Diverter Divert Line Flow Line

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Diverter Flex Joint

C

B D

Current induced loads can cause the Riser to bind as it is run through the Rotary Table and Diverter Housing.

A D

DIVERTER HOUSING REGION

W.L.

D

A

D

CURRENTS

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A STRUCTURE/RISER CONTACT B

BINDING CONTACT, RESULTING IN RISER DAMAGE AND FOAM MODULE DAMAGE.

C MAKE-UP DIFFICULTIES DUE TO ANGLE. D RISER OVERSTRESS.

Lifting Equipment Rig lifting equipment must be able to deploy the Riser with the LMRP/BOP Package without exceeding design capacity.

WAVE HEAVE W.L.

HOOK LOAD INDICATOR

RATED LIFTING GEAR CAPACITY

DYNAMIC LOAD ON LIFTING GEAR

HOOK LOAD NET WEIGHT OF RISER ON LIFTING GEAR

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TIME

AMPLIFIED RISER RESPONSE

MUDLINE

Storm Hang-off of Riser HARD HANGOFF, RISER HEAVES WITH VESSEL

SOFT HANGOFF, RISER HEAVE IS MINIMIZED BY TENSIONER STROKE

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Stay attached during storm conditions

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Disconnect the riser and pull out of the hole

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Hang-off – Hard or Soft

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W.L.

LMRP

Riser Fatigue Considerations ‹ ‹

Wave Loads Environmental Conditions Riser Pipe

Current-induced Vortices

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⇒ Steady ⇒ Current ⇒ ⇒

VIV Excitation Due to Currents Vortex shedding due to steady current acting on a pipe results in pipe dynamic motions and fatigue.

Drift-Off/Drive-Off D E G R A D IN G S T A T U S G REE N

P REP FO R E DS

E D S T IM E ( A P P R O X . 60 SEC ON D S)

YE LL O W A LE RT

R E D ALER T

D IS C O N N E C T C I R C L E

V ESSEL O FFSE T FR OM W ELL C EN TE R

G R E E N - N O R M A L O P E R A T IO N S Y ELL O W A LER T - P RE PA RE FO R E DS R E D A L E R T - E D S IN IT IA T E D

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D IS C O N N E C T C IR C L E - E D S C O M P L E T E D , R IS E R D IS C O N N E C T E D

• Disconnect Speed • Control System

• Riser Tension Recoil • Control of Disconnect

Limits for Connected Riser Operations

VESSEL MOTIONS ANGLE

WAVE ACTION

CURRENTS

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ANGLE

MUDLINE

W.L.

C

A

VESSEL OFFSET ANGLE

W.L.

B

POSSIBLE WEAKPOINTS C ANGLE D

E

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MUDLINE F

Riser, Wellhead and Conductor Strength

A

TENSIONERS/TELESCOPIC JOINT

B

RISER

C

FLEX JOINT

D

LMRP/BOP

E

WELLHEAD & CONNECTORS

F

CONDUCTOR PIPE

To prevent failure of Riser/Well System Components, Emergency Disconnect must be completed before vessel offset causes the Riser/Well System to exceed allowable limits.

θ

System Considerations F

System Objective Provide a system level solution for drilling in ultra deepwater drilling:

BOP Flange Wellhead Connector

‹

~6.6 MM ft-lbs

‹ ‹

~7 MM ft-lbs

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~7.7 MM ft-lbs ~8.4 MM ft-lbs

15,000 psi to 20,000 psi rated pressure

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Wellhead System Conductor/ Casing Connectors

‹

BOP Flange Wellhead Connector Subsea Wellhead System Conductor Sizing (Analysis) Conductor/Casing Connectors

~14 MM ft-lbs (40' Below Mudline)

7,000,000 ft.-lbs. Bending @ 15,000 psi

MUST MAINTAIN CLEARANCE IN TELESCOPIC JOINT

Riser Recoil Response

NO SLACK IN WIRE ROPES

W.L.

LMRP LMRP MUST MAINTAIN CLEARANCE ABOVE BOP STACK

BOP

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LMRP

BOP MUDLINE

After riser disconnect, the LMRP must be lifted to prevent contact with the BOP stack during vessel down heave.

Riser Burst Pressure

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Minimal pressure device

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Contingency plan for bubble in riser

W.L.

MUD PRESSURE

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SEAWATER PRESSURE BOP MUDLINE

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Gas in Riser vs Choke/Kill Line

Riser Collapse/Riser Fill-Up Valve Placement

W.L.

During an emergency disconnect, external pressure from seawater can collapse the Riser if the mud column drops too fast.

EMPTY RISER

LMRP

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MUD RELEASE FROM RISER SEAWATER PRESSURE BOP MUDLINE

Torque Loads due to Heading Change

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As vessel heading is changed, excessive torque can be applied to the connected drilling riser.

Wellhead with a rigid lockdown mechanism to enhance fatigue life.

Control Panel Release Piston Indicator Power Piston Indicator

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Latch to 36”

Riser Monitoring Systems and Inspection Methods Daily: ‹ Mud weight ‹ Environmental conditions change ‹ Riser tension and rig location

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Long Term: ‹ Corrosion ‹ Cracks ‹ Wear and Damage ‹ Choke and Kill lines

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Benefits from Composites ‹

General ƒ Increased fatigue life ƒ Elimination of corrosion problems

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Composite Choke and Kill Lines ƒ Provides a 60% weight savings over equivalent steel lines ƒ Can save about 25-30% of the total riser string weight, thus extending an existing rig’s drilling depth accordingly

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Composite Drilling Riser System ƒ Provides a 65% weight savings over steel riser systems ƒ Can increase the drilling depth of an existing rig or platform ƒ Significantly reduces the variable deck weight

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Composite Production Riser ƒ Provides a 60-80% weight savings over equivalent steel risers ƒ Can eliminate the need for tensioners on TLPs and SPARs ƒ Can increase the number of wells for a given vessel ƒ smaller space requirements ƒ less deck weight ƒ Can increase the water depth for a given production system.

VGI Composite Products

X X

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X

Choke & Kill Lines Drilling Risers Production Risers

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Harnessing incredibly strong carbon fiber and durable epoxy matrix to produce light-weight oilfield products

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Composite products are providing solutions to today’s challenges

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Composites enable use of existing rig fleets and production platform designs to go deeper -safer and less expensively.

5,000’ Rig Upgrade to 10,000’

Baseline 5,000’ Water Depth Capable Rig X All Steel Riser System (C&K, booster, hydraulic) X Nominal 2,000 Kip Tension with 15 ppg Mud X 46” Diameter Buoyancy X Deck Weight of 2.3 M lbs X Day Rate of $30k

Steel System

Composite System

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10,000’ Composite Riser Upgrade X System Deck Weight X 5,000’ of Steel Riser Body X 10,000’ of ALL Aux. Lines X Added 3,000’ of Buoyancy X Total

$8.4 Million Savings

3.55 M lbs $2.0 M $11.7 M $1.5 M $15.2 M

OR

10,000’ Steel Riser Upgrade X System Deck Weight X 5,000’ of Full Riser X 7,200’ of 56” Buoyancy X Total

5.8 M lbs $5.3 M $6.1 M $11.4 M

+

Savings in Upgrades on Rig X 12 Months of Docked (50%) X 60” Rotary Table Upgrade X Rig Buoyancy Upgrade ($2.36/lb) X Total

$5.5 M $1.5 M $5.2 M $12.2 M