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Introduction to Subsea Engineering /chesssubseaengineering /chesssubseaengineering Presented by Oseghale Lucas Okohue BEngr. Msc. CIPMP www.chesssubseaengineering.com Online from May 9 th to 23 rd

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Page 1: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Introduction to Subsea Engineering

/chesssubseaengineering /chesssubseaengineering

Presented by

Oseghale Lucas Okohue BEngr. Msc. CIPMP

www.chesssubseaengineering.com O

nline from M

ay 9th to 23

rd

Page 2: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Course Instructor

Name: Oseghale Lucas Okohue

Position: Subsea Engineer Consultant – Production Systems | Drilling Systems

Website: www.chesssubseaengineering.com

Email: [email protected]

[email protected]

Phone: 08139340494

Page 3: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Outlines

Introduction to Subsea Engineering

Subsea Engineering Brief History

Subsea Production System

Subsea Field Architecture

Subsea Distribution System

Subsea Survey, Positioning & Installation

Subsea Installation and Vessels

Subsea Cost Estimation

Flow Assurance & System Engineering

Page 4: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Risk and Reliability

Subsea Equipment RBI

Subsea Hydraulics

Subsea Corrosion and Scale

Subsea Manifold Systems

Pipeline Ends and In-Line Structures

Subsea Connectors and Jumpers

Subsea Wellhead and Trees

Outlines Cont.

Page 5: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Drilling Risers

Subsea Production Risers

Subsea Umbilical Systems

ROV Intervention and Interface

Outlines Cont.

Page 6: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

This introduction to subsea engineering module will discuss the above outline in

five parts:

Part 1: History of Subsea Engineering

Part 2: Subsea Production Systems

Part 3: Flow Assurance and System Engineering

Part 4: Subsea Structures and Equipment

Part 5: Subsea Umbilicals, Risers, and Pipelines

Page 7: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Part 1 : History of Subsea Engineering

/chesssubseaengineering /chesssubseaengineering

Page 8: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

The world’s energy consumption has increased steadily since the 1950s. As shown in the figure below, fossil fuels (oil, natural gas, and coal) still amount

to 80% of the world’s energy consumption

Note: A number of initiatives and inventions in the area of renewable energy

resources are currently in its development phase.

Introduction

Page 9: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Introduction Cont.

The rapid rises in crude oil prices during the late 2000s is a response

to increasing demand for oil and gas.

A detailed investigation into fossil fuels consumed within 1980 to 2004

reveals that almost 80% is oil and gas.

Therefore, the production of oil and gas is of major importance to the

stability of the world’s energy supply.

Page 10: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Brief History

The offshore oil and gas industry started in 1947

The first successful offshore well was done by Kerr-McGee in the GOM

off the coast of Louisiana

Water depth was 4.6 m

Page 11: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Brief History Cont..

Subsea field development concept was suggested in the early 1970.

The concept entails placing wellhead and production equipment on

the seabed with some or all components encapsulated in a sealed

chamber.

The hydrocarbon produced would then flow from the well to a nearby

processing facilities.

These could either be on land or on an existing offshore platform.

Page 12: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Brief History

This concept was the start of subsea engineering.

Systems that have a well and associated equipment below the water

surface are referred as subsea production systems.

Subsea completions in less than 1,000 ft (305 m) water depths are

considered to be shallow-water completion.

Depths greater than 1,000 ft (305 m) are considered to be deepwater

completions.

Page 13: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Brief History

In the past 40 years, subsea systems have advanced from shallow-

water, manually operated systems into systems capable of operating

via remote control at water depths of up to 3,000 meters (10,000 ft).

The subsea technology used for offshore oil and gas production is a

highly specialized field of application that places particular demands on

engineering.

Page 14: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Brief History

These special aspects make subsea production a specific engineering

discipline.

Page 15: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Part 2 : Subsea Production Systems

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Page 16: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Production System

A subsea production system consists of:

Control facilities to operate the well

Subsea completed well,

Seabed wellhead,

Subsea production tree,

Subsea tie-in to flowline system,

Subsea equipment's i.e. jumpers, spool, PLEM, PLAT etc.

Page 17: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Production System

Its complexity can range from:

I. Single satellite well with a flowline linked to a fixed platform, FPSO

(Floating Production, Storage and Offloading), or onshore facilities.

Page 18: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Production System

II. Several wells on a template or clustered around a manifold that transfer

to a fixed or floating facility or directly to onshore facilities.

Page 19: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Production System

The latest subsea technologies have been proven and formed into an

engineering system, namely, the subsea production system.

Components of the Subsea Production Systems:

Subsea Drilling Systems

Subsea Christmas trees and wellhead systems;

Umbilical & Riser systems;

Subsea manifold and jumper systems;

Page 20: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Production System

Tie in & flowline systems;

Control systems;

Subsea Installation;

Page 21: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Relationship among Major Component of a subsea Production System

Page 22: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Field Architecture

Page 23: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Field Architecture - Classification of Subsea Tree

Based on the position of the tree, a subsea system can be categorized as:

dry tree production system

wet tree production system

Note:

Christmas trees and other structures cannot be installed in water depths of

less than 30 m (100 ft). If less than, then jacket platforms can be used.

Water depth can impact subsea field development.

Page 24: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

The goal of subsea field development is to safely maximize economic

gain using the most reliable, safe, and cost-effective solution.

Factors to consider in Subsea Field Development

Deepwater or shallow-water development;

Dry tree or wet tree;

Stand alone or tie-back development;

Hydraulic and chemical units;

Subsea Field Development

Page 25: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea processing;

Artificial lift methods;

Facility configurations (i.e., template, well cluster, satellite wells,

manifolds).

Wash out for the advantages, disadvantages, and limitations of

the above issues on Chess Subsea Field Development module.

Factors to be Considered in Subsea Field Development cont….

http://chesssubseaengineering.com/2015/04/16/subsea-field-development-2/

Page 26: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Distribution Systems

The subsea system is associated with the overall process and all

equipment involved in the arrangement.

It is designed in such a way that safety, environment protection,

flow assurance and reliability are taken into consideration.

Page 27: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

The subsea system is associated with the overall process and all

equipment involved in the arrangement.

Subsea distribution systems consist of a group of products that

provide communication between subsea controls and topside

controls for all equipment via an umbilical system.

Subsea Distribution Systems

Page 28: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea distribution systems may include, but not be limited to, the

following major components:

Topside umbilical termination assembly (TUTA);

Subsea accumulator module (SAM);

Subsea umbilical termination assembly (SUTA), which includes:

• Umbilical termination head (UTH); • Hydraulic distribution manifold/module (HDM) • Electric distribution manifold/module (EDM)

• Flying leads

Subsea Distribution Systems

Page 29: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea distribution assembly (SDA);

Hydraulic flying leads (HFLs);

Electric flying leads (EFLs);

Multiple quick connector (MQC);

Hydraulic coupler;

Electrical connector;

Logic caps.

See advantages, disadvantages, and limitations of the above components

On chess subsea distribution systems module.

Subsea Distribution Systems

http://chesssubseaengineering.com/2015/04/16/subsea-distribution-system/

Page 30: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Surveys

Positioning and soil investigation is one of the main activities for

subsea field development.

Subsea survey can be either geophysical or geotechnical.

Page 31: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Purpose of Subsea Surveys

potential man-made hazards;

natural hazard;

Engineering constraints of a proposed subsea field area;

Potential impact on biological communities;

To determine the seabed and sub-bottom

condition;

Page 32: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

In chess subsea surveys module the following courses will be discussed as

follows:

Establishing vertical route profiles, a contour plan, and the seabed’s

features, particularly any rock outcrops or reefs;

Obtaining accurate bathymetry, locating all obstructions, and

identifying other seabed factors that may affect the development of

the selected subsea field area including laying, spanning, and stability

of the pipeline

Page 33: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Carrying out a geophysical survey of the selected subsea field and route

to define the shallow sub-seabed geology;

Carrying out geotechnical sampling and laboratory testing in order to

evaluate precisely the nature and mechanical properties of soils at the

selected subsea field area and along the onshore and offshore pipelines

and platform locations;

Locating existing subsea equipment (e.g., manifold, jumper, and

subsea tree), pipelines, and cables, both operational and redundant,

within the survey corridor;

Page 34: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Determining the type of subsea foundation design that is normally used for

subsea field development.

http://chesssubseaengineering.com/2015/04/07/subsea-survey-positioning-installation-and-introduction-to-subsea-control-system/

Page 35: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Installation and Vessels

The development of subsea production systems requires specialized

subsea equipment.

The deployment of such equipment requires specialized and expensive

vessel.

These vessels are equipped with diving equipment for relatively shallow

equipment work, and robotic equipment for deeper water depths.

Page 36: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea installation refers to the installation of subsea equipment and

structures in an offshore environment.

Subsea Installation and Vessels

Page 37: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea installation can be divided into two parts:

Installation of subsea equipment

Installation of subsea pipelines and subsea riser

Note:

Installation of subsea equipment such as trees and templates can be

done by a conventional floating drilling rig.

Subsea pipelines and subsea risers are installed by an installation

barge using S-lay, J-lay, or reel lay.

Subsea Installation and Vessels

Page 38: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea equipment to be installed is categorized based on:

weight,

shapes (volume versus line type),

dimensions,

water depth (deep versus shallow).

Subsea Installation and Vessels

Page 39: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

See chess subsea installation and vessels module for installation of

subsea equipment such as trees, manifolds, flowlines, and umbilicals.

Also special vessels used to run the trees and rigless installation is

also discussed.

Subsea Installation and Vessels

http://chesssubseaengineering.com/2015/04/18/subsea-systems-installation-and-vessels-selection/

Page 40: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Cost Estimation

Subsea cost is relatively flat with increasing water depth, when

considering subsea systems as a development option for specific

reservoir and numbers of well required.

For rigid platform cost of development increases

with depth.

Thus; deeper water favors the use of

subsea systems.

Page 41: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Again, considering drilling cost, platform is relatively cheaper than

drillship or semi’s.

Platform is limited for field development due to the following reasons:

water depth,

process requirements,

environment.

Similarly, the use of mobile ships for subsea well drilling increases its

cost.

Subsea Cost Estimation

Page 42: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Again, the use of mobile drill ship units for subsea wells increases its

drilling cost.

Therefore, situations where a relatively small number of wells are

needed favor the use of a subsea system.

Subsea Cost Estimation

Page 43: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Capex & Opex Subsea costs refer to the cost of the whole subsea project.

Energy companies look at subsea cost in terms of capital expenditures

(CAPEX) and operating expenditures (OPEX).

Page 44: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Capex CAPEX is the total amount of investment necessary to put a project into

operation.

Capex cost includes:

cost of initial design,

engineering,

construction,

installation

Page 45: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Opex OPEX is the expenses incurred during the normal operation of a facility, or

component after the installation labor, material, utilities, and other related

expense.

Opex cost includes:

Operational cost,

Maintenance cost,

Testing cost,

Other related expenses

Page 46: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Opex OPEX is the expenses incurred during the normal operation of a facility, or

component after the installation labor, material, utilities, and other related

expense.

Opex cost includes:

Operational cost,

Maintenance cost,

Testing cost,

Other related expenses

Note: Chess Subsea Module on Cost Estimations covers subsea cost

estimates in details.

Page 47: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Chess Subsea Module on Subsea Cost Estimations covers subsea cost

estimates in details.

Subsea Cost Estimation

http://chesssubseaengineering.com/2015/04/16/subsea-field-development/

Page 48: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Controls “The subsea production control system is defined as the control system operating

a subsea production system during production operations according to ISO

13628-6.”

Page 49: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Controls

The subsea control system is the heart of any subsea production system.

It is relatively cheap when compared to the cost of drilling, line pipe,

installation, etc.

Thus, control systems are usually low on the list of initial project priorities.

However, ignoring the complexity, the number of components and interfaces

can lead to problems with installation and commissioning and to long-term

reliability issues.

Page 50: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Controls

The subsea control system is the heart of any subsea production system.

Chess Subsea Control System Module covers the principles and

characteristics of subsea production control systems. The advantages,

disadvantages, and limitations are also compared. The government

regulations, industry codes, recommended practices, and

environmental specifications that apply to subsea control systems are

detailed.

http://chesssubseaengineering.com/2015/04/16/subsea-control-system/

Page 51: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Power Supply

Power supply is a key factor in subsea processing.

The subsea power supply is an important component in the systems

necessary for processing the well stream at the seabed close to the wells.

Not having the power supply system in place can stop the development of

subsea processing.

Page 52: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Power Supply

Chess Subsea Power Supply Module focuses on the following three main areas:

The power supply system’s components and technologies are also described in this

module

Electrical power unit (EPU);

Uninterruptible power supply (UPS);

Hydraulic power unit (HPU).

http://chesssubseaengineering.com/2015/04/16/subsea-power-supply/

Page 53: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Project Execution and Interfaces

The success of any project depends significantly on project execution.

Project execution will allow for timely corrective action or redirection of the project.

Project execution is relevant at all stages of a project.

Project execution and interfaces become more intense and complex as

activities increase in number, diversity, and geographical spread.

The project manager must set the expectation that the project management

team understand its project execution system and the quality of data available.

Page 54: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Project Execution and Interfaces

Project execution does not have its own momentum and it is, therefore, critical

that it be proactively driven by the project manager.

Page 55: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Project Execution and Interfaces

Chess Subsea project execution and interface module covers the

requirements for subsea project execution and interfaces with the

accumulated knowledge and experience of project managers to guide all

involved parties in managing project activities.

Additionally, this module addresses the challenges of creating seamless

interfaces and establishes the methodology and tools for identifying

interface issues between the various functional groups.

http://chesssubseaengineering.com/2015/04/16/subsea-project-execution-and-interfaces/

Page 56: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Part 3 : Flow Assurance and Systems Engineering

/chesssubseaengineering /chesssubseaengineering

Page 57: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Flow Assurance and System Engineering

System engineering discipline activities are broadly classified into three primary

service areas:

Production system design;

System integration;

Equipment application and development;

Page 58: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Classification of System Engineering

System engineering discipline activities are broadly classified into three primary

service areas:

Page 59: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Operations

After the production system has been installed, numerous operations are in

place to ensure safe and pollution-free operations and support the

continued flow of hydrocarbon. The following are typical post installation

operations:

Commissioning and start-up (start-up could be “cold” or “hot”);

Normal operations;

Production processing;

Chemical injection;

Routine testing

Page 60: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Operations

Maintenance and repairs (remotely operated vehicle [ROV], routine surface); Emergency shutdown;

Securing facilities (e.g., from extreme weather events);

Intervention.

In many cases the technology and techniques applied to support

production activities in deepwater are similar in scope to developments in

shallow water.

Page 61: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Subsea Operations

Deep water does add a level of complexity to the project, particularly

subsea developments.

A significant amount of work is necessary for proper planning,

simulations (steady-state and transient),design, testing, and

system integration before the deepwater development moves

forward.

Page 62: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Commissioning and Start-Up

Operations typically begin with systems integration testing (SIT) at a

shore base or vendor or manufacturer’s facility.

Mobilization to and the start-up of installation at the offshore location can

involve a large number of vessels, including:

drilling unit, support boats, derrick barge, transport barges

and tugs, pipelay vessels, ROVs, and divers.

Production from the well at this point will include completion fluids and

reservoir fluids.

Page 63: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Commissioning and Start-Up

These may be flared/burned, treated, and discharged overboard, or

transported to shore for disposal at an approved location.

The cleanup phase of bringing a well / field on line typically last 2 to

5 days.

Page 64: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Production Processing

Production processing equipment is generally the same for both shallow

and deepwater developments.

The production system may involve several separators, a series of safety

valves, treaters, compressors, pumps, and associated piping.

For deepwater facilities, the production system may be designed to

process higher rates of flow.

These could include production from multiple developments commingled

at a common host facility.

Page 65: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Production Processing

crude oil separation,

water injection equipment,

gas compression,

chemical injection,

control systems for subsea

production equipment, and

associated piping.

The main surface production processing system components might

involve:

Page 66: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Production Processing

One area that does differ is the need to account for vessel motion that can

be induced by environmental forces on these floating production facilities.

In these conditions, production separators require specialized

designs.

Page 67: Online from May 9 to 23 Introduction to Subsea Engineering · PDF fileSubsea Equipment RBI Subsea Hydraulics Subsea Corrosion and Scale Subsea Manifold Systems Pipeline Ends and In-Line

Chemicals Injection

Fluid problems in deepwater are critical issues i.e.

colder seabed,

produced water,

cold temperatures,

condensates,

paraffin, and

asphaltenes contents in the oil.

All these can compromise the viability of a development project.

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Chemicals Injection

The use of chemicals in offshore oil production processes is not a new

approach.

Some of the chemicals used are:

corrosion inhibitors,

workover / packer fluids (weighted clear fluids, bromides, chlorides,

etc.),

hydrate and paraffin inhibitors,

defoamers,

solvents (soaps, acids),

glycol, and diesel.

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Chemicals Injection

These chemicals are typically used for batch treatment i.e. small-volume continuous injections or remedial treatments such as workover operations.

Material safety data sheets are required for all chemicals used offshore.

Carbon-steel components of the production system that are wetted by the

produced fluid are protected by corrosion inhibitors.

Material selection is a critical factor in the proper design of a production

system.

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Chemicals Injection

Thus, material selection requires information about the composition of the

produced fluid.

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Hydrate Inhibition

Hydrate inhibition is normally associated with batch treatments for the

processes of start-up and shut-down (planned or unplanned).

Continuous injection also occurs when there is induced cooling likely due

to chokes.

Also the natural cooling of pipelines by the cold ambient temperatures of

the seabed.

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Hydrate Inhibition

Methanol is one of the most common hydrate inhibitors used, particularly

for subsea wells and in arctic regions where rapid cooling of the produced

fluid flow (gas and water) can cause hydrate formation.

Methanol is injected into the tree and sometimes downhole just above

the subsurface safety valve while the fluids are hot.

Characteristics and formation of hydrates in subsea production

systems are detailed in the hydrate modules. The solution

methodology and hydrate control designs are summarized.

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Paraffin Inhibition

Paraffin inhibitors are used to protect the wellbore, production tree, and

subsea pipelines/flowlines from plugging.

The injection of these chemical inhibitors is dependent on the composition

of the produced fluids.

Injection can occur continuously at the tree, pipeline, manifold, and other

critical areas while the production flow is hot, and to batch treatments at

production start-up and shut-down processes.

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Paraffin Inhibition

The wax content, pour point, and other factors are determined prior to

beginning production to determine the chemical(s) needed, if any, and the

best method for treatment.

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Asphaltene Inhibitions

Asphaltene inhibitors are injected in the same manner as other inhibitors,

but on a continuous basis.

They form in the production system as the pressure declines to near the

bubble point.

Most development projects require one or all of these chemical inhibitors

to avoid produced fluid problems.

Efforts are under way to improve the performance of the inhibiting

chemicals and to reduce the toxicity of the chemicals.

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Well Testing

Flow testing is done to confirm the producibility of the reservoir and to

locate any boundary effects that could limit long-term production.

An extended well test may be necessary to confirm the development

potential.

A well test could last for several days to a month.

Significant data are gathered about the system from the pressure build-up

stage of a well test.

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Well Testing

Oil recovered as part of the well test will be stored and reinjected, burned, or

transported to shore for sales or disposal; gas is normally flared during the

test.

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Subsea Systems Inspection and Maintenance

Facilities and pipelines require periodic inspections to ensure that no

external damage or hazards are present that will affect the system’s

integrity.

Unlike the shallow-water platform and subsea completions where diver

access is possible, a deepwater system requires the use of ROVs for

surveys and some repairs.

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For floating systems such as the TLP (Tension Leg Platform), the survey

would examine the tendons as well as the hull and production riser.

Inspections of other systems would investigate the mooring system

components as well as the production components (trees if subsea,

pipelines, risers, umbilical, manifold, etc.).

Many of the components of subsea equipment are modular, with built-in

redundancy to expedite retrievals in the event of a failure.

Subsea Systems Inspection and Maintenance

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Mobilization of a drilling rig or specialized intervention vessel would be

required for intervention into any of the subsea systems.

If the production equipment is surface based, the maintenance, retrieval,

and repair would be similar in scope to the conventional fixed platforms.

Subsea Systems Inspection and Maintenance

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Part 4 : Subsea Structures and Equipments

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Subsea Manifolds

Subsea manifolds have been used in the development of oil and gas fields to:

Simplify the subsea system,

minimize the use of subsea pipelines and risers,

optimize the flow of fluid in the system.

The manifold system is an arrangement of piping and /or valves designed to combine,

distribute, control, and often monitor fluid flow.

Subsea manifolds are installed on the seabed within an array of wells to gather

production or to inject water or gas into wells.

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Subsea Manifolds

The numerous types of manifolds range from a simple pipeline end manifold

(PLEM/PLET) to large structures such as a subsea process system.

The manifold may be anchored to the seabed with piles or skirts that penetrate the

mud line.

Note: Size is dictated by the number of the wells and throughput, as well as how the

subsea wells are integrated into the system.

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Pipeline Ends and In-Line Structures

As the oil / gas field developments move further away from existing subsea

infrastructures, it becomes advantageous to consider a subsea tie-in of their

export systems with existing deepwater pipeline systems offering spare transport

capacity.

This necessitates incorporating pipeline end manifolds (PLEMs) at both pipeline

ends to tie in the system.

A PLEM is a subsea structure set at the end of a pipeline.

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Pipeline Ends and In-Line Structures

PLEM is used to connect rigid pipeline with other subsea structures, such as a

manifold or tree, through a jumper.

It is also called a pipeline end termination (PLET).

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Jumpers

A subsea jumper is a short pipe connector that is used to transport production fluid

between two subsea components i.e.

xmas tree and manifold.

A manifold and another manifold, or

a manifold and an export sled

connect other subsea structures such as PLEM/PLETs and riser bases.

Note: In addition to being used to transport production fluid, a jumper can also be

used to inject water into a well.

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Jumpers

The offset distance between the components (such as trees, flowlines, and

manifolds) dictates the jumper length and characteristics.

Note: Flexible jumper systems provide versatility, unlike rigid jumper systems, which

limit space and handling capability.

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Subsea Wellhead

Wellhead is a general term used to describe the pressure-containing component at

the surface of an oil well that provides the interface for drilling, completion, and

testing of all subsea operation phase.

It can be located on the offshore platform or onshore.

Note:

If the wellhead is located onshore; it is referred to as surface wellhead.

If it is settled down on the mudline, in which case it is called a subsea

wellhead or mudline wellhead

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Subsea Wellhead

satellite wells or

clustered well

Subsea wells can be classified as either:

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Satellite Wells

Satellite wells are individual and share a minimum number of facilities with

other wells.

They are usually drilled vertically.

The primary advantage of satellite wells is the flexibility of individual well

location, installation, control, and service

Satellites wells can produce directly to a surface facility (the platform

of a floating vessel) or through a subsea manifold that commingles the

production of several satellite wells

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Satellite Wells

Each well is handled separately, so that its production and treatment can be

optimized.

Exploration or delineation wells in a field can also be reused by completing them

as satellite wells, thereby eliminating the drilling costs associated with a new

well.

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Cluster Wells

When several subsea wellheads are located on a central subsea structure, the

system is referred to as a clustered system.

This arrangement provides the possibility of sharing common functions among

several wells, such as:

manifolded service or

injection lines and

common control equipment

Cluster well configuration requires fewer flowlines and umbilicals, thus reducing

cost.

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Cluster Wells

One disadvantage is that maintainable components are centralized on a clustered

system, it is possible to service more than one well with a single deployment of a

service vessel, thereby saving mobilization costs.

On the other hand, shared functions can reduce the capability to treat each well

separately.

Other disadvantages of clustered systems are that drilling or workover operations

on one well of the cluster may interrupt production from others.

Also special simultaneous drilling and production procedures need to be

implemented.

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Subsea Tree

The subsea production tree is an arrangement of valves, pipes, fittings, and

connections placed on top of a wellbore

Orientation of the valves can be in the:

vertical bore or

the horizontal outlet of the tree

The valves can be operated by electrical or hydraulic signals or manually by a diver

or ROV.

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Part 5 : Subsea Umbilicals, Risers and Flowlines

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Umbilical System

An umbilical, as shown in is a bundled arrangement of tubing, piping, and/or

electrical conductors in an armored sheath that is installed from the host facility to

the subsea production system equipment.

An umbilical is used to transmit the control fluid and / or electrical current necessary

to control the functions of the subsea production and safety equipment i.e. tress,

valves and manifold.

Dedicated tubes in an umbilical are used to monitor pressures and inject fluids

(chemicals such as methanol) from the host facility to critical areas within the

subsea production equipment.

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Umbilical System

Electrical conductors transmit power to operate subsea electronic devices.

Umbilical dimensions typically range up to 10 in. (25.4 cm) in diameter.

The umbilical will include multiple tubing's normally ranging in size up to 2 in. (5.08 cm).

The length of an umbilical is defined by the spacing of the subsea components

and the distance these components are located from the host facility.

Note:

The number of tubes is dependent on the complexity of the production system.

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Production Risers

Risers can be flexible or rigid.

The production riser is the portion of the flowline that resides between the

host facility and the seabed adjacent to a host facility.

Riser dimensions range from 3 to 12 in (76.2 to 304.8 mm). in diameter.

Riser length is defined by the water depth and riser configuration, which can be

vertical or a variety of wave forms.

They can be contained within the area of a fixed platform or floating facility, run in

the water column.

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Subsea Pipeline

Subsea flowlines are the subsea pipelines used to connect a subsea wellhead with a

manifold or the surface facility.

The flowlines may be made of flexible pipe or rigid pipe and they may transport

petrochemicals, lift gas, injection water, and chemicals.

For situations where pigging is required, flowlines are connected by crossover

spools and valves configured to allow pigs to be circulated.

Flowlines may be single pipe, or multiple lines bundled inside a carrier pipe.

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Subsea Pipeline

Both single and bundled lines may need to be insulated to avoid problems

associated with the cooling of the produced fluid as it travels along the seabed.

Subsea flowlines are increasingly being required to operate at high pressures and

temperatures.

The higher pressure condition results in the technical challenge of providing a

higher material grade of pipe for high-pressure, high-temperature (HP/HT) flowline

projects, which will cause sour service if the product includes H2S and saltwater.

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Subsea Pipeline

In addition, the higher temperature operating condition will cause the challenges of

corrosion, down-rated yield strength, and insulation coating.

Flowlines subjected to HP/HT will create a high effective axial compressive force

due to the high fluid temperature and internal pressure that rises when the flowline

is restrained.

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Recommended Books

M. Golan, S. Sangesland, Subsea Production Technology, vol. 1, NTNU (The

Norwegian University of Science and Technology), 1992. Minerals Management Service, Deepwater Gulf of Mexico 2006: America’s

Expanding Frontier, OCS Report, MMS 2006-022, 2006. J. Westwood, Deepwater Markets and Game-Changer Technologies, presented at U.S.

Department of Transportation 2003, Conference, 2003. FMC Corporation, Subsea System, http://www.fmctechnologies.com/en/

SubseaSystems.aspx, 2010.

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Recommended Books

H.J. Bjerke, Subsea Challenges in Ice-Infested Waters, USA-Norway Arctic Petroleum

Technology Workshop, 2009. International Standards Organization, Petroleum and Natural Gas Industries-Design

and Operation of the Subsea Production Systems, Part 1: General Requirements and

Recommendations, ISO, 2005, 13628-1.

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www.chesssubseaengineering.com

Email: [email protected]

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www.chesssubseaengineering.com

Email: [email protected]

/chesssubseaengineering /chesssubseaengineering