CONNECTION TM Certified System Components Subsea Connections
Subsea Connections from Cameron: reliable, versatile links to tie production systems together. Right from the start, the leader Cameron s subsea production experience goes back to the industry s first subsea wellhead completion in 1962. That was in the Gulf of Mexico, using a Cameron Christmas tree. A long string of other Cameron subsea product innovations followed. The legendary U BOP, first hydraulic production controls system, first guidelineless drilling system, first freestanding riser system these are just a few familiar milestones along Cameron s path of leadership. This leadership continues today with such innovations as the SpoolTree Christmas tree and the MOSAIC (Modular Subsea and Integrated Completion) production system. More advances are on the horizon. As the industry pushes into new frontiers, we ll be there, with the technology to do it right. Cameron s experience with diverless flowline connections began with the Fairley field (offshore Brunei) in the late 60s. Making the connections that move produced fluids from subsea wellheads to surface production facilities is a challenge that Cameron has been meeting successfully for decades. We have consistently led the way in the development of subsea connection systems for flowlines, export lines, umbilicals and multibore production lines. Now we ve advanced the state of the art once again. With standardized, preengineered subsea connections that are part of the MOSAIC system. Two types of connections collet and clamp are available in a virtually unlimited array of configurations to satisfy any subsea production system requirement. These McPAC seal plates can be configured to satisfy any subsea system requirement systems are extremely versatile, rocksolid reliable and offered in a full range of sizes and pressure ratings. Common interfaces simplify field development MOSAIC modular subsea components have common interfaces that allow use of a variety of connection systems vertical, horizontal, diver-assist and ROV-assisted. These common interfaces make it possible to use the same connection technology for all components in a field development, including well jumpers, pipeline jumpers, umbilical terminations and pigging loops. This CVC Collet connector McPAC Clamp connector simplifies installation tool requirements, reduces the number of running procedures to be accommodated and minimizes the spare parts inventory. Reusable installation tools reduce costs Installation tools for both vertical and horizontal Cameron subsea connection systems are retrievable and reusable, so multiple connections can be made without additional tool investment. The cost savings add up quickly, especially on larger projects. All the hydraulic systems for connection installation are incorporated in the tools there are no hydraulics on the subsea connections themselves. This simplicity is one of the reasons for the proven reliability of our connections. And for developments requiring fewer connections where reuseable tooling is less important, we can provide integral connectors with self-contained hydraulic actuators. 2
Accessories enhance flexibility A full line of accessories adds to the flexibility of our subsea connection systems. These accessories include pressure caps, metrology devices and stab and hingeover alignment structures. Installing pressure caps on connection hubs permits full use of the pressure system without connecting the hubs to other MOSAIC components. These pressure caps are equipped with control panels for deployment and retrieval by an ROV. Metrology devices enable an ROV to precisely measure angles, offsets and distances between MOSAIC components. These measurements are used to fabricate the jumpers that will connect the components. Stab and hinge-over alignment structures rotate hubs into proper position for connection. They are particularly useful for installing umbilicals. Cameron provides cost-effective engineering solutions Cameron engineers have a long history of standardizing interfaces, optimizing components and fine-tuning proven technology to meet customer needs quickly and cost-effectively. It pays to involve our engineering professionals right from the start, because they can make the most significant contributions to project success at the critical stages of concept selection, front-end engineering design (FEED) and detail design. Cameron subsea connections can be configured to satisfy any production system requirement. Modular Subsea And Integrated Completion systems: The MOSAIC concept MOSAIC systems are the result of a design philosophy that eliminates the usual tradeoffs you expect with a pre-engineered, modular system. With MOSAIC systems, you gain simplified installation procedures, reduced personnel training and faster delivery. And you don t have to give up flexibility, expandability and desirable product features and benefits as you do with ordinary systems. The ordinary approach to modularity is fixed assemblies run progressively to large structures, which are not appropriate for many applications. MOSAIC systems are modular at the component level, standardized to work together in many combinations. The result is a cost-effective system that can be adapted to virtually any subsea job. The MOSAIC system is more easily expanded as field development needs evolve, and its components contain the technology that provides the performance you need. Cameron s subsea connections are an integral part of the MOSAIC system. They re the perfect fit for today s subsea economics. 3
Collet connections cut subsea installation time. Spreader beam installation of CVC jumper Cameron CVC and CHC collet connections are engineered for fast make-up using a push-pull motion. A hydraulically operated actuator ring locks pivoting collet segments under the tapered profile of a hub to form a strong mechanical connection that can handle high separation forces. Pressure is contained by an AX gasket that forms a metal-to-metal seal between the connector and the hub. Resilient rings in the gasket serve as secondary seals. Our collet connectors can be oriented either vertically (CVC) or horizontally (CHC) and are offered in both nonintegral and integral designs. Non-integral connectors, available in pipe sizes up to 20, are positioned and closed by a separate actuator, which is recoverable after use. Integral connectors, available in pipe sizes from 6 to 54, are positioned and closed by internal hydraulic cylinders. The receiver structure and hub support for collet connectors are very compact. This reduces weight and allows other components to be placed closer together to save space. In vertical installations, collet connectors are lowered directly onto the hubs, No draw-together motion is needed to make up the connection, and no flexibility loops are required. Another advantage is that pressure caps and enclosures can be vertically installed and removed. Spreader beams permit guidelineless installation Rigid jumpers with vertically oriented hubs can be installed without using guidelines by running the jumpers on spreader beams from a construction vessel or drilling rig. Installation tools are attached to downward-facing collet connectors at both ends of the jumper, and the rigid spreader beam is attached to the installation tools and the center of the jumper. The jumper is then lowered by crane to its subsea location. This procedure requires a vessel or rig with dynamic positioning (DP) and two cranes. If that combination is not available, the jumper can be run on guidelines using a single crane. On guidelineless installations, an ROV monitors the operation, transmitting images to the surface to guide lowering of the jumper onto the hubs. After the jumper is in position, the ROV operates valves on the installation tools to lock the collet connectors to their hubs and pressure test the gaskets. Once the integrity of the connections has been verified, the ROV releases the installation tools from the connections and the spreader beam from the jumper. The crane then retrieves the spreader beam with the installation tools attached. Installation tools hydraulically draw hubs together To compensate for measurement errors and sled movement, collet connection installation tools have a built-in gimbal of 3 degrees. This, in addition to the capability of the connection system itself to accommodate 17 degrees of ROV Panel Connector Make-Up Cylinders Top Plate Ring Actuator Ring Alignment Funnel Hub Alignment Structure Running Tool Jumper Pipe Soft Land Cylinders Collet Connector CVC System 4
misalignment from the sled seafloor angle, permits connections to be made at high-angles to minimize or eliminate misalignments. Cameron performs a standard test to ensure that rigid jumpers can be successfully connected with up to 6 of offset in the x, y and z axes and as much as 2 degrees of misalignment in pitch, roll and yaw. Because the installation tools are ROV operated, there s no umbilical to worry about. The tool s ROV panel contains the hydraulic control system required to test the connected jumper seal and operate the connector and soft landing system. An alignment funnel guides the initial landing of the tool and connector assembly. Latch dogs in the funnel lock onto the receiver structure as the soft landing system is engaged to hydraulically force the hub and collet connector faces together. This double-acting feature permits hydraulically controlled separation of the hubs for easy and safe gasket replacement. Since the tool latches to the same size connector top plate and actuator ring regardless of bore size, a single tool can be used with 4 to 12 flowline bores. Regardless of size, the connections provide an effective barrier, with hubs and collet dogs environmentally isolated. Collet connection installation tools have mechanical overrides for backup if hydraulic power is lost. A redundant secondary lock system ensures connection integrity by restricting the movement of the actuator ring while the connector is locked on the hub. King Field, Gulf of Mexico Water Depth: 5485 ft (1671 meters) Challenge: Provide an efficient, first-end connection system for Steel Catenary Risers (SCR) to be laid away from deepwater SCR anchor bases to a Dry Completion Unit or FPSO. Solution: Cameron engineers designed the flowline connection system for firstend, stab-and-hinge-over installation using a lay vessel with seabed support from a mono-pile support structure. The hinge-over positions the SCR flowline hubs facing upward for fast, easy attachment of the vertical collet connectors on the rigid, tree-to-flowline jumpers, as well as the flowline pigging loops. Using the same type of collet connector on all components results in several economic benefits for the operator, over and above the installation time saved. Fewer installation tools are needed, the number of running procedures to be accommodated is minimized, and the necessary spare parts inventory is reduced. Gullfaks Field, North Sea Water Depth: 140 meters (460 ft) specified for 600 meters (1969 ft) Running and Connection Tool for Gullfaks being tested Challenge: Tie production/test lines from eight subsea wells to production platform via two customer-designed 7 km flowline bundles. The jumper pre-stressing and connection required pull-in loads and strokes greater than currently available in the industry. The bundles include water heating lines to prevent hydrate formation, requiring the use of dual and triple bore connections. Solution: Cameron designed, built and tested a new tool with the capacity necessary to make up the large, horizontal collet connections the operator required. This ROV-operated Running and Connection Tool (RCT) can handle 8 to 18 nominal pipe, including multi-bores a capability critical to the success of the project because of the number and variety of flowline bundle connections. Twenty-two of the 34 collet connections manufactured by Cameron are multi-bore configurations including 12 x 3 x 3 and 8 x 3 x 3 connectors. Gemini Field, Gulf of Mexico Water Depth: 3400 ft (1036 meters) Challenge: Work within tight time constraints to design, build and deploy a four-well, deepwater gas production system. The project required reliable, vertical connections suitable for fast, guidelineless, ROV installation of four 4 flexible-pipe well jumpers and two 12 rigid-pipe flowline jumpers. Solution: Cameron s proven collet connection technology was adapted to meet the project s requirements within the operator s ambitious time frame. Non-integral collet connectors rated for 5000-psi WP were used on all the jumpers and the 12 pigging loop on the manifold. Installation costs were minimized because the operating tools for both the 4 and 12 connectors could be retrieved and reused. 5
Clamp connections are the most economical solution for many subsea applications. Cameron McPAC clamp-type connection systems are used for everything from large pipelines to small in-field flowlines and umbilicals, in deep water and in shallow. They can be run with or without guidelines and installed with ROV assistance, eliminating the need for divers. Improved McPAC connection tool is ROV operated An improved, high-capacity McPAC Connection tool is an important component of the total package. Connection is a totally separate operation from the deployment method, so it can be performed immediately after deployment or delayed as long as necessary. Hydraulic power to operate the connection tool is supplied by an ROV no guidelines or umbilicals are required. A hydraulic motor in the compact tool drives two jackscrews to make the connection. Hydraulic Motor McPAC hubs ready for shipment Since the motor and the actuating saddle are integrated modules, an ROV can be used both to deploy the tool and to retrieve the seal plate. The tool can also be deployed using guidelines when that method is preferable. After connection of the lines to the hub is completed, the tool is used to pressure test the metal-to-metal seals. It is then retrieved for reuse on the next connection, leaving only the connected lines subsea. Actuating Saddle Metal-to-Metal Seal Clamp Jackscrew Seal Plate McPAC System 6
McPAC end connections now come in two sizes Two sizes of standard hubs and clamps are now available for making first and second end connections of flowline/hydraulic control bundles, electrical cables and pipelines. The larger size is used for large-bore flowlines, multi-bore lines and umbilicals, the smaller size for small- and single-bore lines. HSAS provides final alignment Final alignment and make-up of the clamp are provided by the Hub Support and Alignment Structure, which has a sliding McPAC jumper with HSAS being run support saddle. The connection tool strokes the hub into position. McPAC connections have been successfully used in subsea systems for two decades. McPAC connectors are economical and reliable, two highly desired traits in today s subsea business. A pivoting Hub Support and Alignment Structure (HSAS) with an orienting stab alignment pin permits totally guidelineless connection of horizontal flowlines. When used to make a first end connection, the HSAS is deployed in vertical position and stabbed into the flowline porch structure at the wellhead, where the inboard hub is mounted. Then the HSAS pivots to horizontal and the stab pin latches to the porch base, providing a hinge point for flowline layaway and hub horizontal alignment. Troika Field, Gulf of Mexico Water Depth: 2760 ft (842 meters) Challenge: Design, manufacture, test and install the industry s first fully insulated, deepwater, oil production system to enhance flow assurance. The connections had to be insulated without compromising reliability or installability. Solution: Versatile Cameron McPAC horizontal connections were used throughout Troika insulated clamp connection the system to reduce installation cost and complexity. One of the reasons for the proven reliability of Cameron McPAC clamp-type connections is that no hydraulics are left subsea. This feature provides for a simple means of insulation, which was installed by ROV after test. Only one tool was needed to install all the connections for the 10 rigid pipeline jumpers, the 15-line umbilical and the multi-bore flowline jumpers, each of which had a 4 product line and eight hydraulic lines. If it is ever necessary to retrieve the manifold, the connections can be retracted and the jumpers left in place undisturbed. Malampaya Field, Philippines Water Depth: 850 meters (2789 ft) Challenge: Develop a gas production system with a 30-year life and the flexibility to add more wells if an adjoining field is produced. All materials that would be exposed to gas were to be corrosion resistant, and the operator specified the use of horizontal connectors to permit the manifold to be retrieved, if necessary, without disturbing the jumpers and umbilicals. Solution: Field-proven Cameron clamptype connectors will provide the required long-term reliability. The tool used to install them can be retrieved and reused repeatedly and fits a wide range of connections. That means just one tool can make all the connections for the tree-tomanifold jumpers, pipeline jumpers and umbilicals, substantially reducing the operator s cost. The tree-to-manifold jumpers will have two 1 lines piggybacked on the 6 flowline one for methanol injection and McPAC hubs for Malampaya manifold the other to vent the annulus. Cameron s multi-bore connections will save installation time by attaching all three lines simultaneously when the ROV makes up the jumper connection. 7
Western Hemisphere Cameron PO Box 1212 Houston Texas 77251-1212 Tel 713 939 2211 Fax 713 939 2620 e-mail subsea@camerondiv.com www.camerondiv.com Eastern Hemisphere Cooper Cameron (U.K.) Ltd. 5 Mondial Way Harlington Hayes UB3 5AR Tel 44 181 9901800 Fax 44 181 9901888 e-mail subsea@camerondiv.com www.camerondiv.com Asia Pacific/Middle East Cooper Cameron (Singapore) Pte. Ltd. No. 2 Gul Circle, Jurong Industrial Est Locked Bag Service No. 3 Jurong Town Post Office Singapore 629560 Republic Of Singapore Tel 65 8613355 Fax 65 8616197 e-mail subsea@camerondiv.com www.camerondiv.com MOSAIC, SpoolTree, Cameron, CAMLAST, STM, STC, CAMTROL, McPAC, CVC, CHC and Cameron Willis are trademarks of the Cooper Cameron Corporation, Cameron Division. Cooper Cameron Corporation, Cameron Division, Printed in USA, 8/00, HG/7.5M, WR10002/TC1380