MOSAIC Certified MALAMPAYA Cameron MOSAIC Systems for the Malampaya Project
The Malampaya Project LUZON CALM Loading Buoy UPSTREAM Onshore Gas Plant DOWNSTREAM Alternative Fuel Electricity Power Stations CHINA BURMA LAOS THAILAND Bangkok CAMBODIA VIETNAM SOUTH China Hong Kong T'aipei TAIWAN Quezon City Manila East China Pacific Ocean JAPAN PHILIPPINES PHILIPPINES SOUTH China Malampaya Quezon City Manila Batangas MINDORO 24" Dry Gas Export Condensate Storage MALAYSIA The Malampaya field is located 850 m 16" CRA Flowlines Singapore BORNEO in Block SC38 of the South China in 750 to 1150 meters of Future 16" Flowline 500 km Platform To Land INDONESIA NEW GUINEA water. The subsea production system is located at a water depth of 820 meters. The field is approx- Subsea Manifold imately 80 kilometers off the coast Initially five Malampaya wells will be drilled. 30 km Manifold To Platform Indian Ocean AUSTRALIA of Palawan Island in the Republic of the Philippines. The goal of the project is to supply natural gas to power plants within the Philippines. Shell Philippines Exploration B.V. chose Cameron Modular Subsea and Integrated Completions (MOSAIC) Systems for their Malampaya project. The Malampaya subsea gas production system consists of a cluster well development with initially five Cameron SpoolTree Systems producing to a central subsea production manifold. From the manifold, two 30-kilometer flowlines carry the gas to the platform where it is processed. The dry compressed gas is transported through a 500-kilometer pipeline onshore to the power generation facilities. Condensate is stored in the concrete gravity structure at the base of the production platform and is exported to shuttle tankers through a catenary anchored leg mooring (CALM) offloading system 3 kilometers from the production platform. Each of the wells will be completed using field-proven, modular components that are part of Cameron s MOSAIC product line. The production manifold is retrievable and incorporates the capacity to connect up to ten producing wells, two control umbilicals and two flowlines. It integrates two production headers and a pigging loop. The subsea production trees are 10,000 psi WP Cameron SpoolTree Systems which are installed guidelineless on drill pipe. Each tree incorporates modular components such as Cameron FLS Gate Valves, Cameron Compact Modular (CM) Actuators, Cameron Willis CC40 Subsea Retrievable Insert Chokes, Cameron McPac Flowline Connection Systems, and Cameron DWH Mechanical Dog and Window Collet Connectors. The subsea production control system is the Cameron CAMTROL Advanced Multiplexed Electro-Hydraulic Control System which features standardized, modular components. 2 3
TM Cameron MOSAIC Systems and Subsystems for the Malampaya Project Cameron s Malampaya Project Subsea Components The Malampaya field will be completed using field-proven components from the Cameron MOSAIC product line. The Cameron SpoolTree Subsea Trees - proven over and over in field applications around the world. Subsea Retrievable Insert Chokes - with a selection of actuator assemblies and trim cartridges. CAMTROL Production Control System - standard components which adapt to a variety of field configurations. And other field-proven MOSAIC components. MOSAIC provides flexible modularity to create nearly endless system combinations with reliable and economical subsea equipment. MOSAIC systems are all based upon a combination of standard components. This modular, or building block approach, allows producers to specify pre-engineered components with application-specific features. The Cameron MOSAIC solution for the Malampaya field is one of the myriad of combinations available. Contact us and we will design one for you. Production Manifold System Pile Assemblies and Pile Spacer Template Manifold Support Structure Retrievable Production Manifold Dual Production Headers Pigging Loop Modular Valve Blocks with Jumper Hubs STM Wellhead Systems Completion Guide Bases Casing Hangers, l Assemblies, Wear Bushings Running and Testing Tools SpoolTree Christmas Tree Systems FLS Gate Valves CM Actuators CC40 Subsea Retrievable Chokes and Aqua-Torq Choke Actuators DWH Tree Connectors Hydraulic Tubing Hanger and Running Tool Isolation Sleeve Electro-Hydraulic Umbilical Junction Hubs Running Tools Debris Caps High Pressure Caps Integral Spool Bodies and Protective Structures All Related Running and Testing Tools McPac Well and Flowline Connection Systems Jumper Hubs Hub Support and Alignment Structures McPac Clamp and l Assemblies Jumper Pipe Assemblies PLES Tie-In Porches McPac Hub Connection Tools CAMTROL Production Control System Surface Components Hydraulic Power Unit Electrical Power unit Topside Umbilical Termination Unit Portable Electronic Test Unit Test and Flushing Hydraulic Power Unit Subsea Components Subsea Control Modules Electro-Hydraulic Jumper Umbilicals Subsea Accumulator Units Tree and Manifold Mounted Instrumentation Subsea Distribution Unit Installation/Workover Control System Hydraulic Power Unit with Control Panel Radio Telemetry Link Workover/Tubing Hanger Running Tool Hose Reel and Umbilical Tubing Hanger Reel and Umbilical Diverless Intervention Tooling 4 5
Malampaya System Components The Malampaya project utilizes Cameron MOSAIC Production Systems for the Christmas tree and related positioned five on each side of the manifold. Each block incorporates hydraulically actuated 5 5000 psi WP tion operations. The choke incorporates a fixed body and a unitized plug and cage trim cartridge and actuator assembly. McPac Flowline Connection System All jumper connections to the wells, the pipeline end modules, and the umbilical Control Modules (SCMs). Data monitored by the SCMs is displayed on graphic displays on the platform. systems. Several of the key elements are Cameron FLS Gate Valves and McPac This assembly is latched to the body with termination unit are made with the field- A Hydraulic Power Unit (HPU) and described in detail below. clamp connection hubs. The McPac hub an internal crown connector. It can be proven Cameron McPac Flowline Electrical Power Unit (EPU) provide faces on the well jumpers provide connec- retrieved to the surface, leaving the choke Connection System. hydraulic and electrical power via hoses CAMERON MOSAIC COMPONENTS tion points for the 5 production bore and body subsea. The choke actuator is an The McPac System is a compact, and cables within two additional 1 bores (one for methanol Aqua-Torq stepping actuator which horizontal clamp-type connection system the umbilicals. Production Manifold System The Malampaya production manifold is supported with a three-pile foundation and includes a fixed support structure and retrievable manifold. The manifold has the capacity to connect up to 10 production wells, two Pile Spacer Template Installation control umbilicals and two flowlines. Contingency is provided for a third flowline connection and third injection umbilical as needed later in the life of the field. injection, the other for annulus access). The manifold and jumper system provide a fully welded, super duplex tubing distribution system from the umbilical to the trees for methanol and annulus fluids. All production-exposed surfaces within the subsea system are either inlaid or slid corrosion-resistant materials. STM Wellhead System The Malampaya wellhead system is a Cameron Single Trip Metal ling (STM) Type S Wellhead rated for 10,000psi WP. The 18-3/4 housing hub incorporates a profile designed to accommodate the Cameron DWHC tree connector. SpoolTree Christmas Tree The Malampaya Christmas Trees are 5 x 2 10,000 psi WP guidelineless Cameron SpoolTree systems. The tree spool body is central Subsea Production Manifold hanger is landed. The spool incorporates 5 10,000 psi WP production valves (master, wing, choke isolation) and 2 5000 psi WP annulus valves (master, workover, crossover). Both production and annulus valves are Cameron FLS Gate Valves with Cameron Compact Modular (CM) Actuators. All CM actuators include ROV override capabilities. 1/2 10,000 psi WP needle valves serve as annuls vent valves and provide methanol injection. The SpoolTree system also integrates a 4-1/16 10,000 psi WP Cameron Willis CC40 Subsea Retrievable Insert Choke to regulate production flow. The SpoolTree system latches to the wellhead via a Cameron DWH Mechanical Dog and Window Connector. This connector is designed to meet the bending loads encountered in deepwater. provides precise, incremental steps from open to closed. McPac Well Jumper Connection Hubs Hydraulic Tubing Hanger The Cameron Tubing Hanger is installed with the Cameron Hydraulic Tubing Hanger Running Tool which features a soft-land function. The tubing hanger lands in the SpoolTree bore and is oriented via an orientation sleeve in the hanger. The hanger has a 5 concentric bore with a 5 side production outlet, one downhole hydraulic line and one down- which can be used for everything from large bore pipelines to small flowlines and umbilicals. The system uses the hydraulically powered McPac Hub Connection Tool to mate the seal plate to the hubs which are mounted on the trees, manifold and pipeline end structure. The tool is also used to pressure test the metal-to-metal seals. An ROV powers and operates the tool. The tool is retrieved for use on the next connection, leaving only the clamp and seal plate subsea. CAMTROL Production Control System The CAMTROL Advanced Multiplexed Hydraulic Control System for the Malampaya project is designed to control and monitor ten gas production trees and the manifold. Components of the CAMTROL system are installed on the subsea trees and manifolds at a distance Two umbilicals supply redundant services from the plaform. Each umbilical supplies the entire manifold. ROV-installed, fly-to-place jumpers connect Subsea Control Module between the manifold and Christmas trees for all supply and control functions. Each Subsea Distribution Unit (SDU) is equipped with ROV-retrievable Subsea Accumulator Modules (SAM). The SAMs can be run and retrieved with the SCM running tool. The Subsea Control Modules (SCMs) feature dual redundancy, Cameron HydraQuad couplers and standard interfaces. They control hydraulic and The manifold is configured with two main pipe headers and a pigging loop. Each header includes an ROV-operated 16 2500 lb ANSI Cameron Welded Body Ball Valve in an Inconel material trim. A hydraulically actuated Cameron Welded Body Ball Valve is positioned on the pigging loop. Ten modular valve blocks with integral jumper connection hubs are to the tree assembly and acts as a tubing spool during completion, and as a tree block manifold as the tubing CC40 Retrievable Insert Choke The 4-1/16 10,000 psi WP Cameron Willis CC40 Retrievable Insert Control Choke is utilized to regulate flow during produc- hole electrical line. All lines are capable of continuous monitoring during installation. The production seals are field-proven Cameron RLH metal-to-metal seals with Cameron Metal End-Cap l back-up. The tubing hanger body is prepped to receive the metal-to-metal sealing SSR wireline plug with elastomer back-up. of 30 kilometers from the platform. The CAMTROL system is fully integrated with the platform automation system. It is controlled by means of electronic signals sent to the Subsea associated functions on the trees and manifolds, and acquire data for transmission to the platform. The modules are pressure-compensated. They are light weight, compact and have been specifically designed for deepwater applications. The Cameron Installation/Workover Control System uses multiplex technology for rapid response. It is fully integrated with the CAMTROL control system. 6 SpoolTree Subsea Production System McPac Hub Connection Tool 7
Western Hemisphere Cameron PO Box 1212 Houston, Texas 77251-1212 Tel 713 939 2211 Fax 713 939 2620 Eastern Hemisphere Cooper Cameron (U.K.) Ltd. 5 Mondial Way Harlington Hayes, UB3 5AR England Tel 011 44 181 990 1800 Fax 011 44 181 990 1888 Asia Pacific/Middle East Cooper Cameron (Singapore) Pte, Ltd. Subsidiary Of Cooper Cameron Corporation 2 Gul Circle, Jurong Industrial Est Singapore 629560 Republic Of Singapore Tel 65 861 3355 Fax 65 861 6197 Visit our website at: www.camerondiv.com Cameron, MOSAIC, McPac, Aqua-Torq, CAMTROL HydraQuad, STM and SpoolTree are trademarks of Cooper Cameron Corporation. Inconel is a trademark of Inco Alloys International, Inc. @ Cooper Cameron Corporation, Cameron Division, Printed in USA, 9/00, PAH/5M, TC1444