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- ANGUS MATHER OFFSHORE ENGINEERING AN INTRODUCTION O dor dae 1 A “390060 ACKNOWLEDGEMENTS The author acknowledges with thanks the following Companies for their contributions and cooperation in the preparation of this book. ABB Offshore Technology Amerada Hess Limited Amoco (U.K.) Exploration Company ARCO Brirish Limited Baker Service Tools Bertis Actuators and Controls British Gas ple BK Kendle Engineering Limited BP Exploration Camco Products and Services Chevron U.K. Limited Claxton Engineering Services Limited Conoco (U.K.) Limited Cooper Oil Tool Dockwise N.V. Framo Engineering ÁS Halliburton Energy Services Hydril Inc. Hydrovision Limited Institute of Marine Engineers Institute of Petroleum Kongsberg Offshore a.s. Kvaemer Surveys Lloyd's Register of Shipping Measurement Technology Limited OQilficld Publications Limited RGB Stainless Limited Schlumberger Oilfield Services Shaffer Inc. Shell (U.K.) Exploration and Production Slingsby Engineering Limited SLP Engineering Limited &SR (International) Limited Statoil Stena Offshore Limited Sun Oil Britain Limited Thomas Telford Limited (Offshore Engincer) Varco International Inc Weir Pumps Limired Phorographic acknowledgements: Charles Hodge Photography, Lowestofr Tony Wilks David Gold Richard Loughery Jobn Price vii ACC. Mo 0J=-025) dolida.. BANGALORE a CONTENTS Foreword The Author Preface Acknowledgements Abbreviations Glossary Standards, Guidance Notes and Codes of Practise Table of Colour Plates Chapter One — Offshore Structures and Support Vessels Parr 1 — Offshore Structures Page vi vii viii xv Fixed Steel Structures — Concrete Gravity Base — Tension Leg Platform — Semi-submersible Vessel — Fioating Production Systems — Shuttle Tanker — Self-elevaring Jack-up — Single Point Mooring Part 2 — Support Vessels Offshore Supply Boar — Stand-by Vessels Part 3 — Offshore Installations —Description Accommoadation — Wellheads — Spider Deck — Conductors — Caisson etc Part 4 — Fixed Steel Structures — Installation Introduction — Sub-sea Template — Jacket — Topside Installation — Abandonment Chapter Two — The North Sea History and Legislation Section One — The North Sea Part 1 — The Story so Far History — Gas fields — Oil fields — World Staristics — Field Developments — The Future Part 2 — Oil and Gas Distribution Oil Distribution — Gas Distribution 19 23 26 33 35 43 a 10 0 € Chapter Four — Piping Systems and Process Pressure Vessels 147 Part 1 — Piping Systems 149 Hydrocarbon Process — Process Gas — Condensate — Corrosion Inhibitor — Hydrate Inhibitor — Fuel Gas — Vent — Flare — Utility — Diesel Oil — Compressed Air — Fire Water — Drains — Sodium Hypochlorite Part 2 — Process Pressure Vessels 155 Production Separators — Slug Catchers — Knock Out Drums — Oil/Water Separators — Skimmers — Coalescers — Hydrocylones — Holding Tanks Part 3 — Piping and Pressure Vessel Design 161 Piping Systems Design — Pressure Vessels — Installation and Layout — Specifications Part 4 — Piping Systems — Construction 165 Pipe Schedules — Fittngs — Valve Types — Class Ratings — Specifications Chapter Five — Production 175 Part 1 — Gas Production 179 Gas Process — Wellheads — Slug Carchers — Production Header — Gas Compression — Liquid Process — Condensate System — Produced Water System — Wer Gas Part 2 — Oil Production 187 Oil Processing — Associated Gas — The Gas Process — The Dehydration Process — Natural Gas Liquids — Stabilisation — Swectening Part 3 — Enhanced Oil Recovery and the Oil Drive Meshanisra 199 Oil Drive Mechanisms — Enhanced Oil Recovery — Water Injection — ae Injection — Gas Lift — Deepwell/Submergible Pumps Chapter Six — Underwater Engineering 209 Part 1 — Diving ai1 Air Diving — Saturation Diving — Equipment — Diving Support Vessels — Remotely Operated Vessels Part 2 — Underwater Surveys 217 Splash Zone Examination — Swimaround Survey — Non-Destructive Examinarion — Flooded Member Survey — Marine Growth Measurement — Scour Survey — Cathadie Protection Examinarion — Differential Setilement Survey — Air Gap Measurement xi +00 0€ re) 0 0 Offshore Engineering Part 3 — Sub-sea Wells Subsea Development Options — Subsea Wells — Manifolds and Templates — Sub-sea Flowbase — Pipelines and Risers — Sub-sea Wells — Christmas Trees and Wellheads — Diverless Wellhead Systems — Guideframes — Wellhead Protection Structure Part 4 — Sub-sea Developments Sub-sea Separation — Multiphase Pumping and Metering — Sub-sea Pressure Boosting Chapter Seven — Drilling Part 1 — Introduction The Formation of Oil and Gas — Exptoration — Seismic Surveys — Drilling Programme Part 2 — The Well Well Construction — Intermediate Casing — Completions — Cement Job Part 3 — Equipment Drilling Derrick — Rotary Table — Top Drive — Deill String — Drilling Mud Part 4 — Operations Drill Crew — Making Hole — Making a Trip Part 5 — Well Control Equipment Diverter — Blowour Preventer (BOP) — BOP Operations Part 6 = Drill Ship Equipment Floating Drill Ship Equipment Part 7 — Deviated Wells A Directional Drilling — Horizontal Wells — Geosteering — Measurement While Drilling — Mud Pulse Telemetry — Multi-Lateral Wells Chapter Eight — The Well Component Parts Part 1 — Christmas Tree Suríace Trees — Wellhead Control Panel — Gate Valves and Acruators — Horizontal Trees Part 2 — Surface Wellhead Base Plare/Landing Ring — Starting Head — Casing Head Spools — Tubing Head Spools — Christmas Tree xii 221 229 237 241 245 252 259 263 269 275 285 287 291 a ii re )0 006 Offshore Engineering An Introduction Second Edition By Angus Mather Published by Witherby & Company Limited 32-36 Aylesbury Street, London ECIR 0ET Tel No. 0207-251 5341 Fax No. 0207-251 1296 Internarional Tel No. +44 207 251 5341 Fax No. +44 207 251 1296 E-mail: bookswitherbys.co. uk ww: witherbys.com co Hutton THE AUTHOR The author, Angus Mather commenced his career avith the Ministry of Defence at Her Majesty's Dockyard, Devonport, in 1970 as a Technician Apprentice. This was followed by 10 years service as an Engineer Officer in the British Merchant Navy prior to entering the oil and gas industry. The next 15 years were spent employed both in the contracting industry as Engineering Manager of Kvaerner Oil and Gas Services, and as an Engineer Surveyor for Lloyds Register of Shipping, involved with oil and gas related projects, both on and offshore, in the UK, the Middle East and the Gulf of Mexico. vi +) 000 PREFACE Offshore engineering encompasses a considerable number of very specialized and often completely unrelated disciplines. They can be categorised into threc core activities, namely Construction, Production and Reservoir Engineering and this book has been «written, not as a definitive manual but to provide the reader wirh a basic explanarion of these various activities. lt is hoped that the material contained within this publication will provide the new recruir to the industry with a basic appreciation of what is a relatively complex subject, whilst at the same time providing the more experienced individual with a fuller appreciation of activities outside of their own particular speciality. The decision as to what topies should be included and the depth to which rhey should be discussed are based largely on the authors personal experience of what information is required to create an overall picrure. Whilst frequent references arc made to the oil and gas industries of the North Sea the bulk of the text is of a more general nature and thus applicable to offshore engineering on a world-wide basis. Units of measurement are quoted in both imperial and metric with preference being given to che unit most frequently associated with a particular discipline. Angus C. Mather Suffolk March 2000 vii Ofihore Engineering DoT DP DP DSM DSV DT EECS EEMUA EERA EOR EPC EPIC EPIRB EPS EsD ESDV FARSI FEA FES F&G FPS FPSO FPDSO FEV: FRAMS FRA FRC FSA FSO ESU GA Ses GL HAZ HAZAN HAZOP HF HGT HIPS HP HPHT HsC HSE HSWA HVAC ICP IMO Department of Transport Design pressure Dynamic positioning Diving, safety memorandum Diving support vessel Design temperature Electrical Equipment Certification Service Engineering Equipment Material Users Association Evacuarion, escape and rescue analysis Enhanced oil recovery Engincer, procure and construcr Engineer, procure, install and construcr Emergency position indicating radio beacon Emergency power supply Emergency shutdown Emergency shurdown valve Funetionality, availabilicy, reliabilicy, survivability and interaction. Fire and explosion analysis Fire and explosion strategy Fire and gas Floating production system Floating, production, storage and offloading vessel Floaring, production, drilling, storage and offloading vessel Floaring production vessel Floating riser and mooring system Fire risk analysis Fast rescue craft Formal safery assessment Floating storage and offloading vessel Floating storage unit General alarm Gravity base structure Germanischer Lloyd Hear affected zone Hazard analysis Hazard and operabiliry study High frequency High pressure grease tube High integrity protection system High pressure High pressure and high temperature Health and Safety Commission Health and Safety Executive Health and Safety ar Work Heating, ventilating and air conditioning Independent, Competent Persons International Maritime Organization xvi “1006 a ii ro sds IP Institute of Perroleum Iso Internartonal Standards Organisanon IT Joule Thompson KO Knock out LAT Lowest atmospheric tide LCV Level control valve LED Light emitring diode LEL Lower explosive limit LIC Level indicator controller LNG Liqueficd natural gas LOLER Lifting Operations and Lifting Equipment Regulations LP Low pressure LPG Liguefied petroleum gas LRS Lloyd's Register of Shipping LSA Life saving appliances MAPD Major accident prevention document MAR Management and Administration Regulations MCA Maritime and Coastguard Agency MEG Monoethylene Glycol MHAU Major Hazards Assessment Unit (HSE) MHSWR Management of Health and Safery at Work Regulations MIG Metal inert gas, welding MMSCEF Millions standard cubic feet MMSCED Millions of standard cubic feet a day MLSS Mudline suspension system MLSV Mudline safery valve MPL Magneric parricle inspection MSA Marine Safery Agency (UK), now the MCA MsS5 Manufacturers Standardization Society of the Valve and Fittings Industry, Inc. (USA) MNWA Mineral Workings Act MWP Maximum working pressure NACE National Association of Corrosion Engineers (USA) NAMAS National Material Accreditation Service NB Nominal bore NDE Non-destructive examination NDT Non-destructive testing NEL Narional Engineering Laboratory NRV Nomn-return valve NUI Normally unattended installation OCÊ Ofishore Certification Bureau OIM Offshore Installation Manager OPEX Operating expenditure OsD Offshore Safery Division Ows QOily warer separaror PA Public address xvil ros os TIG TLP TLQ TP TPS TR TRA TSR UEL UHF UKCS UKOOA UL UNS UPS UT Uv VDU WPQR WPS WSE Tungsten inerr gas, welding Tension leg platform Temporary living quarters Test pressure Total platform shutdown Temporary refuge Total risk analysis Temporary safe refuge Upper explosive limit Ultra high frequency United Kingdom Continental Shelf United Kingdom Offshore Operators Association Ltd. Underwriters Laboratory (USA) Universal numbering system Uninterrupted power supply Ultrasonic testing Ultra violer Visual display unir Very high frequency Welding procedure qualification record Welding procedure specification Written Scheme of Examination xix a GLOSSARY Whilst every effort has been made to fully explain the terminology and expressions used within the text of the book, there follows a lise of terms designed to further clarify the more ambiguous references, and to provide a brief definition of some of the more frequently encountered expressions. Accommodation space — Any room used for cating, sleeping, cooking, laundry or recreation, or as an office or sick bay, and any corridor giving access ro any of these rooms, and any storeroom in the vicinity of any of these rooms, Accumulator — À pressure vessel charged with nitrogen gas and used to store hydraulic fluid under pressure for the operation of hydraulic valve acruators. Actuator — À mechanical device for the remote or automatic operation of a valve or choke. Annulus — Space benween concentric casing strings. Associated gas — Naturally occurring reservoir gas found in association with oil, either dissolved in the oil or found asa cap or pocket of free gas above the oil. Azimuthing thruster — Roratable ducted propeller used in conjancrion with a dynamic positioning system to enable ships to maintain position withour the use of anchors. Block — The subdivided areas of the sea for the purpose of licensing to à company for exploration or production rights. In the UK a block is one thirrierh of a quadrant (one degree by one degree) and is approximately 200-250 square kilometres. Blowout — Uncontrolled release of well fluids from the well bore during drilling operations. Bell nipple — Receptacle attached ro the top of the blowout preventer or marine drilling riser which directs the drilling mud returns to the shale shaker or mud pits. BOP — Device attached to the casing head during drilling operations that allows the well to be sealed to confine the well Auids in the well bore. Brown book — The Department of Trade and Industry's annual publication contains a host of facts and figures relevant to oil and gas production in the UK and is available from Her Majesty's Stationary Office. Bubble point — Point at which dissolved gasses begin to vaporise from a liquid. Dependant on temperature, pressure and gas/liquid composition. Caisson — Length of pipe extending vertically downwards ftom an installation into the sea as a means of disposing of waste waters, or for the location of à sea water pump. Casing — Pipe used to line and seal the well and prevent collapse of the borchole. A number of casing strings (lengths) are used in ever decreasing diameters. Cathodic protection — Corrosion protection system which relies on sacrificial anodes or impressed current to protect submerged steel components from corrosion by electrolytic action. Condensate — Volatile liquid consisting of the heavier hydrocarbon factions that condense our of the gas as it leaves the well, a mixture of pentanes and higher hydrocarbons. Conductor — The first, and largest diameter pipe to be inserted (spudded) into the seabed when drilling a well. Tt keeps the hole open, provides a return passage for the deilling mud and supports the subseguent casing strings. 
