Subsea system and method for high pressure high temperature wells
In accordance with the present disclosure, a full top-to-bottom subsea system and method used to drill, complete, produce, and perform interventions on HPHT subsea wells is provided. The disclosed systems and methods involve the use of a controlled multiple barrier system, such as a high integrity pipeline protection system (HIPPS), incorporated into the subsea system to divide the system into two sections. The sections on either side of the barrier may be rated for different pressures, temperatures, and/or flow rates. For example, the first section (upstream of the barrier) is rated for operating at pressures/temperatures/flow rates up to a first (higher) threshold. The second section (downstream of the barrier) is rated for operating at pressures/temperatures/flow rates up to a second (lower) threshold. The disclosed subsea production system methodology, which uses barriers to divide the system components between two pressure ratings, may allow for enhanced development of HPHT reservoirs.
1. A method, comprising:
installing a subsea production system comprising a high pressure subsea wellhead, a tubing head spool (THS), a tubing hanger, a production tree, a riser, and a subsea flowline system by:
installing the high pressure subsea wellhead proximate the sea floor;
installing the THS on the wellhead;
landing the tubing hanger within the THS, wherein the tubing hanger has a secondary barrier valve disposed therein;
installing the production tree on the THS downstream of the tubing hanger with the secondary barrier valve being in a closed position;
remotely actuating the secondary barrier valve from the closed position to an open position after installing the production tree;
coupling the production tree to at least one barrier located downstream of the tubing hanger, wherein the at least one barrier comprises a high integrity pipeline protection system (HIPP S); and
coupling the production tree to the riser via the subsea flowline system;
producing hydrocarbons from a subsea reservoir to a topsides production facility via the subsea production system; and
controlling the at least one barrier in the subsea production system to control a pressure of fluid flowing from components of the subsea production system located upstream of the barrier to components of the subsea production system located downstream of the barrier, wherein at least one of the components located downstream of the barrier is rated for a first maximum pressure, temperature, or flow rate, and wherein all of the components located upstream of the barrier are rated for a second maximum pressure, temperature, or flow rate that is greater than the first maximum pressure, temperature, or flow rate.
2. The method of claim 1 , wherein the subsea reservoir comprises a high pressure and/or high temperature reservoir having a maximum reservoir pressure in excess of approximately 15,000 psi, a maximum temperature in excess of approximately 350 degrees F., or both.
3. The method of claim 1 , wherein at least one of the components located downstream of the barrier is rated for a first maximum pressure of up to approximately 15,000 psi, and wherein all of the components located upstream of the barrier are rated for a second maximum pressure that is greater than approximately 15,000 psi.
4. The method of claim 1 , wherein installing the production tree comprises lowering the production tree toward the THS and installing the production tree via a wireline cable when the secondary barrier valve is in the closed position.
5. The method of claim 1 , further comprising injecting a fluid into the subsea reservoir, wherein the subsea reservoir has a maximum reservoir pressure of less than approximately 15,000 psi, wherein the components located downstream of the barrier are rated for a first maximum pressure of up to approximately 15,000 psi, and wherein all of the components located upstream of the barrier are rated for a second maximum pressure greater than the maximum reservoir pressure plus a pressure margin associated with the fluid injection.
6. The method of claim 1 , wherein installing the subsea production system comprises installing the tubing hanger, the production tree, or both using a BOP completion riser system or a completion workover riser system.
7. The method of claim 6 , further comprising utilizing the BOP completion riser system or completion workover riser system to perform interventions on the subsea production system.
8. A subsea production system, comprising:
a high pressure subsea wellhead;
a tubing head spool (THS) disposed on the wellhead;
a tubing hanger landed within the THS;
a production tree disposed on the THS downstream of the tubing hanger;
a riser;
a subsea flowline system coupled between the production tree and the riser; and
at least one barrier, wherein the barrier is located downstream of the tubing hanger, providing a pressure barrier that controls pressure of fluid flowing from components of the subsea production system located upstream of the barrier and components of the subsea production system located downstream of the barrier, wherein the at least one barrier comprises a high integrity pipeline protection system (HIPPS);
wherein at least one of the components located downstream of the barrier is rated for a first maximum pressure, temperature, or flow rate such that the at least one of the components located downstream of the barrier cannot facilitate fluid flowing therethrough above this first maximum pressure, temperature, or flow rate, and wherein all of the components located upstream of the barrier are rated for a second maximum pressure, temperature, or flow rate such that all of the components located upstream of the barrier facilitate fluid flowing therethrough up to at least this second maximum pressure, temperature, or flow rate, wherein the second maximum pressure, temperature, or flow rate is greater than the first maximum pressure, temperature, or flow rate.
9. The subsea production system of claim 8 , wherein at least one of the components located downstream of the barrier is rated for a first maximum pressure of up to approximately 15,000 psi, and wherein all of the components located upstream of the barrier are rated for a second maximum pressure that is greater than a maximum reservoir pressure of a subsea reservoir plus a pressure margin associated with fluid injection, wherein the second maximum pressure is greater than approximately 15,000 psi.
10. The subsea production system of claim 9 , wherein the second maximum pressure is greater than approximately 20,000 psi.
11. The subsea production system of claim 8 , wherein the at least one barrier comprises the HIPPS in combination with one or more components on the subsea production tree, and wherein the HIPPS is directly coupled to the subsea production tree.
12. The subsea production system of claim 8 , wherein one or more components located downstream of the barrier are rated for the second maximum pressure, temperature, or flow rate to provide a fortified zone extending downstream from the barrier.
13. The subsea production system of claim 12 , wherein the HIPPS comprises a separate module from the subsea production tubing, wherein the HIPPS is coupled to the subsea production tubing via a first flowline jumper, and wherein a second flowline jumper is connected directly to a downstream side of the HIPPS, wherein the second flowline jumper is rated for the second maximum pressure, temperature, or flow rate such that the second flowline jumper located downstream of the barrier facilitates fluid flowing therethrough up to at least this second maximum pressure, temperature, or flow rate.
14. The subsea production system of claim 8 , wherein the high pressure wellhead comprises a mandrel having an outer diameter of approximately 35 inches, wherein the high pressure wellhead is rated for at least 20,000 psi.
15. The subsea production system of claim 14 , wherein the high pressure wellhead has a nominal 18¾ inch diameter bore, and wherein the subsea production tree and the tubing hanger each comprise a nominal 3, 4, or 5 inch diameter production bore.
16. The subsea production system of claim 8 , wherein the HIPPS comprises a separate module from the subsea production tubing, wherein the HIPPS is located at a base of the riser, wherein the HIPPS is coupled between the flowline system and the riser, and wherein the flowline system comprises:
a flowline extending from the subsea production tree to a first manifold;
a second flowline extending from the first manifold to a second manifold;
a third flowline extending from the first manifold to a third manifold;
a fourth flowline extending from the second manifold to the barrier; and
a fifth flowline extending from the third manifold to the barrier, wherein the barrier is located at a base of the riser, and wherein the barrier comprises a HIPPS module disposed between the flowline system and the riser.
17. The subsea production system of claim 8 , further comprising a secondary barrier valve disposed in the tubing hanger, wherein the secondary barrier valve is remotely actuable between a closed position and an open position.