Kvaerner Oilfield Products

COMPANY PROFILE

Subsea Control System Expandable

With additional satellite wells planned in the Falcon Corridor, Pioneer specified Kvaerner Oilfield Products equipment to handle the first five subsea wells.
ffshore operations require close teamwork for a successful outcome. Delivery of products and services are expected to be on time and within budget constraints especially when working with deepwater production operations. For the Falcon project, Pioneers production facilities design team specified field-proven subsea wellhead, flow line and manifolding equipment that would deliver long-term, interventionless service. More importantly, they called for exceedingly reliable controls to operate the seafloor equipment, particularly since there was significant distance more than 32 miles (51.49 km) between the control center on the host platform and the subsea wells. Because of its proven history of reliability, Pioneer chose Kvaerner Oilfield Products (KOP) to supply the subsea control systems at Falcon field, as well as the subsequent satellite field tie-ins along the Falcon Corridor. It was essential that topside and subsea control components reflect a proven, reliable field record, be relatively easy to install, and have broad compatibility with seafloor hardware supplied by other vendors. The KOP contribution at Falcon was a purpose-built production control system that leads from the subsea trees to the subsea manifold, and then on to the host platform. Both Falcon wells are tied into the system, but it is capable of controlling production on five or more wells, each tied back to the manifold.

Typical layout for subsea production operations depicts placement of Kvaerner Oilfield Products subsea tie-in equipment.

MCS features hot stand-by, bumpless failover

In addition to the MCS, which is installed at the platforms MCC equipment room, KOP also installed a remote operator station in the control room. The topside equipment requires a minimal footprint on the host facility, and includes an electrical power unit (EPU) and a hydraulic power unit (HPU). At the subsea location, the MCS is connected by an integrated steel tube umbilical to a control pod on the gathering system manifold. Other control pods are installed directly on the subsea trees. These diverless, guidelineless control pods, relatively light in weight, may be retrieved and reinstalled by lift wire with the aid of a remote operated vehicle (ROV). The pods mate via a linear monolock connection to a receiver plate on the manifold or tree.
The master control station (left) featuring a redundant industrial central processing unit and its companion electrical power unit are the mainstays of Kvaerner Oilfield Products reliable topsides control equipment.

Topside station provides redundancy

The KOP systems topside components on the host platform include a single master control station (MCS) that, with proprietary KOP software and dual industrial personal computers, enables Pioneer personnel to monitor and control gathering line manifolding, as well as the subsea trees and downhole valves for each Falcon well.

Field-proven subsea well controls

Once connected by hydraulic and electrical flying leads, the system controls the wells and their related downhole

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Falcon Corridor: A way into the future

and related products and services. The company, an operating member of the Aker Kvaerner Group based in Oslo, Norway, demonstrates expertise based on more than 75 years experience. A A leading subsea equipment predecessor company of Kvaerner provider Kvaerner Oilfield Products designs, began installing land-based wellheads manufactures and installs wellhead and trees in the 1920s. Since that time, equipment, including trees, controls, through new business development coupled with strategic acquisitions, KOP has become a leading worldwide provider of subsea oil and gas equipment, supporting all aspects of subsea field development. This expertise runs from initial concept screening through front-end engineering, detailed design, procurement, fabrication and manufacturing, assembly and testing, installation, commissioning and life-offield support. The company has also become a leader in providing diverless subsea oil and gas production tie-in systems and pipeline products The KOP modularized approach to subsea systems offers field-tailored solutions by combining proven inhouse building blocks into an optimized architecture. With more than 500 successful diverless subsea conPioneer Falcon subsea control module or control pod nections completed or on (protective cover removed) shows the base plate and order, KOP tie-in technology solenoid valves that control tree functions. has proven to be suitable for all

valves and sensor arrays. For Pioneers Falcon project, these included each wells wet gas flow meter, wellhead control valves, choke indicator, sand detector and various downhole sensors and hardware, including annulus pressure and surface-controlled downhole safety valve. Readings from sensors and valve actuators are relayed back through the pods to the MCS on the Falcon Nest platform. Each wells control pod is fitted with hydraulic connectors, and dual-power and signal supply connections. The hydraulic system is capable of supporting two high-pressure and 20 low-pressure functions. The pod is also fitted with a maximum of four top-mounted ROV mateable connectors. KOP subsea control system pods will be included on each of the newest three scheduled Falcon Corridor satellite wells. Pioneer plans to connect the wells to the existing manifold via infield umbilicals and flying leads.

The remote operator station included with Kvaerner Oilfield Products topside equipment increases system reliability and redundancy.

subsea connections, from small umbilicals to large pipelines. The various KOP tie-in systems feature pressure-tight, reliable and safe umbilical connections, as well as flexible and rigid-pipe installations. The company operates two fullservice umbilical manufacturing yards, one near Oslo and the other at Mobile, Ala.

Houston fabrication yard offers convenience

KOP is a global company and contains a spacious manufacturing facility where the companys Gulf of Mexico subsea equipment is manufactured, assembled and tested before shipment to the field. This location provides a distinct benefit by allowing engineers and executives of oil and gas operating companies who are active in deepwater Gulf of Mexico, to inspect their subsea equipment orders prior to installation without longdistance travel.

Kvaerner Oilfield Products

1255 North Post Oak Road Houston, TX 77055-7215 Tel: (713) 685-5700 Fax: (713) 685-5895 Web site: www.akerkvaerner.com/kop

Falcon Corridor: A way into the future

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