David Simpson - Cameron - Subsea UK

Development & Qualification of an
8” Insert Retrievable Subsea Choke for a
Large Bore Gas Project in Australia
David R Simpson CEng
Subsea Product Manager

Large Bore Subsea Choke : - Insert Retrievable / Non Retrievable
• The subsea Choke is the primary control/wearing element of the SPS
• Choke options include : - Non retrievable Chokes on Flow Control Module (FCM)
• Field Proven 8” nominal Non Retrievable CC80 FNR
• 7,500psi MWP, Max Cv= 1,000
• 66 off units supplied since 2004
- Insert Retrievable Chokes
• No 8” nominal Insert retrievable choke existed
• FCM add weight and complexity including :
- Smaller bore pipe work
- Additional bends
- Fabrication delays
• Routine choke trim change out becomes more complex and costly with a FCM
Cameron CC80FNR
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Subsea Choke & Alternative Locations
• Moving the choke off the tree and onto a manifold, for example, allows more real
estate for larger bore pipe work, therefore reducing erosion risk
• Reduces tree weight and size, with associated installation cost savings
• Large bore insert retrievable choke, remove the need for a FCM & further simplify the
pipe work and manifold configuration
V
V
Subsea X-Mass Tree
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Chevron Wheatstone CC80SR
• During early FEED stage of the Chevron Wheatstone Project, the choke was moved off the tree
and onto the manifold to evaluate perceived tree size, weight and complexity advantages
• The movement of the choke onto the manifold was conditional on a large bore insert retrievable
choke being available
• Cameron Flow Control’s New Product Development group responded to the technology gap
and worked to design & qualify the CC80SR an 8” nominal insert retrievable choke
• Timeline for detailed engineering, prototype build & qualification was just 10 months
• Developments run through the Design for Six Sigma DMADV stage gate process
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CC80SR – Concept Development
• Combine the Field Proven 8” nominal CC80 non retrievable choke
• With a 12” 5k Cameron Vertical Connector (CVC) which is also extensively field proven
• Equals 8” nominal Subsea Insert retrievable Choke
• Max Cv =1,000
• Pressure Rating 7,500psi
• Intervention via Standard CVC R/T
8” CC80FNR
1,000 Cv
8” CC80SR
1,000 Cv
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Cameron Vertical Connector
Collet type Flowline tie-in Connection System
• Trees
• Manifolds
• Templates
• CVC Connector & Gasket Field proven in over 1,000
applications
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Cameron CC80SR Specification
• 8” Nominal Size Insert Retrievable Subsea Choke
• CVC Collet Type Insert Connector
• Cv up to 1,000
• Max WP 7,500psi
• Water Depth 1,500m
• Intervention via Cameron Field Proven 12” 5k CVC R/T
• SLCA Hydraulic Stepping Actuator
• Plug & Cage Trim with Impact Protection
• End Connections : 7 1/16” API 10k
• Weight 3,300kg
• Height 73” (1.85m), OD 36” (0.76m), R/T OD 48” (1.2m)
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Choke
Actuator
CC80SR Insert & Body
R/T
Bumper
Frame
Insert to Body
Seal Pocket
CVC
Connector
W/ SAX
Gasket
Choke Insert
Hydraulic & Electrical
Connectors
Plug & Cage Trim
Choke Body
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Detailed Engineering
Included :-
• FEA connector analysis
• Bumper structure for CVC R/T alignment
• Stab Plate with Hydraulic & electrical connectors
R/T Bumper
Structure
Stab Plate
Running Tool
Guide/Location
Skirt
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Intervention via Cameron 12” 5k CVC R/T
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CC80SR - Prototype Manufacture
• Body Machining & Welding
• CVC Connector Hub F/M
• SAX Gasket
• Connector Fingers machined
forging, prior to being cut
CC80SR Body Assembly during welding
CVC Connector Fingers Machined Forging
SAX Connector Gasket
CVC Connector Hub Finished Machined
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CC80SR - Prototype Assembly
At Cameron’s Subsea Choke Centre
Of Excellence In Longford Ireland
CC80SR Body showing Seal pocket & Stab Plate
CC80SR Insert during Assembly
CC80SR Body Finished Assembly
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CC80SR – Qualification Program
• CC80 Choke & Actuator Field Proven & Qualified
• CVC Connector & Gasket Field Proven & Qualified
CC80SR Choke Qualification Tests
FAT testing to API 17D
• Stab in / Connector Set test with CVC R/T
• Hydrostatic shell test 11,250psi
• Nitrogen Gas Test 7,500psi
CVC Running Tool Interface testing
R/T 3 Degree off vertical plus ±15 o Rotational missalignment
test in all plains
Multiple Stab-in tests
ISO 10423 / API 6A - Annex F PR2
• 7,500 psi MWP
• -35°C to 145°C
ISO 13628-4, API17D Validation
CC80SR Finished Prototype
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CC80SR Qualification Testing
• Hydrotest shell Test
• WP Gas Test
• R/T Interface Testing
• R/T miss-alignment Testing
HYDRO TEST SET-UP
GAS TEST R/T MISS-ALIGNMENT TEST R/T INTERFACE TEST

API 6A/17D Annex F PR2 Qualification
• 20 choke cycles @ 7,500psi & -35 o C, 20 choke cycles @ 7,500psi & +145 o C
• 200 choke cycles @ 7,500psi and ambient temp.
• 3 pressure/ temperatures cycles at extremes (7,500psi, -35 o C to +145 o C)
• 200 pressure cycles @ 7,500psi
CC80SR Choke in Environmental Chamber

CC80SR – Completes Qualification
The largest qualified insert retrievable production choke in the industry
“From VOC to qualified product in just 10 months”
• Close Cooperation with Chevron once Technology
Gap was identified
• Combining field proven elements minimises the
design and qualification risk
• Cross divisional collaboration between Cameron’s
CVC connector and Choke Groups allowed for a
compressed prototype build & qualification time line
• Now entering the project execution phase with the
first of the production units expected for delivery
to the Wheatstone Project Q4 2012
5 th April 2011
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Contact information
David R Simpson CEng.
Subsea Product Manager
Cameron Ireland Ltd.
David.Simpson@c-a-m.com
+353 43 3350636
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