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SUBSEA COMPLETION EQUIPMENT OPERATION AND MAINTENANCE MANUAL FOR TOTALFINAELF MATTERHORN PROJECT

TFE - Matterhorn March 2004

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DISTRIBUTION LIST FOR TOTALFINAELF MATTERHORN PROJECT

TFE - Matterhorn March 2004

Trey Lynch Ricky Coutee Service Department (2) WHE Library Rig Copy

Cameron Cameron Cameron Cameron Cameron

Customer (6 Copies)

TFE

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AMENDMENT INSTRUCTIONS

The Operation and Maintenance Manual contains general and technical information and should be used in conjunction with any associated Publication referred to in text. The book will, as far as is practicable, be kept to the latest standard by the issue of Amendment Instruction Sheets with amended pages. It is important that these are incorporated immediately upon receipt and that their incorporation is recorded in the Amendment Record (following page). Each bears either a page number or a page number and revision number at the bottom. The addition or deletion of technical matter introduced by amendment action will be indicated by the markers thus ⇒……….⇐ to show where the material has been changed (see note below). These markers will be removed when a subsequent amendment to the leaf is issued and additional markers inserted against the new or amended material. When a Section is issued in a completely revised form, the note “Completely Revised” will appear beneath the Section Title; in this case there will be no markers to indicate these changes. Note: In the event of a change to an illustration, the illustration will also be raised to the next revision number, ie: A1 to B1 etc. When an amendment is incorporated, the Revision Number, Date, and Signature of the person incorporating the amendment is to be entered on the Amendment Record.

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AMENDMENT RECORD SHEET

Amendment 0 1

TFE - Matterhorn March 2004

Incorporated By Karen Chan-Reumuth Trey Lynch

Date September 2002 March 2004

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AMENDMENT INCORPORATED

Revision History: Revision Date: Amendment Number: Section All

Page No.

TFE - Matterhorn March 2004

Matterhorn March 2004 1 Rev. Level

Revision Description Complete manuals will be provided.

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TABLE OF CONTENTS 1. 1.1 1.2 1.3 2. 2.1 2.2 2.3 2.4 3. 4. 4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 4.1.8 4.1.9 4.1.10 4.1.11 4.2 4.3 4.4 4.5 5. 6. 6.1 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7

INTRODUCTION .............................................................................................................. 9 Purpose................................................................................................................................ 9 Responsibilities ................................................................................................................... 9 Safety .................................................................................................................................. 9 SYSTEM OVERVIEW .................................................................................................... 10 Field Location ................................................................................................................... 10 Field Information .............................................................................................................. 10 System Description ........................................................................................................... 10 Well Data .......................................................................................................................... 11 SCOPE OF SUPPLY ........................................................................................................ 12 SUBSEA COMPLETION EQUIPMENT ........................................................................ 13 SpoolTree Assembly......................................................................................................... 13 Spool Body / Connector Sub-Assembly ........................................................................... 19 Tree Connector.................................................................................................................. 23 Top Plate / Mechanical Lockdown Assembly .................................................................. 27 Isolation Sleeve................................................................................................................. 30 Injection Valve Block Assembly ...................................................................................... 32 “CM” Actuators (Injection/Annulus)................................................................................ 34 “FLS” Gate Valves (Injection/Annulus)........................................................................... 38 ¾” Hydraulically Operated Gate Valve ............................................................................ 42 ½” 15,000 psi Needle Valves............................................................................................ 43 Tree Hydraulic Components – Flow Schematic ............................................................... 44 Transfer Barrier................................................................................................................. 47 Tubing Hanger .................................................................................................................. 49 Tubing Hanger Wireline Plug........................................................................................... 55 Internal Tree Cap .............................................................................................................. 57 Tree Debris Cap ................................................................................................................ 59 LIFTING REQUIREMENTS ........................................................................................... 61 INSTALLATION AND OPERATING PROCEDURES ................................................. 62 Introduction....................................................................................................................... 62 General Instructions .......................................................................................................... 63 Pressure Tests.................................................................................................................... 63 Corrective Action.............................................................................................................. 63 Procedural Changes .......................................................................................................... 63 ROV Valve Interfaces....................................................................................................... 64 Tree Installation ................................................................................................................ 65 Required Equipment ......................................................................................................... 65 Prepare the Tree for Testing on the Rig Prior to Installation............................................ 66 Prepare Bore Protector Running Tool (BPRT) for BP Installation .................................. 66 Prepare Bore Protector (BP) for Installation..................................................................... 67 Install Bore Protector in the Tree...................................................................................... 67 Prepare the TRT................................................................................................................ 69 Function Test of the TRT.................................................................................................. 70

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6.3.8 6.3.9 6.3.10 6.3.11 6.3.12 6.3.13 6.4 6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.4.6 6.4.7 6.4.8 6.4.9 6.5 6.5.1 6.5.2 6.5.3 6.5.4 6.5.5 6.6 6.6.1 6.6.2 6.6.3 6.6.4 6.6.5 6.7 6.7.1 6.7.2 6.7.3 6.7.4 6.7.5 6.7.6 6.8 6.9 6.9.1 6.9.2 6.9.3 6.10 6.10.1 6.10.2 6.10.3 6.10.4

Prepare the Tree Test Skid................................................................................................ 71 Prepare the Tree ................................................................................................................ 71 Install the Tree on the Stump and Fill Tree ...................................................................... 71 Install the TRT on the Tree............................................................................................... 72 Lock the Tree Connector Onto the Test Stump ................................................................ 74 Prepare the Tree for Testing ............................................................................................. 74 Test the Tree Prior to Installation ..................................................................................... 75 Test the Working Pressure Integrity of the Tree/Stump Connection, Inboard GT Valve, Isolation Sleeve External Test .......................................................................................... 76 Test the Outboard Side of the AWV, SCM, SV1, SV2 Valves ........................................ 77 Test the Outboard Side of AMV, AAV, and XOV Valves............................................... 78 Test the Inboard Side of the IWV and the Outboard Side of IMV ................................... 79 Test the Inboard Side of the IMV, SCM, and SV2, Outside of the Bore Protector.......... 80 Test the Inboard Side of the SV1 and XOV Valves ......................................................... 81 Test the Inboard Side of the AWV Valve......................................................................... 82 Test the Inboard Side of the AAV, AMV, Bore Protector, and Isolation Sleeve ............. 83 Test the Outboard Side of the GT Valve .......................................................................... 84 Prepare the Tree for Running............................................................................................ 85 Unlock the Tree Connector............................................................................................... 85 Change Tree Gasket.......................................................................................................... 86 Prepare the Tree for installation........................................................................................ 86 Install Tree Guidance Stab (Stinger) and Make up TRT to Drill Pipe ............................. 86 Tree Installation Checklist ................................................................................................ 88 Run and Test the Tree ....................................................................................................... 90 Run the Tree...................................................................................................................... 90 Lock Tree to Wellhead...................................................................................................... 90 Test Tree/Wellhead Connection ....................................................................................... 92 Subsea Tree Testing.......................................................................................................... 93 Retrieve TRT and Umbilical............................................................................................. 94 BOP Stack Installation...................................................................................................... 96 Equipment Required ......................................................................................................... 96 Prepare the BOP for Running ........................................................................................... 96 Run BOP / IWOC Umbilical ............................................................................................ 96 Prepare and Run BOP Test Tool and Perform Stack Test ................................................ 97 Run IWOCS and Connect Hydraulic and Electrical Flying Leads to the Tree ................ 97 Subsea Tree Testing.......................................................................................................... 98 Complete Downhole Work per Operator Procedures ....................................................... 98 Bore Protector Retrieval ................................................................................................... 98 Equipment Required ......................................................................................................... 98 Prepare Bore Protector Running / Retrieval Tool............................................................. 98 Retrieve Bore Protector..................................................................................................... 98 Tubing Hanger Installation ............................................................................................... 99 Required Equipment ......................................................................................................... 99 Run Tubing per Operator Procedures ............................................................................. 100 Prepare the Tubing Hanger Running Assembly for Installation..................................... 100 Prepare the Tubing Hanger for Installation .................................................................... 102

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6.10.5 6.10.6 6.10.7 6.10.8 6.11 6.11.2 6.11.3 6.11.4 6.12 6.13 6.14 6.14.1 6.14.2 6.14.3 6.15 7. 8. 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.7.1 8.7.2 9. 10. 10.1 10.2 10.3 10.4 10.5 10.5.1 10.5.2 10.5.3 10.5.4 10.5.5 10.6 10.7 10.8 11. 12. 13.

Make up Tubing Hanger to Tubing String...................................................................... 103 Install THRT and Make up Control Lines to Tubing Hanger......................................... 104 Run and Test the Tubing Hanger .................................................................................... 108 Retrieve THRT / SSTT ................................................................................................... 120 Internal Tree Cap (ITC) Installation ............................................................................... 121 Prepare Internal Tree Cap (ITC) ..................................................................................... 122 Prepare and Install THRT to ITC.................................................................................... 122 Run and Test the ITC...................................................................................................... 124 Disconnect IWOCS Umbilical from Tree....................................................................... 129 Retrieve BOP per Rig Procedures................................................................................... 129 Install Tree Debris Cap ................................................................................................... 130 Required Equipment ....................................................................................................... 130 Prepare Tree Debris Cap ................................................................................................. 130 Run Debris Cap............................................................................................................... 130 Fill Out Subsea Completion Summary ........................................................................... 130 STACK-UP DRAWINGS .............................................................................................. 131 RETRIEVAL PROCEDURES ....................................................................................... 132 Retrieve Tree Debris Cap................................................................................................ 132 Run, Land, and Test BOP per Rig Procedures................................................................ 132 Internal Tree Cap Retrieval (ITC)................................................................................... 132 Retrieve the SSR Wireline Plug...................................................................................... 134 Retrieving the Tubing Hanger with the Hydraulic THRT .............................................. 134 Install the Bore Protector and Retrieve the BOP ............................................................ 136 Retrieve the Spool Tree .................................................................................................. 136 Prepare the TRT and Stinger........................................................................................... 136 Run the TRT and Retrieve the Tree................................................................................ 137 RUNNING TOOL AND TEST EQUIPMENT (RENTAL)........................................... 139 MAINTENANCE AND INSPECTION ......................................................................... 158 Introduction..................................................................................................................... 158 Oils and Lubricants ......................................................................................................... 159 Routine and/or Storage Maintenance.............................................................................. 159 Rubber Goods ................................................................................................................. 160 Tree Assembly ................................................................................................................ 160 General............................................................................................................................ 160 Tree Connector Assembly............................................................................................... 161 Isolation Sleeve Assembly.............................................................................................. 163 Storage Procedures.......................................................................................................... 163 Periodic Maintenance...................................................................................................... 165 Tubing Hanger ................................................................................................................ 166 Internal Tree Cap ............................................................................................................ 167 Tree Debris Cap .............................................................................................................. 167 INTERFACE DRAWINGS ............................................................................................ 168 SSR WIRELINE TOOLS/ACCESSORIES – PROCEDURES / DRAWINGS............. 169 RECOMMENDED SPARE PARTS LIST..................................................................... 170

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1.

INTRODUCTION 1.1

Purpose This manual provides the technical information required for installation and maintenance of the Cameron Subsea Production SpoolTree System for the Matterhorn project.

1.2

Responsibilities It is recommended that a qualified Cameron Service Technician be on site to supervise use.

1.3

Safety This manual is intended to provide complete instructions for safe maintenance, testing, operation, and installation of Cameron’s subsea tree equipment. All rig safety procedures and customer safety policies must be followed and, in general, shall supercede the HSE requirements of this manual. Where conflicts arise, it is appropriate to conduct a job hazard analysis (JHA) with all appropriate personnel to resolve any concerns before proceeding. Safe work practices must be followed during all aspects of equipment use. Work planning meetings should be conducted at appropriate intervals during the work and prior to any new or critical operations. The purpose is to have all personnel involved discuss the possible health, safety and environmental concerns for a particular operation. Suggested JHA meeting points have been identified in this manual and are flagged as: -JHA- .

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2.

SYSTEM OVERVIEW 2.1

Field Location The Matterhorn field is located in the Gulf of Mexico in block Mississippi Canyon 243 (MC243) in 2,810’ of water, about 30 miles SW of the mouth of the Mississippi River and about 100 miles SW of New Orleans, Louisiana.

2.2

Field Information The Matterhorn field is planned to be developed with a 9 slot dry tree floating structure located above the existing exploration well MC243#1. This dry tree structure may be a TLP or a Spar. The structure will not have any drilling capability (except for sidetracks) and all the wells will be predrilled and temporarily abandoned before platform installation. The wells will then be completed with a workover rig (750 HP) installed on the Matterhorn structure. The A6 well will be completed as a water injection well to provide pressure maintenance in support of production on the infield host facility. All the wells except A6 will be tied back to the platform as dry tree completions and will be drilled from a central location, currently planned to be the surface of the exploration well MC243#1. The A6 injector well for the “A” sand will be a subsea well. All wells (including the A6 water injector) will be predrilled with a semi-submersible drilling unit and T&A’d before platform arrival. The A6 well is expected to be the initial well in the drilling program.

2.3

System Description The well is in approximately 2,900 feet of water and is to be drilled from a floating drilling rig using an 18-3/4” 10,000 psi wellhead system. A side valve or horizontal Christmas Tree will be used to complete the well. Installation of the tree will be diverless and guidelineless (GLL). Remote intervention of the tree during installation and workover will be by a Remotely Operated Vehicle (ROV) Water injection will be through a single flowline from a host facility approximately 5,100 feet from the well. The host facility will be either a Tension Leg Platform (TLP) or a Spar. A jumper will be used to connect the flowline to the tree by means of a vertical connection system that interfaces with a vertical hub installed on both the tree and the Pipeline End Termination (PLET).

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Control of the tree will be by means of a direct hydraulic control system. There will be a controls umbilical, supplied by others, terminated to a stab-and-hinge-over Umbilical Termination Assembly (UTA) that lands on the PLET. The UTA will be equipped with a hydraulic junction plate so that an ROV can connect the subsea tree to the UTA by means of a Hydraulic Flying Lead (HFL) hose bundle jumper. A separate Electrical Flying Lead (EFL) will be provided to tie in analogue transmitters mounted on the WI tree. ROV intervention may be used in the initial installation of flowlines and hydraulic and electric flying leads. 2.4

Well Data Number of Wells Water Depth Injection Fluid Chlorine Shut in Wellhead Pressure Injection Pressure Injection Rate

1 2,900 feet De-Oxgenated treated Seawater 1 ppm