SG-5 / SG-5XP Subsea Wellhead System

SG-5

SG-5XP

ABB Vetco Gray

ABB Oil, Gas & Petrochemicals

Section I SG-5/SG-5XP Wellhead System Overview

SG-5 / 5XP Wellhead Systems

The ABB Vetco Gray SG-5/SG-5XP is the most widely used subsea wellhead system in the world today. The complete SG-5 system includes guidance equipment, highpressure wellhead housing, casing hangers, bore protectors, and running, retrieving, and testing tools. An SG-5 wellhead system supports the casing strings inside the subsea wellhead. The high-pressure metal-tometal SG-LTR packoff seals between the casing hanger and the wellhead housing to isolate the casing bore from the annulus for well control. The ABB Vetco Gray H-4 hydraulic wellhead connector latches to the mandrel profile on the SG-5 high-pressure wellhead housing. The H-4 connector acts as the foundation for the BOP stack throughout the drilling operations.

TM

TM

L L L L

Use in guideline and guidelineless drilling, artificial island, and Caisson applications 10,000 psi pressure-containing capability 13-5/8", 16-3/4", and 18-3/4" systems available Compatible with subsea satellite trees multiwell subsea template production systems special deep water subsea production systems tieback systems to a fixed platform or TLP

SG-5 Wellhead System Stackup

1-1

A value-conscious operator in todays competitive market appreciates the many advantages and the reliability of the SG-5 subsea well system:

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Working pressure up to 10,000 psi in combination with high casing loads Simple tools and procedures inherent in a torque-set system provide maximum reliability and serviceability Minimum number of running, retrieving, and testing tools Field-proven single trip system Run and land casing hanger, energize, and test annulus seal all in one trip Metal-to-metal casing annulus seals Casing program flexibility Optional full bore casing hanger running tools Test with wear bushings in place All SG-5 casing hangers have the same external dimensions Will land in any of the three hanger profiles No costly hanger adapters needed Use one packoff -- the SG-LTR -- throughout the system Metal-to-metal seal Reliable Retrievable

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Field-proven with more SG casing hangers and packoffs installed worldwide than all other systems combined Clear passage for cuttings and mud while running the hanger, circulating, and cementing Deep, wide slots for increased flowby in the casing hanger and packoff nut Qualified to API 17D requirements

Although the SG-5 is an established and field-proven subsea wellhead system, ABB Vetco Gray continues an ongoing program of system refinements. Using field data from worldwide offshore operations, SG-5 components undergo testing, analyzing, and improving to enhance their reliability and value to our customers.

SG-5 Wellhead Housing and Casing Hangers

1-2

SG-5XP Subsea Wellhead System

The SG-5XP is a 4-casing hanger system. It has all the standard SG-5 system features plus the added ability to support the additional casing hanger and seal within the high-pressure wellhead housing. The SG-5XP uses a load ring on the 13-3/8" casing hanger to divert casing and test pressure loads directly into the high-pressure wellhead housing instead of the 16" casing hanger. When the 16" casing hanger is not used, an adapter attaches to the bottom of the 13-3/8" casing hanger and is run with the hanger in a single trip.

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Positive landing shoulder in the wellhead housing for the 16" hanger Protected seal area for 16" packoff Run, cement, and test the 16" hanger and packoff in a single trip Uses standard SG-5 tools with the addition of the 16" casing hanger running tool, and 4-hanger test plug

SG-5XP Wellhead Housing and Casing Hangers

1-3

Section II System Characteristics

SG-5/SG-5XP Subsea Wellhead System Components Used a Typical Guideline Drilling Program

SG-5 (18-3/4" System)

Temporary Guide Base and Running Tool Retrievable Drilling Structure and Retrieving Tool Remote Guideline Latch 30" Conductor Wellhead Housing 30" Cam-Actuated Running Tool 18-3/4" SG-5 Wellhead Housing 18-3/4" Wellhead Housing Cam-Actuated Running Tool 18-3/4" LHT Wellhead Housing Running Tool 13-3/8", 9-5/8", and 7" Casing Hangers SG-LTR Packoff Universal Casing Hanger Running Tool 13-3/8", 9-5/8", and 7" Full Bore Running Tools Packoff Running and Retrieving Tool Standard Plug-Type Test Tool 18-3/4" Nominal Seat Protector 13-3/8", 9-5/8", and 7" Wear Bushings 18-3/4" Seat Protector and Wear Bushing Running and Retrieving Tool 18-3/4" Wellhead Corrosion Cap

SG-5XP (Alternative/Additional Equipment)

18-3/4" SG-5XP Wellhead Housing 16" Casing Hanger and Running Tool 16" SG Packoff 16" Full Bore Running Tool 16" Wear Bushing 13-3/8" SG-5XP Casing Hanger Plug-Type Test Tool
2-1

Temporary Guide Base

The ABB Vetco Gray temporary guide base (TGB) is the first piece of equipment run when spudding a subsea well. It anchors the guidelines and serves as a foundation structure throughout the drilling phase. Run with the temporary guide base running tool, the TGB is used as a template to drill the 36" hole. It may not be necessary to use a TGB if the conductor pipe is jetted into place. 100 sq. ft. bearing area O Four guideline attachment points on 6-ft. radius O Four removable anchor spikes penetrate into the sea floor to prevent rotation O 46" I.D. center with J-slot preparation O Conical landing ring for landing gimbal base of drilling guide structure O Compartmented construction and octagon in shape with eight open cavities for holding weight material O Can be reworked O Stack Up: 33" above mudline O Weight: 5,000 lb. empty O Misalignment: Funnel allows for compensation of bottom slope up to 5
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136"

33 "

46"

2-2

Temporary Guide Base Running Tool

Runs the temporary guide base to the mudline on drill pipe. Gimballed stem accommodates minor sloping on the ocean floor O Four J-lugs engage mating J-slots in the temporary guide base O Can be reworked O Weight: 1,835 lb. O Top Connection: 4-1/2" I.F. box O Maximum Misalignment: 10 from level in any direction O Tension Capacity: 150,000 lb. on gimbal bolts
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167-3/4"

45-1/2" 47-1/8"

2-3

Retrievable Drilling Guide Structure

The ABB Vetco Gray retrievable drilling guide structure is a guide base fitted with a landing profile for, and run with, the 30" wellhead housing. The guide structure provides structural support for the 30" housing during cementing and is the primary guidance system for the BOP stack during drilling. The guide structure has a diverless latch for retrieval with the guide structure retrieving tool. A latch ring, attached to four collet-type pin mechanisms, releases from the 30" support plate which can be either a solid gimbal, split gimbal, or a split flat plate. The collets secure the 30" support plate and the guide structure together as an assembly. When a temporary guide base is not used, the gimble can be replaced with the split plate. This plate is secured to the base with chains and retrieved with the base. ROV releasable guide posts on standard 6-ft. radius O Guide post tops accept the remote guideline latch O 30" housing locks into center ring and gimbal assembly with snap ring O Integral anti-rotation device O Guide structure parts are retrievable O Retrieved from the wellhead assembly with the retrieving tool or by divers/ROV O Can be retrieved with corrosion cap in place O Optional level indicator O Can be reworked O Weight: 9,340 lb.
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94-1/4"

131-3/4"

34-1/2"

2-4

Retrievable Drilling Guide Structure

2-5

Retrievable Drilling Guide Structure Retrieving Tool

Latches onto the retrievable drilling guide structure remote release ring to unlock the guide structure from the 30" housing and recover to the surface. Circular in shape with detachable centralizing fins. Tool can retrieve drilling guide structure with corrosion cap installed on the wellhead. Uses spring-loaded latch with J release. Can be reworked O Weight: Approximately 4,000 lb. O Top Connection: NC50 (4-1/2" I.F.) box O Bottom Connection: NC50 (4-1/2" I.F.) pin O Tension Capacity: 100,000 lb.
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70"

102-7/8"

39-3/4"

2-6

Remote Guideline Latch - GL4

Connects a guideline to a post top and provides diverless release/establish ability. Using a remote release connector, it can be run with guideline remote replacement tool or ROV. If a guideline parts, the guideline cutting tool shears the parted line allowing the remote guide line latch to be established on the post top O Automatically latches when mated to a remote guide post O Lowering a weight (go-devil) down the guideline releases the latch
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If a post top equipped with a remote guideline latch suffers a parted guideline, the running tool is jetted into position (after cutting parted line) and the latch recovered without the use of divers. O Can be reworked O Stack Up: 6" on post top O Weight: 197 lb. O Top Connection: Socket to suit guide wire size (3/4" to 1-1/4") O Tension Capacity: 50,000 lb.
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2-1/2"

21-1/4"

8-5/8"

2-7

30" Conductor Wellhead Housing

Lands in and run with the retrievable drilling guide structure, and supports the conductor string. Run with 30" camactuated housing running tool. Internal profile accepts the ABB Vetco Gray highpressure wellhead housing O External profile accepts drilling/production guide base O External slot prohibits rotation of guide base O Cements ports allow exit of surface casing cement returns O Lower end has butt-weld prep for welding to conductor housing extension O Elevator shoulder O Can be reworked O Weight: 1,989 lb. O Bending Capacity: Limited by 30" casing
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35-3/4" 29-3/8"

28"

26-1/2"

2-8

30" Cam-Actuated Running Tool

Runs the 30" housing, drilling guide structure, and 30" casing. Visual Lock and Unlock indication stamped into stem O With left-hand rotation of stem, eight rams, with dual 45 profiles, engage internal wellhead profile O Rams retract with right-hand rotation of stem and overpull of tool O Six removable 3" bull plugs allow conductor string filling or accommodate returns when jetting O Can be reworked O Weight: 3,000 lb. O Top Connection: 6-5/8" reg. box or 4-1/2" I.F. box O Bottom Connection: 4-1/2" I.F. pin (NC 50) O Tension Capacity: Limited by drill pipe
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49"

3-1/2"
29-1/4"

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18-3/4" High-Pressure Wellhead Housing

The 18-3/4" high-pressure wellhead housing lands in the 30" conductor housing on the ocean floor, and suspends the 20" casing string. The internal preparations accept up to three casing hangers and packoff assemblies. The housing has an external profile to receive the H-4 connector on the BOP stack. Internal profile in upper housing body available for either cam-actuated or left-hand threaded running tool O Internal lockdown groove accepts a 10,000 psi tubing hanger in the 7" casing hanger position. O External profile mates with H-4 connector on BOP stack O Stainless steel prep for H-4 wellhead connector VX ring gasket. O Incorporated secondary VT seal gasket preparation
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Lower housing body has butt-weld for heavy-walled housing extension O Housing extension equipped with Squnch Joint or RL-4S connector for quick, easy makeup to the casing string O Locks into the 30" conductor housing O Pre-loaded 18-3/4" to 30" connection system available O Lower reaction ring reduces bending stresses in 20" casing by transferring bending loads to the 30" housing. O Can be reworked O Stack Up: 35-1/4" from top of 30" housing O Weight: 5,350 lb. without extension O Maximum Internal Working Pressure: 10,000 psi
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27" 18-5/8"

35-1/4"

67-1/2"

20-7/8"

17-9/16"

2-10

18-3/4" High-Pressure Wellhead Housing Cam-Actuated Running Tool

Runs the 18-3/4" high-pressure wellhead housing and 20" casing. Seals in high-pressure housing for cementing operations O Visual Lock and Unlock indication stamped into stem O With left-hand rotation of stem, eight rams, with dual 45 profiles, engage internal wellhead profile O Tool disengages with right-hand rotation of stem and overpull of tool
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Removable plugs facilitate filling the casing string O Check valve available to allow the casing bore to adjust for ambient pressure changes O Can be reworked O Weight: 1,369 lb. O Top Connection: 6-5/8" reg. box or 4-1/2" I.F. box O Bottom Connection: 4-1/2" I.F. (NC 50) pin O Tension Capacity: Limited by drill pipe
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60"

3" 18-11/16"

2-11

18-3/4" LHT High-Pressure Wellhead Housing Running Tool

Runs the 18-3/4" wellhead housing and 20" casing string. Blunt start, modified square thread for high strength and easy makeup O Removable plugs to facilitate filling the casing string O Check valve available to allow the casing bore to adjust for ambient pressure changes O Simple one-piece tool provides operational reliability
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Can be reworked Weight: 1,350 lb. O Top Connection: 4-1/2" I.F. (NC50) box (6-5/8" box up available) O Bottom Connection: 4-1/2" I.F. (NC 50) pin O Maximum Internal Working Pressure: 3,000 psi O Tension Capacity: Limited by drill pipe
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3"

5"

81-1/2"

22"

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SG-5 13-3/8", 9-5/8", and 7" Casing Hangers

The ABB Vetco Gray SG-5 casing hanger assemblies consist of a casing hanger body and lockdown ring. To reduce trip time, the packoff assembly is run with the casing hanger, set, and tested once cementing operations are completed. SG-5 casing hangers are available in a wide variety of casing thread sizes and threadforms. Removable lock ring on casing hanger body provides optional lockdown O Internal left-hand running threads allow right-hand release of the casing hanger running tool O Accepts torque-actuated packoff O Flowby provision integral to casing hanger body O Hanger assembly can be run separately, if desired
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18-3/4" x 13-3/8" Casing Hanger

Suspends the 13-3/8" casing string and provides internal left-hand thread running profile and sealing area. Can be reworked O Weight: 555 lb. O Bottom Connection: 13-3/8" customer specified O Internal Working Pressure: 10,000 psi O Flowby Area, landed: 13 sq. in.
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12-3/8"

18-1/2"

18-19/32"

2-13

18-3/4" x 9-5/8" Casing Hanger

Suspends the 9-5/8" (or 10-3/4") casing string and provides internal left-hand thread running profile and sealing area. Can be reworked O Weight: 570 lb. O Bottom Connection: Customer specified O Internal Working Pressure: 10,000 psi O Flowby Area, landed: 13 sq. in.
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18-3/4" x 7" Casing Hanger

Suspends the 7" (or 7-5/8") casing string and provides internal left-hand thread running profile and sealing area. Can be reworked O Weight: 660 lb. O Bottom Connection: Customer specified O Internal Working Pressure: 10,000 psi O Flowby Area, landed: 13 sq. in.
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8-13/16"

6-3/8"

19-1/8"

19-1/8"

18-19/32"

18-19/32"

2-14

SG-LTR Packoff Assembly

The annular seal is made up on an SG casing hanger and the assembly is run in a single trip. After cementing, the packoff is energized and tested prior to retrieving the casing hanger running tool. Used for all casing hangers within a system, except for the 16" SG-5XP hanger O Integral flowby slots O Maximum seal over extended periods, even in high-pressure holes O Low torque-set packoff actuation
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Positive metal-to-metal seal backed up by pre-energized elastomer seal O W-shaped slotted metal insert enhances lower lip retrievability up to 100,000 axial overpull O Damage tolerant: successful testing to 15,000 psi with scored housings and damaged seals O Limited rework O Weight: 186 lb. O Maximum Working Pressure: 15,000 psi
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16-13/32"

14-27/32"

18-19/32"

2-15

Universal Casing Hanger Running Tool

Runs all sizes of SG-5 casing hangers and casing strings, 13-3/8" and smaller, seals during cementing, sets packoff and allows testing of the packoff assembly and BOP stack. Single trip to run, land, and cement the casing string, actuate and test the packoff O Centralizer sleeve helps position the casing hanger/ packoff assembly and running tool concentrically in the wellhead housing O Simple tool provides reliable operation and easy maintenance
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No shear pins or sliding sleeves to set or reset the packoff O Can be reworked O Weight: 1,862 lb. O Top Connection: 4-1/2" I.F. (or 6-5/8" reg. threads available) O Bottom Connection: 4-1/2" non-upset eight round box for subsea cement launching assembly O Maximum Load Rating: Limited by drill pipe
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18-9/16" 3"

66-1/2"

2-16

Full Bore Casing Hanger Running Tools

The full bore casing hanger running tool uses a casing string instead of drill pipe, and can support heavier casing strings below the hanger because of higher axial load capacity. Provides full bore access between running string and casing string in the well. Surface release plugs offer the possibility of using multiple stage cementing techniques O Full bore casing hanger running tool uses the same casing hanger and packoff assemblies as the universal casing hanger running tool O Removable torque keys O Can be reworked
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18-3/4" x 13-3/8" Full Bore Running Tool

Runs the 13-3/8" casing hanger/packoff assembly and casing string, and provides through-bore access for cement plugs.
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Weight: 1,389 lb. Top Connection: 13-3/8" customer specified

18-9/16"

63-1/8"

12-3/8"

2-17

18-3/4" x 9-5/8" Full Bore Running Tool

Runs the 9-5/8" casing hanger/packoff assembly and casing string, and provides through-bore access for cement plugs.
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18-3/4" x 7" Full Bore Running Tool

Runs the 7" casing hanger/packoff assembly and casing and string, and provides through-bore access for cement plugs.
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Weight: 1,363 lb. Top Connection: 9-5/8" customer specified

Weight: 1,610 lb. Top Connection: 7" customer specified

18-9/16"

18-9/16"

58-3/8"

56-11/16"

8-13/16"

6-3/8"

2-18

Packoff Running and Retrieving Tool

Runs, retrieves, and tests all SG packoff assemblies. Selfcontained hydraulic tool. By changing balance sleeve, functions with SG-5XP 16" hanger and packoff. Spring-loaded drive keys torque/un-torque packoff O Can be reworked O Weight: 2,230 lb. O Top Connection: 6-5/8" regular threads O Bottom connection: 3-1/2" API I.F. (NC 38) pin O Maximum Internal Working Pressure: 1,200 psi O Tension Capacity: 120,000 lb. (lock pins)
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18-9/16"

67-3/8"

2-19

Plug-Type Test Tool

Allows periodic testing of the wellhead housing, BOP, and the packoff seals. The tool initially seals in the bottom of the wellhead housing and subsequently on an internal seal surface of each casing hanger. Tests 18-3/4" high-pressure wellhead housing with no hangers installed O Tests 13-3/8" through 7" hangers O Weight: 1,350 lb. O Top Connection: 4-1/2" (NC 50) API I.F. box O Bottom Connection: 4-1/2" (NC 50) API I.F. box
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18-9/16"

49-1/2"

3" 3"

2-20

Seat Protector and Wear Bushings

The 18-3/4" seat protector and wear bushings protect the internal bore sealing surfaces of the wellhead and casing hangers. Run with the seat protector and wear bushing running and retrieving tool.. Can be reworked.

18-3/4" Nominal Seat Protector Bore: 17-9/16"

18-5/8"

13-3/8" Wear Bushing Bore: 12-3/8" Weight: 1,460 lb.

18-9/16"

Weight: 375 lb.

47"

42-5/16"

17-9/16"

12-3/8"

9-5/8" Wear Bushing Bore: 8-13/16" Weight: 449 lb.

18-9/16"

7" Wear Bushing Bore: 6-3/8" Weight: 700 lb.

18-9/16"

23-3/8"

26-1/2"

8-13/16"

6-3/8"

2-21

Seat Protector and Wear Bushing Running and Retrieving Tool

Runs and retrieves the subsea wellhead wear bushings, seat protector, and corrosion cap. Self-contained hydraulic tool O Collapsing lock ring and spring-loaded torque pins O Dart-actuated available where washing wear bushing and wellhead is desired
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Weight: 915 lb. O Top Connection: 4-1/2" (NC 50) API I.F. box O Bottom Connection: 4-1/2" (NC 50) API I.F. pin O Internal Working Pressure: 1,000 psi O Tension Capacity: 80,000 lb. on torque pins
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18-9/16"

50 "

2-22

18-3/4" Wellhead Corrosion Cap

Protects the interior seal surfaces and exterior profile of the wellhead during period of temporary abandonment. Once in place, a corrosion inhibitor can be pumped into the wellhead to displace seawater or drilling fluid and provide a corrosionresistant bath for seal areas. The retrievable drilling guide structure can be retrieved after cap is set. Weight-set and retrieve with 3,000 lb. overpull O Stack Up: 31" above top of wellhead O Weight: 1,770 lb.
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20 " 16-1/16"

66"

32-1/2"

2-23

SG-5XP Subsea Wellhead System Components

The SG-5XP wellhead system has all the standard SG-5 system features plus the added ability to support four casing hangers within the SG-5XP 18-3/4" high-pressure wellhead housing. The system uses the 16" casing hanger, 16" SG seal, 16" wear bushing, and a specifically-designed 13-3/8" casing hanger that transfers casing and test pressure loads directly into the high-pressure wellhead housing, instead of the 16" casing hanger. If the 16" hanger is not used, an adapter is attached to the bottom of the 13-3/8" casing hanger and the two are run together in a single trip. Run, cement, and test the 16" hanger in a single trip O Runs on standard SG-5 tools with the addition of the 16" casing hanger running tool
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18-3/4" SG-5XP Wellhead Housing

Configured like the standard SG-5 housing except for dimensions and the internal preparation for the 16" casing hanger below the 13-3/8" position. Weight: 7,239 lb. O Maximum Internal Working Pressure: 10,000 psi
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2 7"

4 0"

92-3/8"

80-7/8"

17-9/16"

2-24

18-3/4" x 16" SG-5XP Casing Hanger

Suspends the 16" casing string and provides internal left-hang thread running profile and sealing area. Weight: 390 lb. O Bottom Connection: 16" customer specified O Maximum Working Pressure: 5,000 psi O Flowby Area, landed: 6.6 sq. in.
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16" Casing Hanger Running Tool

Runs the 16" SG-5XP hanger, cements, sets the 16" SG packoff, and pressure tests the assembly in one trip. Weight: 1,870 lb. O Top Connection: 4-1/2" I.F. O Bottom Connection: 4-1/2" non-upset eight round box for subsea cement launching assembly O Maximum Load Rating: Limited by drill pipe
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15-1/4"

18-9/16" 6-3/8"

21"

65-1/2"

18-19/32"

2-25

16" SG-5XP Full Bore Running Tool

Runs the 16" casing hanger/packoff assembly and casing string, with though bore access for cement plugs. Weight: 1,100 lb. O Top Connection: 16" customer specified O Maximum Working Pressure: 5,000 psi O Tension Capacity: Limited by drill pipe
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16" SG-5XP Wear Bushing

Protects the internal bore sealing surfaces of the SG-5XP wellhead housing and the 16" SG-5XP casing hanger. Weight: 1,400 lb. O Can be reworked
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15-1/4" 18-9/16"

67-1/8"

57-13/16"

18-19/32" 14-3/4"

2-26

13-3/8" SG-5XP Casing Hanger

Same features as the standard SG-5 casing hangers except an expanding load ring is incorporated to divert the casing and pressure end loads to the housing. Suspends the 13-3/8" casing string and provides internal left-hand thread running profile and sealing area O Run and test with standard SG running and testing tool O Can be reworked O Weight: 600 lb.
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12-3/8"

25-3/4" Unset 25" Set

18-19/32"

2-27

SG-5XP Plug-Type Test Tool

Used to periodically test the wellhead housing, BOP, and 16" through 7" packoff seals.

18-9/16"

63-1/2"

3"

2-28

Section III Abreviated Running Procedure for a Typical SG-5 Guideline Drilling Program

Abbreviated Running Procedure for a Typical SG-5 Guideline Drilling Program

(Consult your ABB Vetco Gray Service Representative for specific instructions for your particular equipment.)

Install the Temporary Guide Base

If the conductor pipe, conductor housing, and permanent guide base structure are jetted into place, it may not be necessary to use a temporary guide base. 1. 2. Set the temporary guide on the spider beams. Fill the compartments with the appropriate weight material. 3. 4. Install the running tool into the J-slots of the guide base by left-hand rotation. Install guidelines into the four pad eyes of the temporary guide base.

5. Run and land the temporary guide base on the ocean floor.

Temporary Guide Base and Running Tool

3-1

Install the Retrievable Drilling Guide Structure and 30" Wellhead Housing
After the temporary guide base has been landed and the guidelines tensioned, the 36" hole is drilled to accommodate the 30" conductor pipe. The 30" wellhead housing, conductor string, and retrievable drilling guide structure are run as an assembled unit in either pre-drilled or jetting operations.

Run 30" Conductor in Pre-Drilled Hole

1. Assemble the guide structure if necessary and install the guide posts with the lock pins provided. 2. Move the guide structure into the moon pool area and install the guidelines. Make up and run the conductor pipe through the guide structure. Running large O.D. conductor pipe is faster when equipped with Squnch Joint or RapidLockTM RL-4 connectors. 3. Attach the 30" wellhead housing joint to the last intermediate joint of conductor pipe and make up the 30" cam-actuated running tool. 4. Land the 30" wellhead housing in the guide and remove the cam-actuated running tool. 5. Run a drill pipe stringer into the conductor string and make up to the bottom of the running tool. 6. Lower the running tool through the rotary and make up into the conductor wellhead housing. 7. Fill the conductor with seawater through the ports on the running tool. (Replace the bull plugs prior to lowering the housing to the ocean floor.) 8. Run and land the entire assembly (retrievable drilling guide structure, 30" wellhead housing, and running tool) in the temporary guide base on the ocean floor. 9. Circulate the hole and cement the conductor in place. 10. Release the running tool with right-hand rotation and retrieve to the surface. 4. 5. 6.

Jet the 30" Conductor

Where the bottom conditions permit, the 30" conductor can be jetted into place. The temporary guide base is not usually used and the 30 wellhead housing, 30" conductor, retrievable guide structure, and guide lines are run in one operation. 1. Attach the 30" wellhead housing to the last joint of conductor pipe and make up the 30" cam-actuated running tool. (Remove the bull plugs on the 30" cam-actuated tool for jetting returns.) Land the 30" wellhead in the guide structure and remove the cam-actuated running tool. A special jetting tool or bit is spaced out in the 30" conductor so that it is 6" outside to 12" inside the bottom of the open-ended conductor. Make up the last joint of the jetting string to the bottom of the cam-actuated running tool. Lower the running tool through the rotary and make up in the 30" wellhead housing. Lower the 30" conductor to the mudline and begin the jetting operation. Continue jetting until the conductor reaches the desired depth.

2. 3.

3-2

Running the retrievable drilling guide structure, 30" wellhead housing, and 30" conductor string into the temporary guide base and pre-drilled hole.

3-3

Jetting the 30" Conductor

3-4

Drill the 26" Hole with Marine Riser and Hydraulic Latch
After the 30" conductor is run, shallow formations or local government regulations may require drilling the 26" hole with returns to the drilling vessel. When these conditions occur, an ABB Vetco Gray Marine Riser System and Hydraulic Latch are used. 1. Install the hydraulic latch and Flex Joint on the marine riser. 2. Run, stab, and lock the hydraulic latch into the 30" wellhead housing on the ocean floor. (The latch locks into the internal 30" cam-actuated running tool profile.) 3. At the surface, install an ABB Vetco Gray KFDSTM diverter in the Marine Riser System to exhaust any flow encountered. Drill out and condition the 26" hole.

4.

5. When it has been determined there is no abnormal pressure in the well bore, retrieve the hydraulic latch to the surface.

Hydraulic Latch

3-5

Install the High-Pressure Wellhead Housing

1. Install the running tool (cam-actuated or threaded) in the high-pressure wellhead housing. 2. Make up and run the 20" casing using RL-4S casing connectors. 3. With the last joint of 20" casing in the rotary table, make up the high-pressure wellhead housing equipped with a 20" Squnch Joint or RL-4S casing connector. 4. Lower the assembly and land in the 30" wellhead housing using the motion compensator. 5. Pick up approximately 30,000 lb. over the string weight to verify that the high-pressure wellhead is locked to the 30" wellhead housing. Circulate and cement the casing as required. Returns are ported through the 30" wellhead housing and guide structure. Release the running tool from the high-pressure housing with right-hand rotation, and retrieve the running tool to the surface.

6.

7.

High-pressure wellhead housing landed in the 30" wellhead housing.

3-6

Run the BOP Stack with the H-4 Wellhead Connector

The remotely-operated hydraulic H-4 wellhead connector connects the BOP stack to the high-pressure wellhead housing. Pull the seat protector, if run in the wellhead, before testing the BOP stack with the universal plug-type BOP test tool. After a successful BOP stack test, pull the test plug, re-run the seat protector in the wellhead housing using the seat protector/wear busing running and retrieving tool.

BOP stack, landed on the high-pressure wellhead housing, with plug-type test tool installed.

3-7

Prepare the Casing Hanger and Packoff for Installation

Prior to running the next casing string, assemble the casing hanger, universal casing hanger running tool, and the packoff along with the subsea-released cementing plugs. 1. Place the casing hanger in a vertical position, and rotate the packoff onto the casing hanger until the packoff stops. (Remove the lock ring if the hanger will not be locked down.) 2. Back the packoff off until the bottom of the packoff is 2-5/8" from the packoff landing shoulder on the casing hanger. This space is known as the initial standoff. 3. Make up the subsea cementing plugs to the universal casing hanger running tool. 4. Stab the casing hanger running tool into the casing hanger, aligning the tool torque keys with the milled slots on the packoff. NOTE: Measure from the bottom of the centralizer sleeve to the packoff landing shoulder and record the dimension. After make up, check this dimension. With full tool/hanger engagement, this dimension should be 1-1/2 to 1-3/4 less. 5. Make up with chain tongs until snug (approximately 3 to 4 turns to the left). NOTE: As the tool makes up with the casing hanger, it simultaneously backs off the packoff, with the ideal final standoff being 4-1/8" to 4-1/4". This measurement is critical to assure sufficient flowby during circulating and cementing operations. 6. Install a protector on the packoff and set the assembly aside.

Universal Casing Hanger Running Tool, Packoff, and Casing Hanger

3-8

Run the Casing Hanger and Packoff

1. Prior to running each casing string, remove the nominal seal protector or wear bushing with the seat protector/wear bushing running/retrieving tool. 2. Run the casing and make up the casing hanger assembly to the last joint of casing. 3. Run and land the casing hanger assembly with motion compensator set to compensate the running string upon landing in the housing. 4. Circulate and cement according to the drilling program. 5. Rotate the running tool to the right approximately four turns to disengage the running tool from the casing hanger running threads. 6. Continue to rotate approximately 4-1/4 turns to the right until a torque build-up is experienced and the SG-LTR metal-to-metal seal is actuated. 7. With the universal casing hanger running tool still in place in the hanger, test the seal and the BOP stack. 8. After a successful test, retrieve the running tool to the surface.

Step 1
Install the casing hanger tool in the hanger/packoff assembly.

3-9

Step 2
Rotate to the left, fully seating the tool in the hanger and the packoff is in running position.

Step 3
Run and land the hanger in the wellhead.

3-10

Step 4
Hanger and tool landed. Cement returns flowby.

Step 5
Hanger landed, packoff set and tested.

3-11

Run and Retrieve Seat Protector and Wear Bushings

Before drilling out, a wear bushing must be installed in the high-pressure wellhead housing to protect the casing hanger and the remaining seal profiles in the wellhead. Wear bushings are run with the same tool as the nominal seat protector.

Install the Wear Bushing

1. Stab the running tool into the wear bushing. 2. Carefully lower the wear bushing and land on the packoff. 3. Rotate the running string slowly to the right until the pins of the wear bushing drop into the vertical slots of the packoff. 4. Continue rotating to J the wear bushing into the packoff until a torque build up occurs. This action also un-Js the wear bushing from the tool. 5. Maintain this slight right-hand torque and pick up on the string, using the motion compensator to confirm that the wear bushing J-pins are locked into the packoff. 6. Let up on the string and pressure the running string to 800 psi maximum to release the lock ring of the tool from the lock ring groove in the wear bushing. 7. Retrieve the tool back to the surface. All sizes are run in the same manner.

Retrieve the Wear Bushing

1. Lower the running tool into the hole and stab into the wear bushing. 2. Adjust the heave compensator to support the running string weight less 2,000 lb. 3. Rotate the running string to the left to engage the torque pins of the tool with the J-slots of the wear bushing and release the wear bushing pins from the packoff J-slots. 4. Retrieve the tool and wear bushing to the surface.

One tool runs and retrieves the nominal seat protector and wear bushings.

3-12

Retrieve and Reinstall a Packoff Retrieve

1. Lower the packoff retrieval and reinstallation tool into the wellhead and land on top of the packoff using the motion compensator. 2. Rotate the tool to the right to drop the J-pins into the vertical slots of the packoff. Turn an additional 1/8 to engage the spring-loaded torque keys in the packoff vertical slots. 3. Rotate the tool to the left approximately 12 turns to remove the packoff assembly. 4. Retrieve the tool and packoff to the surface. 5. Run the mill and flush tool to clean the seal area.

Reinstall
6. Install a new packoff on the running tool and run into the wellhead. 7. Land the packoff on the casing hanger and rotate the tool two turns to the right. 8. Pull up on the running string to verify that the packoff made up to the casing hanger, slack off and continue rotating 10 turns to the right. 9. When the packoff is torqued to requirements, pressure test. 10. After a successful test, bleed off the test pressure and apply approximately 800 psi to the tool to retract the torque keys. 11. Rotate 1/8 turn to the left until a slight torque build up is noticed and retrieve the tool to the surface.

Packoff Retrieval and Reinstallation Tool

3-13

Corrosion Cap
If a well proves to be of commercial significance, it can be capped until the operator wishes to complete it. The ABB Vetco Gray diverless corrosion cap temporarily protects suspended wells. Run on the seat protector/wear bushing running and retrieving tool, the corrosion cap simply stabs over the wellhead, and automatically locks to the outer H-4 profile on the wellhead housing. A diver-assist corrosion cap can be run on a tugger line and secures to the wellhead by manually installing three bolts. With either corrosion cap in place, a bio-degradable corrosion inhibitor can be pumped into the wellhead displacing seawater and drilling fluid and providing a protective bath for the critical sealing areas of the wellhead. The retrievable drilling guide structure can be retrieved with the corrosion cap in place.

Retrievable drillling guide structure retrieved and corrosion cap installed on a suspended well.

3-14

Section IV Additional Equipment for use with the SG-5/SG-5XP Systems

Additional Equipment for Use With the SG-5/5XP Systems

Hydraulic Latch Assembly
O O

H-4 Wellhead Connector

O O

O-ring on lower body assembly provides a seal between the latch and the 30" wellhead housing. Four hydraulic cylinders move the actuator sleeve downward, radially forcing eight locking dogs out into the 30" cam-actuated running tool profile. Available with either two- or four-arm guide frame fitted with guide cones. Optional flange or mandrel top profile.

Hydraulic cylinders have separate primary and secondary hydraulic ports. Locking dogs encompass 356 contact resulting in uniform distribution of bending and tensile loads over a large area of the wellhead. Indicator rod for visual indication of cam ring position. Stainless steel-lined VX gasket ring groove assures a pressure-type seal. Available with clamp, studded, or flange top connection, in a variety of sizes and pressure ratings.

O O

O O O

4-1

30" Wellhead Housing Running and Drill-Ahead Tool

Used to run the 30" wellhead housing and drill pipe in conditions where the conductor can be jetted in, the tool makes up to the internal cam profile of the 30" wellhead housing. The jetting string extends below the drill-ahead tool and carries the 26" BHA. Once the conductor reaches total depth, the stem of the tool is released by right-hand rotation of the drill pipe. The body of the tool unlocks from the stem and remains in place, centralizing the drill string. The drill pipe continues downward and drilling for the 26" hole can begin. Once the 26" hole reaches TD, the drill pipe is picked up and the stem of the tool rises, retrieving the body of the tool from the 30" wellhead housing to the surface.

18-3/4" BOP Isolation Test Tool

Tests the BOP stack while it is landed in the high-pressure wellhead housing. The tool lands on a wear bushing or casing hanger and seals in the housing bore, isolating the casing hanger packoff assemblies from test pressure.

4-2

Utility Guide Frame

O

Guides equipment between the drilling vessel and the temporary guide base or retrievable drilling guide structure before the marine riser is installed.

Side door center section available with spacers, accommodates both drill collars and drill pipe.

Universal Mill and Flush Tool

Removes junk, cement, formation cuttings or gumbo from the area between the casing hanger and wellhead housing. Internal fluid slots run between the running string bore and the cutting teeth on the bottom of the tool providing a flushing action to remove loosened materials.

4-3

Reinstallable Guide Base

Run and installed subsea on an existing wellhead for reentry or guidance of production/completion equipment.
O O O O

Hydraulic running tool latches the guide base to the external profile of the 30" wellhead housing. Safety lock key on the running tool prevents the tool stem from accidentally becoming unjayed during handling.

Guide Base retrievable Posts retrievable

4-4

Emergency Equipment
The SG-5/5XP emergency sealing system consists of an emergency packoff, a 13-3/8" emergency seal assembly, and a 9-5/8" emergency seal assembly.

Emergency Packoff
Used to seal the casing annulus in the event the primary seal area is unusable. Lands on a casing hanger shoulder above the normal seating position, seats against this shoulder with O-rings and against the wellhead housing with a special SG-type seal. Shorter than the standard packoff assembly, the emergency packoff will not interfere with subsequent casing hangers. Run with the packoff running and retrieving tool.

Emergency Seal Assemblies

If the emergency packoff does not seal or cannot be run, then an emergency seal is used. Threads on the lower O.D. profile engage the casing hanger and the elastomer seals seat between the seal assembly and casing hanger as well as the I.D. of the wellhead housing. Run with the running and retrieving tool.

13-3/8" Emergency Seal Assembly

9-5/8" Emergency Seal Assembly

4-5

Section V Tieback Systems

Tieback Systems
The SG-5/5XP wellhead system is easily adapted for use with a fixed platform or TLP tieback completion system. By using the SG-5/5XP 9-5/8" tieback hanger, the production strings can be tied back to the platform. The standard ABB Vetco Gray tieback system locks and seals the 20", 13-3/8", and 9-5/8" casing strings into the SG-5/5XP wellhead system. The 9-5/8" production string has a full metal-to-metal seal. The initial tieback riser lands on the SG-5/5XP wellhead, makes up without rotation while the funnel adapter of the tieback system accommodates angular misalignment and lateral offset. The wellhead equipment used for tieback systems is standard, except for the last casing hanger installed. This casing hanger contains an internal profile for the SG seal preparation and special tieback threads. The last casing string is threaded into the casing hanger by the internal lockdown sub on the adapter, so the casing strings are not rotated. A modified wear bushing on threaded insert protects the sealing and locking areas.

Surface Wellhead

Wellhead Cellar Deck

20" Ti ebac k 13- 3/ 8" Ti ebac k

9-5/8" Tieback

Subsea Wellhead

5-1

20" Internal-lock Tieback Connector

20" External-lock Tieback Connector

5-2

13-3/8" Tieback Adapter

9-5/8" Tieback Torque Tool

5-3

9-5/8" Tieback Adapter with Metal-to-Metal Seal

9-5/8" Tieback Casing Hanger

5-4

9-5/8" Tieback Wear Bushing

5-5