OTC 5402

Gullfaks A Subsea Wells System Development,

Production Startup
by O. Inderberg

and T.W.

Knudsen,

Completion,

and

Statoil

I
Copyright 1987 Offshore Technology Conference
This paper was presented at the 19th Annual OTC in Houston,Texas, April27-30, 1987. The material iS subject to correctionby the author. permission
to COPY is restricted to an abstract of not more than 300 words.

GULLFAKS

ABSTRACT

This paper deals with the Gullfaks

Production

Systems:

Philosophy,

A Subsea

development

plan, technical

and functional

and Statoils

to date in the
including start up. The

various
wells

are connected

form, which

is a PDQ

and Living
operation

objectives

,a~n

Quarters)

Develop

to the Gullfaks

(processing, Dri~lin9
Subsea
Platform.

Accelerate
economic

field is situated

reservoirs

drilling

are heavily

fault through

Recoverable

reserves

are assumed

showed

the whole

Sm3

field.

production
returns.

has changed

_*r_

-tl-

for

from:

1984 : 5 PRODUCERS
1985 : 3 PRODUCERS &
1 WATER INJECTOR
1986

changes

: 4 PRODUCERS &
.
1 WATER INJECTOR

are due to increased

from the drilling

to

and experience

field developments.

STATUS AT FEBRUARY
-V~APRIL

These

depth

and improve

(812x109 SCF) o~

gas.

The water

wells.

that the

of the Gullfaks field

to be 210xI06 Sm3 (1,320x106

Bbls) of oil and 23X109

the effi-

Ihe scope of the subsea part of the GullfakS

faulted with a main

north-south

are:

140 km from

(Figure No. 1) .

A Project
The field appraisal

outside

reservoirs

Gain information

mainland

subsea

Figure No. 2.

A plat-

future

the Norwegian

for incorporating

cient reach of the platform

FIELD

The Gullfaks

PLAN

descriptions

were accomplished.

THE GULLFAKS

DEVELOPMENT

ells as part of the field development

experience

phases,

A SUBSEA

at the field varies

from 13(

new reservoir

knowledg

of the subsea wells

and

simulations.

220 meters.
The subsea wells
non-TFL
wireline

Illustrations

are of a wet satellite

(non-thru-flowline)

typ

; However~

serviceable.

at end of paper
389

...==~=

.-. = ..=.=____ ..= _=. ...=

-_
.

I
he same Christmas

production and water

.s connected

Flexible flowline,

with

a hydraulic

Prior to start of drilling

a separate

umbilical

111 tools required

to be diverless,

for installation

and

vorkover are non-diver

guideposts

i.e.

and

assisted.

life of the subsea production

;Ystem is 10
?he plan
md

start-up

installation

of the Gullfaks

WS-11 weight

system is used in the subsea

A 5-string

casing programme

is used,

30, 20, 16, 13 3/8 and 10

3/4 casing

strings.

A subsea
The tubing hanger

;ystems are shown in Figure

the protective

An 18 3/4, 10,000 psi CAMERON

comprising

for the development,

to the four main

roof.

wells.

years.

guidelines

and retrieves

set wellhead
?he design

the

roof is removed by a guideline

In a single run, the
establishment tool.

umbilical.

is designed

operations,

protective

tool establishes
!he system

Hanger

& Tubing

Each well

injection.

to the platform

m electrical

I Wellhead

tree is used both for

No. 3.

hanger

system allows

to be run, orientated,

the tubing

tested

and

locked in one trip.

;ATELLITE SYSTEM

?he main components

me

of the satellite

shown in Figure No. 4.

system

They consist

of:

Christmas

The Christmas
contains

protective

structure

Christmas

tree System

satellite

control

workover
tools

installation

The Gullfaks

module

system

allowing

Tree System

tree System

Christmas

tree

Christmas

tree cap

Christmas

tree and tree cap running

tool .

and workover.

A satellite

system

is a new

The Christmas

a single

tree valve block

I
The guide

frame provides

protection

The valves

for the

are fitted

for

Structure
ROV override
supported

The protective

structure

type structure

allowing

been designed

to deflect

through

ROV access.

loads.

roof is fitted to the structure

by the frame work.

The Christmas

to absorb
A removable

the Christmas

tree running

is shown in Figure

the Christmas

tree a

tree cap.

No. 5.

Satellite

Control Module

This unit

(Figure No. 4) contains

components
protection

either

tool is used to

to provide

protection.

The structure

shaft

It has

fishing gear, with

and is piled

100 tons anchor dragging

an extension

is an open frame

run or retrieve
a high probability,

Additional

is forged as

block.

valve operators.

overhead

the following:

for diverless

development

Protective

(Figure No. 4)

is installed

subsea.

in the

the bottom

pull in areas after pull in and connection.

of the control

All hydraulic

system

all activ
installed

connections

of the satellite

control

are via
module

I
aYu

SCM) .

The electrical

,nductive couplers

connectors

There is a dedicated

are via

on the outboard

uninterruptible

s:upply (UPS) incorporated

side of

einsure the capability

.he SCM.

elown sequence
Iorkover Control

This system
:un/rekrieve

and operate

system

is designed

the following

mmultiplexed electro/hydraulic

Tubing

control

s;ystern.

tree and tree cap

hanger

pull-in

and connecting

!he complete

tools

subsea control

;ystem is contained
T?he control

of Christmas

transferred

tree valves

from the Gullfaks

:he workover
~ell.

to

c>perate from either a discrete piloted

}
,lydraulic
signal system or from a

;omponents:

Christmas

shut

power.

1
?he subsea control

(Figure No~ 6) s Seal 0

of a controlled

to

in the event of loss of

E)rimary platform

System

power

in the system

A platform

rig during workover

This is achieved

Lree cap and rerunning

:ontrol module

are

within

and monitoring
the satellite

(SCM) , which

is retrievable

Zrom the surface.

to

of the

after removal
the Christmas

of thf

Fhe subsea control

system utilizes

?iscosity water-based

tree

~uicker response

cunning tool.

hydraulic

a 10W

fluid for

times over oil-based

fluids.
Pull-in

and Connection

System
The fluid in the hydraulic

Each satellite
pulled

well has three lines to be

in and connected

umbilical

(Flowline,

and electrical

FLOWLINES

umbilical).

and connection tools are shown

on Figure No. 4. The tools are run on dril

AND UMBILICALS

The reservoir

fluid composition

consolidation

of the oil producing

justify

pipe.

a single

flexible

provides

control

system

pressure,

temperature

hydrocarbon leakage monitoring

and control

the satellite

during

start-up,

failsafe

production

valves

All computer

Manual

instructions

are performed

subsea master

operation

directed

within

of the flexible

possibilities.
pipe have been

with new ones each time a test

The
program is exercised.

from the test/

determine

and

the main

inspection

will

the length of recertification

for the flowline.

from the

control

of the control

from the well control

the platform

commands,

room of the platform

dedicated

on the platform above the termina

The test spools will
tion of the J-tubes.

result

control

of 4,000 psi.

has been to provide

and inspection

operations.

monitoring

sands
The

installed

be replaced

and shut down

concept.

inspection/testing

Test spools

and

and

chosen have an ID of 6

rating

difficulty

relevant

(Figure No. 7)

flowline

flowlines

and a pressure

SYSTEM

special
The subsea

lines car

hydrauli~

The pull-in

SUBSEA CONTROL

control

be displaced.

station.
system

is

modules

on

The umbilicals
cables/hose

deck.
391

are standard

bundles.

flexible

tin

igure No. 8 shows how congested

asily

can become

with anchors

!Iowlines and umbilicals

.renching or overlay

A prerequisite
definition

over

The protection

lowlines, etc.

the seabed

for the above

is a clear

of scope and requirements.

of the

is achieved

and Fabrication

Engineering

by

with mattresses.
The subsea production
the Gullfaks

ROJECT EXECUTION

contracts
!he overall

system was added to

A Project in early 1984. Main

project

execution

are:

A main contractor

was chosen

testing.

and fabrication
Testing

integration

Drilling

and Completion

based control

Offshore

Construction

subsea equipment

were assembled
testing

execution.

Integration

Testinq

development

The purpose

of integration

High complexity

Strong

The total platform

prepare

of equipment

with respect

ko certain

requirements

equipment,

for efficient

on reliability

Several

highly desirable

offshore

installation

operations.

and
Make

during

is to

and personnel

by:

safety.
simultaneous

testing

procedures

and safe offshore

This is achieved

properties.

operations

early June

started.

have been highlighted

factors

reservoir

engineering,

system and the first set of

1985, and integration

Uncertainties

and the first phase of the

Integration

Prototype

to be

for detail

Engineering

in the project

1984.

responsible
fabrication

Phe following

in April

plan is shown

The main activities

.n Figure No. 3.

were established

adjustments

easily

and

proven
while

necessary

or

the equipment

i~

accessible.

completion.
A thorough
equipment
through

debugging/verification
and offshore

an extensive

Gain experience

of

diverless

procedures

Integration

in running

operation

tools for

on TV control.

Test
Test the installation

(.IT)program.

and operating

procedures.
Important
project

factors

execution

to ensure

an efficient
Added

are:

safety

system prior
Definition

Technology

in-house

and verifiec

to going offshore.

of field data

Authorities

Systems

in a debugged

Train personnel

requirements
status/development

for project

control

The integration

both

four phases

and for contractors

Clear contract

plan/strategy

Activity

at required

plans

(Note: early planning

Verification

of design

original

plan was for one year duration.

This was extended

levels

of offshore

testing was divided into

The
over a year.

lasting

work)

by analysisand

due to late delivery

the last Christmas

debugging
testing

test

392

of

tree and the extent of

The integration
found necessary.

phases were:

integration

system

test of the control

rilling,

Completion

and Commissioning

system and first set of subsea

Irilling and completion

equipment.

ithout interfering
Deep water
tested

}latform tow-out

Main components

test.

hanger,

the integral

the workover

workover

control

with the Gullfaks

installation

:ompletion comprises

in this phase were tubing

riser and

was performed
A

in 1986.

of the following

<Activities:

system.
Well completion

Shallow water
and running

test of Christmas

tools together

and connection

Pull-in

tree

and connection

tools.

Land integration

control

test of all subsea

excluding

the platform

system equipment.

The last three integration

performed

and

umbilicals

with pull-in

rhis work was performed

equipment,

of flowline

test phases were

livers.

It clearly

without

supported

the use of

the necessity

>f an integration
iiverless

test in order to achieve

The
performance offshore.

~iverless

operations

proved

to be very

efficient.

by Statoil.
Commissioning

[sin experiences

gained

in the test phases

rere:

of the wells was done as part

of a verification of the connection

A close communication between
operations.
the rig over the well

Lack of verification
phase caused
debugging

in the engineering<

a higher

amount

of

necessary

and the platform is

A clear definition
in this phase.

of organizational
have cleared

than anticipated.

interfaces

before

is essential

starting

to

such

operations.
Lack of proper

configuration

both with respect

documentation

to hardware

caused

control
and

Offshore

Construction

extra work.
In addition

The testing was necessary

place TV cameras

in order to

properly

tools and develop

proper

on diverless

offshore

to the completion

installation

was organized

proved

necessary

develop

all operational

marking.
Fabrication

in order to

of the integration

was achieved.

Structures
and

and Protection

of

and Umbilicals.

test did

not cause any delay on the offshore

This is due to the
completion program.
fact, that a decoupling

of Protective
of Flowlines,

Installation

requirements.

Flowlines
The extension

of subsea equipment

in two contracts:

Installation
Testing

program,

of these activities

Installation

of Protective

Structures was
This installation

done in JulylAugust

1985.

was diver assisted,

but could easily

been a diverless

1
393

operation.

have

Phe laying and trenching

of flowline

.unbilicals was done simultaneously

lse of a combined

These problems

and

It is important

brought

to be

~perations

secondary

so as to have flexibility if
The capability
occur.
simultaneous

operations

temperature

the subsea Christmas

is

conditions
Production

sensor

normal

December

approximately

7 months

before

The extensive

testing

programs

proved

indicated

a temperature

and offshore

SUMNARY

gained,

during

commis-

alarms,

seepages

did not disturb

the production

start-up

or have they been a problem

swamp gas

by pressurizing

to open the

the flowline

and to shear a pump-open

This plug was installed
plug in the tubing.
safety barrier

during

tubing,

of a subsea production

was brought

on from each of three

24 hours

up to mud burners

for removal

Configuration

control

documentation

is a strict requirement

for approximately

allow them to heat up before

into the production

that the equipment

installed

correctly.

testing

and

execution

plan.

6 hours,

evaluations

plan is based on reservoir

which changes

as the geologists

to

receive

The subsea concept

they were

flexible

start-up

were:

planning

in the process

started

train
indication

is a usefull

part of the total project

enough

and improves
new data.

plans must be

to incorporate

this.

work required

careful

at an early stage to ensure

flexibility.

2)

train.

initial

skimming/carry-over

and

is

necessary

Subsea offshore

1)

of equipment

to ensure

The drilling

in the flcwline and

The wells were flowed
respectively.

during

management

after each had

and diesel

Some problems

for

prior to deployment,

good project

Integration

to the burners

turned

Development

temporary

abandonment.

of glycol

for the

OF EXPERIENCE

require

subsea tree valves

been cleaned

systems.
on production

subsea wells within

have matched

system, with high requirements

for

Each subsea well was brought

Production

The

choke.

flowline.

verification

to date.

as an extra

profiles

far

as the

sioning with hydrocarbon

operations

buriedjinsulated

training

smoothly.

Due to the experience

temperature

very well with design criteria

scheduled.

to be very valuable,

start-up went very

measured

22, 1986,

at

flowing

below that read at the platform

First oil was produced

located

(12,000 BPD) , the subsea wellhead

temperature

Start-Up

tree has not performed

During

satisfactorily.

required.

in the multiplex

control mode.

The hydraulic

incidents

of handling

on production

gas flow in

All wells were

the lst stage separator.

ible to plan these and other offshoxe

unforeseen

solved after the first

day, and were due to restricted

by the

laying and mechanical

trenching machine.

were

plan,
of slug flow in the flowlin e

to develop

including

activities,

394

Gullfaks

A Project

a marine

all offshore

in October

1983.

interface

,cKNoWLEDG~NT

!he authors would

Appreciation
md

like to express

their

to the management of Statoil

in the Gullfaks Field

the other partners

Eor allowing

this paper to be presented,

so

that others who have an interest in this

subject, maY avoid some of the problems that
have been observed.

Fig.lGullfaks
field
location.

.
.
e
.
<
.

El
N

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r

<

s . _ .___ _ _

o
z

I i

II

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I;ri

_*,

i?

396

..?

i..-

Fig. 6Workover

control system.
Fig, 7subse*

Fig, 8- flowllne/anchor

397

pattern.

cOntrol system.