GE Installation & Commissioning Quick start guide

GE
Brand
GE
Model
Installation & Commissioning
Type
Quick start guide
GE Oil & Gas
Subsea Systems
From floor to shore
Comprehensive subsea systems and expertise for reliable
production, control and optimized life of field
integrated
& intelligent
Oil and gas companies worldwide are facing incredible challenges with
mature recovery rates, complex resource compositions, remote sites, extreme
environments and increasingly rigorous regulations. The ‘easy oil’ may be gone.
But the smartest technologies are here and continually evolving through
GE Oil & Gas – with unmatched global experience and commitment to our
customers’ future.
GE Oil & Gas products have been at the industry forefront for
over 100 years and we continue today as a leading innovator of
technologies for the entire oil and gas industry from production
wellhead to consumer distribution. We have the unique advantage
of utilizing the unmatched shared resources and knowledge
transfer from the entire global GE organization. The results enable
our customers to get continually higher levels of efficiency,
productivity, safety and value from their assets.
Global ideas converge for oil and gas
Our ‘One GE’ philosophy ensures that we explore all possibilities
for our technologies to increase performance and efficiency. GE
Healthcare diagnostics tools have increased pipeline inspection
capabilities and associated asset integrity. GE Aviation’s engine
advances have enabled milestones in LNG production and many
other areas of the oil and gas industry. Some of our oil and gas
turbomachinery technologies have found their way into pioneering
subsea compression modules.
Investing in industry growth
This level of technology transfer is a unique advantage that
leads to exciting discoveries and advances every day. But it’s
no coincidence. We invest significant resources every year to
introduce new products that are based on real customer feedback
and development goals. GE invested $1.1 billion in research and
development between 2010 and 2012, launching around 90 new
technologies in 2012 alone. Our 2013-2015 investment budget has
increased to $1.9 billion.
Managing risk & optimizing performance
Our designs combine field-proven features with our latest
technologies in a way that minimizes uncertainty and boosts
performance at the same time. This evolutionary development
process lets our customers continually improve their operations
safely and efficiently.
GE’s Global Research Centers are dedicated to this objective,
conducting proprietary studies and working extensively with other
leading organizations and institutions worldwide. We also maintain
Centers of Excellence focused on elevating capabilities in each of
our technology groups. For subsea applications, those facilities
include our Subsea Trees COE, remote-monitoring SmartCenter and
Controls COE that are located in the UK, while our COE for subsea
manifolds and connections systems is in Norway.
Company-wide talent & commitment
We select only the most promising and passionate talent from
around the world. To combat the talent gap that’s facing the oil and
gas industry, we’ve designed specialized recruitment and training
programs focused on experienced professionals from other high-
tech and logistically complex industries.
Our training programs are truly global in scope and encourage
creativity and innovation so successfully that they have been used
as benchmarks and models for other organizations. So, it’s really
no surprise that our people have been responsible for many of the
incredible advances seen in the offshore industry over the past 20
years – and they’ll continue to be responsible for many more to come.
Subsea Systems at work
around the world
6,100 employees
Operating in 11 countries across Europe,
Africa, Asia Pacific and the Americas
11 Manufacturing sites
11 Service facilities
Our technologies have been at the
forefront of the subsea industry since
1962, and deepwater since 1994
We mitigate risk and consider the effects on
people, communities and natural environments in
everything we do. EHS is paramount every day, from
the layout of our workshops, all the way through to
the ecomagination program – a global GE initiative
dedicated to delivering products that are better for
both business and the environment.
Every GE Oil & Gas innovation is driven by a specific
and practical industry requirement. We carefully
evolve product designs with proven technologies,
rigorous testing and qualification processes. Our
objective is to continually deliver measurable
increases in efficiency, reliability, availability and
performance.
Our corporate culture is one of “doing it right” and
always striving to do it better, not only by applying the
best processes and technologies, but by conducting
our operations and relationships with the utmost
honesty and integrity no matter what challenges may
arise.
Integrity
Safety
Quality
Case History: Kizomba
Subsea Production Expansion
Kizomba is a deepwater oil development between 150 to 400 km offshore of Angola.
It consists of three sites with a combined estimate of 2.6 billion barrels of oil.
• KizombaA: including the Hungo and Chocalho fields in up to 4,200 ft (1,280 m)
of water; production began in 2004
• KizombaB: including the Kissanje and Dikanza fields in up to 3,400 ft (1,036 m)
of water; production began in 2005
• KizombaC: including the Mondo, Saxi and Batuque fields in up to 2,400 ft (732 m)
of water; production began in 2008
The Kizomba Satellites project began in 2008 with Phase 1 developing Mavacola and
Clochas assets tied back to Kizomba A and B FPSOs through a looped flowline system.
Phase 2 will develop the Mondo South, Bavuca, Kakocha, Saxi and Batuque assets, all
tied into existing subsea infrastructure at Kizomba A, B and C.
We supplied a range of topsides equipment as well as all core subsea production
equipment for 28 new wells in all. First production from Phase 1 came in July 2012.
Primary manufacturing and assembly were based at our Angola facility. The project
was completed with an industry-leading safety record.
Meeting every challenge
in every depth of water
Smarter technology
Longereldlife
Key subsea systems
• 6 manifolds, ~58 km total flowlines, 1 water injection doubler
• Pipe-in-pipe production flowlines (no new risers)
• 3 dynamic umbilicals (43 km total length)
• Multiphase flow meters at each well for resource allocation
• Single-phase flow meters on injection well jumpers
• Step-over modules to mitigate brownfield congestion
• Control, electrical and chemical injection systems
Our global installed base*
1,369 subsea trees
1,098 subsea control systems
141 subsea manifolds
3,652 nkm pipe produced
GE Global
Research Centers
Niskayuna, USA
Oklahoma City, USA
San Ramon, USA
Rio de Janeiro, Brazil
Munich, Germany
Bangalore, India
Shanghai, China
Subsea Systems main
manufacturing facilities
Aberdeen, UK
Batam, Indonesia
Houston, USA
Jandira, Brazil
Jurong, Singapore
Macae, Brazil
Montrose, UK
Nailsea, UK
Newcastle, UK
Niteroi, Brazil
Sandvika, Norway
Subsea Systems
main service sites
Aberdeen, UK
Broussard, USA
Dusavik, Norway
Houston, USA
Jandakot, Australia
Luanda, Angola
Montrose, UK
Nailsea, UK
Niteroi, Brazil
Onne Port, Nigeria
Perth, Australia
* at time of printing; more information available on request
Key subsea systems
• 20 VetcoGray subsea wellhead systems
• 20 double-capacity VetcoGray subsea trees
• Production monitoring and remote control systems
Case History: Gorgon
Greenfield LNG Project
Gorgon contains about 40 trillion cubic feet of gas. It includes the world’s largest
carbon capture and sequestration project and will have an LNG output of 15 million
tons per year. It is the largest single-resource natural gas venture in Australian history
and one of the largest natural gas projects in the world. GE Oil & Gas has been involved
since the beginning, providing expertise and core technologies for both the onshore
and subsea components of this industry milestone effort.
Our Subsea Systems team began designing subsea production, control and
transmission systems for Gorgon in 2008. Total project scope includes subsea
wellhead systems and trees with retrievable choke modules to control and manage
gas production and production monitoring and control systems so the complete
subsea infrastructure can be remotely controlled from Barrow Island. Our trees are built
specifically for Gorgon’s high flow rates – a 7-inch, full-bore design with twice the
capacity of a typical subsea tree.
The project is progressing well. By mid-2013, we completed 19 subsea trees, 16 of
which have been delivered to Australia. The final four trees are due to be shipped
from Aberdeen by the end of summer 2013. Our first two trees were safely installed in
early-2013 with no significant downtime despite a week-long delay caused by a passing
cyclone. They are now in 1,350 m (4,429 ft) of water at the Jansz-Io field about 190 km
from shore - it is one of the deepest subsea installations ever undertaken in Australia.
In keeping with our unique industry-wide, single-source capabilities, GE Oil & Gas is also
supplying the five power generation trains and three main refrigerant compression
trains for Barrow Island’s gas treatment and liquefaction facilities, and the pioneering
CO
2
sequestration system.
Gorgon’s first gas is expected in 2014.
Pushing boundaries
GE Oil & Gas has been pushing the boundaries of offshore
development for over 100 years - pioneering subsea systems since
1962 and deepwater technologies since 1994. Our systems are
operating in every major production basin, delivering unmatched
production uptime and continually increasing efficiency, reliability
and availability in the most challenging fields around the world.
With developments continually moving into deeper water, we
have already amassed extensive operating experience in these
high-pressure high-temperature (HPHT) applications, with unique
expertise in vertical tree systems – which are operating at nearly all
of our deepest water installations in Brazil and West Africa.
But our commitment doesn’t stop at the product level. We invest
significant resources worldwide to increase localized service
capabilities, knowledge transfer, training and employment. Recent
examples include our new $100 million facility in Jandakot,
Australia and our joint venture with GLS Holdings SA, which includes
a new $175 million manufacturing facility in Angola. Investments
like these create hundreds of direct jobs and countless indirect jobs
and sub-contracting opportunities in each region.
Subsea intelligence
As part of the global GE organization, we regularly take advantage
of leading technologies developed in other industries, and major
company-wide initiatives that help increase subsea equipment
capabilities in ways that other OEMs can’t. Across GE’s customer
base, for instance, our goal of improving asset performance
by just 1% can add $20 billion of annual customer profit. To do
this, we are championing evolution of the ‘Industrial Internet’ –
making major investments in software and analytical tools for
field management and optimization solutions that weren’t even
conceivable just a few years ago.
The first new product from this new focus is an underwater remote
monitoring system called Subsea Integrity Management designed
to increase production reliability for deepwater wells with data
from sensors measuring vibration, temperature and leak detection
for well heads, manifolds and production stations. All our latest
subsea trees, manifolds and connection systems are designed with
integrated smart communications and diagnostics technologies, all
supported around the clock with remote monitoring services that
are second to none.
Northern Carnarvon Basin, NW Australia
MANIFOLDS & CONNECTION SYSTEMS
SUBSEA TREES
SUBSEA CONTROLS
Our first subsea tree was installed in 1963 and we
now have close to 1,400 tree systems operating
across every major production basin in the
world.
GE’s subsea tree portfolio covers all applications
from single-well satellites in shallow water,
to large and complex multi-well deepwater
developments – from low-pressure reservoirs
with artificial stimulation or lift, to high-pressure
high-temperature (HPHT) applications. Current
capabilities include depths to 3,000 m (10,000 ft)
and reservoir shut-in conditions of 121ºC (250ºF)
and 1,035 bar (15,000 psi); and we are continually
evolving technologies that enable moves into
even deeper waters and more challenging
environments.
Field-proven designs include a standard core
structure as the foundation for each tree, to which
pre-engineered modular components (e.g. choke,
meter and valve options) are added to deliver the
configuration that best meets specific project
needs.
Our subsea manifolds and connection systems
accommodate a wide range of configuration
needs and service requirements. Their optimized
size and weight provide high versatility for pipelay
vessels and installation scenarios.
With over 20 years of experience in this
product category and more than 100 GE Oil
& Gas manifolds now operating, our portfolio
spans some of the most challenging subsea
developments in the world – including the largest
deepwater fields, demanding large-bore gas
delivery projects, long step-out developments and
critical flow-assurance applications.
Our expertise covers everything from FEED,
detailed design, sourcing and manufacturing to
global installation campaigns and life-of-field
optimization support and maintenance.
Proven solutions for any field configuration
• Cluster manifolds for shallow-water, diver-
assisted operation
• Cluster manifolds for deepwater operation
• Template manifolds in 2, 4, 6 or 8-slot
configurations
• High-integrity pipeline protection system
(HIPPS) manifolds
• Drilling templates for jackup rig operations
• Stand-alone subsea distribution units (SDUs)
for controls and chemical distribution
• Pipeline end manifolds (PLEMs) for pipeline
systems
• Riser base structures for connection and
manifolding of risers
• Stand-alone satellite well structures
• Internal and external inspection loop systems
for round-trip inspection
• Hard-piped and ROV-deployed distribution
systems
• Vertical and horizontal jumper connections
• Header sizes to 36"
• Suction anchor, skirted mud-mat and piled
foundation systems, with active or passive
leveling features
• Integrated and stand-alone protection
structures
S-Series
shallow water
Maximized safety and efficiency
for jackup drilling in depths up
to 100 m (330 ft) and operating
pressures up to 450 bar
(6,500 psi)
M-Series
medium depth
For installation from semi-
submersible drilling rigs in
depths of 100-750 m (330-
2,450 ft), for 690 bar (10,000 psi)
and 1,035 bar (15,000 psi)
applications, with 5", 6" and 7"
production bores standard
D-Series
deepwater solutions
Highly flexible and configurable
for water, gas or alternating
injection subsea tree systems
for up to 1,035 bar (15,000 psi)
and 3,000 m (10,000 ft), and
optimized for flow assurance
(hydrate and erosion prevention)
Reliability in any water depth
With over 30 years of experience in subsea
controls and more than 1,000 VetcoGray
subsea control modules now operating, our
portfolio spans some of the most ambitious and
challenging subsea developments in the world –
including the world’s longest subsea tieback and
some of the largest deepwater fields.
Our products and expertise deliver power and
communications technologies for subsea-to-shore
applications for distances greater than 100 km.
Modular designs provide retrofit flexibility to inject
the advantages of newer technology and extend
the life of mature fields. Our topside-to-subsea
communications maximize bandwidth while
minimizing system costs. The newly developed
intelligent line-insulation monitoring unit ensures
continuous status monitoring of seabed umbilical
electrical cores. System features reduce capital
and installation costs by minimizing the number of
umbilical supply lines needed.
We operate to the highest standards of safety for
people and the environment, employing rigorous
test, audit and review procedures in everything
we do – minimizing risk at all stages and
maintaining greater than 99% system availability
year after year.
VetcoGray ModPod
This series of highly versatile, field-proven,
multiplexed, electro-hydraulic (mux E-H) subsea
control modules is ideal for both tree-mounted
and manifold-mounted applications. ModPod
is one of the most technologically advanced
components available, providing ultra-reliable
control and monitoring of subsea valves and
instrumentation. Its compact and configurable
design satisfies even
the most challenging
and project-specific
requirements.
VetcoGray SemStar5
™
This award-winning, fifth-generation subsea
electronics module draws on over 30 years of
subsea experience. Flexibility is optimized by
an internal Ethernet data bus supporting TCP/
IP with flexible subsea communications options.
Durability is qualified beyond the requirements of
ISO13628 Part 6 2006, and highly accelerated life
testing (HALT) program validates ruggedness and
reliability. Reliability features include single board
computer, minimized internal wiring, simplified
press fit connectors, built-in diagnostics for each
functional circuit board, and redundant internal
power and communication busses. SemStar5
offers backwards compatibility for legacy subsea
electronics modules and built-in obsolescence
management strategies for electronic
components. Its interfaces meet and exceed
industry standard SIIS (Levels 1, 2 and 3) and IWIS.
POWER & PROCESSING
WELLSTREAM FLEXIBLE PIPE
WELLHEAD & TUBULAR SYSTEMS
We offer much more than a collection of individually
proven subsea products. GE’s Power Conversion
business provides a complete electrification offering
for the oil and gas sector. Our flexible, fully integrated
systems optimize overall field performance in the
most extreme conditions – delivering mission-critical
safety, efficiency and reliability in subsea power
transmission and electrical distribution, processing,
separation and boosting. And we are continually
expanding capabilities for longer step-outs, deeper
fields, more boost, more challenging fluids and
higher performance.
Our expertise is based on significant R&D
investment, extensive testing, close collaboration
with customers and unparalleled in-field
experience – including installations like the
pioneering Troll C subsea separation and boosting
station that has processed hundreds of thousands
of barrels since we delivered it in 1999.
Subsea developers rely on our broad range of
expert support services, including design and
engineering, construction and testing, calculations
and analysis, in-field production monitoring,
erosion modeling, thermal analysis and
operations training based on best practices and
our engineering experience at some of the most
challenging deepwater fields around the world.
Riser, flowlines, fluid transfer lines and jumpers
are critical to offshore oil and gas production
systems. They are subject to extreme
temperatures, pressures, physical stresses and
corrosive materials - yet must still ensure reliable
connections and optimal product flow.
Our portfolio draws on more than 20 years of
research and development, material science and
installation experience in some of the harshest
conditions the industry has to offer - particularly
where water depth and seabed conditions impose
unusual restrictions.
Our products are robust, highly flexible and
adaptable to unique project requirements, offering
proven reliability in highly corrosive conditions.
Every Wellstream product is customized to meet
the specific requirements of each project.
Blue-C
™
subsea compressor
Blue-C is the first subsea gas compression solution,
piloted in 900 m (3,000 ft) of water at the massive
Ormen Lange natural gas field after years of
rigorous staged testing and refinement. Designed
for years of continuous, maintenance-free subsea
operation, the module includes a proven ICL
centrifugal compressor driven by a gas-filled,
high-speed electric motor, stacked in a vertical
orientation and packaged in a single-sealed
housing designed to withstand the surrounding
hydrostatic pressure. The entire unit is NACE
compliant.
An established portfolio
Risers - dynamic lines suspended in the water
column connecting production facilities to subsea
infrastructure
Flowlines - static pipelines used to carry fluids on
the seabed
Fluidtransferlines - typically large diameter
pipelines connecting two structures which are
often dynamic
Jumpers- short lengths of pipe connecting two
fixed structures either above or below water
Integrity management
Utilizing a wide range of monitoring technologies,
including the specialized magnetic technology
developed by MAPS Technology Limited, we deliver
a detailed description of the service history, future
performance and remaining service life of flexible
pipeline structures.
Keybenets
• Reduced operational, safety and
environmental risk
• Enhanced asset life and production availability
• Reduced costs through predictive maintenance
• Extension of service life by preventing
premature retirement of assets as a result of
conservative fatigue assessments
• Ability to retrofit inspection and monitoring
systems to existing risers and flowlines without
compromising integrity
• Possibility of re-using existing pipe at
different locations
Subsea Wellhead Systems
Our subsea wellhead systems provide
mission-critical reliability as operators
push past the boundaries of 10,000-ft
waters, 30,000-ft wells and all the
extreme pressures, temperatures and
risks that go with the territory.
With more than 40 years of in-field
experience we now have over 1,000
systems installed worldwide including
our MS-700, the most widely used
subsea wellhead in the world; our
MS-800 FullBore system for enhanced
structural support in the most extreme
deepwater applications; and our
SlimBore systems with many drill-
through scenarios for improved
completion cycles and use with older,
lower-capacity rigs.
Key features of the MS-800 FullBore
wellhead system include:
• 8 million lbs of load capacity rating
• 2 million lbs of casing hanger running
tool capacity
• High-capacity 16" below-mudline
system with MS sealing
• 515 bar (7,500 psi) annulus sealing
capability
• VX2/VT2 gasket profile: 1,035 bar
(15,000 psi) rating @ 121ºC (250ºF)
(VX2 is PSL4 gas qualified)
• Dual metal-to-metal gasket sealing
• Optional 1.5 MM lbs lockdown
capacity
Specialty Connectors & Pipe
GE’s portfolio of VetcoGray specialty
connectors and pipe is used around the world
for a complete range of fixed and floating
applications. We offer both threaded and
snap connectors. All are precision connection
systems that simplify make-up of large
diameter casing to save valuable rig time.
They are relied upon for challenging drilling
projects including highly deviated wells, gas
wells and high current environments with
fatigue loadings.
Floating Production Systems
We provide a full range of VetcoGray drilling and production
systems for Spar and TLP applications in water depths of
3,000 m (10,000 ft) and beyond. Our advanced designs and
materials withstand extreme pressures, torque and other
mechanical stresses in order to ensure strong seals and
resistance to highly corrosive product mixtures.
Our portfolio includes:
• Adjustable drilling riser (ADR) hanger system
• Drilling riser joints and couplings
• Internal drilling riser tiebacks
• Riser tensioner systems
• Tendon connectors and handling equipment
SERVICE & SUPPORT
SmartCenter support
The GE Oil & Gas SmartCenter is a remote access hub
with secure internet connections to subsea control
systems installed in customers’ production fields around
the world. The facility combines advanced technologies
with concentrated expertise to provide a unique range
of remote support and services for every stage of field
development – from installation and commissioning,
through field startup and onward to routine operational
support, condition monitoring, diagnostics and
production optimization. The remote connectivity also
establishes a platform for easy integration of future
value-added services and technology enhancements.
Key features
• Commissioning and installation backup
• Real-time operator support
• Off-line scenario emulation
• Subsea control facility health
• Obsolescence management
In addition to designing and installing some of the most
advanced technologies in the global oil and gas industry,
we also provide comprehensive planning and lifecycle
support to maximize asset value for decades to come.
24/7 CUSTOMER SERVICE
Installation & Commissioning
We provide the highest level of OEM expertise at this critical stage of the
operation – from engineering setup of core equipment and peripheral
systems to final testing and handover. By integrating customer technical
and operating personnel in all parts of the process, we maximize knowledge
transfer and ensure the most safe and efficient path to production.
• Field Service Engineers
• Technical support
• Remote SmartCenter
• Equipment and tooling rental
• Customer training
Operations & Maintenance
This broad category includes all routine activities required to support our
customers’ usual operating needs. Our service approach ensures safe
maintenance with scheduling to minimize operational disruptions. All repairs,
overhauls and refurbishments adhere fully to our rigorous OEM standards.
• Storage, logistics, and equipment management
• Equipment and tooling rental
• Spares and third-party procurement
• Repair, refurbishment and maintenance
• Remote SmartCenter controls support
Intervention & Enhancement
We can perform any major activity that may be needed during the life of
the field to significantly improve operational/maintenance performance.
Our specialists can enhance oil and gas recovery from existing operations,
optimize production uptime through improved maintenance capabilities, inject
various new technologies for equipment performance upgrades, and improve
sustainability through proactive obsolescence management strategies.
• Field service engineers
• Brownfield upgrade solutions
• Technical support hub
• Controls support hub
• Equipment and tooling rental
Life of Field Management
Every aspect of the field-management mix becomes more complex over
time – so equipment capabilities must be adapted accordingly to ensure
long-term well productivity. We support all stages of field life with a
proactive approach to maintenance, continuous improvement through the
injection of new technologies, and highly flexible service schedules and
upgrade options. We can provide a dedicated GE Oil & Gas Life of Field
Manager, offer specialized training for customer teams, and have a variety
of contractual/operational models to choose from.
• SmartCenter remote support
• Service Centers
• Storage, logistics and equipment management
• Technical support
• Customer training
Flow assurance & production optimization
The ability to match installed operational capability with off-line
SmartCenter analysis provides opportunities for improved production flow
and enhanced recoveries.
Remote monitoring & diagnostics
• Comprehensive condition-based maintenance and operations capability
can be realized by the application of our full remote monitoring and
diagnostics systems
• Monitoring of controls and other subsea systems to assure production
flows by informed maintenance advisories
• Ability to back up operators with trend-based monitoring off-line and
to provide advisories for detection of gradual degradation of offshore
equipment
• Ability to provide predictive maintenance advisories to shift the balance of
maintenance activities and interventions from unscheduled to scheduled
• Predictive fault detection (prognostics) to enable alternative operating
strategies thus maintaining production flows in a controlled manner
subseaservices.[email protected]
GE Oil & Gas
GlobalHeadquarters
Via Felice Matteucci, 2
50127 Florence, Italy
T +39 055 423 211
F +39 055 423 2800
customer[email protected]
Nuovo Pignone S.p.A.
Nuovo Pignone S.r.l.
SubseaSystemsHeadquarters&
SubseaTreesCenterofExcellence
Silverburn House, Claymore Drive
Aberdeen AB23 8GD, UK
T +44 1224 852 000
F + 44 1224 852 434
Vetco Gray UK Ltd.
For complete contact information,
please refer to our website.
geoilandgas.com
The information contained herein is general in nature
and is not intended for specific construction, installation
or application purposes. GE reserves the right to make
changes in specifications or add improvements at any
time without notice or obligation.
GE, the GE Monogram, and imagination at work are
registered trademarks of the General Electric Company.
©2013 General Electric Company
All Rights Reserved
GE_Subsea_Systems_Overview_brochure_A4-071713
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GE imagination at work
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GE Installation & Commissioning Quick start guide

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Quick start guide
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