D l t & Q lifi ti fDevelopment & Qualification of an 8” Insert Retrievable Subsea Choke for a Large Bore Gas Project in AustraliaLarge Bore Gas Project in Australia

David R Simpson CEngSubsea Product Manager

Large Bore Subsea Choke :Large Bore Subsea Choke : -- Insert Retrievable / Non RetrievableInsert Retrievable / Non RetrievableLarge Bore Subsea Choke : Large Bore Subsea Choke : Insert Retrievable / Non Retrievable Insert Retrievable / Non Retrievable

• The subsea Choke is the primary control/wearing element of the SPS

• Choke options include : - Non retrievable Chokes on Flow Control Module (FCM)• Field Proven 8” nominal Non Retrievable CC80 FNR• 7,500psi MWP, Max Cv= 1,000 • 66 off units supplied since 2004

- Insert Retrievable Chokes• No 8” nominal Insert retrievable choke existed

• FCM add weight and complexity including :FCM add weight and complexity including : - Smaller bore pipe work - Additional bends- Fabrication delaysy

• Routine choke trim change out becomes more complex and costly with a FCMCameron CC80FNR

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Subsea Choke & Alternative LocationsSubsea Choke & Alternative LocationsSubsea Choke & Alternative Locations Subsea Choke & Alternative Locations

• Moving the choke off the tree and onto a manifold, for example, allows more real estate for larger bore pipe work, therefore reducing erosion risk

• Reduces tree weight and size, with associated installation cost savings

• Large bore insert retrievable choke, remove the need for a FCM & further simplify the pipe work and manifold configuration

VV VVSubsea X-Mass Tree

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Chevron Wheatstone CC80SRChevron Wheatstone CC80SR

• During early FEED stage of the Chevron Wheatstone Project, the choke was moved off the tree

Chevron Wheatstone CC80SR Chevron Wheatstone CC80SR

and onto the manifold to evaluate perceived tree size, weight and complexity advantages

• The movement of the choke onto the manifold was conditional on a large bore insert retrievable choke being availablechoke being available

• Cameron Flow Control’s New Product Development group responded to the technology gap and worked to design & qualify the CC80SR an 8” nominal insert retrievable choke

• Timeline for detailed engineering, prototype build & qualification was just 10 months

• Developments run through the Design for Six Sigma DMADV stage gate process

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CC80SR CC80SR –– Concept Development Concept Development p pp p• Combine the Field Proven 8” nominal CC80 non retrievable choke

• With a 12” 5k Cameron Vertical Connector (CVC) which is also extensively field proven

• Equals 8” nominal Subsea Insert retrievable Choke

• Max Cv =1,000

Press re Rating 7 500psi• Pressure Rating 7,500psi

• Intervention via Standard CVC R/T

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8” CC80FNR1,000 Cv

8” CC80SR1,000 Cv

Cameron Vertical ConnectorCameron Vertical Connector

Collet type Flowline tie-in Connection System • Trees• Manifolds• Templates• CVC Connector & Gasket Field proven in over 1,000 p ,

applications

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Cameron CC80SR SpecificationCameron CC80SR SpecificationCameron CC80SR SpecificationCameron CC80SR Specification

• 8” Nominal Size Insert Retrievable Subsea Choke

• CVC Collet Type Insert Connector

• Cv up to 1,000p ,

• Max WP 7,500psi

• Water Depth 1 500m• Water Depth 1,500m

• Intervention via Cameron Field Proven 12” 5k CVC R/T

• SLCA Hydraulic Stepping Actuator

• Plug & Cage Trim with Impact Protection

• End Connections : 7 1/16” API 10k

• Weight 3,300kg

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g g

• Height 73” (1.85m), OD 36” (0.76m), R/T OD 48” (1.2m)

CC80SR Insert & BodyCC80SR Insert & BodyCh k

R/T Bumper

CC80SR Insert & BodyCC80SR Insert & BodyInsert to Body Seal Pocket

ChokeActuator

pFrame

Hydraulic & Electrical Connectors

CVCConnector W/ SAX Gasket

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Gasket

Choke InsertChoke Insert

Choke BodyChoke Body

Detailed EngineeringDetailed EngineeringDetailed EngineeringDetailed Engineering

Included :-

• FEA connector analysis

R/T Bumper Structure

FEA connector analysis

• Bumper structure for CVC R/T alignment

• Stab Plate with Hydraulic & electrical connectorsy

Stab Plate

Running ToolRunning Tool Guide/Location Skirt

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Intervention via Cameron 12” 5k CVC R/TIntervention via Cameron 12” 5k CVC R/TIntervention via Cameron 12 5k CVC R/T Intervention via Cameron 12 5k CVC R/T

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CC80SRCC80SR Prototype ManufacturePrototype ManufactureCC80SR CC80SR -- Prototype ManufacturePrototype Manufacture

• Body Machining & Welding• CVC Connector Hub F/M• SAX Gasket• Connector Fingers machined f i i t b i tforging, prior to being cut

CC80SR Body Assembly during welding

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CVC Connector Hub Finished MachinedCVC Connector Fingers Machined Forging SAX Connector Gasket

CC80SR CC80SR -- Prototype AssemblyPrototype Assembly

At Cameron’s Subsea Choke CentreAt Cameron s Subsea Choke Centre Of Excellence In Longford Ireland

CC80SR Body showing Seal pocket & Stab PlateCC80SR Body showing Seal pocket & Stab Plate

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CC80SR Insert during Assembly CC80SR Body Finished Assembly

CC80SRCC80SR –– Qualification ProgramQualification ProgramCC80SR CC80SR Qualification ProgramQualification Program

• CC80 Choke & Actuator Field Proven & Qualified

CC80SR Choke Qualification Tests

• CVC Connector & Gasket Field Proven & Qualified

FAT testing to API 17D• Stab in / Connector Set test with CVC R/T• Hydrostatic shell test 11,250psi• Nitrogen Gas Test 7,500psi

CVC Running Tool Interface testing

R/T 3 Degree off vertical plus ±15o Rotational miss-alignment test in all plains

Multiple Stab-in tests

ISO 10423 / API 6A - Annex F PR2• 7,500 psi MWP• -35°C to 145°C

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ISO 13628-4, API17D ValidationCC80SR Finished Prototype

CC80SR Qualification TestingCC80SR Qualification TestingCC80SR Qualification TestingCC80SR Qualification Testing

• R/T Interface Testing• R/T miss-alignment Testing

• Hydrotest shell Test• WP Gas Test R/T miss alignment Testing

HYDRO TEST SET-UP

GAS TEST R/T MISS-ALIGNMENT TEST R/T INTERFACE TEST

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

CC80SR Choke in Environmental Chamber

CC80SRCC80SR Completes QualificationCompletes QualificationCC80SR CC80SR –– Completes QualificationCompletes QualificationThe largest qualified insert retrievable production choke in the industry The largest qualified insert retrievable production choke in the industry

“From VOC to qualified product in just 10 months”

• Close Cooperation with Chevron once Technology Gap was identifiedGap was identified

• Combining field proven elements minimises the design and qualification risk

• Cross divisional collaboration between Cameron’s CVC connector and Choke Groups allowed for a compressed prototype build & qualification time linecompressed prototype build & qualification time line

• Now entering the project execution phase with the first of the production units expected for delivery to the Wheatstone Project Q4 2012

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5th April 2011

Contact informationContact information

David R Simpson CEng.p gSubsea Product Manager

Cameron Ireland Ltd.David.Simpson@c-a-m.com

+353 43 3350636

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