SPE 30343
Design, Preparation, and Operational Aspects of the Society of Petroleum Engineers
First Horizontal Subsea Trees Installed from a Jack-Up
R A Ferguson, SPE and D R Stewart, SPE, BHP Petroleum Ltd, B Holland, SPE, Holland OCS
and A Thompson, Cooper Oil Tool
Copyright 1995. Society of Petroleum Engineers. Inc.
This paper was prepared tor presentallon at the Offshore Europe Conference in Aberdeen,
5-8 September 1995.
This paper was selecied for presentation by an SPE Program Comm~neefollowing review of
information contained in an abstract submined by the author@).Contents of the paper, as
presented, have not been reviewed by the Soc~etyof Petroleum Engineers and are subject to
correction by theauthor@). The material, as presented, does not necessardy reflect any position
of the Society of Petroleum Engineers, its officers or members. Papers presented at SPE
meetings are subjed to publicat~onreview by Editorla1Comminees of the Soc~etyof Petroleum
Engineers. Permtssion to copy IS restricted to an abstract of not more than 300 words.
Illustrations may not be copied. The abstract should contain conspicuous acknowledgment of
where and by whom the paper IS presented. Wrlte Librarian, SPE, P. 0.Box 833836, R~chardson,
TX 75083-3836, U.S.A.,fax 01-214-952-9435.
Introduction
The Johnston Gas Field lies in blocks 43126a and 43/27 of
the UK sector of the Southern North Sea, 11 km to the
Northeast of the Ravenspurn North production platform
(Figure 1). The water depth at this location is
approximately 145 feet. The field was discovered in April
1990 by the 43127-1 well and successfully appraised in July
1991, by the 43126a-8 well.
The field (Figure 2) is formed by a structural trap
bounded to the Southwest by a NW-SE trending fault and
by structural dip to the north and east. The reservoir itself
comprises Permian Lower Leman sandstone exhibiting
excellent porosity and permeability characteristics.
Recoverable reserves are estimated to be in the range of 155
to 195 BCF. The gas sales contract requires a DCQ of 53
MMSCFD for a six year plateau, with a peak rate of 90
MMSCFD. Two wells located near the crest of the
structure satisfy the production contract requirements,
however a third well may be required in the thrd year of
production. The overall field life is expected to be 13 years.
This paper describes the selection, design and
installation, in this field, of the first horizontal subsea trees
to be installed from a jack-up.
Development Plan
Two primary development options were considered for
developing the Johnston Field; a "not-normally manned"
satellite platform or a subsea installation, both of which
would be tied back to the Ravenspurn North processing
facilities. Evaluation of both these options concluded that
the subsea installation was preferred, due to shorter lead
time for fabrication and lower initial capital expendture.
The Johnston subsea structure contains a three slot
drilling template, a protection frame incorporating a spare
11
fourth slot, production and methanol injection manifolds,
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and the subsea control equipment. The template and
protection frame were designed to be installed either
sequentially or in one piece, the choice of which was to be
determined by delivery constraints.
The Johnston field development was 'fast-track', first
gas was produced ahead of schedule and under budget,
some 14 months after project sanction. The procurement of
the trees was also 'fast-track', the wellhead equipment was
tendered, design finalised, manufactured, tested and
installed w i t h 12 months.
Prior to placing the order for the trees, the operator in
conjunction with the tree manufacturer, carried out a
detailed technical review and HAZOP of the horizontal tree
concept. Both parties were fully satified that the spooltree
design was the preferred option for the Johnston
development.
These advantages of horizontal trees are discussed
throughout this paper, however, the primary advantages
were considered to be :
Reduced capital and installation costs
Reduced delivery times
Reduced size allowing easier handling
Horizontal 'Spooltree'
The Johnston mudline spooltree is shown in Figures 3 and
4. The 5000 psi spooltree comprises the main spool body
with an integral hydraulic 5-118" production master valve
(HMV), and an integral manual 2" annulus master valve
(MAV). The 5-118" hydraulic production wing valve
(PWV), the 2" hydraulic service wing valve (SWV), the 2"
hydraulic annulus cross-over valve and the 2" hydraulic
annulus drilling valve are in separate valve blocks bolted to
the main spool body. The tubing hanger is landed within
the spool body and is ported horizontally to allow flow into
the production valvcs.
The production master and the production wing valves
provide the main well control barriers in the production
flow path. The well barriers in the vertical bore are
provided by two independent, positively sealing plugs. The
lower plug is set in the tubing hanger, the upper plug is set
within a high pressure cap set inside the spool body above
2 DESIGN, PREPARATION, & OPERATIONAL ASPECTS OF THE
FIRST HORIZONTAL SUBSEA XMAS TREES INSTALLED FROM A JACK-UP
the tubing hanger. The service wing valve allows for
injection of methanol between the master and wing valves.
Conventional subsea trees are termed "concentric" or
"dual" depending on the arrangement of the annular access
through the tubing hanger. During work-over the spooltree
design provides annular access around the hanger. The
annulus flow path from surface runs between the
completion landing string and the riser down to the tubing
hanger, communication is then via the annulus drilling
valve and the manual annulus valve.
A cross-over line from the annulus is tied into the flowline
downstream of the choke, this enables venting of annulus
pressure into the flowline. The actuated cross-over valve
and a check valve are installed on the line to prevent
production pressure reaching the annulus.
Wellhead temperature and pressure are monitored between
the production master and wing valves. Annulus pressure is
monitored between the annulus master and the cross-over
valves. Pressure monitoring ports are isolated by double
block and bleed valves.
The tubing hanger lands in the spool body with the main
metal to metal seals above and below the production outlet
being energised by a tapered bore. The tubing hanger is
precisely oriented in the spool by a key-on helix
mechanism, the orientation aligns the production port in
the hanger with the spool valves but the precision is
required to accommodate the tolerances of a dowhole gauge
instrument penetrator. Communication to the DHSV is
through a pressurised gallery on the outside of the hanger
body. The tubing hanger OD is 12", suitable for running
through the 13 518" BOP stack.
The tree to wellhead connector is hydraulic, with a manual
over-ride. The riser to tree connector is a 13-518" hydraulic
collet type.
A high pressure cap seals the bore of the spool body above
the tubing hanger providing a secondary barrier. A wireline
plug is set within the high pressure cap to provide wireline
access without recovering the cap.
A debris cap is installed on top of the tree to protect the re-
entry hub and the high pressure cap. The debris cap was
specifically designed to be ROV retrievable.
All manual valves on the tree, including all test and bleed
valves, can be functioned by an ROV. The hydraulic valves
have ROV over-rides. All ROV functions are performed by
docking a work-class ROV on the ROV interface plate.
Figure 5 shows the multiple docking stations and the tool
interfaces, all locations are clearly identified .
12
SPE 30343
In order to deploy the work-over controls system and to
allow changing over the stab plates to production, a work-
over running tool, WORT, was designed. The design was a
combined effort between the tree, ROV and control system
contractors. The WORT was deployed on the tree with the
work-over controls made-up to the tree. The WORT
included ROV docking points for the ROV to changeout the
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stab plates. The WORT was retrieved on the riser.
During production the electrical and hydraulic functions on
the tree and on the template are controlled from the
Ravenspurn North control room using an electro-hydraulic
system. Dual subsea control modules are located on the
template. During work-over the functions are controlled
from a control panel on the rig. At the end of completion
operations control is transferred to production by changing
over stab plates using the ROV.
Compared to a conventional subsea tree, the spool tree is
significantly smaller. The height from the wellhead hub to
the top of the tree is 53.6" and it weighs only 14.75 tons.
The size of the tree results in reduced cost, easier handling
offshore and would allow the use of a smaller protective
structure. The design of the spooltree as one main,
relatively small, spool and a number of bolt-on valve blocks
allowed for manufacturing of several components to
proceed in parallel thereby reducing delivery time.
Running a subsea completion from a jack-up is
operationally much simpler than from a floater. No rig
heave offers the advantage of greater control on the
application of weight and torque allowing the use of simple
running and pulling tools. No heave also eliminates
swabbing of the equipment through the stack and riser,
allowing for simple seals to be used.
ROV Intervention
It was recognised at an early stage that diver intervention
during the drilling and completion operations would not be
viable. Although air dwing would have been possible "on
bottom" times were very limited. Installation of a saturation
diving spread on the jack-up rig was impossible due to
space limitations and mobilisation of a dwing support
vessel would have been commercially restrictive. The
elimination of diver operations also provided additional
safety advantages.
All subsea work required during the drilling and
completion phases was therefore designed to be carried out
using a work-class ROV. The main functions to be carried
out by the ROV were :
Observation of subsea operations
Installation/removal of the guidelines
SF% 30343 R A FERGUSON, B HOLLAND, A THOMPSON
Operating manual valves
Engaging downhole gauge penetrator
Instalationlremoval of stab plates
Debris cap installation
The ROV to tree interface was recognised as being critical.
The ROV contractor was selected at the same time as the
tree supplier, the two companies then worked in close c+
operation to design a ROV-friendly system.
A specifk ROV with an X-Y-Z tool deployment unit was
selected, the ROV panel on the tree was then designed with
docktng points and tool interfaces to suit. The hydraulic
stab plates were designed by the control system contractor
to suit the ROV.
Prior to shipping equipment offshore a dry integration test
between the ROV and the tree was caried out. The tool
deployment unit was installed onto the ROV interface panel
and all ROV functions were performed.
A dummy ROV was built and used to ensure that the access
in and around the template and protective structure was
suitable.
Rig Selection
Prior to selecting the jack-up rig to drill and complete the
Johnston wells the additional operational requirements for
installing a subsea tree were considered. The following list
of specific requirements was generated :
Space for a work class ROV system in an
accessible location.
Minimum height of 13 ft below the cantilever
deck to facilitate handling of the Xmas tree, test
base and lifting cap.
Space for three 5 ton air tuggers under the
rotary, to provide guidelines.
Facility to skid the rig floor and have access,
through the rotary, to the main deck, to permit
handling of the Xmas tree.
A tensioning system to support a 16"
completion/workover riser with 60 tons surface
tension, and a lateral restraint to support the 30"
conductor.
Accommodation for 38 personnel in adhtion to
the rig's normal drilling and catering
complement.
Space for the hydraulic control line control
panel and umbilical(s).
Large deck area to accommodate the additional
drilling and completion risers and well test
equipment.
Craneage, both under the cantilever deck and for
working boats, capable of handling the Xmas
tree system.
3
Three of the tendered rigs were considered suitable for the
work, with minor modifications. On the selected rig the
only modifications required were the upgrading of the
conductorlriser tensioning system and installation of the
guidelineltugger system.
OVERVIEW OF OPERATIONS
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Drilling Operations
The casing programme consisted of 30", 20", 13-318" and
9-518" strings and a 7" liner. The 30" was supported on the
template, subsequent casings were supported on positive
landing shoulders in the wellhead. The wellhead used was a
drill through mudline system which incorporated a 13-518"
high pressure housing allowing direct installation of the
subsea tree.
Drilling operations were carried out using two diagonally
opposite guidelines. No surface wellhead was used, the
surface BOP'S being installed drectly onto the drilling
risers.
The two wells 43/27-51 and 43/27-52 were drilled
consecutively prior to commencement of completion
operations. The operator is very experienced in this area of
the southern North Sea and as expected drilling operations
were completed successfully and on target.
Completion Operations
The completion design is shown in figure 6. This is very
similar to the operators conventional platform completion
for a Southern North Sea high rate gas well. One change
was required as a consequence of selecting the spool tree
system. The restricted ID of 4.65" through the tubing
hanger led to the selection of a 5-112" downhole safety
valve, DHSV, in a 7" completion. The tubing above the
DHSV was maintained at 5-112" to the tubing hanger. A
permanent downhole temperature and pressure gauge was
installed to enable monitoring of the reservoir from the
Ravenspurn North Platform.
Setting operational targets for the first completion using a
mudline spool tree was very uncertain. However,
considering the potential operational advantages of the
spool tree an aggressive target of 14 days was set to
complete the well. The completion phase is defined as :
Running, cementing and cleaning out the liner
Running CBL over liner
Pulling tieback strings
Running the subsea tree on the riser
Nippling up the BOP
Running the completion clw TCP guns
Perforating and flow testing the well
Suspending the well
4 DESIGN, PREPARATION, & OPERATIONAL.ASPECTS OF THE
FIRST HORlZONTAL SUBSEA XMAS TREFiS INSTALLED FROM A JACK-UP
In order to achieve such a target it was realised that first
class performance of equipment and personnel would be
required. Prior to the start of completion operations, the
operator, in conjunction with all of the major suppliers and
service companies, carried out a series of design reviews,
operational training and teambuilding exercises. Every
detail of contractor interfaces was discussed and agreed. All
contractors shared in the objective of achieving the targets
set and all contractors participated in an incentive payment
scheme for target achievement.
Completion operations on each well commenced with the
installation of the spool tree. The tree was skidded under
the cantilever and picked by the rig. The tree was then run,
with the WORT installed, on the 16" riser using a three
guidewire system. The tree was oriented on the template by
engagmg the guideposts. The work-over control lines were
made up to the work-over stab plate on the tree prior to
running.
The TCP guns, completion assemblies and production
tubing were made-up and run into the well. The tubing
hanger was installed with an isolation sleeve over the
production port to maintain well control while running.
The gauge instrument line and the DHSV control line were
terminated into the hanger. The hanger was run with the
DHSV locked open, communication to the gauge and
DHSV was not maintained while landing the hanger. As
the tubing hanger entered the seal bore surface control of
the DHSV was immediately resumed.
After landing the hanger a number of pressure tests were
carried out, the ROV was used extensively for opening and
closing manual valves and monitoring pressure. The ROV
was then used to make-up the instrument connection by
driving forward the electrical penetrator to engage the
connector in the tubing hanger. Real time monitoring of the
downhole gauge was then possible through the ROV
umbilical, via a penetrator on the ROV panel.
The well was then perforated, cleaned-up and a full well
test performed. Well J1 was tested at a rate of 140 mmscfld,
this confirmed that the 5-112" tubing down to the DHSV
would not cause a significant flow restriction.
The well was suspended with three tested barriers, the
DHSV, the plug in the tubing hanger and the high pressure
cap with plug installed.
The ROV was then used to disengage the work-over stab
plates and make-up the production control stab plates.
The performance of these completion operations was
monitored very closely using the charts shown in Figures 7
and 8. On the 'first well, J2, completion operations were
SPE 30343
carried out in just 11.92 days. As a result of some minor
problems on J1 completion time was 14.29 days, missing
the target by just 7 hours. However the overall target of 28
days for the two wells was beaten by 1.79 days.
CONCLUSIONS
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The design, preparation and installation of two subsea
spooltree systems in the Johnston field was highly
successful.
The design is innovative and fit for purpose. The lack of
significant installation problems reflects on the high
standard of design engineering. The engineering
involvement continued with key design personnel workmg
offshore throughout the tree installation period.
Detailed preparation for the offshore operations including,
design reviews, training and teambuilding, contributed to
the successful installation programme.
The time from award of the contract to the delivery of the
first tree was only 9 months. This short delivery time
contributed to the overall success of the Johnston project.
The spool tree system was highly cost effective, not only in
the capital cost of the trees but in the rig time saving
provided by the systems operational advantages. The total
cost to drill and complete one of the Johnston wells was
approximately £5 Million.
Acknowledgements
The authors wish to thank the management of BHP
Petroleum and Cooper 011 Tool for permission to publish
this paper, as well as to the Johnston Field partners; British
Gas E & P Ltd, Brasoil UK Ltd, Lasmo (ULX) Ltd, Hardy
Oil and Gas (UK) Ltd, OD & G Dev Co Ltd, Enterprise Oil
plc, and Monument Oil and Gas.
The authors also wish to thank all of the Subsea
Offshore and Rowan Drilling personnel who contributed to
the success of the project.
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ACV

FIGURE 4 - SPOOL TREE HYDRAULIC SCHEMATIC

FIGURE 3 - SCHEMATIC OF JOHNSTON SPOOL TREE
 Tubing Hanger

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5.5" tubing

5.5" TRSV

7" Tubing

Wireline Nipple

Downhole Gauge

PBR

Packer

4.5" Tubing

b
Wireline Nipple

FIGURE 5 - ROV INTERFACE PANEL Perforated Joint

Wireline Nipple
Re-Entry Guide
Perforations

TCP Fish

FIGURE 6 - COMPLETION SCHEMATIC

 FIGURE 7 - WELL 43127-502 COMPLETION PERFORMANCE

CBL
PULL TIEBACX STIUNCB
RUN& TLBT TREE co-OR
NIPPLE UP BOP'S
RUN GYP0
RUNTCP GUNS& SWMSZXBLlEB
RUN TUBING& PDHG LINE
RUN & S E I WlRELmE PLUG

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SEX PA-
PULL WlRELmE PLUG
SHEAR PBR & PULL BACX
DJSPLACCTUBINGTO D m E L
STAB m O PBX& M - O W
TLBT TUBING & HANG=
PEWORATE& --UP W
FLOW TLBT WEW.
LEAK OF? TEST DKBV
RUN& TLBT TBGHGR PLUG

.,
PULL LANDING IITIUNG
IION,SEI & TLBT HI CAP & PLUG
NrnBOP'S & PULL 16" mm
m s u u DEBI(UI c o r n
PECOvrR G W n v I m x 1
PI(FPdllET0 MOVETO JO1 1

30 25 20 15 10 5 0 0 1 2 3 4 5 6 7 8 9101112131415
OPERATION TlME (HOURS1 CUMULATIVE DAYS

FIGURE 8 - WELL 43127-501 COMPLETION PERFORMANCE

TIMEACCRWEWLOCCING& LLNm
SKDkROM JM,RUN G W E W R F S
PULL D E m m CAP
RUN&TESTTREE
NIPPLE UP BOP'S
PULL H I G H P ~ S U P ECAP
RUN TCP GUNS & SUB MSZXBLlEB

-
RUN TUBING & PDHG LINE
RUN & 8 E I WlRELmE PLUG
S E I PA-
PULL PLUG
SHEAR PBR & PULL BACX
DJSPLACETUBING TO D ~ E L
STAB EJIO PBR& LbM)-OF?
TLBT TUBING & HANGEX
P r a F O I U I L & CLEmJ-m WEW.
SmWEW.INIORBOILDUP
INTIUL FLOW PFRIOD
s m waL (RUN STATIC PLT)
FLOW WLZL (RUN DYNAMIC PIT)
smwm.LINmALsmLom)
P O 0 4 RIG DOWN PLT
LEAK OF? TLBT DHSV
RUN& TEST TBG HGR PLUG
PULL LANDING IITRmG
RUN.8EI & TLBT HI CAP & PLUG
Nrn BOP'S & PULL 1VllI901
INSTALL DE
Bm COvrR
PECOvrRGmDnvImx
PI(FPAIIET0 MOVE OF? LOCATION
30 25 20 15 10 5 0 0 1 2 3 4 5 6 7 8 9101112131415
OPERATION TlME (HOURS) CUMULATIVE DAYS