Workover Systems Product Catalog Workover Systems Product Catalog 2 Workover Systems Product Catalog 3 Intervention and Workover Systems Aker Solutions delivers oilfield products, systems and services. Our knowledge and technologies span from reservoir to production and through the life of fields. Increasing oil recovery is essential in today’s energy-hungry world, so advanced technology to enable subsea well intervention is of great importance. Aker Solutions has a wide range of solutions for most of the well control activities required during the life of an oil or gas field. The product portfolio for well control is the result of the combined efforts of Aker Solutions’ Workover Systems, Subsea Controls and Enovate units. Aker Solutions offers market leading open-water systems, turnkey landing string solutions for jackup and conventional rig applications, capping and containment solutions and riserless well intervention systems. The Aker Solutions’ open-water systems have unique qualities that are a step change for the oil and gas industry. The unique X-vendor architecture of our light well intervention system enables subsea tree installations and field-life maintenance on any subsea tree from any subsea vendor. This is accomplished with the highest safety standards. The unique X-vendor architecture of our light well intervention system enables subsea tree installations and field-life maintenance on any subsea tree from any subsea vendor Aker Solutions’ light well intervention workover system can be operated by semi-submersible rigs, drillships or light intervention vessels. The system provides large-bore access to any well, which facilitates coiled tubing and wireline operations. Aker Solutions aims to be the preferred life-of-field partner for oil and gas producers. The company’s market-leading technology as well as growth of its personnel and competence in products, systems and operations serve that ambition. Workover Systems Product Catalog 4 Workover Systems Product Catalog 5 HSE Health, safety and the environment (HSE) is a core value at Aker Solutions and at the top of the agenda for our Workover Systems unit. We take personal responsibility for HSE because we care about people, the environment and our company. We continuously strive for zero accidents to personnel, material and non-material assets. We have tailor-made and well-proven HSE processes and tools to ensure our HSE message reaches employees everywhere. These include Just Care™, the very essence of what HSE means to all of us. They also include Just Rules, which describe the absolute requirements for an incident-free workplace and operations. Our local HSE networks, annual self-assessments and new HSE leadership program help ensure the highest standards are maintained. These initiatives aim to create an HSE mindset that draws lessons from serious incidents to prevent a reoccurrence. Employees are the key to our success. We travel the world to promote our HSE vision through all levels of the organization. We have adopted the same approach in our efforts to ensure quality in all we do. To help improve quality we measure all execution processes with key performance indicators (KPIs) shown monthly in a global KPI dashboard which visualizes leading and lagging quality indicators. Activities that contribute to improved performance as well as consequences of quality deviations are reported at all levels and presented as cost-of-quality figures. Top management is measured and has a particular responsibility for global processes that drive improvements. Workover Systems Product Catalog 6 Workover Systems Product Catalog 7 Subsea Lifecycle Services (SLS) Aker Solutions is dedicated to helping its customers maintain and optimize their assets and achieve enhanced production rates and increased oil recovery. We provide comprehensive and integrated services for life-of-field management, support services and operational maintenance. This support focuses on obtaining the highest standards of technical integrity and delivering the most effective lifecycle solutions, maximizing the systems’ availability, maintainability and safety. Through our regional service bases and central support we can deliver globally integrated subsea lifecycle services including: Installation and commissioning of systems Rental of installation and intervention tools Intervention support Maintenance, repair and spares supply Refurbishment and re-certification Customer property management, including storage and preservation Operational and technical support Re-supply of brownfield equipment Manpower support Integrated operations Condition monitoring Our service base locations include: Angola: Luanda Australia: Perth Brazil: Rio das Ostras India: Kakinada Malaysia: Labuan Nigeria: Port Harcourt Norway: Aagotnes, Kristiansund and Hammerfest UK: Aberdeen USA: Houston, Mobile Workover Systems Product Catalog 8 Workover Systems Product Catalog 9 The multiWOCS™ Product Family Modular, versatile and scalable, Aker Solutions’ workover control system is a universal solution for subsea well installation and intervention. Built with field-proven components, the system enables safe well control on any subsea tree, from any vendor. One system - Any well - All fields Expandable capabilities multiWOCS™ enables increased hydrocarbon recovery through cost-effective well intervention by translating the variations and complexities of subsea fields into a standardized topside interface. With multiWOCS™, any rig can operate on any subsea field, with one workover system run by the same competent crew, using the same interface. Add-ons allow an existing multiWOCS™ system to be expanded to new fields and functionalities. The multiWOCS™ system can also be customized to suit particular operational needs. With the establishment of Aker Solutions’ multiWOCS™ reference laboratory, it is now possible to develop a new range of services tailored to clients’ specific needs and which can be added to new and deployed systems. Utilization, uptime, operational window and safety maximized by design A complementary family of multiWOCS™ products is being configured to provide a flexible solution for open-water and landing string operations. Common interfaces and component modules will ensure rapid deployment and fast operations. The standard multiWOCS™ master control unit (MCU) and hydraulic power unit (HPU), a scaled down (LT) version of the standard units and an auxiliary HPU to handle mineral-based fluids will comprise the multiWOCS™ product suite and accommodate all workover scenarios and variations in well equipment and operating fluids. All systems will be offered as part of a comprehensive package, providing training, hardware-in-the-loop pre-deployment testing of software and hardware upgrades, 24/7 operational support and lifecycle services. Features and benefits: Cross-vendor and cross-field capabilities Customization, flexibility and shorter lead times enabled by modular design Reduced hook-up and test effort due to standard interfaces Compact design for easy integration Simplified maintenance User friendly software platform and Human Machine Interface (HMI) Comprehensive lifecycle support Workover Systems Product Catalog 10 The multiWOCS™ Product Family multiWOCS™ The Aker Solutions multiWOCS™ provides full electro-hydraulic control of subsea trees (XT) and workover equipment. The multiWOCS™ is a robust, modular, flexible and space-saving workover control system. It includes a 48-function hydraulic power unit (HPU) and master control unit (MCU) for cross-vendor operation. Both are fitted within standard 20’ stackable containers which gives flexibility in terms of topside handling and location. The accumulator section can be lifted out of the HPU for ease of transport. The multiWOCS™ control functions and modes of operation are configurable with dedicated MCU software, which allows the system’s capability to be upgraded easily. The MCU provides control and status monitoring of all the main functions in the multiWOCS™ system, including hydraulic, pneumatic, and electric power supply and distribution systems. Remote control of the HPU provides an improved working environment with less noise, no fumes from hydraulic fluid, and increased space and natural light in the control room. The standard multiWOCS™ system can perform multiple operations, including XT installation, Tubing Hanger Running (THR) with a drill pipe landing string, THR with landing string (Expro ELSA and Expro 7300/7400), and open-water workover. Main system components multiWOCS™ control container assembly multiWOCS™ supervisory control and data acquisition (SCADA) system multiWOCS™ HPU container assembly Shutdown panels Reel and umbilical system Umbilical disconnect system Subsea interface package for Aker Solutions’ well control systems (when required): workover control module, electronic power unit, and subsea safety and communication unit Standard configuration of multiWOCS™: MCU: Provision for installing 3 XT subsea power and com- munications units to support cross-vendor operations HPU: 48 hydraulic functions, 6 low-pressure (LP) and 6 high-pressure (HP) regulators, delivery via 4 multiple quick connect (MQC) plates Workover Systems Product Catalog 11 Customized multiWOCS™ Scalable multiWOCS™ LT The modular design of the multiWOCS™ system allows customized units to be built from the same subassemblies as the standard system. Such customized systems provide unique solutions to customer needs, while benefiting from a common support infrastructure with the standard multiWOCS™ units. Fully compatible with the multiWOCS™, the customized units are designed to be easily added with minimum hook-up time. The next family member, the multiWOCS™ LT, will be designed to undertake specific workover operations. Utilizing the same sub-assemblies as the standard multiWOCS™ system, its modular design will allow delivery with a selectable number of hydraulic functions. Customized multiWOCS™ examples: 12-function Brayco HPU: for the simultaneous supply of water-based and mineral-based fluids Common interfaces and component modularity between the standard multiWOCS™ and multiWOCS™ LT systems enable cross-system utilization of existing equipment pools. As with all multiWOCS™ products, the system will enjoy the same support structure (operator pool, recertification processes and spares inventories), product improvements, and related services as the standard multiWOCS™ system. 48-function Brayco HPU: to deliver a tailor-made cross-vendor intervention solution Optimized containers: to better match field-specific procedures Standard configuration of multiWOCS™ LT: MCU: Single XT configuration HPU: 12-24 hydraulic functions, LP & HP delivery via 2 MQC plates 13’ stackable MCU and HPU containers Workover Systems Product Catalog 12 Supervisory Control And Data Acquisition (SCADA) The operational efficiency and safety of any equipment depend on a clear and highly reliable user interface. So Aker Solutions has developed the multiWOCS™ SCADA system. Designed and built in-house by a dedicated engineering team, the SCADA system is based on best practices from the nuclear and power industries and incorporates years of hands-on operational experience of Aker Solutions’ engineers. The human machine interface (HMI) provides a comprehensive overview of all modes of workover operations in an uncluttered format that makes irregular notifications, such as alarms, immediately identifiable. Full redundancy of subsea control is achieved through two independent communication channels. The SCADA system is constructed from commercially available off-the-shelf components, making it easy to maintain. A reference laboratory with a replica SCADA system enables the SCADA development and test team to conduct rigorous hardware-in-the-loop (HIL) testing of the system. Hardware simulators for software development testing complement the HIL test facility. Automated test routines ensure accurate and extensive testing of the SCADA system. Used across the multiWOCS™ product family, the multiWOCS™ SCADA system provides a common interface and control system to off-shore operators and support teams. Operational experience is thereby compounded, resulting in the highest levels of operational efficiency and safety. Services available through the SCADA reference laboratory: Additional functionality (e.g. well types, fields and operations) for deployed systems Expert support for off-shore operations (including replication of off-shore systems) Software maintenance service via Aker Solutions’ Subsea Lifecycle Services Hardware maintenance and obsolescence management Customized training Development of new data-base products for equipment management, efficiency optimization and other applications Aker Solutions offers operator training on the SCADA system. Workover Systems Product Catalog 13 Workover Systems Product Catalog 14 Workover Systems Product Catalog 15 The riserLOCK™ Family Aker Solutions has developed the riserLOCK™ 7.10 workover riser connector for use on standard and special workover riser joints. riserLOCK™ 7.10 riserBIND™ The riserLOCK™ 7.10 system provides a step change in safety and riser running efficiency. The riserBIND™ automated connection tool has been developed to make up and break out the riserLOCK™ 7.10 workover riser connector. It is designed for remote operation, giving the driller access to operational data and information from his chair. The riserLOCK™ 7.10 workover riser connector is used on standard and special riser joints. The connector is based on upset pipe technology. It eliminates the need for welding and provides optimal fatigue life and recertification performance in open-water and inriser applications. 7 3/8” bore diameter 10k working pressure Non-welded riser No load bearing threads Optimized for fatigue capacity Eliminates manual makeup Nace (sour service) compliant A radio control panel is available for contingency operations. This automated tool enables quick make and break, accelerating the run time and minimizing the risk of injury to personnel. The riserLOCK™ 7.10 workover connector in combination with the riserBIND™ automated connection tool enables: Reduced connection time Maximised fatigue life and re-certification performance Increased work safety as it eliminates the need for human operations in the “redzone” Workover Systems Product Catalog 16 The riserLOCK™ Family - Safety Joint The Aker Solutions safety joint is a newly qualified product, developed to minimize or prevent the impact of structural damage and permanent leakage of well barriers caused by abnormal load conditions. The safety joint is designed to break off before any load combination of effective tension, bending moment and internal overpressure exceeds the yield capacity threshold of the permanent well barriers. It enables safe and quick disconnection of the riser string in case of any accidental scenario listed below: Failure or lockup of riser tensioners or heave compensator Dysfunction in mooring line or dynamic positioning (DP) causing the vessel to move off location Loss of stickup and stroke margin causing stroke-out and high riser tension In combination with Global Riser Analysis (GRA), this safety joint has several unique features which bring significant operational and HSE improvements: Increases operational envelope and safety margins. The pressure-balanced design ensures a consistent release load independent of internal pressure Limits the impact of recoil energy as the safety joint releases. In case of safety joint separation, the water dampers prevent instantaneous strike-out of the riser and potential hazards to workers and rig infrastructure. Ensures safer well control via automatic initiation of Emergency Shutdown (ESD). The control system on the Emergency Disconnect Package (EDP) monitors the breakaway part of the safety joint and initiates shutdown of the well barrier elements in case of separation of the breakaway part. Reduces risk of spillage. Inner and outer barrels of the safety joint are of telescopic design and allow sufficient time for closure of well barrier elements and well containment, preventing leakage of riser content to sea. Allows the riser to be run in harsher weather and environmental conditions thanks to a strong mode functionality that temporarily increases joint capacity. Workover Systems Product Catalog 17 The riserLOCK™ Family - Heave Eliminator The Aker Solutions heave eliminator is designed to limit the relative movement between the rig and topside equipment, improving safety for offshore personnel during rigging and tool building. The heave eliminator also provides greater flexibility and efficiency as operations normally performed in the derrick can be carried out on the drillfloor. The heave eliminator makes it possible to latch onto the marine riser telescopic joint and to latch/ unlatch the workover riser inside. When unlatched, the telescopic joint is free to move and hence eliminates much of the relative vertical movement of the Surface Flow Tree (SFT). Features and benefits: Enlarges the operational window when rigging tool strings to 4 meters heave and beyond Reduces the need for work at height on top of the SFT and Coiled Tubing Tension Frame (CTTF), as the entire intervention tool string can be built in advance on the drillfloor while all the intervention equipment, SFT and landing joint are not connected with the rest of the riser system Obviates the need for a tension joint and a tension ring adapter as it is replaced with a heave eliminator, which latches onto the base of the marine riser telescopic joint. Utilizes the drilling riser telescopic joint, flex joint and diverter system already existing on the rig Avoids positioning high-loaded joints in rotary during storm hang-off as the riser system can hang off in the flex joint by disconnecting the HP riser from the HP latch Enables easier and quicker repair or replacement of the seals compared with other heave eliminator solutions Main system components: High-pressure (HP) latch - A ’dog type’ con- nector which enables the landing, latching and sealing of the HP sleeve HP sleeve - An assembly of standard workover riser pipe with the SFT on top and an interface to the HP latch at the bottom Transition/cross-over to a marine riser telescopic joint Workover Systems Product Catalog 18 The riserLOCK™ Family Lubricator Valve Riser Monitoring System The Aker Solutions Lubricator Valve is based on a ‘failas-is’ single or dual valve design. The Aker Solutions Open Water Lubricator Valve (OWLV) can cut various sizes and grades of wire and coiled tubing. The wellSENSE™ Riser Monitoring System (RMS) measures selected features in the Completion/Workover (C/WO) riser system at selected locations. The information is used for lifetime analyses of the riser system. The RMS interfaces topside to the multiWOCS™. The modular design makes the system configurable to suit the requirements of various applications. The system can be upgraded by adding strain gauges in several locations or by adding other types of sensors to perform measurements. Features and benefits: Utilizes ‘fail-as-is’ design Enables well isolation from below without pressure on close control line Provides upper string pressure test capability Allows for chemical injection Incorporates dropped object/impact protector Riser Management System As the next step towards more predictable and safer operations, Aker Solutions is developing a Riser Management System. This system will provide evaluation of the fatigue to each riser joint based on actual readings from the Riser Monitoring System in combination with Global Riser Analysis (GRA) results and actual position of each riser joint in the system. Increases utilization by optimizing the tally before each operation based on the fatigue status Optimizes the riser inspection program based on actual usage Reduces uncertainty linked to the impact of various operations Workover Systems Product Catalog 19 Watch our animation: www.akersolutions.com/workover-riser Workover Systems Product Catalog 20 Workover Systems Product Catalog 21 Well Control Aker Solutions’ well control portfolio provides the equipment and technologies required to secure and access subsea reservoirs. Developed and qualified to deliver robust and reliable performance at all times, it ensures the highest levels of system safety throughout well operations. The major assemblies are built from modular elements and include: Surface Flow Tree (SFT) to enable test production and surface access to the well Lower Workover Riser Package (LWRP) consisting of: Emergency Disconnect Package (EDP) to retain the fluid in the riser and enable rapid disconnect of the system from the well Lower Riser Package (LRP) to secure the well in any operational scenario and remain subsea as a barrier following a disconnection of the system from the well Aker Solutions delivers assemblies at the forefront of the market with respect to safety and operational efficiency to provide the operator with the right tool for the right job. The major assemblies topside and subsea utilize standardized and qualified valve and connector technology as building blocks. These consist of standard elements, such as cavities, gates, seats and actuators, for the following valves: 2 1/16” surface valve 2 1/16” subsea valve 4 1/16” surface valve 7 1/16” surface valve 7 3/8” subsea valve (cutting wire and coil) 7 3/8” En-Tegrity (safety head) Workover Systems Product Catalog 22 Well Control Surface Flow Tree (SFT) Emergency Disconnect Package (EDP) The main purpose of the SFT is to allow for test production, well kill and a studded flange interface to wireline and coiled tubing systems. The EDP provides quick disconnection of the riser in case of vessel drift off/drive off. It is used to run and retrieve the lower riser package (LRP), which functions as a subsea blowout preventer in workover operations. Features and benefits: 2 of 7 1/16” fail-as-is surface valves (surface pro- duction master valve and surface swab valve) 4 of 4” fail-safe-close valves, 2 on each side outlet, to enable maximized flow rates in clean-up or well kill operations The side outlet actuators are equipped with hydraulic override The SFT design incorporates pressure and temperature sensors as well as a chemical injection port Features and benefits: The connection between the workover riser and the EDP is facilitated by the riserLOCK 16” connector EDP connector enables high-angle release of the workover riser system from the well barrier in case of an emergency quick disconnect (EQD) To ensure capacity and functionality to circulate the riser content after an EQD, the EDP is equipped with X-over valve above the retainer valve (RV) The RV is designed and tested to cut and seal with Aker Solutions’ latest 7-3/8” cutting gate valve technology Control and monitoring of the remotely operated functions via the electro-hydraulic workover control module (WOCM) ensures quick response times. The WOCM installation can be configured to enable the WOCM to be subsea retrievable Dual barrier bleed-off design avoids trapped pressure between the production isolation valve (PIV) and RV in the event of an EQD High-angle Workover Systems Product Catalog 23 Lower Riser Package (LRP) System assembly overview The LRP functions as a well barrier element during completion, workover and potentially plug and abandonment operations. The LRP assembly also ensures distribution of hydraulic and electrical supply between the EDP, XT and downhole equipment. Features and benefits: Enables well kill, chemical injection and circulation Surface Flow Tree (SFT) 4 1/16” FSC surface gate valve capabilities while maintaining dual barriers in any operational mode/state Incorporates the production isolation valve (PIV) and the safety head for cutting capability and sealing integrity Equipped with pressure and temperature sensors which provide feedback to the multiWOCS™ for topside monitoring Features capability to provide third-party XT control, enabling cross-vendor well interventions and completions The LRP’s lower connector is designed as a standard industry API flange for easy interface with any potential third-party XT adapter Automated makeup tool for riserLOCK™ 16.10 Emergency Disconnect Package (EDP) Lower Riser Package (LRP) multiTREE™ XTAC High Angle EDP Connector En-Tegrity Shear Seal Ram Workover Systems Product Catalog 24 Well Control 4 1/16” FSC surface gate valve The Aker Solutions gate valve and actuator are of failsafe-close design and enable high well cleanup/test production velocities in challenging reservoirs. The valve employs metal-to-metal sealing technology to seal gate to seat and seat to body. The interfaces are designed so that the seats are pre-loaded to the gate, ensuring sealing at a very low differential pressure. Features and benefits: 4-1/16” bore for increased flowing and cleanup capability in SFT Integrated independent primary and secondary hydraulic operations High-performance ultra-dense tungsten carbide coated Inconel 725 material in gates and seats All internal wetted valve surfaces qualified with CRA-coated material (Inconel 625) Closing time less than 1 second Advanced makeup tool for riserLOCK™ 16.10 Driven by HSE, this upgrade to the standard EDP enables remote makeup of the riserLOCK™ 16.10 connector used between the lower stress joint and the EDP. Features and benefits: No manual work at height in moonpool Reduced risk of pinch points due to guided run-in of stress joint Accelerated makeup and test of connection More accurate preloading of connection to ensure high integrity operations Workover Systems Product Catalog 25 High Angle EDP Connector The En-Tegrity Shear Seal Ram The EDP Connector enables safe disconnection of the EDP from the LRP. The Aker Solutions High-Angle EDP Connector provides open-water workover systems with the latest and most robust connector on the market. The connector has undergone extensive testing for pressure, temperature and loads and proved its capability to ensure great predictability and robustness in operation. The En-Tegrity Shear Seal Ram is a significant step towards increased well integrity for the industry. Designed by Enovate Ltd (an Aker Solutions’ company), this market-leading product provides significant improvement in terms of safety and operational reliability. Features and benefits: Enables disconnect angle well above industry requirements - at 12° in the connector Enlarges operational window for deep and shallow waters, reducing the risk of ’out-of-zone’ operations Includes water dampers to ensure safe and easy subsea re-connect Incorporates two independent sets of hydraulic cylinders to actuate disconnect function Utilizes robust sealing technology with qualified primary metal seal and contingency seals Features and benefits: Metal-to-metal sealing which significantly reduces risk of erosion and leaks Market-leading cutting capability Single valve to cut and seal with wireline, drill pipe, tool joints and casing in the bore Debris (>15% sand) and high well flow tolerant design Workover Systems Product Catalog 26 multiTREE™ Operations Upgrade Kit The multiTREE™ operations upgrade kit is a future development planned as a single upgrade package to the system. It enables installation, completion, intervention and workover activities on any XT/TH system, including all verification and interfacing activities. Features and benefits: Accelerated upgrade to enable multiTREE™ oper- ations on a new field Fully verified and quantified system performance System prepared for early integration testing No complex IP sharing agreements Fully verified in advanced software lab before mobilization or integration testing This upgrade consists of three subsystems: multiTREE™ XTAC/THAC, multiTREE™ STCU and multiTREE™ System Integrity Verification. multiTREE™ XTAC/THAC The XT Adapter Connector (XTAC) interfaces with the standard cross-vendor interface on the lower end of the well control package. This high-capacity flange uses standardized seal and flange configurations to cross over the XT-specific XTAC assembly. The multiTREE™ Tubing Hanger Adapter Connector (THAC) is required to interface the completion string for installation. This provides a standardized interface to the Tubing Hanger Running Tool (THRT) and provides hydraulic passthrough for the control functions to the TH system. These products enable the system to interface mechanically with any XT/TH system Workover Systems Product Catalog 27 multiTREE™ STCU A standardized interface has been established within the multiWOCS™. This allows the multiTREE™ Subsea Tree Control Unit (STCU) to be integrated with minimal complexity and without complex protocol and control integration. All necessary controls equipment, such as XT HPU, HFL, EFL, jumpers, are defined, integrated and verified as part of the offering. Enables an efficient plug-and-play add-on to ena- ble control of any XT/TH system multiTREE™ System Integrity Verification When enabling multiTREE™ operations, verification of the system capability is critical to ensure highintegrity operations. This is done by providing the following services: Interfacing Operations procedures Global Riser Analysis (GRA) Hydraulic analysis Integration testing Contact Aker Solutions Headquarters Snarøyveien 36 1364 Fornebu (visiting) P.O. Box 94 1325 Lysaker (postal) Norway Tel: +47 67 82 60 00 Fax: +47 67 82 64 00 www.akersolutions.com/wos
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