neqsim-subsea-and-wells

NeqSim Subsea & Wells Skill

Reference for subsea production system design, well mechanical design, SURF cost estimation, and tieback analysis using NeqSim.

Subsea Development Architecture

A typical subsea development consists of:

Reservoir → Wells → Subsea Trees → Jumpers → Manifold → Flowlines → Riser → Host
                                                    ↑
                                            Umbilical (power, control, chemicals)

Equipment Classes in NeqSim

Well Design

Casing Design (API 5C3 / NORSOK D-010)

SubseaWell well = new SubseaWell("Producer-1", stream);
well.setWellType(SubseaWell.WellType.OIL_PRODUCER);
well.setCompletionType(SubseaWell.CompletionType.CASED_PERFORATED);
well.setRigType(SubseaWell.RigType.SEMI_SUBMERSIBLE);
well.setWellLocationType(WellCostEstimator.WellLocationType.SUBSEA_WET_TREE);

// Geometry
well.setMeasuredDepth(3800.0);
well.setTrueVerticalDepth(3200.0);
well.setWaterDepth(350.0);
well.setMaxWellheadPressure(345.0);
well.setReservoirPressure(400.0);

// Casing program
well.setConductorOD(30.0);          well.setConductorDepth(100.0);
well.setSurfaceCasingOD(20.0);       well.setSurfaceCasingDepth(800.0);
well.setIntermediateCasingOD(13.375); well.setIntermediateCasingDepth(2500.0);
well.setProductionCasingOD(9.625);    well.setProductionCasingDepth(3800.0);
well.setTubingOD(5.5);
well.setTubingWeight(23.0);
well.setTubingGrade("L80");

// Barrier elements (NORSOK D-010 two-barrier principle)
well.setPrimaryBarrierElements(3);
well.setSecondaryBarrierElements(3);
well.setHasDHSV(true);

// Drilling schedule & costs
well.setDrillingDays(45.0);
well.setCompletionDays(25.0);
well.setRigDayRate(540000.0);

// Mechanical design
well.initMechanicalDesign();
WellMechanicalDesign design = (WellMechanicalDesign) well.getMechanicalDesign();
design.calcDesign();
design.calculateCostEstimate();

// Results
double burstDF = design.getProductionCasingBurstDF();     // >= 1.10
double collapseDF = design.getProductionCasingCollapseDF(); // >= 1.00
double tensionDF = design.getProductionCasingTensionDF();   // >= 1.60
boolean barrierOk = design.isBarrierVerificationPassed();
double totalCost = design.getTotalCostUSD();
String json = design.toJson();

Dry vs Wet Wells

Use WellCostEstimator.WellLocationType to distinguish subsea wet-tree wells from platform dry-tree wells. The same flag is carried by SubseaWell and fed into WellMechanicalDesign.calculateCostEstimate().

SubseaWell wetWell = new SubseaWell("Subsea producer", stream);
wetWell.setWellLocationType(WellCostEstimator.WellLocationType.SUBSEA_WET_TREE);

SubseaWell dryWell = new SubseaWell("Platform producer", stream);
dryWell.setWellLocationType(WellCostEstimator.WellLocationType.PLATFORM_DRY_TREE);

API 5CT Casing Grades

NORSOK D-010 Design Factors

SURF Cost Estimation

SURFCostEstimator

SURFCostEstimator surf = new SURFCostEstimator();
surf.setRegion(SubseaCostEstimator.Region.NORWAY);
surf.setNumberOfWells(4);
surf.setWaterDepthM(350.0);          // m
surf.setTreePressureRatingPsi(10000);
surf.setTreeBoreSizeInches(6.0);
surf.setHorizontalTrees(true);
surf.setManifoldSlots(4);
surf.setNumberOfPLETs(2);
surf.setNumberOfPLEMs(1);
surf.setNumberOfJumpers(4);
surf.setJumperLengthM(30.0);
surf.setUmbilicalLengthKm(27.0);
surf.setUmbilicalHydraulicLines(8);
surf.setUmbilicalChemicalLines(2);
surf.setUmbilicalElectricalCables(2);
surf.setIncludeRisers(true);
surf.setFlexibleRiser(true);
surf.setRiserDiameterInches(12.0);
surf.setRiserLengthM(525.0);
surf.setInfieldFlowlineLengthKm(8.0);
surf.setExportPipelineLengthKm(25.0);
surf.setExportPipelineDiameterInches(12.0);
surf.setContingencyPct(0.35);        // FRACTION, not a percent - see the warning below

surf.calculate();
double surfCapex = surf.getTotalSURFCostUSD();
double subseaHardware = surf.getSubseaCostUSD();
double umbilicals = surf.getUmbilicalCostUSD();
double risers = surf.getRiserCostUSD();
double flowlines = surf.getFlowlineCostUSD();
List<Map<String, Object>> lineItems = surf.getLineItems();

WARNING: setContingencyPct takes a FRACTION, not a percent

Despite the Pct in the name, both SURFCostEstimator.setContingencyPct and WellCostEstimator.setContingencyPct multiply the subtotal by the value as given:

est.setContingencyPct(30.0);   // WRONG - contingency = 30 x subtotal
est.setContingencyPct(0.30);   // RIGHT - contingency = 0.30 x subtotal

The symptom is a cost that is roughly 100x too large and still looks internally consistent, e.g. a subsea gas well at 2 295 MUSD instead of 96 MUSD. Always sanity-check the result against getCostBreakdown() / getLineItems(), where the reported contingencyPct field shows the value actually applied.

Regional Cost Factors

Tieback Analysis

Workflow

1. Define the satellite field (reservoir, fluid, wells)
2. Define candidate host facilities with available capacity
3. Configure tieback options (distance, diameter, insulation, boosting)
4. Screen flow assurance (hydrate margin, arrival temperature, pressure drop)
5. Estimate SURF CAPEX for each option
6. Rank by NPV or unit technical cost

Usage

TiebackAnalyzer analyzer = new TiebackAnalyzer();

// Define host
HostFacility host = new HostFacility("Platform Alpha");
host.setAvailableCapacity(30000.0);   // boe/d spare capacity
host.setProcessingPressure(70.0);     // bara
host.setLocation(61.5, 2.5);         // lat, lon

// Define options
TiebackOption opt1 = new TiebackOption("Direct Tieback");
opt1.setFlowlineLength(15.0);
opt1.setFlowlineDiameter(10.0);
opt1.setWaterDepth(350.0);
opt1.setInsulationType("wet_insulation");

TiebackOption opt2 = new TiebackOption("Boosted Tieback");
opt2.setFlowlineLength(30.0);
opt2.setFlowlineDiameter(12.0);
opt2.setWaterDepth(450.0);
opt2.setHasBooster(true);
opt2.setBoosterType("multiphase_pump");

analyzer.setHost(host);
analyzer.addOption(opt1);
analyzer.addOption(opt2);
analyzer.setFluid(reservoirFluid);

TiebackReport report = analyzer.analyze();
// report contains: pressure drop, arrival temperature, hydrate margin,
// SURF cost, NPV ranking, flow assurance verdict per option

Subsea System Configuration

Complete Subsea Layout

SubseaProductionSystem subseaSystem = new SubseaProductionSystem("Field Layout");
subseaSystem.setArchitecture(SubseaProductionSystem.SubseaArchitecture.MANIFOLD_CLUSTER);
subseaSystem.setWellCount(6);
subseaSystem.setManifoldCount(2);          // 2 manifolds x 3 wells
subseaSystem.setWaterDepthM(400.0);
subseaSystem.setTiebackDistanceKm(30.0);   // km to host
subseaSystem.setUmbilicalLengthKm(32.0);   // slightly longer routing
subseaSystem.setFlowlineDiameterInches(12.0);
subseaSystem.setTubingDiameterInches(6.0);
subseaSystem.setCostRegion(SubseaCostEstimator.Region.NORWAY);
subseaSystem.setWellLocationType(WellCostEstimator.WellLocationType.SUBSEA_WET_TREE);
subseaSystem.setIncludeRisers(true);
subseaSystem.setFlexibleRiser(true);
subseaSystem.setProductionRiserCount(1);
subseaSystem.setReservoirDevelopmentCostMusd(25.0);
subseaSystem.setReservoirFluid(reservoirFluid);

subseaSystem.build();
subseaSystem.run();

int treeCount = subseaSystem.getTrees().size();
int jumperCount = subseaSystem.getJumpers().size();
int manifoldCount = subseaSystem.getManifolds().size();
int pletCount = subseaSystem.getPLETs().size();
int plemCount = subseaSystem.getPLEMs().size();
int umbilicalCount = subseaSystem.getUmbilicals().size();
int flexibleRiserCount = subseaSystem.getRisers().size();
int steelRiserCount = subseaSystem.getSteelRisers().size();

SubseaProductionSystem.SubseaSystemResult result = subseaSystem.getResult();
double surfCapexMusd = result.getTotalSubseaCapexMusd();
double wellsMusd = result.getWellCostMusd();
double reservoirMusd = result.getReservoirCostMusd();
double developmentCapexMusd = result.getTotalDevelopmentCapexMusd();

SubseaProductionSystem.build() creates the main process and design equipment: SubseaWell, SubseaTree, SubseaJumper, SubseaManifold, PLET, PLEM, SimpleFlowLine, Umbilical, and risers. With setFlexibleRiser(true) risers are generated as FlexiblePipe; with setFlexibleRiser(false) steel/rigid risers are generated as vertical SimpleFlowLine unit operations. All of these classes expose mechanical design objects, and SURFCostEstimator includes trees, manifolds, PLETs, PLEMs, jumpers, umbilicals, risers, flowlines, and pipelines in the SURF CAPEX. The result separates SURF, well, reservoir, and total development CAPEX.

Flowline and Pipeline Sizing

Steady-State Pipe Flow

// Beggs & Brill multiphase correlation
PipeBeggsAndBrills pipeline = new PipeBeggsAndBrills("Export Line", feedStream);
pipeline.setLength(50000.0);           // m
pipeline.setDiameter(0.508);           // m (20 inch)
pipeline.setPipeWallRoughness(5e-5);   // m
pipeline.setAngle(0.0);               // horizontal
pipeline.setNumberOfIncrements(50);

// With formation temperature gradient (subsea/buried)
pipeline.setFormationTemperatureGradient(4.0, -0.03, "C");
// 4°C at seabed, -0.03 °C/m depth gradient

pipeline.run();
double pressureDrop = feedStream.getPressure() - pipeline.getOutletPressure();
double arrivalTemp = pipeline.getOutletTemperature() - 273.15;  // °C

Free-span screening (DNV-RP-F105)

For an explicit current DNV-RP-F105 2025-12 basis, use DnvRpF105FreeSpanScreeningKernel. Supply surveyed span/pipe geometry, a separate hydrodynamic diameter, accepted effective modal mass and axial force, normal current/wave inputs, and verified project response triggers. The kernel reports a simply supported first-mode frequency and common dimensionless groups only.

Do not use PipeMechanicalDesignCalculator.calculateAllowableSpanLength(...) as F105 evidence. It is a legacy fixed-assumption estimate with fallback/cap behavior. Do not turn the typed kernel's caller-controlled response triggers into PASS/FAIL against DNV: soil and span-shoulder stiffness, multi-span interaction, detailed VIV/direct-wave response, ULS/FLS, fatigue, monitoring, and intervention remain a controlled external assessment.

Corroded-pipeline screening (DNV-RP-F101)

For an explicit current DNV-RP-F101 2019-09+AMD:2025-09 basis, use DnvRpF101CorrodedPipelineScreeningKernel only for one verified isolated longitudinal metal-loss defect under internal pressure. Supply assessment wall thickness, measured maximum depth and axial length, caller-controlled depth allowance, characteristic ultimate tensile strength, internal/external absolute pressures, and a verified project-controlled pressure factor.

Keep interacting/complex defects, combined longitudinal compression, probabilistic and inspection- accuracy models, corrosion growth, crack/dent/gouge/blister or weld damage, repair, inspection interval, and fitness-for-service approval external. M-506 rate prediction is not inspected defect sizing. RP-F101 does not replace DNV-ST-F101 pressure containment, collapse, propagation/local buckling, interaction, fatigue, pressure cases, de-rating, safety class, ovality, fabrication, or installation-strain checks.

Pipeline Mechanical Design

AdiabaticPipe pipe = new AdiabaticPipe("Pipeline", feedStream);
pipe.setLength(50000.0);
pipe.setDiameter(0.508);

PipelineMechanicalDesign mechDesign =
    (PipelineMechanicalDesign) pipe.getMechanicalDesign();
mechDesign.setMaxOperationPressure(150.0);
mechDesign.setMaterialGrade("X65");
mechDesign.setDesignStandardCode("DNV-OS-F101");
mechDesign.calcDesign();

double wallThickness = mechDesign.getWallThickness();  // mm
String report = mechDesign.toJson();

DNV-RP-F109 On-Bottom Stability Screening

Use DnvRpF109OnBottomStabilityKernel for typed, fail-closed vertical and lateral screening of a pipeline, cable, or umbilical. The exact supported edition is 2021-05+AMD 2025-09. Supply every project coefficient, factor, soil resistance, environmental load case, and submerged weight explicitly; there are no numerical project defaults.

Build DnvRpF109OnBottomStabilityInput with the exact edition, matching asset and equipment types, geometry, engineering-basis reference, and one or more explicit LoadCase values. Call DnvRpF109OnBottomStabilityKernel.calculate(input, context) and retain its readiness findings and full input provenance. See docs/process/dnv_rp_f109_on_bottom_stability.md for the complete Java pattern.

The absolute-static route calculates normal Morison drag/inertia and lift, then checks vertical equilibrium and horizontal demand against friction plus explicit passive soil resistance. External-response routes check supplied displacement at 0.5D, 10D, or a project limit, and require affirmative response-model validity plus a traceable basis. NeqSim does not reproduce generalized design tables, generate dynamic response, qualify pipe-soil inputs, or claim DNV conformity. Treat every result, including a pass, as CALCULATED_REVIEW_REQUIRED.

Flowline Cooldown and No-Touch Time

After a planned or unplanned shutdown, an insulated subsea flowline or riser cools toward the seabed temperature. The no-touch time is how long operators can wait before the fluid reaches the hydrate formation temperature (plus a safety margin) and remedial action (depressurization, MEG/methanol injection) is required. NeqSim couples a live fluid to a lumped cooldown engine with SurfCooldownAnalyzer.

// Live fluid carries composition; analyzer auto-extracts density, Cp, hydrate Teq
SurfCooldownAnalyzer analyzer = new SurfCooldownAnalyzer(fluid);  // SystemInterface
analyzer.setInternalDiameter(0.254);        // m
analyzer.setWallThickness(0.0159);          // m
analyzer.setInsulationThickness(0.060);     // m
analyzer.setInsulationConductivity(0.17);   // W/m·K (wet insulation, PP foam)
analyzer.setSeabedTemperature(4.0);         // °C
analyzer.setHydrateMargin(3.0);             // K above hydrate Teq
analyzer.setRequiredNoTouchTimeHours(8.0);  // operational target (optional)

// Either give an overall U-value directly, or let the layer model compute it:
analyzer.setOverallUValue(2.5);             // W/m²·K  (skip for layer calc)

analyzer.calculate();
double noTouch = analyzer.getNoTouchTimeHours();
String verdict = analyzer.getVerdict();     // OK / MARGINAL / CRITICAL / NO_HYDRATE_RISK
double hydrateTeqC = analyzer.getHydrateEquilibriumTemperatureK() - 273.15;
double tau = analyzer.getTimeConstantHours();
String json = analyzer.toJson();

How it works:

• Clones the fluid, runs TPflash + initProperties, and reads getDensity("kg/m3") and getCp("J/kgK") for the lumped thermal mass.
• Computes the hydrate equilibrium temperature via hydrateFormationTemperature(). If the fluid has no free water (no hydrate risk), the verdict is NO_HYDRATE_RISK.
• Delegates the transient to PipelineCooldownCalculator (exponential lumped cooldown, layer or direct U-value). No-touch time is the time to reach hydrateTeq + margin.
• Verdict bands: with a required no-touch time, OK ≥ required, MARGINAL ≥ 0.75×, else CRITICAL. Without one, OK ≥ 12 h, MARGINAL ≥ 6 h, else CRITICAL.

Basis: project thermal-management requirements and API RP 17A subsea-system context. DNV-RP-F109 is an on-bottom stability document and is not a cooldown or no-touch-time basis. This is a screening-level lumped model — use a distributed transient thermal-hydraulic tool for detailed design.

package: neqsim.pvtsimulation.flowassurance — SurfCooldownAnalyzer, PipelineCooldownCalculator.

Artificial Lift Screening

ArtificialLiftScreener alScreener = new ArtificialLiftScreener();
alScreener.setReservoirPressure(250.0);     // bara
alScreener.setWaterDepth(350.0);
alScreener.setGOR(200.0);                   // Sm3/Sm3
alScreener.setWaterCut(0.30);
alScreener.setDepth(3000.0);                // m TVD
alScreener.setProductionRate(5000.0);       // boe/d

// Screen all methods
Map<String, String> recommendations = alScreener.screen();
// Returns: {"ESP": "RECOMMENDED", "Gas Lift": "FEASIBLE",
//           "Rod Pump": "NOT_RECOMMENDED", ...}

Gas Lift Design

GasLiftCalculator gasLift = new GasLiftCalculator();
gasLift.setWellDepth(3000.0);
gasLift.setReservoirPressure(250.0);
gasLift.setProductionRate(5000.0);
gasLift.setGLR(500.0);                    // Sm3/Sm3
gasLift.setInjectionPressure(150.0);      // bara

double optimalGLR = gasLift.calculateOptimalGLR();
double injectionRate = gasLift.calculateInjectionRate();

// Multi-well gas lift optimization
GasLiftOptimizer optimizer = new GasLiftOptimizer();
optimizer.addWell(well1, gasLift1);
optimizer.addWell(well2, gasLift2);
optimizer.setTotalGasAvailable(500000.0);  // Sm3/d
Map<String, Double> allocation = optimizer.optimize();

For a choke-back / open-up decision across a well fleet under multiple shared facility ceilings (gas handling + produced-water/PWRI + lift-gas budget) with discrete on/off locks, use ChokeAndGasLiftAllocationOptimizer + StrupeOkeReport (neqsim.process.fielddevelopment.integrated). Build each well's response with GasLiftPerformanceCurve.fromWellSystem(...). See the neqsim-production-optimization skill for the full pattern.

Design Standards Reference

Common Subsea Design Pitfalls