Mechanical Characteristics and Structural Innovation of a Deepwater Subsea Wellhead System

To improve the bending resistance and support the domestic development of deepwater subsea wellhead equipment, a three-dimensional finite element model (FEM) of the SXW-15 subsea wellhead system was established in ANSYS Workbench considering contact nonlinearity and rigid-locking mechanisms. Based on representative deepwater drilling and completion conditions, the effects of the friction coefficient, locking preload, blowout preventer (BOP)/lower marine riser package (LMRP) top load, casing hanger internal pressure, and tubing load on the ultimate bending capacity of the system were systematically investigated. The results show that the bending capacity increases with increasing friction coefficient and locking preload, whereas it decreases with increasing top load and tubing weight. The internal pressure of the casing hanger exhibits a pronounced nonlinear influence on the bending resistance, and the maximum bending capacity occurs at an internal pressure of approximately 4000 psi. Based on the mechanical analysis, several innovative designs were proposed, including a layered load-bearing structure, a gravity-set metal sealing assembly, a self-supporting rigid-locking mechanism, and an integrated multifunctional tool system, aiming to improve load-transfer efficiency, connection stiffness, and high-pressure sealing stability. Land-based testing and offshore field applications were subsequently conducted to verify the engineering applicability of the system. The subsea wellhead system with innovative designs maintained satisfactory structural integrity and sealing reliability under conditions of 15,000 psi internal pressure and 12.7 million lb axial load. Good agreement was obtained between finite element predictions and field test results. The present study provides theoretical support and guidance for the structural designs and engineering applications of deepwater subsea wellhead systems.