US20260168347A1
2026-06-18
19/345,978
2025-09-30
Smart Summary: A new system helps change how underwater production systems work by adding alternative flow paths. These paths can bypass certain parts of the system or add new features. It includes a bridging module that connects the production area to the flowline, using a flow control module to manage the flow. There’s also a sleeve that can block the main flow path when needed. Additionally, an adapter connects to a control module, allowing for better management of support systems for the production equipment. 🚀 TL;DR
A system to reconfigure a subsea production system includes at least one alternative flow path. The alternative flow paths circumvent certain parts of the subsea production system or introduce new functionality into the subsea production system. The system includes a bridging module to allow alternative flow paths between a Christmas tree (XT) production bore and the flowline connector, wherein the flow path passes through a flow control module (FCM). The system also includes a sleeve extending into a bore of the XT configured to block an XT production flow path. The system further includes a valve assembly coupled to an outlet flow path on the XT. The system further includes an adapter assembly coupled to a subsea control module (SCM), wherein the adapter assembly is configured to reroute support systems for the XT to one or more valve assemblies.
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E21B33/0353 » CPC main
Sealing or packing boreholes or wells; Surface sealing or packing; Well heads; Setting-up thereof specially adapted for underwater installations Horizontal or spool trees, i.e. without production valves in the vertical main bore
E21B33/035 IPC
Sealing or packing boreholes or wells; Surface sealing or packing; Well heads; Setting-up thereof specially adapted for underwater installations
This application is a continuation-in-part of U.S. patent application Ser. No. 18/984,204, filed Dec. 17, 2024, titled “VERTICAL ISOLATION AND FLOW TREE SYSTEMS AND METHODS,” the full disclosure of which is hereby incorporated by reference in its entirety for all purposes.
The present disclosure relates to wellbore operations. Specifically, the present disclosure relates to production and/or injections systems, such as subsea systems, for hydrocarbon recovery and/or injection.
In oil and gas exploration, a subsea Christmas tree (XT) is a stack of vertical and horizontal valves installed on a subsea wellhead. The XT provides a controllable interface between the well and production facilities and may be composed of a variety of valves, which may be used for testing, servicing, regulating, or choking the stream of produced oil, gas, and liquids coming up from the well below, with the main valves arranged in a horizontal or vertical portion of the bore respectively. The XT, is part of the well integrity system which forms the main components for the well control. If the XT is damaged during service, the well is often shut in and the XT is recovered. With a Vertical XT system (VXT), the well completion is finished before installing the VXT. Since the tubing hanger rests on the wellhead, the XT can be recovered without having to recover the downhole completion. By contrast, in a horizontal XT system (HXT) the well completion is installed in the tree body instead of the wellhead. The tree is installed onto the wellhead before completion of the well. As a result, recovery of the downhole completion is required before the XT can be recovered, which is a time consuming and expensive process.
Applicant recognized the problems noted above herein and conceived and developed embodiments of apparatuses, systems and methods, according to the present disclosure, for downhole systems.
In an embodiment, a subsea system includes a horizontal Christmas tree (HXT) and a vertical isolation flow (VIFT) system. The HXT includes one or more HXT structural elements, a completion extending into a wellbore associated with the HXT, a production assembly, and one or more auxiliary supplies. The VIFT system includes a sleeve extending into the completion, the sleeve blocking an HXT production flow path. The VIFT system also includes a vertical XT (VXT) fluidly coupled to a bore extending through the sleeve. The VIFT system further includes a VIFT assembly including at least a bridging module arranged axially below a flow control module (FCM), wherein the bridging module is configured to both block an original inlet flow path associated with the production flow path and to direct a new flow path, associated with the VXT, into the FCM. The VIFT system also includes a subsea control module (SCM) assembly including at least an adapter plate, wherein the adapter plate is configured to reroute at least a portion of the one or more auxiliary supplies to the VXT.
In an embodiment, a system to convert a subsea Christmas tree (XT) includes a sleeve extending into a bore of XT configured to block an XT production flow path and a bridging module coupled to an inlet flow path of a flow control module (FCM). The sleeve is configured to block a XT flow path associated with the XT production flow path and to direct a new flow path, associated with a valve assembly, into the FCM. The system also includes an adapter assembly coupled to a subsea control module (SCM), wherein the adapter assembly is configured to reroute one or more support systems for the XT to the valve assembly.
In an embodiment a subsea system includes a Christmas tree (XT), a completion extending into a wellbore associated with the XT, a processing apparatus having an apparatus inlet and an apparatus outlet, and a vertical isolation flow tree (VIFT) system. The VIFT system includes a closure in a flow path of the XT, a valve assembly fluidly connected to an outlet of the XT, and a bridging module having a first inlet, a first outlet, a second inlet, and a second outlet. The first inlet is fluidly coupled to a flow outlet of the valve assembly, the first outlet is fluidly coupled to the apparatus inlet, the second inlet is fluidly coupled to the apparatus outlet, and the second outlet is fluidly coupled to a production flow line.
The foregoing aspects, features, and advantages of the present disclosure will be further appreciated when considered with reference to the following description of embodiments and accompanying drawings. In describing the embodiments of the disclosure illustrated in the appended drawings, specific terminology will be used for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms used, and it is to be understood that each specific term includes equivalents that operate in a similar manner to accomplish a similar purpose.
FIG. 1 is a schematic side view of an embodiment of an offshore drilling operation, in accordance with embodiments of the present disclosure;
FIG. 2A is a perspective view of an embodiment of a horizontal Christmas tree (HXT), in accordance with embodiments of the present disclosure;
FIG. 2B is a schematic diagram of an embodiment of a flow configuration for an HXT, in accordance with embodiments of the present disclosure;
FIG. 3A is a schematic diagram of an embodiment of a flow configuration for a converted HXT, in accordance with embodiments of the present disclosure;
FIG. 3B is a cross-sectional view of a sleeve positioned within an HXT, taken along 3B-3B, in accordance with embodiments of the present disclosure;
FIG. 4A is a perspective view of an embodiment of a vertical isolation flow tree (VIFT) assembly, in accordance with embodiments of the present disclosure;
FIG. 4B is a perspective view of an embodiment of a portion of a bridging module, in accordance with embodiments of the present disclosure;
FIG. 4C is a perspective cross-sectional view of an embodiment of a flow configuration including a bridging module, in accordance with embodiments of the present disclosure;
FIG. 4D is a perspective cross-sectional view of an embodiment of a flow configuration including a bridging module, in accordance with embodiments of the present disclosure;
FIG. 4E is a perspective cross-sectional view of an embodiment of a flow configuration including a bridging module, in accordance with embodiments of the present disclosure;
FIG. 4F is a perspective view of a representation of modified flow path for an HXT, in accordance with embodiments of the present disclosure;
FIG. 4G is a schematic diagram of an embodiment of a reconfigured XT, in accordance with embodiments of the present disclosure;
FIG. 4H is a schematic diagram of an embodiment of a reconfigured XT, in accordance with embodiments of the present disclosure;
FIG. 4I is a schematic diagram of an embodiment of a reconfigured XT, in accordance with embodiments of the present disclosure;
FIG. 5A is a perspective view of an embodiment of a portion of a VIFT system, in accordance with embodiments of the present disclosure;
FIG. 5B is a perspective view of an embodiment of a modified subsea control module (SCM) assembly, in accordance with embodiments of the present disclosure;
FIG. 5C is a perspective view of an embodiment of a sandwich plate, in accordance with embodiments of the present disclosure;
FIG. 5D illustrates a partial and simplified schematic view of an SCM assembly, in accordance with embodiments of the present disclosure;
FIGS. 6A-6F illustrate a sequence of steps for converting an HXT to a vertical XT (VXT), in accordance with embodiments of the present disclosure;
FIG. 7 is a flow chart of an example process for installing a VIFT system onto an HXT, in accordance with embodiments of the present disclosure; and
FIG. 8 is a flow chart of an example process for redirecting a flow path of an HXT, in accordance with embodiments of the present disclosure.
The foregoing aspects, features, and advantages of the present disclosure will be further appreciated when considered with reference to the following description of embodiments and accompanying drawings. In describing the embodiments of the disclosure illustrated in the appended drawings, specific terminology will be used for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms used, and it is to be understood that each specific term includes equivalents that operate in a similar manner to accomplish a similar purpose.
When introducing elements of various embodiments of the present disclosure, the articles “a”, “an”, “the”, and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Any examples of operating parameters and/or environmental conditions are not exclusive of other parameters/conditions of the disclosed embodiments. Additionally, it should be understood that references to “one embodiment”, “an embodiment”, “certain embodiments”, or “other embodiments” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, reference to terms such as “above”, “below”, “upper”, “lower”, “side”, “front”, “back”, or other terms regarding orientation or direction are made with reference to the illustrated embodiments and are not intended to be limiting or exclude other orientations or directions. It should be further appreciated that terms such as approximately or substantially may indicate +/−10 percent.
Embodiments of the present disclosure are directed toward a modular assembly for a vertical isolation and flow tree (VIFT) system that may be used to redirect a production flow from an installed XT, which may be a horizontal XT (HXT), to a new production outlet. Accordingly, embodiments may be deployed in order to establish a new flow path using a series of conversion subsea structures and/or assemblies without removing the entire structure of the XT. However, in at least one embodiment, systems and methods may also be incorporated into new installations to provide flexibility during life of a field. For example, an XT may be installed with the VIFT to provide an option for a variety of different flow paths and/or injection paths based on operating conditions. Systems and methods may include the VIFT system to divert the production flow from a well, for example by blocking flow from the XT production wing block through the XT reentry mandrel and into a valve assembly, which may include a vertical XT (VXT), of the VIFT system. The VXT is provided as one example and various embodiments may deploy one or more valve assemblies for a redirected flow path.
Additionally, embodiments may also provide assemblies and sub-assemblies for restoring flow to a jumper/flowline through one or more bridging modules located under (e.g., vertically lower) the XT flow control module. In one or more embodiments, controls and/or chemicals may be rerouted from the XT to the VIFT system (e.g., to one or more components of the VIFT system) via one or more adapter assemblies. The adapter assemblies may include, in at least one embodiment, one or more adapter plates located below the control module and one or more sandwich plates located on the subsea distribution controls and/or chemical supply plates. Additionally, unused chemical connections may be isolated on the XT or one or more of the adapter assemblies. In at least one embodiment, systems and methods the present disclosure may address and overcome problems with maintaining production from in-situ XTs, where traditional methods pull the XT and the completion. Embodiments of the present disclosure may include one or more modular systems and/or sub-systems that may be used to divert the production flow from the well without having the pull the XT and the completion, while still providing access to the completion and maintain one or more structural components of the XT. Accordingly, embodiments reestablish production without pulling the XT and completion, which is difficult, time consuming, and costly, and further enable access to an existing well, thereby reducing operational costs and reducing lost production. Systems and methods may also enable transfer of one or more chemical supplies to the XT while diverting chemicals to the VIFT system (e.g., to one or more components of the VIFT system). Embodiments also provide a dual barrier that may be retrofitted and removed, which may restore systems back to an original state.
In at least one embodiment, systems and methods of the present disclosure may be deployed to enable production through an HXT, as one non-limiting example, even in situations where the HXT is damaged or otherwise non-operational (e.g., damaged to the point where the HXT would need retrieval and/or replacement), by converting the HXT into a spool and/or by removing one or more components of the HXT while maintaining certain structural or flow elements for use with a modified flow path. As a result, one or more embodiments may be used to adapt the existing infrastructure of the HXT and convert the HXT using the VIFT to include one or more valve assemblies without pulling the completion or the HXT. Systems and methods of the present disclosure may, at least in part, deploy one or more bridging modules to isolate an original outlet flow path and divert the flow toward a secondary flow path, thereby bypassing the damaged components of the HXT while still tying into the original flowline (e.g., export system). By way of example, one or more sleeves may be used to block or otherwise block off different flow paths of the HXT to divert the flow and vertically bypass one or more valves. The flow may then be directed into the bridging module in order to disrupt the original flow and reestablish a new flow path, which as discussed herein, may tie into an original flowline.
One or more embodiments of the present disclosure may relate to a subsea system, which may be formed of one or more components and/or assemblies, as discussed herein. It should be appreciated that various embodiments may omit or otherwise not use particular components and/or assemblies of the system, and/or may integrate one or more components or assemblies into a common structure. In at least one embodiment, the subsea system may include, at least in part, a vertical isolation flow tree (VIFT), a bridging module, a subsea control module (SCM), a multiple quick connection (MQC) sandwich plate, and/or a tubing head (TH) isolation sleeve. Systems and methods of the present disclosure may deploy one or more components of the subsea system in order to isolate or otherwise modify one or more flow paths associated with a subsea connection, such as a wellhead. Modification or isolation of different flow paths may include modifying an inlet flow path, modifying an outlet flow path, and/or combinations thereof. As one non-limiting example discussed herein, one or more embodiments may incorporate the bridging module to block a current inlet flow path and form a new inlet flow path. In at least one embodiment, the new inlet flow path may be associated with a new outlet flow path or an existing outlet flow path. As one non-limiting example discussed herein, one or more embodiments may incorporate the bridging module to use an existing inlet flow path, but to block an existing outlet flow path and redirect outlet flow along a new outlet flow path.
FIG. 1 is a side schematic view of an embodiment of a subsea drilling operation 100. It should be appreciated that one or more features have been removed for clarity with the present discussion and that removal or inclusion of certain features is not intended to be limiting, but provided by way of example only. Furthermore, while the illustrated embodiment describes a subsea drilling operation, it should be appreciated that one or more similar processes may be utilized for surface applications and, in various embodiments, similar arrangements or substantially similar arrangements described herein may also be used in surface applications. Furthermore, a drilling application is provided as a non-limiting example and various systems or methods could also be used in other applications, including recovery, inspection, data collection, and/or the like. The drilling operation includes a vessel 102 floating on a sea surface 104 substantially above a wellbore 106. As noted, the vessel 102 is for illustrative purposes only and systems and methods may further be illustrated with other structures, such as floating/fixed platforms, and the like. A wellbore housing 108 sits at the top of the wellbore 106 and is connected to a blowout preventer (BOP) assembly 110, which may include shear rams 112, sealing rams 114, and/or an annular ram 116. One purpose of the BOP assembly 110 is to help control pressure in the wellbore 106. The BOP assembly 110 is connected to the vessel 102 by a riser 118. During drilling operations, a drill string 120 passes from a rig 122 on the vessel 102, through the riser 118, through the BOP assembly 110, through the wellhead housing 108, and into the wellbore 106. It should be appreciated that reference to the vessel 102 is for illustrative purposes only and that the vessel may be replaced with a floating/fixed platform or other structure. The lower end of the drill string 120 is attached to a drill bit 124 that extends the wellbore 106 as the drill string 120 turns. Additional features shown in FIG. 1 include a mud pump 126 with mud lines 128 connecting the mud pump 126 to the BOP assembly 110, and a mud return line 130 connecting the mud pump 126 to the vessel 102. A remotely operated vehicle (ROV) 132 can be used to make adjustments to, repair, or replace equipment as necessary. Although a BOP assembly 110 is shown in the figures, the wellhead housing 104 could be attached to other well equipment as well, including, for example, a tree, a spool, a manifold, or another valve or completion assembly.
One efficient way to start drilling a wellbore 106 is through use of a suction pile 134. Such a procedure is accomplished by attaching the wellhead housing 108 to the top of the suction pile 134 and lowering the suction pile 134 to a sea floor 136. As interior chambers in the suction pile 134 are evacuated, the suction pile 134 is driven into the sea floor 136, as shown in FIG. 1, until the suction pile 134 is substantially submerged in the sea floor 136 and the wellhead housing 108 is positioned at the sea floor 136 so that further drilling can commence. As the wellbore 106 is drilled, the walls of the wellbore are reinforced with concrete casings 138 that provide stability to the wellbore 106 and help to control pressure from the formation. It should be appreciated that this describes one example of a portion of a subsea drilling operation and may be omitted in various embodiments. In at least one embodiment, systems and methods of the present disclosure may be used for drilling operations that are completed through a BOP and wellhead, where a casing hanger and string are landed in succession. As noted above, configurations with respect to a sea floor or any offshore application are for illustrative purposes and embodiments of the present disclosure may also be utilized in surface drilling applications.
Various embodiments of the present disclosure may be directed toward one or more modular and/or removable components that may use existing XT infrastructure in order to convert a flow path for an XT into a redirected flow path without removing the all or substantially all of the infrastructure of the XT. Systems and methods may include one or more modules or components, which may be independently positionable, to redirect one or more flow paths, reuse fluid or communication systems of the XT, and/or the like. Furthermore, systems and methods may enable access without pulling a completion while maintaining production with reduced installation costs.
Systems and methods of the present disclosure may be directed toward one or more wellbore operations, which may include operations such as production/recovery and/or injection, among others, to reconfigure an existing XT to have a modified flow path without removing, for example, an existing completion associated with the existing XT. One or more embodiments may be used to reduce costs and time associated with operations, including production and/or injection, in which recovery of an existing XT may include removal of a completion prior to recovery of the existing XT. One or more embodiments may include subsea production and/or injection systems, which may include XTs. In at least one embodiment, the XT may include, at least in part and as non-limiting examples, one or more of flow control modules (FCMs), chemical distribution systems, subsea control modules (SCMs), and/or flowline connectors. The FCMs may be used to regulate flow and may further include other processing apparatuses and instrumentation, including as non-limiting examples multi-phase flow meters, sensors (e.g., pressure sensors, temperature sensors, corrosion sensors, etc.), and/or injection points for chemicals and sampling. Furthermore, the chemical distribution systems that may be related to XTs may be used to supply to the XT, via umbilical or dedicated hoses, various chemicals or additives for distribution to selected injection points. In at least one embodiment, the selected injection points may be located downhole, in the XT, in the FCM, in the flowline, and/or in a template structure. Furthermore, the SCMs may be used to receive control signals from a remote operator station and translate to control signals controlling functions on the XT, which for instance can include operation of valves, chokes, regulators, and pumps. In operation, the SCMs may communicate with sensors located on or around the XT and related equipment. The flowline connectors may be used to connect the production outlet from the XT to a flowline to export the produced fluids to a production facility like a platform, a floating production storage and offloading (FPSO), or onshore production facility. Accordingly, several operating units may be associated with XTs, which may create a complex structure and network for production and/or injection operations. Removing and reconfiguring each portion of the system, for example to recover the XT, may be time consuming and expensive. Embodiments of the present disclosure may be used to reconfigure one or more flow paths associated with XTs in order to enable reuse of one or more portions of existing equipment and/or to modularly replace or reconfigure one or more sub-systems.
Subsea production systems may require reconfiguration during their operational life. It may be desirable to reconfigure the subsea production system to suit changes in reservoir pressures. By way of non-limiting example, it may be desirable to place a high integrity pressure protection system (HIPPS) module in the well stream during initial production when well pressure may be high, and later remove the HIPPS module when pressures have reduced to utilize the HIPPS module elsewhere. Additionally, one or more portions of the XT may be replaced with a module containing different functionality, such as converting a production system into an injection system. As another example, reconfiguration may include placing a flow measuring device in the well stream after service, for example to enhance monitoring capabilities or the like. Additional non-limiting reconfiguration examples that may be used with embodiments of the present disclosure include at least replacing a module on the subsea production system to gain access for connecting a fluid intervention system to the flow path to inject fluids into the wellbore or flowline, or to empty the flowline of undesirable fluids; circumventing flow of fluids where composition has changed over time to redirect the flow away from components which may have limited compatibility with the new fluid composition; and/or installing new technology into the well stream during the lifetime of the field. Additionally, subsea production systems may require reconfiguration during their operational life to mitigate damage to equipment in service, which may include isolating a damaged barrier which functions prevent hydrocarbons or water leak out into the external environment; replacing a sensor which are no longer accurate, or which has stopped working; isolating from pressurized fluids a component where corrosion, erosion, or other degradation mechanisms have compromised the integrity of the component; redirecting flow to circumvent a blocked low path; and/or redirecting a control signal to a new operator in case an existing operator malfunctions (e.g., a valve actuator).
Systems and methods of the present disclosure may be used to enable continued hydrocarbon production without the recovery of a downhole completion and XT, which may include in one or more non-limiting embodiments an HXT, thereby enabling damaged or otherwise unused in-service components to be circumvented. Embodiments may also be used in new installation and/or with replacement installations to provide future options for fields in later production and/or injection years. In at least one embodiment, a subsea system, which in one or more embodiments may be referred to as a vertical isolation flow tree (VIFT) system includes one or more flow control and well barrier elements, a completion sleeve extending into an existing wellbore, and a block of valves (e.g., a valve assembly) which provide a controllable interface to the installed system. Systems and methods may also incorporate an internal tree cap (ITC) to provide a second barrier above a swab valve. The ITC may also provide a latching interface for an intervention landing string. Additionally, systems and methods associated with the subsea system may further include, a flowline connector, and one or more auxiliary supplies. In at least one embodiment, the auxiliary supplies may include chemical supply lines, control lines, power supply lines and other service lines which again may as an example include test and vent lines.
As discussed herein, in at least one embodiment, a sleeve extends into a bore of the XT, with the sleeve blocking an XT production flow path to a first outlet in the XT. The system also includes a valve assembly fluidly coupled to an outlet on the XT, where the XT outlet is in fluid communication with a bore extending through the sleeve. The valve assembly may take the form of a secondary XT, such as a VXT, but may also or alternatively be an HXT, a cap, and/or a set of valves, among other options. The system may further includes a bridging module arranged in fluid communication with an outlet from the valve assembly and an FCM, wherein the bridging module includes a first inlet in fluid communication with the outlet from the valve assembly, a first outlet in fluid communication with an inlet on the FCM, a second inlet in fluid communication with an outlet on the FCM, and a second outlet in fluid communication with a flowline connector. One or more embodiments may further include an SCM assembly including at least an adapter assembly, which may also be referred to as an adapter plate, wherein the adapter plate is configured to reroute at least a portion of the one or more auxiliary supplies to the valve assembly. Systems and methods may also include one or more additional adapter assemblies, which may also be referred to as at least one multiple quick connection (MQC) sandwich plate, wherein the MQC sandwich plate includes a first MQC plate connectable with an associated MQC plate on the subsea system, for example on the XT or FCM, and a second MQC plate connectable with an umbilical or hose bundle. The MQC sandwich plate can be selectively configured to allow auxiliary lines from the umbilical or hose bundle to communicate with corresponding functions in the subsea system, for example valves, chokes, or connectors in the XT, FCM, or a template structure, or to be redirected to at least one subsea connectable connector on the sandwich plate for rerouting to an alternative function in the subsea system via flying leads.
In an embodiment, the bridging module includes an additional inlet in fluid communication with an outlet on the XT, wherein upon connecting the bridging module to the outlet in the XT the outlet on the XT is closed. The closure may be effected by components such as a blind bore in the bridging module, a blind seal ring, or a sealing device (e.g., a plug) retained in the bore by the bridging module connector.
In an embodiment, the bridging module is connected to a connector half on the XT, wherein the connector half on the XT includes an outlet in fluid communication with the XT and an inlet in fluid communication with a flowline. The bridging module includes an interface for its first outlet and second inlet arranged to be connectable with a connector also compatible with the connector half on the XT. The FCM may be selectively connected to the connector half on the bridging module or the connector half on the XT, respectively, when the bridging module is present or not. The connector halves may be a hub, a mandrel, or any other type of subsea mateable connector. The connectors may also include auxiliary supplies.
In one or more alternative embodiments, the bridging module is arranged to interface with two separate connectors, one located on the XT and a second connector located in a template structure or as a part of a flowline. The bridging module may include a similar interface with two connectors for selectively connecting an FCM to the XT or bridging module.
Additionally, in one or more embodiments, the bridging module is arranged with a second outlet for fluidly connecting to a flowline. The second outlet on the bridging module may be configured to close an alternative flow path from the FCM/bridging module connector to the flowline connector. The flow path from the second outlet on the bridging module to the flowline connector may include a connector half arranged to be connected to the flowline connector. The connector half may be arranged for connecting to the flowline connector, which in at least one embodiment, may be structurally supported by a flowline connector half on the XT, a structural element of the XT, or by a template.
In an embodiment, systems and methods of the present disclosure may include at least one of the features described herein reconfigure a subsea production system to redirect flow away from a portion of an installed subsea XT, wherein at least a portion of the XT is no longer operating as intended. The flow may redirected through the bore of the sleeve, through a valve assembly via a bridging module to an FCM, and onto a flowline connector via a bridging module.
In one or more embodiments, the sleeve blocking a production flow path in the XT is replaced with a closed valve or plug in the flow path of the XT. The valve assembly may be fluidly connected to an outlet in the XT, wherein the closed valve or plug is directing the flow towards the outlet in the XT. Closures which may be otherwise present in the flow path between the now closed flow branch and the outlet may be opened or removed to allow flow into the valve assembly.
In an embodiment, systems and methods including at least one of the features described herein are used to reconfigure a subsea production system to redirect flow away from a portion of an installed subsea XT, wherein at least a portion of the XT is no longer operating as intended. The flow may be redirected via a bridging module to an FCM and onto a flowline connector via a bridging modules third outlet.
In at least one embodiment, the flow through an XT is redirected to flow out via the re-entry mandrel of the XT, wherein a valve assembly is fluidly connected to the re-entry mandrel.
In at least one embodiment, redirected auxiliary supplies include at least one hydraulic or electrical control line to operate at least one valve in a valve assembly. Furthermore, the redirected auxiliary supplies may include at least one electric or optical line to operate at least one sensor, choke, or other instrumentation in the valve assembly. Additionally, the redirected auxiliary supplies may be used to operate at least one or more combinations of hydraulic, electric, and optical lines to control functions in the valve assembly.
In at least one embodiment, redirected auxiliary supplies include at least one hydraulic or electrical control line to operate a valve or choke in an FCM. Furthermore, the redirected auxiliary supplies may include at least one electric or optical line to operate at least one sensor or other instrumentation in the FCM. Additionally, the redirected auxiliary supplies may be used to operate at least one or more combinations of hydraulic, electric, and optical lines to control functions in the FCM.
In an embodiment, a system to convert an HXT into a VXT includes a sleeve extending into a bore of the HXT configured to block an HXT production flow path. The system also includes a bridging module coupled to an inlet flow path of a flow control module (FCM), wherein the bridging module is configured to block an HXT flow path associated with the HXT production flow path and to direct a new flow path, associated with the VXT, into the FCM. The system further includes an adapter assembly coupled to a subsea control module (SCM), wherein the adapter assembly is configured to reroute support systems (e.g., auxiliary systems) for the HXT to the VXT.
In another embodiment, a method includes retrieving an SCM from an XT. The method also includes coupling an adapter assembly to the SCM to form an SCM assembly. The method further includes installing the SCM assembly into a first opening of the XT. The method includes retrieving a flow control module (FCM) from the XT. The method also includes coupling a bridging module to the FCM to form an assembly. The method includes installing at least a portion of the assembly into a second opening of the XT. The method also includes installing a valve assembly onto the XT.
In an embodiment, a method includes closing a flow path in an XT to redirect flow to an alternative outlet, locating a valve assembly fluidly connected to the alternative outlet of the XT and locating a bridging module in fluid communication with an outlet from the valve assembly, wherein the bridging module includes a first inlet fluidly connected to an outlet of the valve assembly, a first outlet and a second inlet fluidly connected to an FCM and a second outlet fluidly connected to a flowline connector.
In an embodiment, a method includes locating a bridging module in fluid communication with an outlet from a XT, the inlet and outlet of a FCM and further to locate a flow path from an outlet on the bridging module to a flowline connector, wherein the bridging module includes a first inlet, a first outlet, a second inlet, a second outlet closing an alternative flow path to a flowline connector and a third outlet fluidly connected to a flowline connector. In a variation of this embodiment at least one sensor or chemical injection branch is located in or on the flow path between the third outlet of the bridging module and the flowline connector.
In an embodiment, a method includes locating an SCM adapter on a subsea production system to redirect auxiliary supplies.
In an embodiment, a method includes locating an SCM adapter on a subsea production system to redirect auxiliary supplies, wherein the subsea system includes at least a valve assembly or a bridging module.
In an embodiment, a method includes locating at least one MQC sandwich plate on a subsea production system to redirect auxiliary supplies.
In an embodiment, a method includes locating at least one MQC sandwich plate on a subsea production system to redirect auxiliary supplies, wherein the subsea system includes at least a valve assembly or a bridging module.
It should be understood that the direction of flow may be reversed, thus the apparatuses, systems, and methods disclosed herein are equally applicable to injection systems as to production systems.
FIG. 2A illustrates a schematic representation of an HXT 200, which may be used with embodiments of the present disclosure. This example has removed various components for simplicity with the following discussion. Furthermore, while the example is shown with reference to the HXT 200, it should be appreciated that other XTs may be used within the scope of the present disclosure. The illustrated embodiment includes a subsea control module (SCM) 202, a flow control module (FCM) 204, and a frame 206. As discussed herein, a flow path may be regulated and/or controlled by one or more valves, which may be within one or more flow passages associated with the FCM 204 and/or the HXT 200, to direct hydrocarbons toward one or more production lines. It should be appreciated that the FCM 204 may include other processing apparatuses, including as non-limiting examples chokes to regulate flow; flow meters to measure flow; high integrity protection systems (HIPS) to protect the flowline from overpressure; chemical injection points to inject chemicals into the flow path; fluid intervention access points to inject fluids into the wellbore; and/or sampling points to remove samples from the well stream. Furthermore, various other processing capabilities may also be integrated into the FCM 204. The illustration includes a re-entry mandrel which facilitates connection of a BOP or other subsea well intervention systems which may be used to gain access into the wellbore.
In operation, wellbore fluid may be directed through a completion supported in the HXT 200, which may protrude into the ground below the HXT 200 and penetrate the earth down to the reservoir. In the HXT 200, the completion may direct the wellbore fluid to one or more production flow paths, which may route and/or direct the wellbore fluid into the FCM 204 and out through the production assembly 210 (e.g., flowline connector, flowline assembly, etc.). Embodiments of the present disclosure may be used to replace one or more components of the HXT 200 and/or to reconfigure the HXT 200 such that wellbore fluid is no longer directed through the production flow path and, instead, is diverted into a new flow path associated with an installed valve assembly. The conversion of the HXT 200 may include removal of one or more components and reinstalling additional or alternative components into one or more openings 212 or regions of the HXT frame 206. For example, the frame 206 may refer to one or more structural components and/or associated infrastructure, which may include openings, support systems, valves, piping, chemical connections, and/or the like. Systems and methods may also reuse and/or redirect various components associated with the HXT 200, such as using existing hydraulic and/or electrical connections to provide control to the installed valve assembly. Similarly, various chemicals may be rerouted or otherwise redirected so that the valve assembly and/or other associated components may continue operation without additional removal or structural modification to the HXT 200. Systems and methods may be directed toward installation of a VIFT system and/or a valve assembly onto a subsea structure associated with a horizontal tree, by-passing the existing flow from the HXT through the vertical tree system, and then operating the newly installed system such that the flow is reconnected to the same subsea structure while being routed through the vertical tree system.
FIG. 2B illustrates a schematic representation of a flow configuration 220 for the HXT 200. As discussed, one or more components may be omitted for clarity and conciseness, such as various sensors (e.g., pressure sensors, temperature sensors, etc.), valves, bypass lines, hangers, and/or the like. Furthermore, while only certain valves may be identified and discussed herein, the HXT 200 may include a number of different valves, as illustrated in FIG. 2B. In this configuration a wellhead 222 is illustrated, which may include a connector, to secure the HXT 200 to the wellhead 222. A valve 224 is shown within a wellbore, which may be casing valve, which may be used to, at least partially, block in flow for the wellbore. A production flow path 226 extends through the wellhead 222 and the HXT 200, which may include one or more closures in the production bore, such as, but not limited to, plugs, caps, and/or combinations thereof. Variations of caps include small valves for testing purposes, large valves to allow access for workover tools. Alternatively, plugs or blind caps may be used to selectively close and open the bore of the cap. In operation, valves 232 are arranged along a takeoff 234 associated with the production flow path 226. In this example, the takeoff 234 may refer to a flow path extending from the production flow path 226. As discussed herein, when positioning a closure in the production flow path 226, the closure will block flow into the takeoff 234, while still enabling flow through other portions of the production flow path 226. The takeoff 234 may also be referred to as an original flow path for the HXT 200 in embodiments where the VIFT system is used to convert an existing XT. In this example, the takeoff 234 is shown to extend off of the production flow path 226. Further shown is an annulus flow path 236 with its own respective valves 230.
In operation, if one or more components of the takeoff 234 and/or components associated with the takeoff 234 are damaged or otherwise inoperable, the HXT 200 may need to be taken out of service, retrieved, repaired, and then repositioned for operation. The process of removing the HXT 200 is expensive and time consuming, leading to both costs associated with retrieval and downtime for the wellbore. Embodiments of the present disclosure may address and overcome this problem by providing one or more modular adapters to reconfiguring the HXT 200 to continue production, which may include, in one or more non-limiting embodiments, converting the HXT 200 into a VXT. Additionally, or alternatively, the HXT 200 may be reconfigured to gain new or added functionality in the XT. Reconfiguring the HXT 200 may provide significant savings because the completion can be left in place, as opposed to traditional systems where HXT recovery includes first removing the completion.. In other words, the reconfiguration may reuse certain infrastructure of the HXT 200, such as the frame 206 and/or the like, thereby enabling a cheaper and faster repair, reducing downtime and repair expenses by avoiding the costly operation of pulling and reinstalling the completion.
FIG. 3A illustrates an example schematic diagram of a modified flow configuration 300 that may be implemented by embodiments of the present disclosure. As discussed herein, installation of the VIFT system may reroute an existing flow configuration (e.g., the flow configuration 220) to redirect flow through a valve assembly using one or more modular components, such as the bridging module discussed herein. In this configuration 300, a series of conversion subsea structures/assemblies form the VIFT system to support the conversion of the installed HXT 200. The VIFT system diverts the flow away from the wing block assembly 320 and to the re-entry mandrel. For example, a sleeve 304 may be inserted through the original XT re-entry mandrel to block flow into the takeoff 234, thereby forming a redirected production flow path 306 (e.g., new production flow path). The redirected production flow path 306 may also include a variety of components for operation, such as various valves, sensors, jumpers, and/or the like. Furthermore, the valve assembly 302 may include the cap 228, which in this example is an internal cap. In this manner, systems and methods of the present disclosure may be used to reroute or otherwise modify a flow path for the HXT 200 by using the VIFT system. As discussed herein, prior to restoring the flow to the jumper/flowline, through a bridging module 402 fluidly coupled to the HXT FCM 204, controls and chemicals may be rerouted from the HXT 200 to the VIFT system via one or more adapter assemblies, which may include in one or more non-limiting embodiments an adapter plate, an MQC sandwich plate, and/or the like. The one or more adapter assemblies may be used to reroute or redirect fluids and/or the like. Any unused chemical connections may also be isolated on the HXT 200. The chemical supply lines may also be isolated in the MQC sandwich plate.
In this example, the sleeve 304 extends into a bore 310 of the HXT 200 to block flow along the takeoff 234, as shown in FIG. 3B. For example, the sleeve 304 may extend into a tubing hanger, which suspends the completion from the HXT 200. In one or more embodiments, the sleeve 304 uses elastomeric sealing in order to prevent leakage into the takeoff 234, but it should be appreciated that other sealing configurations like metal-to-metal seals may be used with various embodiments of the present disclosure. In operation, as the flow (e.g., production flow, tubing head flow, hanger flow, etc.), enters the bore 310, the flow is blocked from entering the takeoff 234 associated with the wing block of the HXT 200, and therefore, flows upward through the sleeve 304 and into the valve assembly 302. In this manner, systems and methods may block or otherwise restrict flow from the original flow path of the HXT 200 to the illustrated modified flow path (FIG. 3A) to maintain production to a flowline connector 322 while continuing to use certain components of the HXT 200, thereby reducing and/or eliminating costs associated with removing and recovering the HXT 200.
FIG. 4A illustrates a perspective view of an embodiment of a VIFT assembly 400 that may be used with embodiments of the present disclosure. As discussed herein, the VIFT assembly 400 may include one or more components used to form an overall subsea system. In this example, the FCM 204, which may be a different FCM 204 than the original FCM 204 of the HXT 200 or a new/modified FCM 204, is fluidly coupled to a bridging module 402. In this configuration, the FCM 204 is further positioned axially above the bridging module 402, although the bridging module 402 may be arranged at other locations in one or more embodiments. The illustrated bridging module 402 is used to block or otherwise restrict flow along an original flow path (e.g., a flow path associated with the HXT 200, such as the takeoffs 234 shown in at least FIG. 3A) and to receive and direct flow into the FCM 204 using a diverted flow line 404. As discussed herein, the diverted flow line 404 may receive flow from a valve assembly, such as the non-limiting example of the VXT, which is one example of the valve assembly 302, and then direct the flow into the FCM 204 using the bridging module 402 as an intermediate flow component. One or more embodiments may further incorporate an outlet flow path associated with the bridging module 402 that may reuse an existing flow path and/or form a new flow path, as discussed herein.
In this example, the VIFT assembly 400 is a modular component that may be installed and integrated into the existing infrastructure of the HXT 200, such as to reuse portions of the frame 206, reuse or adapt electrical/chemical connections, and/or the like. In at least one embodiment, the bridging module 402 may be positioned and configured to reuse the existing FCM 204 while receiving flow from the diverted flow path 404. In one or more embodiments, the FCM 204 may be repurposed and/or reused from the HXT 200. For example, the FCM 204 may be removed from the HXT 200, brought to a surface location, such as a vessel, and then be mounted on the bridging module 402 and/or a modular frame structure 406, which may collectively form one or more portions of the VIFT assembly 400. As shown, the modular frame structure may include frame components to support the FCM 204 and the bridging module 402, along with additional frame components to support the diverted flow line 404, which may extend outside, at least partially, of an original footprint of the HXT 200. It should be appreciated that the frame components are provided by way of example and that one or more support structures may extend off of other frame components and/or may reuse or adapt existing HXT components without additional modifications. Because the VIFT assembly 400 may be installed from a surface location, such as a vessel, an alignment post 408 may be integrated into the modular frame structure 406 to simplify installation. For example, the alignment post 408 may be used for installation of the one or more valve assemblies, as discussed herein.
In operation, the VIFT assembly 400 may be aligned with and positioned to fluidly couple to the HXT 200. Furthermore, at least a portion of the VIFT assembly 400 may be supported by, at least in part, an existing portion of the HXT frame 206. Accordingly, the VIFT assembly 400, with the FCM 204 fluidly coupled thereto, may be brought back into position on the HXT infrastructure to process the wellbore fluid. As discussed herein, by mounting the FCM 204 onto the VIFT assembly 400, the bridging module 402 sits between the wellhead and the FCM 204, which may enable modification of the flow path when used, for example, in combination with the sleeve 304 (FIG. 3B).
FIG. 4B illustrates a partial cross-sectional top perspective view of an embodiment of the bridging module 402, which may be used with embodiments of the present disclosure. In this example, the bridging module includes a protective and insulating shell 420. In at least one embodiment, the bridging module 402 is primarily an interconnection spool designed to locate between the FCM 204 and a mounting hub for the FCM within the XT structure infrastructure. In operation, the bridging module 402 isolates and bypasses the upstream connection coming from the XT production wing block (e.g., along the takeoff 234) and the FCM 204 while providing a side inlet to allow fluids from the valve assembly to connect on to the inlet of the FCM 204, for example, via interconnecting spools and a vertical mandrel connector between the valve assembly and the bridging module. Furthermore, the produced fluids are redirected through the interconnection spool back to the original production flowline connector of the host XT. The bridging module 402 may further include various components that are not illustrated or described for clarity and conciseness, such as a mounting clamp assembly, among other features.
FIG. 4C illustrates a cross-sectional schematic view of an embodiment of the bridging module 402 arranged below the FCM 204 in order to divert and redirect flow, as discussed herein. In this example, the bridging module 402 is arranged to block an inlet flow passage 440 that would be used for the HXT (e.g., be fluidly connected with flow take off 234) in a pre-modified configuration. For example, the illustrated bridging module 402 includes a solid portion 442 extending to and capping a passage associated with the inlet flow passage 440. The illustrated solid portion 442 is one non-limiting example, and various alternative configurations may include, for example, a blanking seal. Instead, the bridging module 402 includes an alternative first inlet 444, enabling the bridging module 402 to be an intermediate spool that both isolates the original inlet 440 and brings in the flow via the alternative inlet 444. Thereafter, the FCM 204 can be reused because the flow would continue through the existing process and out to the original jumper, as illustrated by the arrows. Additionally, in one or more embodiments, a different interface and new or modified FCM 204 may be used. In at least one embodiment, the connector interfaces between the bridging module and XT, and between the bridging module and FCM, can be the same allowing interchangeability.
As discussed herein, the configuration shown in FIG. 4C may be directed toward at least one embodiment in which an original inlet flow path (e.g., inlet flow passage 440) is blocked via at least the solid portion 442. Instead of using the inlet flow passage 440, the incorporation of the bridging module 402 redirects inlet flow to the alternative first inlet 444, which may receive a fluid flow from the diverted flow line 402, as shown in FIG. 4A. However, in this example, the original outlet flow passage is maintained. That is, a flow path 450 of the existing system extends through the bridging module 402 (e.g., the flow path 450 is aligned with the bridging module 402) and an original outlet 452 is used for the fluid flow. Accordingly, the example configuration of FIG. 4C may be directed toward at least one embodiment in which the inlet flow path is modified, but the outlet flow path is maintained.
FIG. 4D illustrates a cross-sectional schematic view of an embodiment of the bridging module 402 arranged below the FCM 204 in order to divert and redirect flow, as discussed herein. In this example, the bridging module 402 is arranged such that the inlet flow passage 440 is maintained from the original tree configuration, but the outlet is now redirected, as compared to FIG. 4C, which used the original outlet 452. As a result, the original inlet flow passage 440 is maintained, but a diverted flow path 454 (e.g., a second outlet 492 discussed with reference to FIG. 4G) may be used, for example, to change the output production lines. The diverted flow path 454 is shown as being fluidly coupled to the flow path 450, but instead of continuing to the original outlet 452, is blocked a solid portion 456, which may form a portion of the bridging module 402. In at least one embodiment, downstream piping may be damaged or otherwise ready for replacement. However, as discussed herein, the downstream piping configurations may be coupled to the tree, and therefore, replacement may lead to pulling the tree. Embodiments may enable the use of the bridging module 402 to repair/replace portions of the production flow line by redirecting flow to a new outlet (e.g., along the diverted flow path 454), as discussed herein, while maintaining the original inlet flow passage 440. As a result, the FCM 204 can be reused because the flow would continue through the existing process and out to the original, or a modified, jumper, as illustrated by the arrows. Additionally, in one or more embodiments, a different interface and new or modified FCM 204 may be used. In at least one embodiment, the connector interfaces between the bridging module and XT, and between the bridging module and FCM, can be the same allowing interchangeability.
As discussed herein, the configuration shown in FIG. 4D may be directed toward at least one embodiment in which an original inlet flow path (e.g., inlet flow passage 440) is maintained while the original outlet 452 is blocked via at least the solid portion 456. Instead of using the original outlet 452, the incorporation of the bridging module 402 redirects flow along the outlet flow path 450 to the diverted flow path 454. However, in this example, the inlet flow passage 450 is maintained. That is, the flow path 450 of the existing system extends through the bridging module 402 (e.g., the flow path 450 is aligned with the bridging module 402) and the original outlet 452 is blocked so that the diverted flow path 454 is coupled to the flow path 450. Accordingly, the example configuration of FIG. 4D may be directed toward at least one embodiment in which the inlet flow path is maintained, but the outlet flow path is modified.
FIG. 4E illustrates a cross-sectional schematic view of an embodiment of the bridging module 402 arranged below the FCM 204 in order to divert and redirect flow, as discussed herein. In this example, the bridging module 402 is arranged to block and inlet flow passage 440 that would be used for the HXT (e.g., be fluidly connected with flow take off 234) in a pre-modified configuration, similar to the configuration of FIG. 4C. For example, the illustrated bridging module 402 includes the solid portion 442 extending to and capping a passage associated with the inlet flow passage 440. The illustrated solid portion 442 is one non-limiting example, as discussed herein. Instead, the bridging module 402 includes the alternative first inlet 444, enabling the bridging module 402 to be an intermediate spool that both isolates the original inlet 440 and brings in the flow via the alternative inlet 444.
As discussed herein, the configuration shown in FIG. 4E may further be directed toward a configuration in which the bridging module 402 is used to redirect the outlet flow, similar to the configuration in FIG. 4D. As a result, both the original inlet flow passage 440 is blocked and the original outlet 452 is also blocked, for example, by the solid portion 456, which is shown as one non-limiting example configuration. Embodiments may enable the use of the bridging module 402 to repair/replace portions of a production flow line by redirecting flow to a new outlet (e.g., along the diverted flow path 454), as discussed herein, while also using the alternative inlet 444.
As discussed herein, the configuration shown in FIG. 4E may be directed toward at least one embodiment in which both an original inlet flow path (e.g., the inlet flow passage 44) and an original outlet (e.g., the original outlet 452) are each blocked in favor of alternative inlets and outlets, respectively. Instead of using the inlet flow passage 440, the incorporation of the bridging module 402 redirects inlet flow to the alternative first inlet 444, which may receive a fluid flow from the diverted flow line 402, as shown in FIG. 4A. The flow path 450 through the bridging module 402 may then be maintained, for at least a portion of the bridging module 402, and is then redirected along the diverted flow path 452. Accordingly, the example configuration of FIG. 4C may be directed toward at least one embodiment in which both the inlet flow path and the outlet flow path are modified
FIG. 4F illustrates a perspective view of an embodiment of a flow configuration 460 that may be used with embodiments of the present disclosure in which the bridging module 402 is installed below the FCM 204 in order to form a diverted flow path, as discussed herein. The illustrated embodiment includes a first flow representation 462 corresponding to the original flow path of the HXT 200 and a second flow representation 464 corresponding to the new flow path via incorporation of one or more components of the VIFT system, such as the bridging module 402, the sleeve 304, the valve assembly 302, and/or combinations thereof.
Turning to the first flow representation 462, a pre-modified HXT will receive fluid from the wellbore along the production flow path (not visible) that will then branch out horizontally at the takeoff 234, which is schematically represented by the first flow representation 462 but would not be otherwise visible due to the frame and associated components. The takeoff 234 would then direct the fluid through the HXT valves and into the FCM 204 at the inlet flow passage 440. Embodiments of the present disclosure eliminate the first flow representation 462 using the sleeve 304 (not visible) to block the takeoff 234 so that flow is redirected into a valve assembly 302, which may include the VXT. Embodiments further incorporate the diverted flow line 404 (e.g., the new production flow path 306), from the valve assembly 302, to provide the fluid to the bridging module 402 at the alternative inlet 444. As shown, the flow then continues through the FCM 204 and out to a jumper or other connection associated with the flowline connector 210. Accordingly, systems and methods may be used to address problems or leakages with the HXT while continuing to use various HXT infrastructure, such as various structural elements, frames, valves, chemicals, and the like.
FIG. 4G illustrates a schematic representation of an embodiment of a system 470 to reconfigure a flow path associated with an XT 472, which may be associated with one or more XTs discussed herein, such as the HXT 200, among other options. In the illustrated configuration, a bridging module 474 is positioned to redirect a flow path of the XT 472. As shown, an original flow path 476 (which may correspond to the first flow path 462 and/or be associated with the original outlet 452) is blocked, using the bridging module 474, in favor of a new outlet flow path 478 (which may correspond to the second flow path 464) to redirect flow from an FCM 480 to a flowline connector, which may be new flowline connector 482A or an original flowline connector 482B, thereby permitting fluid flow out of the XT 472 and into a flowline 484. In at least one embodiment, the configuration in FIG. 4G may correspond to the redirected flow of FIG. 4E, in which both a new inlet and new outlet flow are established using the bridging module.
In this example, the illustrated bridging module 474 includes a first inlet 486 to receive an inlet flow, a first outlet 488 coupled to an inlet of the FCM 480, a second inlet 490 coupled to an outlet of the FCM 480, and a second outlet 492 to direct flow to the flowline connector 482. In this example, the second outlet 492 may correspond to the diverted flow path 454 shown in FIG. 4E. Embodiments of the present disclosure may reuse or reconfigure existing components, such as one or more chemical injection branches 494 and/or various sensors 496. One or more embodiments may include new components in the new flow path 478, to replace similar components in the old flow path 476 or alternatively to reconfigure the system to provide additional functionality by including new components in the new flow path 478.
FIG. 4H illustrates a schematic representation of an embodiment of a system 458 to reconfigure a flow path associated with the XT 472, which may be associated with one or more XTs discussed herein, such as the HXT 200, among other options. In the illustrated configuration, the bridging module 474 is positioned to redirect a flow path of the XT 472. As shown, the original outlet flow path 476 (which may correspond to the first flow path 462 and/or the original outlet 452) is blocked, using the bridging module 474, in favor of the new flow path 478 (which may correspond to the second flow path 464 and/or to the diverted flow path 454) to redirect flow from the FCM 480 to the flowline connector, which may be the new flowline connector 482A or the original flowline connector 482B, thereby permitting fluid flow out of the XT 472 and into the flowline 484.
In this example, the illustrated bridging module 474 reuses the original inlet flow passage 440 of the XT 472. For example, the bridging module 474 may be used in embodiments where the original inlet is operational, but one or more downstream areas for the production components (e.g., tubular components, branch outlets/inlets, connections, sensors, valves, etc.) are damaged or otherwise in need or repair or replacement, thereby enabling continued use of the operational portion of the XT 472 with only modifications to the production tubing. Accordingly, in this example, flow enters through the inlet flow passage 440 and into the first inlet 486, where the flow is directed through the bridging module 474 and into the FCM 480 at the first outlet 488. Flow may then pass through the FCM 480 and reenter the bridging module 474 at the second inlet 490. The bridging module 474 may then further divert the flow from the original flow path 476 to the new flow path 478 via the second outlet 492, which may correspond to the diverted flow path 454 shown in FIG. 4D. In this manner, flow is directed toward the flowline 484, which may be coupled to one or more flowline connectors (e.g., the original or new flowline connectors 482A, 482B). In at least one embodiment, the configuration in FIG. 4H may correspond to the redirected flow of FIG. 4D, in which the original inlet is reused but a new outlet flow path is formed by the bridging module.
FIG. 4I illustrates a schematic representation of an embodiment of a system 498 to reconfigure a flow path associated with the XT 472, which may be associated with one or more XTs discussed herein, such as the HXT 200, among other options. In the illustrated configuration, the bridging module 474 is positioned to redirect a flow path of the XT 472. As shown, the original outlet flow path 476 (which may correspond to the first flow path 462 and/or the original outlet 452) is maintained, while the original inlet 440 is blocked, in favor of the alternative flow path (e.g., the alternative inlet 444). Accordingly, flow may be maintained along the original flow path 476 to the flowline connector, which may be the new flowline connector 482A or the original flowline connector 482B, thereby permitting fluid flow out of the XT 472 and into the flowline 484.
In this example, the illustrated bridging module 474 reuses the original outlet flow passage 476. However, in this example, flow enters through the alternative flow passage 444 (represented by the inlet flow) and into the first inlet 486, where the flow is directed through the bridging module 474 and into the FCM 480 at the first outlet 488. Flow may then pass through the FCM 480 and reenter the bridging module 474 at the second inlet 490. The bridging module 474 may then further direct the flow to original flow path 476 via the second outlet 492. As shown in this example, the second outlet 492 is at a different position compared to the configurations shown in FIGS. 4G and 4H because the original flow path 476 is used (e.g., the flow path 452 in FIG. 4C), as opposed to the new flow path 478 (e.g., the flow path associated with the diverted flow path 454). In this manner, flow is directed toward the flowline 484, which may be coupled to one or more flowline connectors 482 (e.g., the original or new flowline connectors 482A, 482B). In at least one embodiment, the configuration in FIG. 4I may correspond to the redirected flow of FIG. 4C, in which the original inlet is replaced but the original outlet is used.
FIGS. 5A-5C illustrate a perspective views of an embodiment of a VIFT system 500 and/or components thereof, which may be used with embodiments of the present disclosure. In this example, the VIFT system 500 includes multiple different modules (e.g., components, systems, sub-systems, sub-assemblies, assemblies, etc.) that may be incorporated into existing HXT infrastructure, such as the frame 206 and/or the like. In this example, the VIFT system 500 includes the bridging module 402, the valve assembly 302, an adapter plate 502 associated with the SCM 202, one or more sandwich plates 504, and one or more components of the VIFT assembly 400 (e.g., components such as the diverted flow line 404, the modular frame structure 406, and/or the alignment post 408, etc.). In at least one embodiment, the VIFT system 500 may be used to reconfigure one or more flow paths for the HXT. In this manner, the HXT may not need to be pulled when there is a leak or failure, or other maintenance concern. Instead, operators may install one or more components of the VIFT system 500 to redirect flow and continue operating the well.
As shown, the frame 206 continues to support various features of the VIFT system 500, such as the bridging module 402 positioned under the FCM 204. Additionally, the modular frame structure 406 and diverted flow line 404 are also supported by and integrated into the frame 206, thereby providing a smaller footprint than alternative configurations, such as installing a separate HXT or processing system next to the existing HXT. The valve assembly 302 (not pictured), would be installed at the top of the frame 206 to couple to the diverted flow line 404 and may be placed by using the alignment post 408, for example by arranging a mating component to attach to the alignment post 408 to ensure the valve assembly 302 is installed in a desired orientation.
Embodiments of the present disclosure may also include the adapter plate 502 associated with the FCM, as shown in FIG. 5B. The adapter plate 502 may be used to repurpose redundant HXT control functions to control the valve assembly 302. As discussed, because the bridging module 402 may remove or otherwise block the original flow path of the original HXT, the functions need to be transferred over to the valve assembly 302. For example, one or more components such as isolation valves, sensors, chemical injection points, and/or the like may be moved and replaced using the valve assembly 302. As a result, the adapter plate 502 may be included to take away the functions that are no longer needed for the HXT and repurpose those connections onto the valve assembly.
FIG. 5C illustrates the one or more sandwich plates 504 that may be used to enable transfer of chemical supplies to the HXT and to divert chemicals to the valve assembly 302. In operation, stabs associated with the sandwich plate 504 and associated chemical hoses, are sized to support the required chemical flowrate in conjunction with the supply/injection pressures.
In one or more embodiments, the MQC sandwich plate includes a first MQC 510 for connecting towards an umbilical or hose bundle 514 through auxiliary supplies to the XT. A second MQC 512 connects the sandwich plate 516 to the XT MQC plate. At least one subsea mateable coupling redirects at least one auxiliary line towards the VIFT system. One or several auxiliary supplies can be isolated in the MQC sandwich plate.
Accordingly, systems and methods may use the VIFT system 500 to redirect flows associated with undersea XTs. In one or more embodiments, the VIFT system 500 includes a set of modules/assemblies that work together to redirect the production flow of an installed HXT and direct/control the flow to a new production outlet. One or more embodiments may include a VXT as the valve assembly; the bridging module to switch the production flow path from the HXT to the VXT; a sleeve (e.g., a tubing hanger production straddle sleeve) to direct the produced fluids within the HXT tubing hanger to the VXT; an internal tree cap (ITC) to provide a second barrier above the swab valves of the VXT; the SCM adapter plate to provide production controls to one or more components of the VXT; and the sandwich plate to enable transfer of the chemical supply to the HXT and divert chemicals to the VXT.
FIG. 5D illustrates a partial and simplified schematic view of the SCM 202 with the adapter plate 502 connected to the XT via an SCM mounting base (SCMMB) 520. In this example, a number of lines connect from the SCM 502 to a wider subsea production system, where the number is selected as an example to illustrate the principle and is not intended to limit a number of potential lines or connections extending to and/or from the SCM 502. The lines exiting the SCM 202 connect to corresponding lines in an adapter spool 522 via couplers or connectors 524. In the adapter spool 522, some lines are directed to connect to corresponding lines in the HXT via the SCMMB 520. Other lines in the adapter spool 522 are redirected to a new connector (e.g., an MQC Plate or any other suitable device, such as a multi port hot stab). Additionally, in the example, a flying lead 526 is connectable to the new connector to connect the lines from the SCM 202 with new functions in the VIFT System. In one or more embodiments, some lines in the HXT may no longer be required, and therefore, are shown blanked at the connection between the SCMMB 520 and the adapter spool 522. The control functions in the SCM 202 previously associated with the now redundant functions in the XT are thus shown redirected towards the VIFT System.
FIGS. 6A-6F illustrate representations in a sequence for converting the HXT using the VIFT system 500. FIG. 6A includes the HXT 200 including the SCM 202 and the FCM 204 supported by the frame 206. In operation, it may be desirable to modify the HXT 200 using one or more components of the VIFT system 500. As shown in FIG. 6B, the SCM 202 may be retrieved and the SCM 202, or a different SCM 202, may be coupled to the adapter plate 502 and then reinstalled within the structure of the HXT 200, for example within a slot 212. Next, FIG. 6C illustrates retrieval of the FCM 204 and the installation of the VIFT assembly 400, such as the bridging module 402 coupled to the FCM 204 and modular frame structure 406 along with the alignment post 408. In at least one embodiment, the FCM 204 may be reused. In other embodiments, the FCM 204 used for the installation may be a different FCM 204. One or more components may be directed toward the slot 212 to modify the flow path for the HXT.
FIG. 6D illustrates an example configuration after installation of the VIFT system 500, including the SCM 202 with the adapter plate 502 and the FCM 204 with the bridging module 402. As shown, when compared to FIG. 6A, there is a vertical difference at certain locations due to the additional of the adapter plate 502 and the bridging module 402. Furthermore, one or more embodiments may also install the one or more sandwich plates 504. FIG. 6E illustrates running of the valve assembly 302, which may then lead to the installation of the various leads/hoses to transfer operation from the HXT to the valve assembly 302. In one or more embodiments, the alignment post 408 may be used to position the valve assembly 300, for example by a mating connection 600 that is aligned with the alignment post 408 during installation. Furthermore, the ICT may be run or may be preinstalled prior to installation of the valve assembly 302. In this manner, systems and methods may convert the HXT 200 flow path to use a different flow path associated with a valve assembly. FIG. 6F illustrates a side view of the valve assembly 302 installed and positioned on the HXT 200 to redirect flow. For example, the mating connection 600 may receive the alignment post 408 to enable the valve assembly 302 to be arranged on the frame 206.
FIG. 7 illustrates a flow chart of an example process 700 to convert a flow path for an XT (e.g., an HXT) to different flow path using one or more valve assemblies that may be used with embodiments of the present disclosure. For this process, and all other processes discussed herein, different steps or actions may be performed in a different order, or in parallel, unless explicitly stated otherwise. In this example, an SCM is retrieved from an XT 702, which as discussed herein, may include an HXT in various embodiments. The SCM may be pulled from a structural infrastructure of the XT. In at least one embodiment, the SCM may be coupled to an adapter assembly to form an SCM assembly 704. The SCM may be coupled to the adapter assembly at a surface location, such as a vessel. Additionally, the SCM may be replaced and the SCM assembly may include a different SCM in various embodiments. In at least one embodiment, the SCM assembly may then be installed into a first opening of the XT 706. The first opening may correspond to the same position as the original location of the SCM. As a result, no new infrastructure may be used to incorporate the SCM assembly, enabling reuse of the XT, or at least portions thereof.
In one or more embodiments, an FCM may be retrieved from the XT 708. The FCM may then be coupled to a bridging module to form at least a portion of a VIFT assembly 710. As discussed herein, the FCM may be reused and coupled to the bridging module at a surface location, such as a vessel, or a different FCM may be coupled to the bridging module to replace the original FCM associated with the XT. Additionally, in various embodiments, the VIFT assembly may further include additional structural components, such as a frame or alignment post, among other options. The VIFT assembly may then be installed into a second opening of the XT 712, which may be the same opening that the original FCM was removed from. As discussed, the VIFT assembly may be incorporated into the original infrastructure of the XT, thereby reducing or eliminating embodiments where the XT is entirely recovered. After installation of the VIFT assembly, one or more embodiments may then install a valve assembly 714 onto the XT. The valve assembly may be a VXT in one or more embodiments. Upon installation of the valve assembly, various routing configurations may be formed to bypass the original XT flow path in favor of the valve assembly.
FIG. 8 illustrates a flow chart of an example process 800 that may be used with embodiments of the present disclosure. In this example, a sleeve is installed within a flow bore of an XT such that the sleeve blocks one or more outlet passages 802. The sleeve may be arranged to block a passage toward a wing valve block and/or additional passages. A bridging module may then be fluidly coupled to an FCM of the XT 804. For example, the bridging module may be arranged to receive a redirected flow path associated with the sleeve. In at least one embodiment, the bridging module is installed axially lower than the FCM of the XT. In one or more embodiments, a valve assembly is installed onto the XT 806 and a diverted flow line is coupled between the valve assembly and the bridging module 808. The use of the diverted flow line may cause flow through the diverted flow line to flow through the FCM 810, for example via a coupling between the bridging module and the FCM. In this manner, the XT may be converted to use an alternative flow path.
Embodiments may also be described in view of the following clauses:
1. A subsea system, comprising:
2. The subsea system of clause 1, wherein the VIFT assembly further comprises:
3. The subsea system of clause 2, wherein the VIFT assembly further comprises:
4. The subsea system of clause 1, further comprising:
5. The subsea system of clause 1, wherein the VIFT system reuses at least a portion of the one or more HXT structural elements and the HXT is not removed from a subsea location for installation of the VIFT system.
6. A system to modify a subsea Christmas tree (XT), comprising:
7. The system of clause 6, further comprising:
8. The system of clause 7, further comprising:
9. The system of clause 6, further comprising:
10. The system of clause 6, wherein the first bridging module inlet corresponds to an original XT flow path.
11. The system of clause 6, wherein the first bridging module inlet corresponds to a modified XT flow path and the bridging module, when installed axially below the processing apparatus, further blocks the original inlet via the blocking region.
12. The system of clause 6, wherein the second bridging module outlet corresponds to a modified outlet flow path different from an original outlet flow path.
13. The system of clause 6, wherein the second bridging module outlet is configured to couple to an existing outlet flow path.
14. A system to modify a subsea Christmas tree (XT), comprising:
15. The system of clause 14, wherein the first bridging module inlet corresponds to an original XT flow path.
16. The system of clause 14, wherein the second bridging module outlet corresponds to a modified outlet flow path different from an original outlet flow path.
17. A subsea system, comprising:
18. The subsea system of clause 17, wherein the closure in the flow path is at least one of a sleeve, a closed valve, or a plug.
19. The subsea system of clause 17, wherein the processing apparatus is a flow control module (FCM).
20. The subsea system of clause 17, further comprising:
21. The subsea system of clause 17, further comprising:
22. The subsea system of clause 17, wherein the bridging module is configured to close at least one of a flow outlet from the XT or a flow path towards a flowline connector.
23. The subsea system of clause 17, wherein the second outlet is fluidly coupled to a first flowline connector.
24. The subsea system of clause 23, wherein a second flowline connector in fluid communication with the second outlet is structurally supported by at least one of the first flowline connector, a structural element of the XT, or a structural element of a template.
25. The subsea system of clause 17, wherein the XT is a horizonal XT and the valve assembly is a vertical XT.
26. A subsea system, comprising:
27. The subsea system of clause 25, wherein the VIFT assembly further comprises:
28. The subsea system of any of clause 26 or 27, wherein the VIFT assembly further comprises:
29. The subsea system of any of clauses 26-28, further comprising:
30. The subsea system of any of clauses 26-29, wherein the VIFT system reuses at least a portion of the one or more HXT structural elements and the HXT is not removed from a subsea location for installation of the VIFT system.
31. A system to modify a subsea Christmas tree (XT), comprising:
32. The system of clause 31, further comprising:
33. The system of clause 32, further comprising:
34. The system of any of clauses 31-33, further comprising:
35. The system of any of clauses 31-34, wherein the first bridging module inlet corresponds to an original XT flow path.
36. The system of any of clauses 31-35, wherein the first bridging module inlet corresponds to a modified XT flow path and the bridging module, when installed axially below the processing apparatus, further blocks the original inlet via the blocking region.
37. The system of any of clauses 31-36, wherein the second bridging module outlet corresponds to a modified outlet flow path different from an original outlet flow path.
38. The system of any of clauses 31-38, wherein the second bridging module outlet is configured to couple to an existing outlet flow path.
39. A system to modify a subsea Christmas tree (XT), comprising:
40. The system of clause 39, wherein the first bridging module inlet corresponds to an original XT flow path.
41. The system of any of clauses 39 or 40, wherein the second bridging module outlet corresponds to a modified outlet flow path different from an original outlet flow path.
42. A subsea system, comprising:
43. The subsea system of clause 42, wherein the closure in the flow path is at least one of a sleeve, a closed valve, or a plug.
44. The subsea system of any of clauses 42 or 43, wherein the processing apparatus is a flow control module (FCM).
45. The subsea system of any of clauses 42-44, further comprising:
46. The subsea system of any of clauses 42-45, further comprising:
47. The subsea system of any of clauses 42-46, wherein the bridging module is configured to close at least one of a flow outlet from the XT or a flow path towards a flowline connector.
48. The subsea system of any of clauses 42-47, wherein the second outlet is fluidly coupled to a first flowline connector.
49. The subsea system of clause 48, wherein a second flowline connector in fluid communication with the second outlet is structurally supported by at least one of the first flowline connector, a structural element of the XT, or a structural element of a template.
50. The subsea system of any of clauses 42-49, wherein the XT is a horizonal XT and the valve assembly is a vertical XT.
The foregoing disclosure and description of the disclosed embodiments is illustrative and explanatory of the embodiments of the invention. Various changes in the details of the illustrated embodiments can be made within the scope of the appended claims without departing from the true spirit of the disclosure. The embodiments of the present disclosure should only be limited by the
following claims and their legal equivalents.
1. A subsea system, comprising:
a horizontal Christmas tree (HXT), comprising:
one or more HXT structural elements;
a completion extending into a wellbore associated with the HXT;
a production assembly; and
one or more auxiliary supplies; and
a vertical isolation flow tree (VIFT) system, comprising:
a sleeve extending into the completion, the sleeve blocking an HXT production flow path;
a vertical XT (VXT) fluidly coupled to a bore extending through the sleeve;
a VIFT assembly including at least a bridging module arranged axially below a flow control module (FCM), wherein the bridging module is configured to both block an original inlet flow path associated with the production flow path and to direct a new flow path, associated with the VXT, into the FCM; and
a subsea control module (SCM) assembly including at least an adapter plate, wherein the adapter plate is configured to reroute at least a portion of the one or more auxiliary supplies to the VXT.
2. The subsea system of claim 1, wherein the VIFT assembly further comprises:
a diverted flow line extending between the VXT and the bridging module, wherein the diverted flow line is arranged, at least in part, outside of a footprint associated with the HXT; and
a modular frame support configured to support at least the diverted flow line.
3. The subsea system of claim 2, wherein the VIFT assembly further comprises:
an alignment post associated with the modular frame support, wherein a mating component of the VXT is configured to engage the alignment post during installation of the VXT.
4. The subsea system of claim 1, further comprising:
one or more sandwich plates to direct flow from the one or more auxiliary supplies.
5. The subsea system of claim 1, wherein the VIFT system reuses at least a portion of the one or more HXT structural elements and the HXT is not removed from a subsea location for installation of the VIFT system.
6. A system to modify a subsea Christmas tree (XT), comprising:
a bridging module coupled to an inlet flow path of a processing apparatus, wherein the bridging module comprises:
a first bridging module inlet to intercept flow from a valve assembly;
a blocking region to block an original inlet associated with the subsea XT;
a first bridging module outlet to direct the flow toward the inlet flow path;
a second bridging module inlet to receive the flow from the processing apparatus; and
a second bridging module outlet to direct the flow along a production flow path; and
an adapter assembly coupled to a subsea control module (SCM), wherein the adapter assembly is configured to reroute one or more support systems for the XT to the valve assembly.
7. The system of claim 6, further comprising:
a diverted flow line extending between the valve assembly and the bridging module, wherein the diverted flow line is coupled to the first bridging module inlet; and
a modular frame support configured to support at least the diverted flow line.
8. The system of claim 7, further comprising:
an alignment post associated with the modular frame support, wherein a mating component of the valve assembly is configured to engage the alignment post during installation of the valve assembly.
9. The system of claim 6, further comprising:
a sleeve extending into a bore of the XT configured to block an XT flow path.
10. The system of claim 6, wherein the first bridging module inlet corresponds to an original XT flow path.
11. The system of claim 6, wherein the first bridging module inlet corresponds to a modified XT flow path and the bridging module, when installed axially below the processing apparatus, further blocks the original inlet via the blocking region.
12. The system of claim 6, wherein the second bridging module outlet corresponds to a modified outlet flow path different from an original outlet flow path.
13. The system of claim 6, wherein the second bridging module outlet is configured to couple to an existing outlet flow path.
14. A system to modify a subsea Christmas tree (XT), comprising:
a bridging module coupled to an inlet flow path of a processing apparatus, wherein the bridging module comprises:
a first bridging module inlet;
a first bridging module outlet to direct the flow toward the inlet flow path;
a second bridging module inlet to receive the flow from the processing apparatus; and
a second bridging module outlet to direct the flow along a production flow path; and
an adapter assembly coupled to a subsea control module (SCM), wherein the adapter assembly is configured to reroute one or more support systems for the XT.
15. The system of claim 14, wherein the first bridging module inlet corresponds to an original XT flow path.
16. The system of claim 14, wherein the second bridging module outlet corresponds to a modified outlet flow path different from an original outlet flow path.
17. A subsea system, comprising:
a Christmas tree (XT);
a completion extending into a wellbore associated with the XT;
a processing apparatus having an apparatus inlet and an apparatus outlet; and
a vertical isolation flow tree (VIFT) system, comprising:
a closure in a flow path of the XT;
a valve assembly fluidly connected to an outlet of the XT; and
a bridging module having a first inlet, a first outlet, a second inlet, and a second outlet;
wherein the first inlet is fluidly coupled to a flow outlet of the valve assembly, the first outlet is fluidly coupled to the apparatus inlet, the second inlet is fluidly coupled to the apparatus outlet, and the second outlet is fluidly coupled to a production flow line.
18. The subsea system of claim 17, wherein the closure in the flow path is at least one of a sleeve, a closed valve, or a plug.
19. The subsea system of claim 17, wherein the processing apparatus is a flow control module (FCM).
20. The subsea system of claim 17, further comprising:
a subsea control module (SCM) assembly including at least an adapter assembly, wherein the adapter assembly is configured to reroute at least a portion of one or more auxiliary supplies to the VIFT system.
21. The subsea system of claim 17, further comprising:
a sandwich plate, wherein the sandwich plate is configured to reroute at least a portion of the one or more auxiliary supplies to the VIFT system.
22. The subsea system of claim 17, wherein the bridging module is configured to close at least one of a flow outlet from the XT or a flow path towards a flowline connector.
23. The subsea system of claim 17, wherein the second outlet is fluidly coupled to a first flowline connector.
24. The subsea system of claim 23, wherein a second flowline connector in fluid communication with the second outlet is structurally supported by at least one of the first flowline connector, a structural element of the XT, or a structural element of a template.
25. The subsea system of claim 17, wherein the XT is a horizonal XT and the valve assembly is a vertical XT.