FIELD OF THE INVENTION
The present invention relates to mounting a module, in particular a subsea control module, on an underwater structure of a subsea hydrocarbon production well, in particular part of an underwater tree of a subsea hydrocarbon production well.
BACKGROUND OF THE INVENTION
A subsea hydrocarbon production well is controlled by a subsea control module (SCM), which is, typically, mounted on a Christmas tree located above the well head. A substantial part of the subsea hydrocarbon production business is maintenance of such wells, that sometimes involves replacement of an SCM, either due to a failure of the original or to meet the need to update the capability of the control system. The cost of manufacture of small quantity SCM replacements to the original design is not only prohibitive but often impractical due to obsolescence. This invention resolves this problem.
It is sometimes necessary, or more cost effective, to replace the SCMs fitted to an old system with more modern versions. The mounting arrangements of the old SCMs are invariably different from the modern designs. Further, different manufacturers have supplied SCMs with different configurations of base plate interfaces, including alignment, hydraulic, electrical and locking features. For example, some SCM base plates are circular and thus totally incompatible with current designs.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a method of mounting a subsea control module on a structure comprising part of an underwater tree of a subsea hydrocarbon well, the method comprising lowering the module to the structure and attaching the module to the structure with an adapter between it and the structure and with portions of the module being coupled with portions of the structure.
Typically, the method is carried out after removal of an existing subsea control module so that the module replaces said existing module.
The module could be lowered with said adapter attached to it or, alternatively, lowered with said adapter attached to said structure.
Typically, said portions of the module and the structure are selected from the group consisting of electrical, hydraulic and optical connections.
By virtue of the use of adapters, both passive (i.e. involving connectors only) and active (i.e. also including sensors, valves or other active devices) to interface current designs of SCMs with older designs, the invention overcomes the problems of obsolescence, and enables the well operator to reap the benefits of cost reductions from larger quantity manufacture, the improved reliability of modern designs and enhanced capability and performance.
By way of example, the invention enables compatibility between old Vetco Gray SCMs with circular base plates and current Vetco Gray designs with square base plates and with the base plates and locking mechanisms of SCMs of Aker Solutions (formerly Aker Kvaerner) and others.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an application of the invention, prior to installation, in a case where the method of locking an SCM is the same as for a modern Vetco Gray SCM (known as Podlock), but the SCM it is to replace is an older version with a different base plate;
FIG. 2 shows the SCM of FIG. 1 assembled to an adapter;
FIG. 3 shows the SCM with the adapter of FIG. 2, installed on a mounting plate of a Christmas tree;
FIG. 4 shows a further case in which the locking method is different from the Vetco Gray standard, with the adapter effecting a conversion;
FIG. 5 is a schematic flow diagram illustrating steps for mounting a subsea control module on a structure comprising part of an underwater tree of a subsea hydrocarbon well; and
FIG. 6 is a schematic flow diagram illustrating steps for mounting a subsea control module on a structure comprising part of an underwater tree of a subsea hydrocarbon well according to another embodiment.
DETAIL DESCRIPTION OF THE INVENTION
FIG. 1 illustrates, diagramatically, prior to installation, a modern SCM 1, with a multiplicity of connectors 2 of various possible types (hydraulic, electrical, optical, etc) mounted on its rectangular base, although for ease of illustration only four are shown. A locking shaft 3 protrudes from the rectangular base of the SCM 1. The tip of the locking shaft 3 has a male tapered cross and is rotated, during installation, typically by a remotely operated vehicle (ROV), from the end of a shaft 4 which protrudes from the top of the SCM 1. The method of locking the SCM 1 to a subsea structure of a hydrocarbon well, in particular a mounting plate on a Christmas tree, is by the location of the male cross on the shaft 3 with a corresponding cross-shaped orifice in the Christmas tree SCM mounting plate and rotating the shaft 4, by typically 45 degrees. Also, on each side, one of a pair of bolting posts 5 is provided on the base of SCM 1.
To fit the SCM 1 to an old system, an adapter 6 is provided. The adapter 6 comprises: a rectangular plate 7, housing corresponding connectors 8 in positions that match those of the SCM 1; a base plate 9, with dimensions that match those of the SCM mounting plate 10 of the Christmas tree to which the SCM is to be fitted; and a locking shaft extension 11. The base plate 9 houses hydraulic and electrical connectors 12, mounted in the required positions to interface with Connectors 13 on the mounting plate 10. The mounting plate 10 originally interfaced with an earlier design of SCM and with connectors in different positions from current SCM designs. Thus, the adapter 6 carries hydraulic pipes and electrical cabling 14, to provide the correct hydraulic and electrical interfacing between the modern SCM 1 and the original SCM mounting plate 10. The adapter is fitted with a shroud 15, shown in sectioned view, to protect the hydraulic and electrical interconnections 14. Since in this case the locking mechanism is the same, the adapter 6 carries shaft 11 through the adapter with a female cross-shaped orifice at the top and a male cross at the bottom so as to provide an extension of the SCM locking shaft 3. The whole adapter arrangement permits the installation of a standard, unmodified SCM.
FIG. 2 shows the first stage of installation, in which the SCM 1 is mated with the adapter 6. The adapter 6 has been bolted to the SCM, 1 to facilitate transportation and installation, by bolts 17 received in posts 5. The adapter 6 is locked to the SCM 1 by locking the extension shaft 11 to shaft 3 by rotation and inserting locking pins, the shaft 3 and extension 11 providing the retention force once installed with the bolting only dealing with handling loads up to this point. Locking the SCM to the adapter allows the complete assembly to be lowered to the seabed, to mate with the mounting plate 10 on the seabed located Christmas tree.
FIG. 3 shows the SCM 1, complete with the adapter 6, mated to the Christmas tree mounting plate 10. Mating is facilitated by a location collar 16. The locking of the whole assembly is achieved, typically by an ROV, by rotating the locking shaft 3 via the shaft 4 at the top of the SCM 1, the rotation being transmitted through the locking shaft extension 11. Reference numeral 18 designates the hydraulic pipes and electrical cabling of plate 10.
FIG. 4 illustrates a case where the locking arrangement of the SCM being replaced is different from a modern Vetco Gray SCM, for example the mechanism fitted to a competitor's SCM. The principle of the adapter remains the same as the previous example, the rectangular plate 7 and its connectors 8 interfacing with the modern SCM 1, and the plate 9 with its connectors 12 being configured to match the existing Christmas tree mounting plate 10. In this case, the locking shaft extension is different from the previous example as it adapts the male tapered cross at the tip of the SCM locking shaft 3 to the appropriate locking mechanism of the original SCM, i.e to match the mechanism in the tree mounting plate 10. Thus the extension shaft 19 in the adapter 6 has a female cross-shaped orifice at its top and the appropriate locking interface at the bottom. Again the adapter 6 is bolted to the SCM 1 for handling purposes as described above, the locking shaft 3 and extension shaft 19 providing the clamping force once installed.
There are a number of alternative options for the installation process for the adapter, each of which has advantages and disadvantages.
Referring to FIG. 1, such alternative options include:
- a) Dispensing with the locking shaft extension 11 and replacing it with a mechanism to lock the adapter 6 to the mounting plate 10 so that the adapter remains attached at the seabed. This has the advantage that the SCM 1 can be replaced (without the need to disturb the adapter) with a standard modern SCM, i.e. full interchange-ability, but has the disadvantage that the installation process involves two operations and special tooling to lock down the adapter.
- b) Bolting the adapter to the SCM for handling as above and dispensing with the locking shaft extension 11 but replacing it with an extended locking shaft 3.
- c) Other possible arrangements for attaching the adapter could include the use of modern high power magnets to retain the adapter to the SCM during installation.
- d) Replacing the SCM connectors with hydraulic and electrical penetrators. This has the advantage of reducing the number of couplers and connectors, which are expensive, but has the disadvantages that the assembly will not interface with standard SCM test jigs.
The adapter removes the need for expensive engineering design modifications to current SCMs to enable them to replace older designs of SCMs.
The adapter removes the need to redesign an older design of SCM to overcome obsolescence and the resultant low quantity manufacturing costs.
The adapter also enables well operators to take advantage of the improved performance and reliability of a modern SCM when replacing ageing equipment.
The concept also allows well operators to have flexibility of supply contractors to replace existing SCMs since it can be applied to interface any old design of SCM with any new design.
Referring to FIG. 5, according to an embodiment of the present invention, a method of mounting an SCM 1 on a structure comprising part of an underwater tree of a subsea hydrocarbon well can include removing an SCM of an existing design from a mounting plate/receptacle 10 of the underwater tree (block 51) (performed when an SCM of existing design is prior installed), attaching an adapter 6 to the mounting plate/receptacle 10 of the underwater tree (block 53), lowering an SCM 1 of a different and/or more modern design to the mounting plate/receptacle 10 (block 55), and attaching the SCM 1 to the adapter 6 (block 57) to thereby couple the SCM 1 having the different and/or more modem design with the mounting plate/receptacle 10 of the underwater tree.
Referring to FIG. 6, according to another embodiment, the method can include removing an SCM of an existing design from the mounting plate/receptacle 10 (block 61) (performed when an SCM of existing design is prior installed), attaching an SCM 1 of a different and/or more modem design to the adapter 6 configured to couple with both the SCM 1 of the different and/or more modem design and a mounting plate/receptacle 10 of an existing design configuration (block 63), lowering the SCM 1 attached to the adapter 6 to the mounting plate/receptacle 10 (block 65), and attaching the adapter 6 to the mounting plate/receptacle 10 (block 67) to thereby attach the SCM 1 of a different and/or more modern design to the mounting plate/receptacle 10 of the underwater tree.
While this invention has been described and shown in some of its forms, it should be apparent to those skilled in the art that it is not so limited but is susceptible to various changes without departing from the spirit and scope of the invention. In the drawings and specification, there have been disclosed illustrative embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation, the scope of the invention being set forth in the following claims.
Patent Grant
8720576
