Christmas Tree Upgrading Module for Hydraulic Valve Control
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Solution Overview
Problem
Christmas tree installations and umbilicals in offshore petroleum recovery face issues of functional faults in control modules and leakage, with limited availability of new control modules and spare parts, and high-pressure hydraulic systems prone to shutdown due to pressure limitations.
Innovation Solution
The method involves retrofitting a Christmas tree with an upgrading module containing a control unit, high-pressure hydraulic pump, second high-pressure valve package, and hydraulic reservoir, connected to the umbilical for hydraulic fluid supply, and integrating electrical and control cables to replace the existing control module, along with a low-pressure pump and chemical pump for extended functionality and redundancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a control module is used to control hydraulic valves in the Christmas tree, then valve control functionality is achieved, but functional faults occur and availability of spare parts is limited
Solution Approach 1:
The patent replaces the electronic control module with a purely mechanical valve control system. The mechanical valve control unit uses mechanical linkages and actuators directly connected to the hydraulic valves, eliminating electronic components that are prone to functional faults and have limited spare part availability. This substitution maintains valve control functionality while improving reliability and ease of repair through mechanical means.
2Stress or pressure
If high-pressure hydraulic fluid is supplied through the umbilical to the valve package, then valve actuation is achieved, but pressure limitations cause shutdown and the system is prone to leakage
Solution Approach 1:
The patent segments the hydraulic system into two separate systems: a low-pressure hydraulic system for actuating the valves and a high-pressure hydraulic system for power generation. The low-pressure system operates at manageable pressures that are less prone to leakage, while the high-pressure system is isolated to specific power generation functions. This segmentation reduces overall system leakage risk while maintaining the necessary pressure levels for valve actuation.
Solution Approach 2:
The patent introduces a mechanical intermediary system that transfers power from hydraulic pressure to mechanical motion without requiring high-pressure hydraulic fluid to travel through long umbilical cables. The intermediary mechanism converts hydraulic pressure locally into mechanical actuation forces, eliminating the need for high-pressure hydraulic lines over long distances and reducing leakage points.
3Ease of repair
If the valve cap is removed for installing tools for scale removal and well-killing, then maintenance access is achieved, but the Christmas tree is exposed to environmental hazards
Solution Approach 1:
The patent employs a nested design where maintenance tools and equipment are stored within the valve cap assembly itself. The valve cap contains internal compartments and mounting structures that accommodate scale removal tools, well-killing equipment, and other maintenance instruments. This nesting allows all necessary maintenance operations to be performed with the valve cap remaining installed, protecting the Christmas tree from environmental hazards while providing full maintenance access.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution extends the operational life of Christmas trees and umbilicals by reducing pressure requirements in high-pressure pipes, enhancing reliability through redundant systems, and allowing for reduced pressure operation, while also addressing leakage issues and enabling continued operation without immediate valve cap removal for maintenance.
Implementation Method 1
a high-pressure hydraulic pump, which is supplied with hydraulic fluid from a pipe (26) in the umbilical (22) or from another pipe in the umbilical
Data Source
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AI summary
A method and a device for extending at least the lifetime of a Christmas tree (10) or an umbilical (22), the Christmas tree (10) being provided with a high-pressure hydraulic valve package (12) and a low-pressure hydraulic valve package (14) and the umbilical (22) including electrical power and control cables (24) and hydraulic pipes (26, 28), and the method including - retrofitting an upgrading module (50) including at least a control unit (62), a hydraulic high-pressure pump (66), a second high-pressure hydraulic valve package (61 ), and a hydraulic reservoir (70) onto or at the Christmas tree (10), - supplying the high-pressure pump (66), directly or via the reservoir (70), with hydraulic fluid from a pipe (26, 28) in the umbilical (22), the high-pressure pump (66) being connected to the second high-pressure hydraulic valve package (61), - connecting the second high-pressure hydraulic valve package (61 ) to a downhole safety valve (32); - connecting the electrical power and control cables (24) of the umbilical (22) to the control unit (62), and - connecting control cables (64) between the control unit (62) and valves in the low-pressure hydraulic valve package (14).