Christmas Tree Upgrading Module for Umbilical Failure Resilience
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Solution Overview
Problem
Existing Christmas tree installations face issues such as functional faults in control modules, valve leakages, insufficient monitoring, and umbilical leakages, leading to delayed production and limited availability of spare parts, particularly in safety-critical offshore petroleum recovery systems.
Innovation Solution
The method involves retrofitting a Christmas tree with an upgrading module featuring a second control module, hydraulic low-pressure pump, and chemical pump, connected via ROV-activatable tube and wire connections, allowing for redundant systems and temporary supply from a vessel, reducing reliance on high-pressure umbilicals and enabling continued operation even with umbilical damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a Christmas tree is equipped with a control module and hydraulic valve packs for offshore petroleum recovery, then the ability to control production and safety functions is improved, but the risk of functional faults and valve leakages increases over time
Solution Approach 1:
The invention applies preliminary action by pre-installing ROV-activatable backup connections and alternative supply paths during the initial setup phase. These backup systems remain dormant during normal operation but can be activated remotely when failures occur, extending the operational lifetime without interfering with normal production control functions.
Solution Approach 2:
The invention changes the operational parameters by enabling temporary high-pressure supply from vessels when umbilical high-pressure lines are damaged. This parameter change allows the system to maintain production control functions even when the original umbilical connection is compromised, thereby extending reliable operation beyond the original design lifetime.
2Reliability
If the umbilical is used to supply hydraulic fluid and electrical power to the Christmas tree, then the control and monitoring functions are improved, but the risk of umbilical leakages and delays increases
Solution Approach 1:
The invention introduces vessels as intermediary supply sources that can temporarily provide hydraulic fluid and electrical power when the umbilical is damaged. This intermediary solution eliminates the production delays that would otherwise result from waiting for umbilical repairs or replacements, maintaining continuous operation.
Solution Approach 2:
The system dynamically switches between normal umbilical supply mode and temporary vessel supply mode based on operational conditions. When umbilical damage is detected, the system transitions to using vessels as the supply source, and this dynamic adaptability is controlled through ROV-activatable connections that can be engaged or disengaged as needed.
3Power
If high-pressure hydraulic systems are used for valve control in the Christmas tree, then the valve actuation capability is improved, but the impact of umbilical damage on production control increases
Solution Approach 1:
The invention applies beforehand cushioning by pre-deploying ROV-activatable backup connections and alternative high-pressure supply paths from vessels. These cushioning measures are in place before umbilical damage occurs, providing immediate protection against loss of valve actuation capability and preventing harmful production control failures.
4Ease of manufacture
If the Christmas tree is designed with standard valve packs and control modules, then the initial installation is simplified, but the ability to extend operational lifetime is limited
Solution Approach 1:
The invention segments the control and supply system into modular components: standard valve packs remain for normal operation, while ROV-activatable backup connections and alternative supply paths are added as separate extendable modules. This segmentation allows the base system to remain simple for initial installation while enabling lifetime extension through additive modifications.
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 enhances the operational reliability and extends the lifetime of Christmas trees by enabling the second control module to take over control operations, reducing fluid pressure, and allowing for temporary supply from a vessel, thereby addressing weaknesses in existing control modules and umbilicals.
Implementation Method 1
a hydraulic low-pressure pump (48) with a second low-pressure hydraulic valve pack (45)
Implementation Method 2
a chemical pump (55) with a chemical reservoir (57) and a chemical tube (56)
Implementation Method 3
retrofitting an upgrading module (40) to or by the Christmas tree (10) and connecting the upgrading module (40) to the Christmas tree (10) with ROV-activatable tube and wire connections
Data Source
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AI summary
A method and a device for extending the lifetime of a Christmas tree (10), the Christmas tree (10) being provided with at least a first high-pressure hydraulic valve pack (12), a first low-pressure hydraulic valve pack (14) or a first chemical valve pack (16), and the Christmas tree (10) being arranged to be connectable to an umbilical (22) which comprises at least electrical power or control cables (24), hydraulic tubes (26, 28) or chemical tubes (30), and the method comprising the following steps: - retrofitting an upgrading module (50) to or by the Christmas tree (10) and connecting the upgrading module (50) to the Christmas tree (10) with the necessary number of tube and wire connections, the upgrading module (50) comprising a second control module (62), and at least a hydraulic high-pressure pump (66) with a second high-pressure valve pack (61) and a hydraulic reservoir (70), a hydraulic low-pressure pump (80) with a second low-pressure hydraulic valve pack (82) and a hydraulic reservoir (86) or a chemical pump (92) with a chemical reservoir (96); - supplying the second control module (62) with electrical power and control signals via the umbilical (22) or from a vessel; and - supplying at least the high-pressure pump (66), the low-pressure pump (80) or the chemical pump (92), directly or indirectly via their respective reservoirs (70, 86, 96), with hydraulic fluid via the umbilical (22) or from a vessel.