Function Spool Segmentation for Modular Wellhead Control
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Solution Overview
Problem
Conventional subsea wellhead assemblies require large and costly tubing hangers to accommodate multiple auxiliary passages, leading to inefficiencies and high manufacturing costs due to the need for customization and potential for unnecessary functionality, as well as the need for tree replacement when downhole functionality changes over the life of the well.
Innovation Solution
The implementation of a function spool and function mandrel that separates auxiliary function passages from the tubing hanger, allowing for modular installation of downhole functionalities as needed, reducing the size and cost of the horizontal tree and tubing hanger, and enabling easier upgrades without replacing the entire tree.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the tubing hanger is enlarged to accommodate multiple auxiliary passages, then the downhole functionality is improved, but the size and cost of the drilling riser and BOP increase
Solution Approach 1:
The patent divides the tubing hanger into two separate components: a standard tubing hanger and a function spool. The function spool contains all the auxiliary passages for hydraulic, electrical, and optical components, while the tubing hanger itself remains compact. This segmentation allows the tubing hanger to maintain a small diameter suitable for standard drilling equipment while still providing comprehensive downhole functionality through the attached function spool.
Solution Approach 2:
The function spool acts as an intermediary component that connects to the tubing hanger. It serves as a separate module that houses auxiliary passages and connections for various downhole components, allowing these functions to be added without increasing the size of the main tubing hanger or requiring larger drilling risers and BOPs.
2Adaptability or versatility
If the tubing hanger is made larger to include more auxiliary passages, then the auxiliary functionality is improved, but the manufacturing cost increases
Solution Approach 1:
By segmenting the auxiliary functions into a separate function spool, the patent allows for standardized production of both the tubing hanger and function spool. This modular approach enables manufacturers to produce each component independently using standard processes, reducing the need for costly custom manufacturing of large, complex integrated tubing hangers with multiple auxiliary passages.
Solution Approach 2:
The function spool is designed as a universal module that can be attached to standard tubing hangers. This multi-functional component provides hydraulic, electrical, and optical connections through a single standardized interface, allowing the same function spool design to serve multiple wells and applications without requiring custom manufacturing for each specific configuration.
3Adaptability or versatility
If the tree is replaced to add downhole functionality, then the functionality is improved, but the time and cost increase
Solution Approach 1:
The patent creates a dynamic, modular system where the function spool can be independently added or modified without replacing the entire tree assembly. This allows the downhole functionality to be adapted and upgraded over time through simple attachment of additional function spools or modification of existing ones, rather than requiring complete tree replacement when functional requirements change.
Solution Approach 2:
By separating the auxiliary functions into a detachable function spool, the patent enables independent modification of this component while the main tree and tubing hanger remain in place. This segmentation allows operators to add, remove, or modify downhole functionalities by working only with the function spool, significantly reducing the time and cost compared to replacing the entire tree assembly.
Data Source
AI summary
A production assembly and method for controlling production from production tubing supported by a tubing hanger in a well including a wellhead. The assembly includes a function spool engaged with the wellhead and a tree engaged with the function spool. The tubing hanger is landable in the tree bore such that the production tubing is supported in the well by the tree. A function mandrel separate from the tubing hanger is engaged with the production tubing and positionable inside the function spool bore. The function mandrel includes a passage connected to a line extending into the well that is connectable with a port in the function spool such that communication with a downhole component through the line is allowable from outside the function spool.