Subsea Tubing Hanger Alignment Using Inductive Orientation Sensing
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Solution Overview
Problem
The current methods for installing a tubing hanger in a subsea wellhead are imprecise, leading to a high risk of misalignment, which necessitates costly and time-consuming rework, with an estimated cost impact of 75 to 100 million Norwegian Kroner and a duration of 7 to 10 days.
Innovation Solution
A system for sensing alignment of the tubing hanger using inductive sensors and complementary elements, allowing real-time confirmation of correct orientation before the removal of the high-pressure riser and blowout preventer, thereby reducing the need for costly remedial processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional alignment methods without real-time sensing are used, then the installation process is simpler, but the alignment precision deteriorates leading to misalignment risk
Solution Approach 1:
The patent replaces traditional mechanical alignment methods with an inductive sensing system that uses electromagnetic fields to detect the position and orientation of the tubing hanger. The inductive sensors mounted on the wellhead communicate with complementary elements on the tubing hanger, providing real-time alignment data without mechanical contact, thereby achieving higher precision while maintaining operational simplicity.
Solution Approach 2:
The patent introduces an intermediary sensing system consisting of inductive sensors and complementary elements that mediate between the wellhead and the tubing hanger. This intermediary system provides real-time feedback on alignment status, enabling precise alignment measurement without direct mechanical interaction between the wellhead and tubing hanger components.
2Reliability
If alignment checking is performed only after BOP and riser removal, then the installation process is faster initially, but costly rework must be performed
Solution Approach 1:
The patent implements preliminary alignment verification by installing inductive sensors on the wellhead before the tubing hanger is installed. This allows alignment to be checked and corrected during the installation process itself, rather than waiting until after BOP and riser removal. The real-time feedback enables immediate corrective action, preventing the need for costly and time-consuming rework later.
Solution Approach 2:
The patent establishes a feedback loop where inductive sensors continuously monitor the alignment of the tubing hanger relative to the wellhead during installation. This real-time feedback allows operators to immediately detect and correct alignment deviations, ensuring high reliability and preventing the need for subsequent rework that would otherwise be necessary.
3Manufacturing precision
If tight orientation tolerances of +/- 1.5-2 degrees are enforced, then connection quality improves, but the risk of exceeding tolerances increases
Solution Approach 1:
The patent replaces traditional mechanical alignment methods with an inductive sensing system capable of measuring angular position and orientation with high precision. The system can detect deviations within the tight tolerance range of +/- 1.5-2 degrees, providing the measurement capability needed to consistently achieve and verify compliance with these stringent tolerances, thereby improving both connection precision and tolerance compliance reliability.
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
Enhances precision in tubing hanger installation, minimizing the risk of misalignment and associated rework, thereby reducing costs and rig time by ensuring accurate alignment before the installation of the subsea vertical Xmas tree system.
Implementation Method 1
A system for sensing alignment around a vertical well axis of a tubing hanger with respect to a subsea template
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The invention relates to the alignment of a tubing hanger (14) when installed in a subsea wellhead (11). Sensors (39a,b; 40a,b) detect when the orientation is correct and send a signal to the surface to provide positive confirmation of correct orientation, before a XMT (15) is installed on the wellhead (11) and the HP riser (31) removed, etc.