Subsea Test Tree Mandrel Control Module Segmentation
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Solution Overview
Problem
Subsea wells face challenges in ensuring safe and controlled emergency shutdowns due to the lack of effective mechanisms to prevent unwanted fluid releases, particularly in deep water environments where existing systems may fail to maintain safety integrity levels.
Innovation Solution
A subsea test tree system with integrated shut-off valves and a control module mounted on an interior mandrel, coupled with a control system that includes hydraulic and electrical components, ensures independent control over the well, enabling safe shutdowns and fail-safe configurations even in the event of communication loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a subsea control system uses existing control mechanisms, then the system structure is simpler, but it fails to maintain safety integrity levels in deep water environments
Solution Approach 1:
The control system is divided into separate functional modules: a control module mounted on an interior mandrel and an exterior control module. This segmentation allows each module to be optimized independently for its specific function while maintaining overall system reliability in deep water environments.
Solution Approach 2:
The control module is mounted on an interior mandrel that is nested within the subsea control system structure. This nesting arrangement protects the control components from harsh deep water conditions while maintaining system functionality and integrity.
2Reliability
If the system uses redundant shut-off mechanisms, then the safety integrity level improves, but the device complexity increases
Solution Approach 1:
The shut-off function is divided into multiple independent mechanisms: a first shut-off mechanism and a second shut-off mechanism. Each mechanism can operate independently to prevent unwanted fluid releases, providing redundancy without requiring a single complex system.
Solution Approach 2:
The system incorporates fail-safe configurations where shut-off mechanisms are designed to automatically close in the event of communication loss or system failure. This beforehand cushioning ensures that safety functions are maintained even when primary control systems fail.
3Ease of operation
If the control module is mounted on an interior mandrel, then the control system achieves independent control over the well, but the manufacturing complexity increases
Solution Approach 1:
The control system is segmented into distinct modular components that can be manufactured and tested separately before assembly. The control module on the interior mandrel is designed as a separate unit, allowing for simplified manufacturing processes while achieving independent control capability.
4Reliability
If the system includes fail-safe operations for communication loss, then the safety integrity level improves, but the device complexity increases
Solution Approach 1:
The system incorporates fail-safe configurations where shut-off mechanisms are designed to automatically close in the event of communication loss or system failure. This beforehand cushioning ensures that safety functions are maintained even when primary control systems fail.
Solution Approach 2:
The control system includes self-diagnostic and self-protecting capabilities that automatically detect communication losses and activate fail-safe modes without requiring external intervention. This self-service approach maintains safety integrity while reducing the need for complex external monitoring systems.
Data Source
AI summary
A technique enables protection of subsea wells. The technique employs a subsea test tree designed to ensure control over the well in a variety of situations. The subsea test tree is formed with at least one shut-off valve to protect against unwanted release of fluids from the subsea test tree. The subsea test tree also is coupled with and controlled by a control system having a subsea control module mounted to an interior mandrel.