«2 United States Patent Borsheim 00914575082 US 9,145,750 B2 *Sep. 29, 2015, (10) Patent No. 4s) Date of Patent: ($4) METHOD AND DEVICE FOR EXTENDING AT LEAST THE LIFETIME OF A CHRISTMAS: TREE OR AN UMBILICAL, (75) Inveator:Torfinn Borsheim, Sandaes (NO) (73) Assignee: Subsea Solutions AS, Sandnes (NO) (©) Notice: Subject to any diteluimer, the term of this patent is extended or adjusted under 35 BISC. 1344b) by 173 days. ‘This patent is subject to a terminal dis- claimer, (21) Appl. No, (2) PCT Filed: (86) PCT Ne. $371 (0). (2), (4) Date 13/982,735 Jan, 25,2012 PCT/NO2012/000008 Now.27, 2013 (87) PCT Pub. No WO2013/112084 PCT Pubs, Date: Aug. 1, 2013 (63) Prior Publication Data US 20140151060A1 Jun, 5, 2014 G0) Forsign Application Priority Data 2,201 (NO) 20110186 May 24,2011 (NO) 20110764 (1) Ince ENB 72 (2006.01) EXIB 37038 (200601) (2) US.CL cre F210 33/035 (2013.01), E21 330385 (G01301) (58) Field of Classification Search CPC ... F2IB3¥ORS; F2IB 3/0355; P21 34/08 usp 1660368 See application file for complete search history, 66) References Cited US. PATENT DOCUMENTS 3994560 A 7975 Baugh £17000 11197 Naeger (Continved) POREIGN PATENT DOCUMENTS. Wo 200sitsas86 Az (OTHER PUBLICATIONS ro2008 Intemational Search Report for parent aplication PCT/NO2O12 (000008, aving a malin date of Ape 24,2012 (Continved) Primary Examiner — Matthew Buck Assistant Examiner — Aeon Lembo (14) Attorney, Agent, or Firm —Andras Intellectual Property Law, LLP on ABSTRACT A method and a deviee are for extending atleast the Het ‘of a Christmas tre or an umbilical. The Christmas tre is provided witha high-pressure hydraulic valve package and a low-pressure hytaulie valve package and the umbilical includes electrical power and contro exbles and hydraulic pipes. The method inchidesretrofiting an upgrading module Sncluding at Feast a conteol unit, a hydraulic high-peessnre pump, second high-pressure hydraulic valve package, and a hydraulic reservoir onto or at the Christmas tee; supplying the high-pressure pump, dirsctly or via the reservoir, with Ihydrauli Hui from pipe inthe umbilical, de high-pressure pump being connected tothe second high-pressure hydraulic valve package; connecting the second high-pressure hydra lic valve package toa dowabole safety valve; connecting the electrical power and control cables of the umbilical to the control unit; and connecting cantol cables between the con- {nol unit and valves in the low-pressure hydraulic valve pack- age, 11 Claims, 4 Drawing SheetsUS 9,145,750 B2 Page 2 66) References Cited 469086 m2* 62019 Donal al Yeo) SSinots mae 5301) Donate tees US. PATENT DOCUMENTS E5700 Be 112019 Donal ea foot 20la Donald at Ione AO errt rr 2014 Sundaranian call. 1oaa4e et eee ee Sinate we 201d Doalfeea loi 7992.633 82011 Donald etal 166'75.12 3.776.853 B2* 7/2014 Donald eta. ts6is47 Foss BE, BERL Dons e255 auustiseo Al” 82005 Johansen ta Hhccoe? B+ L201 Dont ta leoaer S0s1.600 Be 12012 Donald wee 22012 Donald et al 166°75.12 (OTHER PUBLICATIONS 532012 Donald ta [38% rien Opinion for pret appition PCTINO20120000%, S2005 BES 53013 Domid eta teak | Mea miling date of Ap. 25.2012. S361861 BES 102013 Dont etal Woot Sdoreo B+ 10201 Dont a Iedeh — *ited by examinerU.S. Patent Sep. 29, 2015 Sheet 1 of 4 US 9,145,750 B2 A) 20/26 30-/ Fig, 1U.S. Patent Sep. 29, 2015 Sheet 2 of 4 US 9,145,750 B2 50 7880), “4 Grey Vee Neat ———— 52 C4 > |-——70 28—_ ~72 24— \ 18— 1 z—t 1o~] a —31 24 = —40 a j 22 / ] es/26/ 307 4U.S. Patent Sep. 29, 2015 Sheet 3 of 4 US 9,145,750 B2 50 Fig, 3U.S. Patent Sep. 29, 2015 Sheet 4 of 4 US 9,145,750 B2 7880-100) 61\63) yey \ 68/58, 62—__ \ | \ a \ 60-74 (/ { 64 Jen I To: J ——1 | } —6 } asec! a0/ | —2 | ~34 —EI=~32 8 IUS 9,145,750 B2 1 METHOD AND DEVICE FOR EXTENDING AT LEAST THE LIFETIME OF A CHRISTMAS, ‘TREE OR AN UMBILICAL. (CROSS-REFERENCE TO RELATED "APPLICATIONS, ‘This application is the U.S. national stage application of Interational Application No. PCT/NO2012/040008, fed Jan. 25, 2012, which intemational application has not yet been published and which application is incorporated herein by reference, The Iterations application claims priority of Norwegian Patent Application No. 20110186, fill Feb. 2, 2011, and Norwegian Patent Application No. 20110764, filed May 24,2011, which applications are incorporated herein by reference, BACKGROUND ‘This invention relates toa method oFextending a least the lifetime of a Christmas tree of an umbilical. More particw- larly, it relates toa mthod of extending east the lifetime of 1 Christmas tree or an timbilical, the Christmas tee being provided witha high-pressure hydraulic valve package and a low-pressure hydraulic valve package. The invention also includes a device for practising the method During the recovery of petroleum offshore, it bas tumed ‘out that thee is @ noed © excoed the originally intended technica-economic life of well equipment. This also applies to safety-critieal components sueh as a Christmas tree with associated valves and control apparatuses, ‘A Christmas toe located ot the seabed has often heen ‘aided onta a production tubing head via guide posts. The ‘Christmas tee communicates with equipment onthe surface via a so-called umbilical which may typically comprise ‘cables for elecric power and signals, optical bres fr signal transmission, pipes for hytreulie fluid under high pressure an low pressure and pipes for the supply of chemicals. eis ‘common far the Christmas tre to be provided witha valve ‘cap which forms a barier betwen the annulus, the produc= tion bore and the surroundings. The valve cap must be removed when suitable tools that ate provided with connec- tions for liquids that are used forthe removal of scale and for well killing ar to be installed, “The tems high pressure and low pressure are not exact, as they vary between the different suppliers, Roughly speaking, ‘a pressure hetween 100 an 300 has is characterized a8 a1 pressure whereas pressure above 300 bars is characterized asahigh pressure. By pressures below 1OObars,actuatorsand, valves may take a so-called “fil safe" postion, which will ‘often shut down the petroleum production, ‘The lydraulie uid are typically caried to, respectively high-pressure valve package and a low-pressure valve pack- age on the Christmas tee, the high-pressure valve package ‘communicating with a downhole safety valve, whereas the Jow-pressure valve package communicates with, among ‘other things, a numberof atuators principally for valve con= two inthe Christmas tre. Electric power and contol signals are carried (0 a subs ‘merged contro! module on oat the Christmas tee. The con- ‘tol module which is coateolled from the suelaces connected to the different hydraulic valves in the valve packages, thereby controlling the different valve funetions inthe Christ ‘Koown Christmas tree installations exhibit in particular two weaknesses which emerge after a long time in apertion. The control module is prone to fusetional faults while, tthe 2 same time, the availabilty of new control modules of thekind in question, and also of spare parts therefore, i imite. ‘The umbilical with associated components is proneto leak ages. SUMMARY The invention has for its abject to remedy orreduce atleast. ‘one of the drawbacks of the prior at. ‘The object is achieved in aevordance with the invention through the features which are specified in the description below and in the claims that follow. ‘A method of extending atleast the lifetime of « Christmas tree or an umbilical is provided, the Christmas toe being provided with high-pressure hydrsulie valve package and a low-pressure hydraulic valve package and the umbilical including electrical power and control cables and hydraulic pipes, the method ineluding: reciting an upgrading module including atleast a con- ‘wolunit,ahydraulichigh-pressure pump, second high- pressure hydraulic valve package, and « hydraulic res ervoir onto or atthe Christmas tree; supplying the high-pressare mp, directly or via the res ‘ervoir, with hydraulic id from a pipe inthe umbilical, the hja-pressure pump being connected tothe second high-pressure hydravli valve package: ‘connecting the second high-pressure hydraulic valve packs ‘age toa downbole safety valve: ‘connecting the electrical power and contol eables ofthe ‘umbilical to the contro nit; and connecting contol eables between the control unit and ‘valves in the low-pressure hydraulic valve package By extending eletreal power and control cables toa new ‘contol unit swhich includes at least a second high-pressire hydraulic valve package, the contol unit being arranged 10 control existing and new valves of the Christmas tree, an existing unreliable control module is made redundant, Fur: ther, the pressure may he lwvere inthe high-pressure pipeot ‘the umbilical asthe high-pressure pump now provides forthe supply of hyeroulic uid at sufficient presse to the igh- pressire hycaulic valve package Alternatively, the high-pressure pump may be supplied \with hydaulie fad from low-pressure pipe or another pipe in the unnbilial. ‘The method may further include: providing the upgrading module witha low-pressure pump ‘which is contolled by the control unit and which is ‘connected to valves in second low pressure hydraulic valve package; ‘connecting second low-pressurchydnvulic valve package to actuators in the Christmas tee, and supplying the low-pressure pump with hydraulic Mud, ‘iretly or via a reservoir, from pipe in the umbilical ‘The hydraulic-uid supply pipe of the umbilical may, of course, havea lower prestire than that characterizes "Tow pressure” in the introduction. The method may include providing the upgrading module with a chemical pump ‘which is coniolled by the control unit and which is ‘connected Wo chemical valve or directly tothe prodive- tion tings supplying the chemical pump witha chemical, directly or ‘ia a reservoir from a pipe in the umbilical ‘The method may include providing the upgrading module with a valve cap and placing the upgrading module on the Christmas tree after a Separate valve cap has been removedUS 9,145,750 B2 3 A method of installing the upgrading module onthe Chist- mas tee may inelude: removing the separate Christmas tree cap by means of a suitable tool: Winehing the upgrading module down to dhe Christmas auiing the upgrading module in to the guide posts ofthe ‘well by means of a thruster located on the upgrading module; lowering the upgrading module onto the guide post; and ‘connecting the Christmas ee cap ofthe upgrading module to the Christmas te. ‘After that, the electric an hydraulic components are con nected as deseribed above, “The method ean be prictsed by means of an upgrading ‘module for retrofitting onto or ata Christmas tee, the Christ- ‘mas tree being provided witha high-pressure hydraulic valve package and a low-pressure hydraulic valve package and the ‘umbilical including electrical power and control eables and hydraulic pipes, the upgrading module being characterized by being provided with an electric control unit which is con- rcctable tothe poser and control wires of an wmbiical and includes « hydraulic high-pressure pump which is eonnect- able directly, or indietly via a reservoir, to the pipe of an ‘umbilical and to at lest a valve in a second high-pressure hydraulic valve package and to the control unt ‘The upgrading module may be provided with a hydraulic low-pressure pump which is connectable directly, or indi- recily Viaa reservoir, othe low-pressure hydraulic pipe of aa ‘umbilical and to atleast valve in the seoond low-pressure hydraulic valve package and to the control unit. ‘he upgriding module may be provided with an accumu lator onat east the outlet ofthe hydraulic high-pressure pump ‘or the hydric low-pressure pomp, ‘he control units connected oa valve package for chemi cal injotion The upgrading module may’ be provided! with a chemical pump whieh is connectable directly, or indirectly via areser- ‘oir othe pipe ofan umbilical andto at least a chemical valve ‘or directly to the production tubing, The upgriding module may be provided with an accumu Jator on the outlet of the chemical pump, “The upgrading module may be provided with a bu ‘Christmas tre cap al with guides that ft complementarly, ‘on the same guide posts asthe Christmas tee ‘The components ofthe upgrading module may bearranged ‘as double systems witha main system anda backup system t0 ‘ensure operation iP component should fail. The high-pres- ‘ure pump and associated components may be replaced by & pressure intensifier whieh is supplied with fu from a lovs= pressure system, for example tis also possible to interonnect several upgrading mod= ules belonging to different Christmas toes, for example the ‘umbilical belonging to one of the Christmas trees should suffer substantial damage, orto increase the reliability ofthe ‘Christmas tees in an entire area The method and the device according to the invention remedy weaknesses of existing control modules for Christ- ‘mas tees while, at thesame ime, the Mid pressure in existing "umbilicals may be reduced considerably. tis also possible to utilize other pipe bores in the umbilieal for the supply of hydraulic uid ita pipe ore should become unable By the use ofa reseroirin theupgrading module, the same pipebore Jnthoumbilieal may be used for noth the supply and the retura ‘of Hid 0 o 4 BRIBE DESCRIPTION OF THE DRAWINGS In what follows is described an example of @ preferred ‘method and embodiment which is visualized inthe aecom- panying dmwings in whic: FIG. 1 shows schematically a submerged well wth a prior ant Christmas tee; FIG. 2 shows schematically an upgrading module accord ‘ng o the invention, the upgrading module being positioned fon the Christmas tee; FIG. 3 shows seematically the upgrading module of FG. 2 in an alternative embodiment and FIG. shows schematically the upgrading module of FIG. 2 in further embodiment DETAILED DESCRIPTION OF THE DRAWINGS Inthe drawings, the reference numeral indicates subsea well with an outer pipe 2, for example in the formof acasing, and a production tubing 4, wherein an annulus 6 i formed between the outer pipe 2 and the production tubing 4 “The production tubing 4 is hung ofT in a production tubing head 8, there being a Christmas tree 10 placed on the progue- ‘ion tubing head 8 ‘The Christmas tee 10 is provided with a high-pressure hydraulic valve package 12, a low-pressure hydeaulic valve package 14 and a chemieal valve package 16 ‘Via contol wires 20, the different valve packages 12, 14, 16areconirlled from acontrol module 18 located atoron the Christmas tree 10. The valve packages 12, 14, 16 and the ccntrol module I8are often constituted by an assembly whic is indicated, in the figures, by means ofa stippled rectangle. ‘An umbilical 22 extending to a plant, not shown, on the surface includes electrical wires 24 for electric power and control signals, high-pressure pipe 26, a low-pressure pipe 2B and a chemical pipe 30. “The electical wires 24 are connected to the conto] module 18, the high-pressure pipe 26 to the high-pressure hydraulic valve package 12, the low-pressure pipe 28 tothe low-pres- sure hydraulic valve package 14 and the chemical pipe 30 10 ‘chemical valve 31 which sactivated by means the chemi cal valve package 16. ‘The hih-pressurehydrulic valve package 12 is connected toa dosinhole safety valve 32 by means ofa safery-valve pipe 34. The low-pressure hydraulic valve package 14 is eon- nected by means of actuator pipes 3610 actuators 38 in the CCarisimas tree, The chemical valve 31 is connected to the production tubing 4 by means of a chemical bore 4, The Christnas toe 10 is provided with aChristmas ree cap 442. and, beyond that, includes a great number of components, ‘ot shown, which are known to person skilled i the art Reference is ow madetoFIG. 2. An uparading mode 80 is positioned on the Christmas tee 10 by means of guides 52 ‘which ft onthe guide posts $4 ofthe well I. The upgrading ‘msde $0 is provided with a built-in Christmas tree cap 56 ‘whieh fits complementarily on the Christmas tree 10 and as the sane Functions asthe Christmas tree cap 42, but ‘whieh is additionally provided with a supply pipe 58 with a valve 60 for Iiguids used for the removal of seale and for ‘well-killing. The valve 60 may be ROV-operated or hydra Tically operated as itis indicated by the stippled line in FIGS. 2-4. The pressure below thevalve 60 ismeasuredby meansof pressure gauge 63 and the value istansmitted to the contol ‘uit 62. The purpose ofthe pressure gauge 63 is to enable reading ofthe pressure below the valve 60, for example darUS 9,145,750 B2 5 ing maintenance work. The pressure here may also reveal Teakages in valves furherbelow, for exampleina swab valve, not shown, ‘The upgrading module $0 is provided witha sscond high- pressurehydraulc valve package 61 and acontrol unit 62, the ‘contol unit 62 being connected, directly of via the contol module 18, to the electrical wires 24 of the umbilical 22, ‘controlling the different valve packages 14, 16, 61 via the ‘contol wires 64, th contol wires 20 from the conto] module 18 being disconnected A jgl-pressure pump 66 is located in the upgrading mod ‘ule $0 ands supplied with hydraulic Mid at reduced pressure fiom the high-pressure pipe 26 which is disconnected Irom the high-pressure hydraulic valve package 12. The high-pres- sure pump 66 is connected 0 the second high-pressure hydraulic valve package 6 by means of «high-pressure pipe 68. A reservoir 70s connected to the inlet side ofthe high- pressure pump 66 whilean accumulator 2isconnectedto the ‘utltside ofthe high-pressure pump 66. The high-pressure pump 66 is controled from the control unit 62 via a contol Wire 74, Tasially nocessary valves that are not necessary for the explanation oftheinvention arent shown, ava personskilled Jn the art will be acquainted withthe purposes and operation thereof In this prefered exemplary embodiment, the uparading module 50 also includes thester 76, alight source 78 a a ‘camera 80. ‘When the upgrading module $0 isto be installed the origi- ral Christmas tre cap 42 is removed by mans of a stable ‘ool not shown, The upgrading module $0 is winched down to the Christmas tre 10, alter which the upgrading module 50 remote-controlled by means of te thruster 76, Fight source 78 tnd camera 80 i positioned in such » way that the guides S2 ‘correspond with the guide posts 54, Altematively, a remotely ‘operated vehicle may be used for the positioning operation After the upgrading module $0 has been set down on the (Christmas tree 10, the Christmas tee cap 56 is connected to the Christmas tree 10, The supply’of the high-pressure pump 66 is connected to the high-pressure pipe 26 of the umbilical 22, the outlet of the high-pressure pump 66 being connected to the second high-pressure hydric valve package 61. The ‘electrical powerand contro cables 24 ofthe umbilical 22 are feonnecied to the control unit 62, aad contro cables 64 between the control unit 62 and valves inthe hydraulic valve packages 14,16, 61 that have not been connected already are ‘connected ‘Thus, during operation, the control unit 62 has takenoverat Jeast the contro functions ofthe control madule 18, whereas the high-pressure pipe of the umbilical 22 may work at @ substantially reduced pressure. IG, 3 shows an alternative exemplary embodiment, ia ‘which the upgrading module fs provided with low-pressure pump 82 and is supplied wih hydraulic Mid at rednced pressure from the loxe-pressure pipe 28 which is disconnected from the low-pressure hydraulic valve package 14. The los- pressure pump 82 is connected fo a second low-pressure hydraulic valve package 88 by means ofa low-pressure pipe ‘84. A reservoir 86 is connected tothe inet side of the low= pressure pump 82 whileanaecumulator88isconnected tothe ‘tlt side ofthe low-pressure pump 82, The low-pressure pump 82 is controlled from the Control unit 62 via @ control ‘wire 90, Tnthis exemplary embodiment, the high-pressure pump 66 so supplied! ith hydrmolc id vi the low-pressure pipe 0 o 6 ‘The operation ofthe low-pressure pumnp 82 corresponds to that explained in connection with the high-pressure pump 66 above, FIG. 4 shows a further exemplary embodiment, in which a chemical pump 92 is arranged, whieh is supplied with a chemical, sualy at reduced pressure, fom the chemical pipe 30 which is disconnected from the chemical valve 31. The chemical pump 92 is consected tothe chemical valve 31 by ‘means of 3 chemical conduit 94.4 reservoir 96 is connected to the inlet side of the chemical pump 92 while an aocunn- Jator 98 i connected to the outlet side ofthe chemical pump 92. The chemical pump 92 is controlled from the contr sit {62 via a conteol wire 100, whereas the chemical valve M is ‘cnirolled from the control unit 62 via a control wire 64 The operation ofthe chemical pump 92 corresponds to that cexplainad in eonsection with the high-pressure pump 66 above. Itmay be added thatthe reservoir 9 may be divided 10 be able to hold, for example, both a chemical and methanol The methanol is supplied by means of a pipe, not show in the umbilical 2 and te chemical pump 92 is provided with change-over valve, not shown, tobe ableto draw the desired chemical ‘Whenever there is a need to remove sale or kil the well liquids for this may be supplied va the supply pipeS8 without the valve cap $6 having to be removed fr ‘The invention claimed is 1.A method! of extending at fest the lifetime of Christ ‘ma tee oe an umbilical, the Christmas tee being provided ‘with a high-pressure hyeraulic valve package and a low pressure hydraulic valve package and the umbilical ineluding electrical power and control cables and hydraulic pipes, the method comprising: ‘reiofiting an upgrading mode inching atleast con- ‘vol unit ahydraulichiph-pressure pump, second high- pressure hydmulic valve package and a hydraulic eser- Sir onto or at the Christmas tee; supplying the high-pressure pump, directly or vi the re ‘ervoi, with hylaulie Mid om a pipe inthe umbilieal, the high-pressure pump being connected tothe second high-pressure hydravlie valve package: ceannecting the second high-pressir hydraulic valve pack: ‘age to & downhole safety valve; connecting the electrical power and control cables of ‘umbilical tothe contol unit and connecting control cables between the control unit and ‘valves in the low-pressure hydraulic valve package. 2. The method in agcordance With claim 1, further com: rising: providing the upgrading module witha low-pressure pump ‘which is contolled by the control unit and which is ‘connected to valves ina second low-pressure hydraulic valve package; ‘connecting the second lo-pressure hydraulic valve pack ‘oge to actuators and supplying the low-pressure pump with hydraulic uid, lietly oF via @ second reservoir, from a pipe in the uasbilial 3. The method in accordance with elaim 1, further come i providing the uparading module with a chemical pump ‘which is contolled by the control unit and which is ‘connected toa chemical valve or directly to prodction bing: supplying the chemical pump with a chemical disetly or ia a third reservoir from a pipe inthe umbilical 4. The method in accordance with claim I, further com= prising providing the upgrading module with Christmas reeUS 9,145,750 B2 1 ‘cap which includes a supply pipe, and placing the upgrading module on the Christmas tee alter a separate valve cap has boon removed, '5. An upgrading module for retrofitting onto or ata Christ. ‘mas ioe ofa ubilial, the Christmas tee being provided With « high-pressure lydnmulic valve package and a lvs- pressure hydraulic, valve package and the umbilical inchad- fing electrical pawer and control eables and hydraulic pipes, the upgmding module comprising an electric contol tit which is connectable to the power and control cables of the ‘umbilical and includes a yu high-pressure punsp which is connectable, directly or indirectly to as reservoir, to the "umbilical and to atleast a valve in a second high-pressure hydraulic valve package and to the contro! unt 6. The upgrading module in accordance with elaim &, ‘wherein the upgrading, module comprises a hydraulic low= pressure pump which is connectable diretly orindiretly via second reser to the pipe of the umbilieal and to atleast fvalveina second low-pressure hydraulic valve packageand to the control unit. 8 7. The upgrading module in accordance with claim 8, wherein the upgrading module comprises chemical pump whieh is connoctable, directly or indiretly vi a thin reser voir tothe pipe ofthe umbilical and to at least a chemical valve or directly to production tubing. 8. The upgrading module in accordance with claim 5, wherein the upgrading module is formed with 2 built-in Christmas ire cap which is provided wth a supply pipe. 9. Tho upgrading module in accordance with elaim 6, rein an accumulator i connected to at leat a outlet of the hydraule high-pressure pump or the hydraulic low-pees- sure pom, 10, The upgrading module in secondance with claim 5, ‘wherein the contol unit is connceted to a chemical valve package for chemical injection 1. The upgrading module in aecontance with elaim 5, ein the upgrading module comprises guides which fit complementaily on guide posts of a well