METHOD AND APPARATUS TO EFFECT INJECTION OF FLUIDS INTO A SUBSEA HORIZONTAL TREE

Abstract

An apparatus for effecting injection of fluids into a subsea horizontal tree includes a fluid injection tree cap having a body with a bore extending therethrough so as to open at one end to a top of the body. An isolation valve is cooperative with the bore of the body so as to open or close fluid flow through the bore. The fluid injection tree cap is connected to the horizontal subsea tree. The horizontal subsea tree has only a single crown plug therein. The bore of the fluid injection tree cap communicates with an annulus of the horizontal subsea tree. The horizontal subsea tree has valving therein so as to selectively direct fluid from the bore of the tree cap to the annulus of the well or to the horizontal subsea tree.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority from U.S. Provisional Patent Application Ser. No. 62/371,953, filed on Aug. 8, 2016.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not applicable.

INCORPORATION-BY-REFERENCE OF MATERIALS SUBMITTED ON A COMPACT DISC

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to subsea horizontal trees. More particularly, the present invention relates to systems for injecting fluids into such a subsea horizontal trees. Additionally, the present invention relates to apparatus for maintaining the dual barrier system within the subsea horizontal tree.

2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98

Conventional wellhead systems include a wellhead housing mounted on the upper end of a subsurface casing string extending into the wellbore. A riser and blowout preventer are then installed. During the drilling procedure, the blowout preventer is installed above the wellhead housing (i.e. a casing head) to provide pressure control as casing is installed, with each casing string having a hanger on its upper end for landing on a shoulder within the wellhead housing. Upon completion of this process, the blowout preventer is replaced by a Christmas tree installed above the wellhead housing, with the tree having a valve to enable the oil or gas to be produced and directly into flowlines for transportation to a desired facility.

The horizontal Christmas tree replaces the conventional casing and tubing heads of the generally vertical Christmas trees. The horizontal Christmas tree comprises a spool with a generally horizontal through port mounted above and in axial alignment with a horizontal through port in the wellhead housing. The hangers for the casing strings are supported one above the other within the bore of the wellhead housing, and the tubing hanger for the production or tubing string is supported in the bore of the spool to suspend the production string within the casing strings.

The vertical bore through the tubing hanger of a horizontal tree may be closed by a wire line tool to connect the production fluid through aligned side ports (generally horizontal through ports) in the hanger and spool for recovery and delivery of production fluid to a suitable location. A redundant seal may be provided by well cap installed in the tree above the tubing hanger, with the vertical bore aligned with that of the tubing string closed by a crown plug.

Typical horizontal subsea trees contain two independently installed and tested crown plug assemblies. These crown plug assemblies can be located together in an extended tubing hanger or separately in the tubing hanger and an independently installed internal tree. These crown plugs create a dual barrier system that isolates the main production flow path of the tubing hanger and the environment.

Typical horizontal subsea trees also include a small bore flow path that connects the main upper mandrel of the tree to the annulus portion of the subsea tree. There is typically one or two valves located in this flow path so as to isolate the annulus portion of the tree to the environment. The annulus flow path enters the mandrel either above both crown plugs or sometimes between the crown plugs. The annulus portion of the tree is connected to the production portion of the tree through cross-over piping and valving.

In order to facilitate injection of chemicals into horizontal tree, the crown plugs must be removed to gain access to the production flow path. In some cases, fluid may be pumped into the annulus portion of the tree directly from the upper mandrel into the production flow path through the cross-over piping without removing the crown plug. In the event that the crown plug is removed to facilitate injection, the proper well control and barrier philosophy must be put into place to prevent spills to the environment.

For certain horizontal subsea trees that require more continuous injection of fluids, it would be beneficial to remove the upper crown plug in order to expose the annulus flow path. As such, a device is required so as to maintain the required dual barriers in order to provide the required secondary metal-to-metal barrier, provide the necessary intervention to isolate the upper mandrel of the tree in order to allow injection of fluids in the testing of the seals, and to provide the required hub connection to allow for the connection of hose/pipe/equipment to facilitate injection of fluids into the tree cap and thus into the upper mandrel of the subsea tree.

In the past, various patents have issued relating to subsea trees. For example, U.S. Pat. No. 5,992,526, issued on Nov. 30, 1999 to Cunningham et al., shows a deployable tree cap for deployment on a subsea production hub of a subsea tree. The tree cap has a lightweight body with parallel planar sides and including suitable openings in slots for mounting the various operating elements. A seal plate structure includes a piston connected to a seal plate having a pair of downwardly projecting tubular steel members for fitting within the production bore and annulus bore of the tree hub in a sealed landed position. Fluid pressure is applied to a fluid line to urge a piston and seal plate downwardly into a sealing landed position.

U.S. Pat. No. 7,677,319, issued on Mar. 16, 2010 to D. Baskett, discloses a retrievable tree cap for use in a subsea tree. The tree cap is installed and retrieved using a remotely operated vehicle. Hydraulic pressure is used to lock the tree cap onto the subsea tree and to set the tree cap seals. The tree cap is locked onto the subsea tree before setting the seals within the concentric bore. The tree cap includes a locking means that engages a profile within the subsea tree regardless of the radial orientation of the tree cap. The tree cap is used to hydraulically isolate an annulus bore from the production bore of the subsea tree. The tree cap provides for the injection of a corrosion inhibitor within a cavity of the tree cap.

U.S. Pat. No. 8,087,465, issued on Jan. 3, 2012 to Huang et al., provides a locking tree cap for use in a subsea tree. The tree cap is installed and retrieved using a remotely operated vehicle. The tree cap includes the flexible collet fingers the lock the tree cap to a tree spool. The deflected collet fingers are adapted to extend into the recess of the tree spool when the tree cap has been landed on the tree spool.

U.S. Pat. No. 8,230,928, issued on Jul. 31, 2012 the Cuiper et al., teaches a low-profile internal tree cap having a running configuration and a latched configuration to be selectively secured to a tree spool. The tree cap includes an inner sleeve movable between upper and lower positions. The movement of the inner sleeve to the lower position simultaneously engages a locking profile within the tree spool and energizes a sealing element around the exterior of the tree.

U.S. Patent Application Publication No. 2014/0060849, published on Mar. 6, 2014 to Pathak et al., discloses a cap system for use on subsea equipment, including a horizontal tree. The cap system includes a cap assembly that has the flexibility of installation and retrieval. The cap assembly includes a debris cap assembly in engagement with the cap assembly. The cap assembly interface has to provide the ability to inject in bleed fluids into the main bore and an annulus bore of the subsea tree independently and without removal of the debris cap assembly.

Canadian Patent No. 2428165, issued on Aug. 12, 2008 to I. Donald, teaches a flow diverter for use through a tree cap. The flow diverter assembly has a flow diverter to divert fluids flowing through the production bore of the tree from a first portion of the production bore to the cap, and to diverge the fluids back from the cap to a second portion of the production bore for recovery therefrom via an outlet. The flow diverter is detachable from the cap to enable insertion of the flow diverter through the cap.

It is an object of the present invention to provide a method and apparatus which maintains dual barriers against the release of fluids to the environment.

It is another object of the present invention to provide a method and apparatus that maintains a secondary metal-to-metal barrier on the subsea tree.

It is another object of the present invention provide a method and apparatus that effects the injection of fluids and the testing of seals within the subsea horizontal tree.

It is another object of the present invention to provide a method and apparatus that facilitates connection of the tree cap to external piping in order to inject fluids into the subsea tree.

These and other objects and advantages of the present invention will become apparent from a reading of the attached specification and appended claims.

BRIEF SUMMARY OF THE INVENTION

The present invention is a fluid injection tree cap that comprises a body for attachment to a mandrel of the subsea tree. A bore extends through the body so as to have one end opening at the top of the body and an opposite end opening into the mandrel of the subsea tree. An isolation valve is provided on the body or in cooperation with the bore of the body in order to open or close the bore. This isolation valve is, in particular, positioned above the body of the tree cap. A hub is adapted to allow for the connection of piping on the side of the isolation valve opposite the body.

The present invention can further include the horizontal subsea tree. In this subsea tree, one crown plug has been removed. The subsea tree has the mandrel at the upper end thereof. A small bore flow path extends from the annulus of the subsea tree to the mandrel. A tubing hanger is located in the annulus. A lower connector is provided on the subsea tree in order to connect the subsea tree to the wellhead. Valving is provided on the annulus flow paths and on the production flow paths of the subsea tree in order to direct fluids from the bore of the tree cap to an annulus of the well or to production tubing or to the subsea tree. The fluid injection tree cap is in a metal-to-metal seal with the mandrel of the subsea tree.

The present invention is also a method for effecting injection of fluids into a subsea horizontal tree. This method includes the steps of: (1) affixing a fluid injection tree cap onto a mandrel of the subsea horizontal subsea tree; (2) removing a crown plug from the subsea tree so as to expose an annulus flow path; (3) connecting the tree cap to a fluid-delivering pipe; and (4) opening a valve so that fluid from the piping flows through a bore in the body of the tree cap and into the upper mandrel of the tree and into the annulus portion of the subsea tree. In the method of the present invention, fluid can then be directed either into the annulus of the well bore or into the production side of the tree.

In this method of the present invention, an isolation valve is provided between a hub that is connected to the fluid-delivering pipe and the tree. In this method, the isolation valve is opened so as to allow fluid to flow from the pipe into the bore of the tree cap.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a schematic illustration showing the application of the tree cap of the present invention onto a horizontal subsea tree.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, there is shown the apparatus 10 of the present invention for effecting injection of fluids into a subsea horizontal tree 12. In particular, the tree cap 14 is applied onto the upper mandrel 16 of the subsea tree 12. The subsea tree 16 has a lower connector 18 that is secured to the wellhead 20. A tubing hanger 22 is positioned within the bore 24 of the hanger portion of the subsea tree 12.

The tree cap 14 includes a body 26 that has a bore 28 extending therethrough. In the preferred embodiment the present invention, this bore is a two inch bore. However, the bore can be larger or smaller. An isolation valve 30 is connected to the bore 28. The isolation valve 30 can be manually or remotely operated. For example, an ROV actuator 32 can be used with the isolation valve 30 so as to open or close the isolation valve. A hub 34 is connected to the bore 28 and located on a side of the isolation valve 30 opposite to the body 26. The hub 34 allows the bore 28 to be connected to an injection system, such as a fluid-delivering pipe. The cap 14 also includes a wellhead-type of connector 36 or similar device that locks onto the upper mandrel 16 of the horizontal subsea tree 12 and provides a metal-to-metal seal.

In the subsea horizontal subsea tree 12, there is illustrated in broken lines a crown plug 38. This illustration is to show the location of the crown plug 38 prior to removal. In actual operation, when the tree cap 14 is positioned on the mandrel 16, the crown plug 38 is removed so as to expose the annulus flow path of the subsea tree 12.

The subsea tree 12 includes an annulus flow path 40 therein. An annulus workover valve 42 extends outwardly of the subsea tree 12 and allows fluid flow into the annulus. The annulus workover valve 42 can be controlled or actuated by a remotely operated vehicle or can be actuated from a surface location. The annulus workover valve 42 allows workover fluids to be introduced into the apparatus 10. The annulus master valve 44 is connected to the annulus and extends to the bore 28 of the subsea tree 12 so as to allow annulus fluids to be delivered into the bore. An annulus auxiliary valve 46 is also provided so as to extend to the bore 24. A line 48 will extend from the annulus workover valve 42 and from the annulus so as to pass to the bore 28.

Production fluids can flow through line 50 from the wellhead 20, through the connector 18, through the hanger 22 and toward a series of production valves. The first valve 52 is the production master valve so as to control the flow of production fluids outwardly of the subsea tree 12. A production wing valve 54 is connected in line with the master production valve 52. A crossover valve 56 allows fluids from the bore 28 or from the annulus 40 to pass therethrough and into the production fluids flowing along line 50. A production isolation valve 58 is positioned along line 60 so as to stop the flow of fluids through the line 50. A hub 62 is formed at the end of the line so as to allow the production line 50 to ultimately be connected to piping so that production fluids can be ultimately delivered to a surface location.

Typical horizontal subsea trees contain two independent crown plugs in the bore 24 so as to isolate the main production flow path from the environment. However, for certain horizontal subsea trees that require more continuous injection of fluids, it would be beneficial to remove the upper crown plug 38 so as to expose the annulus flow path. In order to maintain the required dual barriers, the externally-fitted fluid injection tree cap 14 is installed with the necessary valving and connection points. This fluid injection tree cap 14 provides the required secondary metal-to-metal barrier by this locking connection with the mandrel 16. It also provides the necessary intervention valves to isolate the upper mandrel of the tree. This effects injection of fluids in the testing of the seals. The tree cap 14 also provides the required hub connection system so as to allow for the connection of a hose/pipe/equipment or to facilitate injection of fluids into the tree cap and thus into the upper mandrel of the subsea tree. The fluid injection tree cap 14 can be installed permanently or semi-permanently in order to facilitate a single or routine fluid injection program.

In the method of the present invention, fluid injected from the tree cap 14 into the upper mandrel 16 and through the annulus auxiliary valve 46 will flow into the annulus portion of the subsea tree. Fluid can then be directed either into the annulus of the well or into the production side of the tree.

The foregoing disclosure and description of the invention is illustrative and explanatory thereof. Various changes in the details of the illustrated construction or in the steps of the method can be made within the scope of the present claims without departing from the spirit of the invention. The present invention should only be limited by the following claims and their legal equivalents.

Claims

1. An apparatus comprising:

a fluid injection tree cap having a body with a bore extending through the body so as to open at one end of said body, said fluid injection tree cap having an isolation valve cooperative with said bore of said body so as to open or close a flow of a fluid through said bore;

a horizontal subsea tree having only a single crown plug therein, said horizontal subsea tree having said fluid injection tree cap affixed to an upper end thereof such that said bore of said fluid injection tree cap communicates with an annulus of said horizontal subsea tree; and

a well connected to said horizontal subsea tree, said well having an annulus, said horizontal subsea tree having valving therein so as to selectively direct fluid from said bore of said tree cap to said annulus of said well or to said horizontal subsea tree.

2. The apparatus of claim 1, said horizontal subsea tree having a tubing hanger positioned in said annulus of said horizontal subsea tree.

3. The apparatus of claim 1, said well being a wellhead, said horizontal subsea tree having a connector at a lower end thereof that is affixed to said well.

4. The apparatus of claim 1, said isolation valve positioned above said body of said fluid injection tree.

5. The apparatus of claim 1, said horizontal subsea tree having a mandrel at the upper end thereof, said fluid injection tree cap being connected by a metal-to-metal seal with said mandrel.

6. The apparatus of claim 1, said annulus of said horizontal subsea tree having a workover valve cooperative therewith so as to allow workover fluids to flow to said bore of said body of said fluid injection tree.

7. The apparatus of claim 2, further comprising:

a line extending from said well and through said tubing hanger and outwardly of said horizontal subsea tree so as to cause production fluid to flow outwardly of said horizontal subsea tree.

8. The apparatus of claim 1, said valving of said horizontal subsea tree selectively directing fluid from said bore of said tree cap to production tubing extending outwardly of said horizontal subsea tree.

9. An apparatus comprising:

a fluid injection tree cap having a body with a bore extending through said body so as to open at one end at a top of said body, said fluid injection tree cap having an isolation valve cooperative with said bore of said body so as to open or close a flow of fluid through said bore; and

a horizontal subsea tree having only a single crown plug therein, said horizontal subsea tree having said fluid injection tree cap affixed to an upper end thereof such that the bore of said fluid injection tree cap communicates with an annulus of said horizontal subsea tree, said horizontal subsea tree having valving therein so as to selectively direct fluid from the bore of the tree cap to an annulus of a well or to the horizontal subsea tree or to production tubing.

10. The apparatus of claim 9, said horizontal subsea tree having a tubing hanger positioned in said annulus of said horizontal subsea tree.

11. The apparatus of claim 9, further comprising:

a well connected to said horizontal subsea tree, said well having an annulus, said valving of said horizontal subsea tree selectively directing fluid from said bore of said tree cap to the annulus of the well.

12. The apparatus of claim 11, said well having a wellhead, said horizontal subsea tree having a connector at a lower end thereof that is affixed to said wellhead.

13. The apparatus of claim 9, said isolation valve positioned above said body of said fluid injection tree cap.

14. The apparatus of claim 9, said horizontal subsea tree having a mandrel at the upper end thereof, said fluid injection tree cap being connected by a metal-to-metal seal with said mandrel.

15. A method of effecting injection of fluids into a subsea horizontal tree, the method comprising:

affixing a fluid injection tree cap onto a mandrel of the horizontal subsea tree;

removing a single crown plug of said horizontal subsea tree so as to expose an annulus flow path;

connecting the fluid injection tree cap to a fluid-delivering pipe; and

opening a valve so that the fluid-delivering pipe flows through a bore in a body of the fluid injection tree cap and into the mandrel of the horizontal subsea tree and then flows into an annulus portion of the horizontal subsea tree.

16. The method of claim 15, further comprising:

directing fluid from the annulus portion of the horizontal subsea tree into an annulus of a well.

17. The method of claim 15, further comprising:

directing the fluid from the annulus portion of the horizontal subsea tree to a production side of the horizontal subsea tree.

18. The method of claim 15, further comprising:

connecting an isolation valve to the fluid injection tree cap and of the fluid-delivering pipe.

19. The method of claim 18, further comprising:

opening the isolation valve so as to allow fluid to flow from the fluid-delivering pipe into the bore of the fluid injection tree.

20. The method of claim 15, further comprising:

affixing a tubing hanger into a bore of said horizontal subsea tree.