Portable hydrostatic test tool

Hydrostatic test tool 100 comprises frame 161; pressurizer 120; connection system 110; control system 130; data communicator 140; power supply 150; device handler 162; and buoyancy unit 163. Hydrostatic test tool 100 can be used to perform an in situ seal test of subsea equipment connectors with limited support from external systems, allowing optimization of subsea operations by not requiring constant support from underwater vehicle 5, which could be used to perform other tasks while the test is being carried out, optimizing the total time of support vessel 6 and reducing operational cost. Hydrostatic test tool 100 typically requires interfacing with underwater vehicle 5, e.g., an ROV or AUV, only for deployment/installation and data communication, if at all.

BACKGROUND

Subsea equipment installation often requires connection between equipment (e.g., x-tree to production jumper, flowline to a pipeline end termination (PLET), etc.) and/or internal modules (manifold valve module, x-tree choke valve module, etc.), which are based on subsea connector technology. In order to ensure proper connection and avoiding leakage of fluids (e.g., hydrocarbons, chemicals, etc.) to sea, the sealing properties of subsea connectors must be verified in situ.

Currently, in situ subsea connectors seal test is performed, most of the times, with the support of a remotely operated vehicle (ROV), which pressurizes hydraulic fluid into subsea connectors' test chambers via a standard hot stab interface. The operation consists of pressurizing a small volume of fluid (3-5 liters), holding the pressure after it reaches the specified value and checking for stabilization. Due to small volume and strict acceptance criteria, this process can take up to 2 hours per connector, a period of time that the associated ROV must be standing by since it is responsible for pressure control and monitoring. In case other operations are required, such other operations are executed only after the seal test is done (if only one ROV is available), increasing the total operational time.

Thus, there is a need for a system and method to perform the required functions for the hydrostatic testing of a subsea equipment components with a limited support from other systems such as an ROV. By meeting this need, the ROV can be available to perform simultaneous activities while the test is underway, optimizing the total time of a support vessel and reducing operational cost. Further, such system could also expand the capabilities of autonomous underwater vehicles (AUVs) supporting operations of in situ seal test of subsea connectors.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

As used herein, “subsea equipment” comprises Christmas trees, manifolds, pipeline terminations with associated connection systems, e.g., rigid jumpers, and the like, or a combination thereof. Typically, such subsea equipment comprises a hot stab receptacle.

In a first embodiment, referring generally toFIG.1, hydrostatic test tool100comprises frame161; hydraulic fluid pressure conduit22to allow hydrostatic testing; pressurizer120disposed at least partially in frame161and in fluid communication with hydraulic fluid pressure conduit22; connection system110disposed at least partially in frame161and adapted to interface with subsea equipment3, where connection system110is in fluid communication with pressurizer120; control system130disposed at least partially in frame161and operatively in communication with pressurizer120and connection system110; data communicator140, e.g., data transceiver141, disposed at least partially in frame161, typically configured for bidirectional data communications; power supply150disposed at least partially in frame161and operatively in communication with pressurizer120, connection system110, control system130, and data communicator140; device handler162disposed at least partially in frame161and adapted to interface with underwater vehicle5; and buoyancy unit163disposed at least partially in frame161and adapted to reduce weight of hydrostatic test tool100in water. Although described herein in a subsea context, hydrostatic test tool100may be used for other than subsea use, e.g., for onshore seal testing of subsea connectors during assembly and acceptance testing.

Frame161typically provides physical integration for, and protects, system components and typically comprises carbon steel, aluminum, composite material, or the like, or a combination thereof.

In embodiments, pressurizer120generates hydraulic pressure and further comprises hydraulic pressure generator121; pressure source interface124in fluid communication with hydraulic pressure generator121; fluid reservoir123in fluid communication with hydraulic pressure generator121; and a predetermined set of valves122which are operative to hold and release pressure and which area in fluid communication with hydraulic pressure generator121and fluid reservoir123. Hydraulic pressure generator121may comprise an electric pump, a hydraulic pump, a pressure intensifier, an external pressure source, or the like, or a combination thereof. In addition, the predetermined set of valves122may comprise a manual valve, an electrically actuated valve, a solenoid valve, a hydraulically actuated valve, or the like, or a combination thereof. Typically, pressure source interface124comprises a hot stab interface. Fluid reservoir123typically comprises a bladder reservoir, a rigid reservoir, or the like, or a combination thereof.

In embodiments, control system130further comprises data processor133and one or more of pressure transducer131, which measures hydraulic pressure, operatively in communication with data processor133; flowmeter132, which measures the quantity of hydraulic flow, operatively in communication with data processor133and which may comprise a digital flowmeter; data logger134, which measures pressure readings, operatively in communication with data processor133where data logger134further comprises data store136such as a hard drive or a solid-state disk drive; and display135operatively in communication with data processor133. Data processor133may comprise a programmable logic controller (PLC), a central processing unit, a microcontroller board, or the like, or a combination thereof. Display135may comprise a predetermined set of light emitting diode (LED) lights, an LED Display, or the like, or a combination thereof.

If present, data transceiver141may comprise an underwater acoustics data transceiver, an underwater inductive data transceiver, an underwater optics data transceiver, an underwater radio frequency data transceiver, an underwater microwave data transceiver, a regular wireless IEEE 802.11 data transceiver, or the like, or a combination thereof.

Power supply150provides power to components of hydrostatic test tool100that require power, e.g., electrical power. Power supply150typically comprises power source151, e.g., a battery, an external electrical power source, or the like, or a combination thereof, and may further comprise power distributor152.

Device handler162typically comprises an ROV handle or a tooling interface such as the Oceaneering International, Inc. OMNI™ tooling interface.

Buoyancy unit163typically comprises a predetermined set of foam blocks.

In certain embodiments, hydrostatic test tool100further comprises underwater vessel interface20(FIG.3) in fluid communication with connection system110.

In the operation of exemplary embodiments, hydrostatic test tool100can be used to perform an in situ seal test of subsea equipment connectors with limited support from external systems, allowing optimization of subsea operations by not requiring constant support from underwater vehicle5, which could perform other tasks while the test is being carried out. In this manner, underwater vehicle5may be available to perform simultaneous activities while the test is underway, optimizing the total time of support vessel6and reducing operational cost. Hydrostatic test tool100typically requires interfacing with underwater vehicle5, e.g., an ROV or AUV, only for deployment/installation and data communication, if at all. Underwater vehicle5, if used, typically installs and retrieves hydrostatic test tool100from a hot stab receptacle on subsea equipment3which, in turn, receives hydraulic fluid from hydrostatic test tool100through the hot stab interface to pressurize a subsea connector seal test chamber. Where underwater vehicle5comprises an AUV, the AUV may be able to support seal tests of subsea connectors operations.

As described below, hydrostatic test tool100is capable of pressurizing an interface seal; controlling and monitoring pressure; and transmitting readings. Testing pressurization, holding pressure, monitoring pressure, and releasing pressure typically occur without requiring a continuous connection to underwater vehicle5.

Hydrostatic test tool100is typically deployed from support vessel6to a predetermined subsea location, e.g., along a seafloor or at or near a predetermined water depth, and underwater vehicle5, e.g., a remotely operated vehicle (ROV) or autonomously operated vehicle (AUV), is used to install hydrostatic test tool100proximate to or on a predetermined subsea equipment3, where installing comprises engaging pressure source interface124into subsea equipment receptacle4. However, deployment of hydrostatic test tool100from support vessel6to a subsea operation location may be done in multiple ways, e.g., use of a dedicated deployment basket and/or from within an ROV or AUV basket, cage, toolbox, or the like.

In embodiments, underwater vehicle5installs hydrostatic test tool100by engaging its hot stab interface111into a subsea equipment receptacle. Engagement of pressure source interface124into subsea equipment receptacle4is confirmed, e.g., by use of valving or sensors or the like or a combination thereof, and, once engagement is confirmed and hydrostatic test tool100is installed, hydrostatic test tool100used to perform hydrostatic testing via connection system110and operate independently without the continuous assistance of underwater vehicle5. Once hydrostatic test tool100is installed, hydrostatic test tool100is capable of independently performing the hydrostatic testing of a subsea connector as well as recording and processing the test data.

The testing typically involves providing hydraulic fluid to the predetermined subsea equipment3from hydraulic fluid pressure conduit22to pressurize a subsea connector seal test chamber of subsea connector3under test; and, as soon as pressurization begins, using control system130to measure and record pressure levels and obtain a predetermined set of test data. Typically, once pressurization is started, hydrostatic test tool100keeps on pressurizing until a desired test pressure level is achieved and, once achieved, the desired test pressure level triggers isolation of the hydraulic pressure within the subsea connector to allow stabilization and demonstrating sealing integrity.

The predetermined set of test data are recorded in data logger134and storing the recorded test data in data store136; once pressure reaches a specified level for executing the seal test, using hydrostatic test tool100to isolate and hold the pressure within connection system110to allow stabilization; continuing to monitor pressure levels over a predetermined time period; and processing the test data.

If a pressure drop rate is detected after a predetermined period of time, the pressure drop is analyzed according to a predetermined set of analysis criteria. If the pressure drop rate is lower than or equal to a predefined pressure drop rate criterion, a successful test pass status is generated. If the pressure drop rate is higher than the predefined pressure drop rate criterion, an unsuccessful test fail status is generated. Once pressure readings have been processed during the predefined period of time, the result of the test indicated to notify operations crew of the test result.

Stored data may be retrieved from hydrostatic test tool100using underwater vehicle5. Moreover, underwater vehicle5may remain available to perform simultaneous activities while the test is underway.

If pressure source interface124comprises a hot stab interface, the hydraulic fluid may be provided to the predetermined subsea equipment3from hydraulic fluid pressure conduit22through the hot stab interface.

In certain embodiments, hydrostatic test tool100is unpressurized at the time of installation and pressurization started after pressure source interface124is completely engaged to the subsea equipment's receptacle.

Typically, hydrostatic test tool100keeps the connector pressurized until the hydrostatic test tool evaluates that the test is completed and, once the test is completed, trapped pressure from the subsea equipment is released.

Recorded test data may be transmitted to an external system, where such transmission may or may not occur subsea.

After testing, underwater vehicle5may retrieve hydrostatic test tool100from the subsea equipment receptacle and the operation finalized, after releasing the pressure and confirming the results. Alternatively, the test sequence may be repeated, in which case retrieval of hydrostatic test tool100is not required.

The foregoing disclosure and description of the inventions are illustrative and explanatory. Various changes in the size, shape, and materials, as well as in the details of the illustrative construction and/or an illustrative method may be made without departing from the spirit of the invention.