Patent Description:
Subsea torque tools are required to perform a range of tasks on subsea infrastructure and equipment, such as to apply torque to actuate rotating components of valves, or to lockdown or release clamps on equipment for the oil and gas industry. Typically, these rotating components are designed to be actuated at a specific torque, and when required to rotate a subsea component, an operator of a remotely operated vehicle (ROV) torque tool will choose the correct socket size and apply the appropriate torque so that the tool does not impart a torque greater than the maximum capability of the subsea component. The component may fail or become damaged if the torque applied thereto by a torque tool is excessive. The retrieval of the subsea component for repair or replacement can be difficult and expensive.

The range of tasks that an ROV torque tool is required to perform necessitates that the torque output of the tool must be changed depending on the torque requirements of the task. When applying torque, the torque tool latches to the subsea component with a latch mechanism separate from the socket mechanism to provide stability and prevent rotation between the torque tool and the subsea component. The latch mechanism, however, may be unreliable, having the tendency to lock up during operation or during loss of power. For example, a torque tool may not be able to disengage from a subsea component if power is lost during operation.

Therefore, there exists a need for a torque tool with a latch mechanism that is reliable and consistent, even during moments with losses of power.

<CIT> discloses a tool according to the preamble of claim <NUM> and describes a hydraulically powered subsea torque tool with hydraulically actuated latches biased to a retracted position by a spring. <CIT> describes a flying lead orientation tool and a mating tool having a latch biased to a disengaged position.

Embodiments disclosed herein relate to tools and methods for applying torque to subsea components utilized in the oil and gas industry.

According to the invention, a torque tool to apply torque to a subsea component with a ROV is disclosed. The tool includes a tool housing, a socket drive to rotate within the tool housing, and a latch mechanism. The latch mechanism includes a latch configured to move with respect to the tool housing between an engaged position to engage the subsea component and a disengaged position to disengage the subsea component, and a biasing mechanism configured to bias the latch from the engaged position towards the disengaged position, characterised in that the latch mechanism further comprises a collar positioned within and configured to move with respect to the housing such that, as the collar moves with respect to the housing, the latch rotates with respect to the housing; wherein the biasing mechanism is positioned between the housing and a collar and is configured to bias and move the collar with respect to the housing, and thus bias and move the latch through the collar.

In an embodiment, an electric motor is configured to move the latch from the disengaged position towards the engaged position.

In yet another embodiment, a method of applying torque to a subsea component using the torque tool of the invention is disclosed. The method includes receiving electric power at the torque tool, receiving a control signal at the torque tool, latching the torque tool to the subsea component using the electric power based upon the control signal, providing torque to the subsea component from the torque tool, and unlatching the torque tool from the subsea component.

It is contemplated that elements disclosed in one embodiment may be beneficially utilized with other embodiments without specific recitation.

Embodiments of the present disclosure relate to a torque tool for use subsea with an ROV to provide torque to a subsea component. The tool includes a tool housing and a socket drive that rotates within the tool housing. The socket drive is used to engage and provide torque to the subsea component. The tool further includes a latch mechanism to engage with and disengage from (e.g., latch with and unlatch from) the subsea component, such as to secure the tool to the subsea component when providing torque. The latch mechanism includes one or more latches that move with respect to the tool housing between an engaged position to engage the subsea component and a disengaged position to disengage the subsea component. The latches are used to hold the tool in place and prevent axial movement between the tool and the subsea component. An example subsea component may be a receptacle mounted on a subsea structure or a stab plate attached to a flying lead.

The latch mechanism includes a biasing mechanism configured to bias the latch from the engaged position towards the disengaged position. Additionally, the latch mechanism may include an electric motor to move the latch from the disengaged position towards the engaged position. In one embodiment, when power is not provided to the electric motor, the electric motor allows the latch to move from the engaged position towards the disengaged position without applying an electrical load against movement of the latch. The torque tool is able to receive electric power, such as from the ROV or from the surface, and provide the electric power to the electric motor. The torque tool is able to receive control signals, such as also from the ROV or from the surface, to control the electric motor.

<FIG> provide multiple views of a torque tool <NUM> in accordance with one or more embodiments of the present disclosure. In particular, <FIG> and <FIG> are perspective views of the torque tool <NUM>, and <FIG> is an exploded view of the torque tool <NUM>. The tool <NUM> is for use subsea with an ROV <NUM> to latch to and provide torque to a subsea component. The tool <NUM> includes a housing <NUM> with a socket drive <NUM> positioned within and rotatable with respect to the housing <NUM>. The tool <NUM> further includes a drive mechanism <NUM> to provide torque to the socket drive <NUM>, such as for rotating the socket drive <NUM>. The socket drive <NUM> is used to provide torque to the subsea component with the drive mechanism <NUM> generating and providing the torque used by the socket drive <NUM>.

The drive mechanism <NUM> includes one or more motors to provide torque to the socket drive <NUM>. For example, the drive mechanism <NUM> as shown includes a first motor <NUM> and a second motor <NUM>, each capable of providing different torques or torque ranges to the socket drive <NUM>, such as through a drive extension <NUM>. In one or more embodiments, one or both of the first motor <NUM> and the second motor <NUM> may be an electric motor, such as an electric direct drive motor. Further, the housing <NUM> of the tool <NUM> is formed from one or more components (e.g., sub-housings) coupled with each other. For example, the first motor <NUM> and the second motor <NUM> each are shown as separate components with distinct housings from each other, though the motors <NUM> and <NUM> may share housings with the housing <NUM> of the tool <NUM>. Further, a latch mechanism <NUM> discussed below includes a latch housing <NUM>, though the latch housing <NUM> may be included within or referred to as part of the housing <NUM> of the tool <NUM>. Thus, though the tool <NUM> is shown as having multiple components used to form the housing <NUM>, discussed more below, the tool <NUM> is not so limited and may have more or less components used to form the tool <NUM> and/or the housing <NUM> without departing from the scope of the present disclosure.

The tool <NUM> includes a latch mechanism <NUM> with a latch housing <NUM> and one or more latches <NUM> movable between an engaged position and a disengaged position. In particular, the latch <NUM> is movable to an engaged position with respect to the latch housing <NUM> to engage a subsea component, and is movable to a disengaged position with respect to the latch housing <NUM> to disengage a subsea component. The engaged position of the latch <NUM> may also be referred to as the extended or latched position, and the disengaged position of the latch <NUM> may also be referred to as the retracted or unlatched position.

The latch mechanism <NUM> is used to engage and latch the tool <NUM> to the subsea component when providing torque to the subsea component through the socket drive <NUM>. The latch mechanism <NUM> secures the tool <NUM> to the subsea component to prevent the tool <NUM> from axially moving with respect to the subsea component, therefore enabling the tool <NUM> to maintain engagement with the subsea component and provide torque through the socket drive <NUM>. Discussed more below, the latch mechanism <NUM> includes a biasing mechanism to bias the latch <NUM> from the engaged position towards the disengaged position. Additionally, the latch mechanism <NUM> includes an electric motor to move the latch <NUM> from the disengaged position towards the engaged position. In one embodiment, when power is not provided to the electric motor of the latch mechanism <NUM>, the electric motor allows the latch <NUM> to move from the engaged position towards the disengaged position without applying an electrical load (e.g., force or resistance) against movement of the latch <NUM>.

Referring still to <FIG>, the tool <NUM> includes a handle <NUM> coupled to the housing <NUM> for the ROV <NUM> to grip and move the tool <NUM> through the use of the handle <NUM>. A nose cone <NUM> is included within the tool <NUM>, such as coupled to the tool housing <NUM> and/or the latch housing <NUM>, with the socket drive <NUM> rotatable with respect to the nose cone <NUM>. The nose cone <NUM> may be used to help guide the tool <NUM>, or the socket drive <NUM>, into engagement with the subsea component. Further, the socket drive <NUM> may include one or more sockets 116A and 116B of different sizes to engage with different sized subsea components. The sockets 116A and 116B may be nested and movable with respect to each other, such as by having a smaller socket 116A positioned within and movable with respect to a larger socket 116B. For example, when engaging a subsea component with the larger socket 116B, the smaller socket 116A moves with respect to the larger socket 116B by retracting into the tool <NUM> to receive the subsea component into the larger socket 116B.

Further, the torque tool <NUM> includes an electronics section <NUM> to receive electric power for the tool <NUM>. The electronics section <NUM> may receive electric power from the ROV <NUM>, as shown, and/or from the surface, such as from a support structure (e.g., vessel or rig) located on or above a surface of the sea. The electric power may be provided to the electronics section <NUM> using a cable <NUM>, umbilical, tether, or similar structure capable of transmitting electric power. The electric power is provided from the electronics section <NUM> to the electric motor(s) of the latch mechanism <NUM>, as needed. Additionally or alternatively, the electronics section <NUM> may include a power source, such as a battery, to store and provide electric power. Further, in one or more embodiments, the electronics section <NUM> may include a power generator to generate electric power.

The electronics section <NUM> may additionally or alternatively be used to receive control signals for the tool <NUM>. For example, the electronics section <NUM> may receive control signals for controlling electric motor(s) of the latch mechanism <NUM>. In such an embodiment, the electronics section <NUM> may include a controller that receives the control signals from the ROV <NUM> and/or the surface. The control signals may be sent to the electronics section <NUM> using the same medium as the electric power (e.g., the cable <NUM>), or the control signals may be separately sent to the electronics section <NUM>, such as through a separate cable or wirelessly.

<FIG> provide multiple views of the latch mechanism <NUM> in accordance with one or more embodiments of the present disclosure. In particular, <FIG> is an exploded view of the latch mechanism <NUM>, <FIG> is a cross-sectional view of the latch mechanism <NUM> with the latches <NUM> engaged with a shoulder <NUM> of a subsea component <NUM> to latch to the subsea component <NUM>, and <FIG> is a cross-sectional view of the latch mechanism <NUM> with the latches <NUM> disengaged from the shoulder <NUM> of the subsea component <NUM> to unlatch from the subsea component <NUM>. In one or more embodiments, one or more motors <NUM>, such as an electric motor, are included within the latch mechanism <NUM> to move the latches <NUM>. A motor <NUM> is shown as corresponding to each latch <NUM>, though only a single motor <NUM> or more than two motors <NUM> may be used to move the one or more latches <NUM>. The motors <NUM> are used to move the latches <NUM> from the disengaged position towards the engaged position. The motors <NUM> may also be used to move the latches <NUM> from the engaged position towards the disengaged position. If an electric motor, the motors <NUM> may include brushless DC electric motors.

In the above embodiments, multiple latches <NUM> and multiple motors <NUM> are shown included within the tool <NUM>. As mentioned above though, the tool <NUM> may include one or more latches <NUM>, and one or more motors <NUM>. In an embodiment in which multiple latches <NUM> are included with the tool <NUM>, the latches <NUM> may be positioned opposite each other with respect to an axis <NUM> of the tool <NUM>, as shown. Similarly, the motors <NUM> may be positioned opposite each other with respect to the axis <NUM> of the tool <NUM>, as shown.

The latches <NUM> are shown as rotating between an engaged position (<FIG>) and a disengaged position (<FIG>) with respect to the latch housing <NUM> and/or with respect to the subsea component <NUM>. In particular, a collar <NUM> is positionable within and/or movable with respect to the latch housing <NUM>, such as by having the collar <NUM> move along the axis <NUM>. As the collar <NUM> moves with respect to the latch housing <NUM>, the latches <NUM> rotate with respect to the latch housing <NUM>. The latches <NUM> are shown as each received within a slot <NUM> of the collar <NUM> to engage and move the latches <NUM> as the collar <NUM> moves with respect to the latch housing <NUM>. The latches <NUM> are shown as rotatably mounted to the latch housing <NUM> using pins <NUM>. The latches <NUM> are biased against the collar <NUM> to further facilitate engagement between the latches <NUM> and the collar <NUM>, such as by using springs mounted around the pins <NUM>.

To move the latches <NUM> with the motors <NUM> and the collar <NUM>, a lead screw <NUM> and a nut <NUM> are coupled between each of the motors <NUM> and the collar <NUM> to convert or translate rotational motion from the motors <NUM> to linear motion for the collar <NUM>. For example, the lead screw <NUM> is coupled with the motor <NUM> such that motor <NUM> is able to rotate the lead screw <NUM>. More particularly, a drive coupling <NUM> is coupled between the lead screw <NUM> and the motor <NUM> to provide the rotation from the motor <NUM> to the lead screw <NUM> through the drive coupling <NUM>. The lead screw <NUM> is received within and is threadedly coupled with the nut <NUM> such that the rotational motion of the lead screw <NUM> is converted or translated to linear motion of the nut <NUM> through the threaded engagement. The lead or pitch of the thread of the lead screw <NUM> may, for example, be up to six times the diameter of the lead screw <NUM> or more. Further, the nut <NUM> is coupled with the collar <NUM> such that as the nut <NUM> linearly moves (e.g., parallel to the axis <NUM>), the collar <NUM> moves with the nut <NUM> (e.g., along the axis <NUM>). In this way, as the motors <NUM> provide rotational motion, the motors <NUM> are able to linearly move the latches <NUM>, through the collar <NUM>, the lead screws <NUM>, and the nuts <NUM>.

A bearing assembly <NUM> and/or a seal assembly <NUM> may be included within the latch mechanism <NUM> to facilitate rotation and/or sealing within the latch mechanism <NUM>. For example, as shown, the bearing assembly <NUM> may be positioned about the drive coupling <NUM> and between the drive coupling <NUM> and the latch housing <NUM>. If no drive coupling <NUM> is present, the bearing assembly <NUM> may be positioned about the lead screw <NUM> and between the lead screw <NUM> and the latch housing <NUM>. The bearing assembly <NUM> is used to facilitate rotation of the drive coupling <NUM> and/or lead screw <NUM> within and with respect to the latch housing <NUM>. Further, as shown, a seal assembly <NUM> may be positioned about the drive coupling <NUM> and between the drive coupling <NUM> and the latch housing <NUM>. If no drive coupling <NUM> is present, the seal assembly <NUM> may be positioned about the lead screw <NUM> and between the lead screw <NUM> and the latch housing <NUM>. The seal assembly <NUM> is used to facilitate sealing about the drive coupling <NUM> and/or lead screw <NUM> within and with respect to the latch housing <NUM>. Furthermore, in one or more embodiments, a motor carrier <NUM> may be used to facilitate mounting and prevent rotation of the motor <NUM> within the tool <NUM>. The motor carrier <NUM> is positioned about the motor <NUM> with the motor carrier <NUM> positioned between the motor <NUM> and the housing <NUM>.

As mentioned above, the latches <NUM> are biased from the engaged position towards the disengaged position. As such, a biasing mechanism <NUM> is included with the tool <NUM> to bias the latches <NUM> from the engaged position towards the disengaged position. In this embodiment, the biasing mechanism <NUM> is positioned between the latch housing <NUM> and the collar <NUM> to bias and move the collar <NUM> with respect to the latch housing <NUM>, and thus bias and move the latches <NUM> through the collar <NUM>. The biasing mechanism <NUM> is shown as a spring, and more particularly a wave spring, positioned within the latch housing <NUM> and about the axis <NUM>. However, other biasing mechanisms, such as a compressible material or gas, may be included within the torque tool <NUM> to bias the latches <NUM> from the engaged position towards the disengaged position without departing from the scope of the present disclosure.

The motors <NUM> of the latching mechanism <NUM> may be configured such that, when electric power is not provided to the motors <NUM>, the motors <NUM> allow the latches <NUM> to move from the engaged position towards the disengaged position without applying an electrical load (e.g., a force or a counter-torque) against the movement of the latches <NUM>. Thus, other than frictional loads or forces, the motors <NUM> will freely rotate or spin in the opposite direction to allow the latches <NUM> to move from the engaged position towards the disengaged position. In the event of a power loss, this may enable the biasing mechanism <NUM> to bias and push against the collar <NUM> such that the slot <NUM> of the collar <NUM> forces the latches <NUM> to move from the engaged position towards the disengaged position, thereby disengaging or unlatching the tool <NUM> from a subsea component. Because the nut <NUM> is fixed to the collar <NUM>, then as the collar <NUM> and the nut <NUM> are moved by the biasing mechanism <NUM>, the threaded engagement between the nut <NUM> and the lead screw <NUM> causes the lead screw <NUM> and, thus the motor <NUM>, to rotate or spin in the opposite direction.

Additionally, the tool <NUM> may be pulled, such as by the ROV <NUM> through the handle <NUM>, to also move the latches <NUM> from the engaged position to the disengaged position to disengage the tool <NUM> from the subsea component. As the tool <NUM> is pulled away from the subsea component, the outer ends of the latches <NUM> are forced against the portion of the subsea component to which the latches <NUM> are latched, which causes the latches <NUM> to rotate about the pins <NUM> and force the collar <NUM> and the nut <NUM> to move back toward the disengaged position. Because the nut <NUM> is fixed to the collar <NUM>, then as the collar <NUM> and the nut <NUM> are moved by the pull force applied to the latches <NUM>, the threaded engagement between the nut <NUM> and the lead screw <NUM> causes the lead screw <NUM> and, thus the motor <NUM>, to rotate or spin in the opposite direction.

If it is desired to keep the tool <NUM> engaged and latched with the subsea component, electric power may be provided to the motors <NUM> to lock the motors and prevent the motors <NUM> from freely spinning and allowing the latches <NUM> to move from the engaged position towards the disengaged position. Additionally or alternatively, one or more position sensors 180A-C may be coupled to one or more components of the latch mechanism <NUM>, such as operably coupled to the latch <NUM>, the collar <NUM>, the lead screw <NUM>, and/or the nut <NUM> to measure a position of the latch <NUM>, the collar <NUM>, the lead screw <NUM>, or the nut <NUM>. For example, as shown in <FIG>, a position sensor 180A may be positioned adjacent the latch <NUM>, such as secured to the latch housing <NUM>, to measure a position of the latch <NUM>. A position sensor 180B may also be coupled to the collar <NUM>, and/or a position sensor 180C may be coupled to the drive shaft <NUM>, each to measure the position of one or more components within the latch mechanism <NUM>. The position sensors 180A-C may measure the position such that electric power is provided to the motors <NUM> of the latch mechanism <NUM> to maintain the position of the latches <NUM>, as desired.

Referring still to <FIG>, one or more components are positioned or coupled between the drive mechanism <NUM> and the socket drive <NUM> to provide torque from the drive mechanism <NUM> to the socket drive <NUM>. In particular, a drive extension <NUM>, a gearbox <NUM>, and a drive shaft <NUM> are coupled between the drive mechanism <NUM> to the socket drive <NUM> to translate or provide torque from the drive mechanism <NUM> to the socket drive <NUM>. In this embodiment, the drive mechanism <NUM>, and more particularly the second motor <NUM>, is coupled to, such as directly engaged with, the drive extension <NUM>. The second motor <NUM> is coupled to the drive extension <NUM> through a male and female coupling or engagement, such as with a key <NUM> of the second motor <NUM> that couples or engages with a groove <NUM> positioned or formed within the drive extension <NUM>. Similarly, the first motor <NUM> is coupled to the second motor <NUM> through a male and female coupling or engagement, such as with a key <NUM> of the first motor <NUM> that couples or engages with a groove <NUM> positioned or formed within the second motor <NUM>.

The drive extension <NUM> is coupled to the gearbox <NUM> to provide torque from the drive mechanism <NUM> through the drive extension <NUM> and to the gearbox <NUM>. The gearbox <NUM> may be used to provide speed and torque conversions from the drive mechanism <NUM> to the socket drive <NUM>. For example, in one embodiment, the gearbox <NUM> includes a step down gearbox with a fixed ratio. Further, the gearbox <NUM> is coupled to the drive shaft <NUM>, which in turn is coupled to or engaged with the socket drive <NUM>. The drive extension <NUM>, the gearbox <NUM>, the drive shaft <NUM>, and/or additional components are, thus, used to provide torque from the drive mechanism <NUM> to the socket drive <NUM>.

As discussed above, the electronics section <NUM> is able to receive electric power for the tool <NUM> and/or receive control signals for the tool <NUM>. Thus, the electronics section <NUM> may be used to provide electric power to the motors <NUM> of the latch mechanism <NUM>, as needed, and may be used to control the motors <NUM> of the latch mechanism <NUM>, as needed. Further, if the motor <NUM> and/or the motor <NUM> of the drive mechanism <NUM> are electric, the electronics section <NUM> may be used to provide electric power to the motors <NUM> and <NUM> of the drive mechanism <NUM>, as needed, and may be used to control the motors <NUM> and <NUM> of the drive mechanism <NUM>, as needed.

A torque tool in accordance with the present disclosure may be able to provide better control, such as in a tool with all electric motors, and may be able to disengage or unlatch from a subsea component in the event of power loss. For example, the latch mechanism is mechanically durable and strong enough to prevent the torque tool from unintentionally unlatching from the subsea component, but also is able to unlatch and release from the subsea component during a power loss. The latch mechanism may hold the latches in place, such as in the latched positioned, by shorting out the motors of the latch mechanism. Additionally or alternatively, position sensors may measure positions of one or more components of the latch mechanism to maintain the position of the latches, as desired. If electric power is lost, the motors of the latch mechanism may freely rotate to allow the latches to move to the unlatched position, such as from the biasing mechanism biasing against the latches, and/or by pulling on the tool to move the latches to the unlatched position. Furthermore, a torque tool in accordance with the present disclosure may only have electric motors, or may be suitable for all electric operation, and thus is less likely to pollute the environment from leaking of hydraulic oil common with other torque tools.

Claim 1:
A torque tool (<NUM>) configured to apply torque to a subsea component with a remotely operated vehicle (ROV) (<NUM>), comprising:
a housing (<NUM>);
a socket drive (<NUM>) configured to rotate within the housing (<NUM>); and
a latch mechanism (<NUM>) comprising:
a latch (<NUM>) configured to move with respect to the housing between an engaged position to engage the subsea component and a disengaged position to disengage the subsea component; and
a biasing mechanism configured to bias the latch from the engaged position towards the disengaged position;
characterised in that:
the latch mechanism (<NUM>) further comprises a collar (<NUM>) positioned within and configured to move with respect to the housing (<NUM>) such that, as the collar moves with respect to the housing, the latch rotates with respect to the housing;
wherein the biasing mechanism (<NUM>) is positioned between the housing (<NUM>) and the collar (<NUM>) and is configured to bias and move the collar (<NUM>) with respect to the housing, and thus bias and move the latch through the collar.