ON A HYDRAULIC CIRCUIT

The present invention relates to an apparatus and method for compensating for subsea pressure in a hydraulic circuit, and particularly, but not exclusively for compensating for subsea pressure in a closed-loop hydraulic circuit.

The prior art discloses a wide variety of pressure compensation systems for underwater hydraulically actuated devices. In many underwater pressure compensation systems such as closed-loop subsea hydraulic power systems , it is desirable to maintain sufficient pressure within the system (an "overpressure") to prevent the ingress of seawater into the system. In certain closed-loop systems, the fluid used in the system is re- circulated; but when subsea systems are at a substantial depth below the water surface designs that would withstand the pressure at such depths require inordinate and excessively strong enclosures. To overcome this problem, "pressure-compensated" systems have been developed in which a subsea equipment housing or enclosure need only withstand a pressure differential between the external pressure exerted on the enclosure by the water and an internal pressure which is maintained within the enclosure. In certain applications hydraulic fluid within an enclosure is pressurized by a spring that applies a force to a piston.

In certain prior art subsea actuators , the actuator is not only remote from the hydraulic supply which is at the surface, but there can also be a substantial elevation difference. For example, with a pressure such as 207 bars (3000 psi) at the surface, the actual pressure at the actuator will be increased substantially

beyond that by the weight or hydrostatic head of the fluid. The actual operating pressure of the accumulator is increased since the opposite side of the piston must discharge the hydraulic fluid either against the static head of a return line or against ambient seawater pressure, where water compatible hydraulic fluid is used. Seawater at a depth of 2040m (6700 feet) has a static head of about 207 bars (3000 psi) . Accordingly, for an effective operating pressure of 207 bars (3000 psi) , the actual pressure at the actuator, and therefore at the accumulator is actually 415 bars (6000 psi) . A gas filled accumulator pressurized to 207 bars (3000 psi) at the surface would have the gas compressed to one half the volume at the operating depth and only half the hydraulic fluid would be available, while alternately the accumulator would have to be twice as large and, for an accumulator of the type which uses a compressed spring, this would require that the spring be compressed with an input force equivalent to 415 bars (6000 psi) initially. This becomes an exceedingly large and cumbersome mechanical spring system.

US-A-3, 987,708 discloses a system which uses a conventional gas charged accumulator with the high gas pressure providing the motive force for the accumulator and is depth compensated by means of a small hydraulic piston having one side open to the ambient, or sea pressure to provide depth compensation. This avoids the problem of the increased compression of the accumulator gas, but still requires that the accumulator be pre- charged to full gas pressure at the surface. It also contains extremely high pressure gas which must be sealed over a long period of time .

US-A-4,777,800 discloses a hydraulic system

accumulator designed to discharge its hydraulic capacity at a pre-selected pressure level, and designed to operate at a pre-selected depth, for instance, the known depth of a subsea wellhead. Charging of the accumulator at the surface is not required, the charge being developed as the accumulator is lowered to the desired depth. A piston assembly has a large diameter piston effectively exposed to the ambient pressure of the seawater and a small diameter piston effectively exposed to the hydraulic system pressure. The opposing side of each piston is exposed to contained low pressure gas. The differential area of the pistons causes the accumulator to build-up a predictable unbalanced force against the hydraulic fluid as a function of depth to which the accumulator is lowered.

The inventor has recognised that closed-loop hydraulic circuits can be used with a pressure compensation apparatus of the invention, which closed- loop hydraulic circuits require relatively large amounts of hydraulic fluid to flow from a reservoir to operate equipment, and then be re-circulated back to the reservoir, such as those used in operating a blowout preventer .

For the avoidance of doubt, subsea is intended herein to mean below water, the water being of any kind, such as , but not limited to : any saline water found in any sea; or fresh water, such as that found in a fresh water lake or brackish water such as that found in an estuary. In accordance with the present invention, there is provided an apparatus for compensating for subsea pressure on a hydraulic circuit, the apparatus comprising a body defining a chamber having a piston slideably

arranged therein, the body having an opening in front of an outer side of the piston, hydraulic fluid in the chamber behind an interior side of the piston, the hydraulic fluid for communication with a hydraulic circuit characterised in that the piston has a piston rod connected to the piston and slideably arranged in a piston rod chamber and a pressure apparatus for applying fluid pressure in the piston rod chamber to the second piston rod. The piston rod may be a solid cylinder and may be of circular, square, oblong, triangular or any other shaped cross-section. The piston rod may be hollow and may have a total cross-sectional area, which is small relative to the cross-sectional area of the outer or inner surface of the piston. The pressure apparatus preferably provides a positive pressure on the piston rod, although may provide a negative pressure. Preferably, the hydraulic circuit is a closed loop hydraulic circuit.

Preferably, the communication between the hydraulic fluid in the chamber behind the piston an interior side of the piston and the hydraulic fluid in the hydraulic circuit is fluid communication.

Preferably, the piston rod is connected to the interior side of the piston such that surface area of the outer side of the piston is greater than surface area of the inner side of the piston subjected to the hydraulic fluid in the chamber. Advantageously, the pressure apparatus comprises a vessel having a volume of pneumatic fluid therein. Preferably, the pneumatic fluid is compressed pneumatic fluid, which may be compressed before being lowered into the sea. The pressure apparatus may be lowered with the hydraulic circuit into the sea or may be located at a distance from the hydraulic circuit

and may be located onboard a supply vessel or intermediate floating platform. Advantageously, the pressure apparatus comprises a line having hydraulic fluid therein. The line connected to the piston rod chamber. Preferably, the hydraulic fluid is separated from the compressed pneumatic fluid by a bladder or diaphragm. Advantageously, the pressure apparatus comprises an accumulator.

Preferably, the opening has an area less than the area of the outer side of the piston. The opening open into the sea allowing sea water to flow therethrough. Advantageously, the amount of hydraulic fluid in the chamber is at least 379 litres (100 gallons) . Preferably, the apparatus further comprises a spring with a portion thereof in contact with the outer surface of the piston, the spring biased against the piston and urging the piston away from the first opening. The other end of the spring may be biased against the body.

Preferably, the apparatus further comprises an auxiliary pressure compensator. Advantageously, the auxiliary pressure compensator is in fluid communication with the chamber for applying a minimum desired force to the operational hydraulic fluid in the interior chamber. Advantageously, the auxiliary pressure compensator comprises an enclosure having an opening in fluid communication with the exterior and a piston movably mounted within the enclosure, the piston exposed to fluid exterior to the enclosure so that pressure of fluid exterior to the auxiliary enclosure applies pressure via the piston on the operational hydraulic fluid within chamber .

The present invention also provides a subsea system comprising a hydraulic circuit and a pump apparatus for

providing operational power fluid to a subsea device, the subsea system comprising at least one apparatus as claimed in any preceding claim. Preferably, the subsea device is at least one of: a blowout preventer; a coiled tubing unit; and a subsea wellhead connector.

Preferably, the pump apparatus comprises a pump and a motor for driving the pump. Advantageously, the subsea system further comprises accumulator apparatus in fluid communication with the pump for receiving operational hydraulic fluid from the pump and for maintaining the fluid under pressure for later use. Preferably, the subsea system further comprises valve apparatus for selectively placing the pump apparatus in fluid communication with the subsea device. Advantageously, the subsea system further comprises a control system for controlling the pump system and the subsea device . Preferably, the subsea system further comprises umbilical apparatus for providing power to the control system and communication between the control system and control apparatus remote from the control system. Preferably, the subsea system further comprises an intermediate floating station .

Preferably, the amount of operational hydraulic fluid in the interior chamber is at least 379 litres (100 gallons) or is about 450 litres (120 gallons) . Advantageously, the auxiliary compensator for applying a minimum desired pressure to the operational hydraulic fluid in the interior chamber; and/or wherein the auxiliary compensator's auxiliary enclosure has an opening in fluid communication with the exterior of the auxiliary enclosure and with the first opening, and an auxiliary piston movably mounted within the auxiliary enclosure, the auxiliary piston exposed to fluid exterior

to the auxiliary enclosure so that pressure of fluid exterior to the auxiliary enclosure applies pressure via the auxiliary piston on the operational hydraulic fluid. Thus compensating for the pressure differential The present invention also provides a method for compensating for subsea pressure on a hydraulic circuit, the method comprising the steps of lowering the hydraulic circuit into deep water, the hydraulic circuit being provided with a body defining a chamber having a piston slideably arranged therein, the body having an opening in front of an outer side of the piston, hydraulic fluid in the chamber behind an interior side of the piston, the hydraulic fluid for communication with a hydraulic circuit characterised in that the piston has a piston rod connected to the piston and slideably arranged in a piston rod chamber and a pressure apparatus for applying fluid pressure in the piston rod chamber to the second piston rod, the pressure apparatus providing a positive or negative pressure as required. Preferably, the pressure of the hydraulic fluid in the hydraulic circuit is maintained slightly above the pressure of the deep water immediately external the hydraulic circuit.

The present invention, in certain aspects, discloses a pressure compensation system for subsea apparatus which has one or more hydraulic power units used in a closed- loop hydraulic fluid system. In certain aspects, such subsea apparatus employs one or more hydraulic fluid reservoirs and/or accumulators which releasably hold operational amounts of hydraulic fluid at a pressure slightly greater than the pressure of water exterior to the reservoir for selectively operating subsea equipment and systems, e.g. BOP' s, coiled tubing units, and subsea wellhead connectors. The reservoir and/or accumulator (s)

can require a substantial amount, for example 190, 380, 1900 litres (50, 100, 500 gallons) or more of hydraulic fluid which can entail the flow of this substantial amount of fluid from a reservoir to the accumulator (s) . The reservoir is initially charged at a pressure slightly higher than the pressure of the water to be encountered at depth and the reservoir is pressure compensated so that at depth it is not damaged or destroyed. This pressure compensation is accomplished according to certain aspects of the present invention with a piston that is movably disposed in a main piston housing which includes the reservoir for the system's operational hydraulic fluid. A piston rod has one end connected to the piston within the housing and another end projecting through the housing. An outer face of the piston is exposed to the pressure of the water (e.g. sea water) which pushes on the exterior of the piston. The end of the piston rod projecting from the housing moves sealingly in and out of a rod chamber. A fluid reservoir is in fluid communication with the interior of the rod chamber and applies fluid (gas, hydraulic fluid) under pressure to the piston rod sufficient to adjust the pressure of the operational hydraulic fluid within the reservoir of the operational hydraulic fluid. The area of the interior surface of the piston is less than the area of the exterior surface of the piston (the area on which the sea water pressure is applied) in an amount equal to the area of the piston rod. Thus, the applied pressure of the gas on the piston rod end need only apply a pressure equal to the sea water pressure to perfectly balance the system. Reducing the applied pressure below the sea water pressure creates an overpressure of the operational hydraulic fluid. For example, with a piston

having an area of about 0.55 square metres (855 square inches) (diameter 0.84m (33")) and a piston rod with an area of 0.009 square metres (14 square inches), a 57 litre (15 gallon) nitrogen system can apply nitrogen at 127 bars (1840 psi) in the rod chamber to the piston rod end to compensate (with an overpressure of 1. lbars (16 psi)) for a sea water pressure on the piston's exterior of 200bars (2900 psi) .

Pressure compensation systems for closed-loop hydraulic fluid reservoirs (in one aspect, subsea) , and such pressure-compensated reservoirs; Such pressure- compensated reservoirs which can effectively handle significantly large flows of fluid into and out of the reservoir; Such systems which can effectively provide a desired internal overpressure for such subsea reservoirs; and

Such systems in which certain parts not exposed to high differential pressure can be made of relatively low- strength and/or relatively light weight materials (e.g. chamber enclosures made of aluminum, structural steel sheet, or plastic and pistons made of the same materials) with a minimum of parts requiring high-strength materials .

For a better understanding of the present invention, reference will now be made, by way of example, to the accompanying drawings, in which:

Figure 1 is a schematic view of a prior art apparatus comprising a pressure compensated reservoir;

Figure 2 is a schematic view of a system in accordance with the present invention, the system comprising an apparatus in accordance with the present invention in a coil tubing module and a further apparatus in accordance with the present invention in a blowout preventer module located at a seabed, with umbilical chords extending therefrom to an intermediate floating body and a further umbilical chord extending from the intermediate floating body to a surface vessel; Figure 3 is a schematic view of a first embodiment of an apparatus in accordance with the present invention; Figure 4 is a schematic view of a second embodiment of an apparatus in accordance with the present invention; Figure 5 is a schematic view of a third embodiment of an apparatus in accordance with the present invention; Figure 6 is a schematic view of a fourth embodiment of an apparatus in accordance with the present invention; Figure 7A is a schematic view of part of an apparatus in accordance with the present invention; and Figure 7B is a schematic view of part of an apparatus in accordance with the present invention.

Figure 1 illustrates schematically one typical prior art system for providing pressure compensation for hydraulic fluid F in a hydraulic fluid reservoir R which is in fluid communication with an apparatus A which is operated by the selective and controlled application of the hydraulic fluid F. A hollow body B has a piston P movably and sealingly mounted therein. The pressure of

sea water S admitted through an opening 0 in the body B pushes against an outer face T of the piston P, pushing the piston P inwardly. Thus, the pressure of the sea water is applied to both the interior and to the exterior of the reservoir effecting the desired pressure compensation. A spring 6 biased between the piston face F and an inner wall W of the body B applies a force to the piston P, thereby providing additional pressure to the fluid F. Such systems work well if the volume of fluid F in the reservoir R is relatively constant with a maximum change in overall volume of 7.5 to 11.5 litres (2-3 gallons) or if the total overall volume is small, for example, 7.5 to 11.5 litres (2-3 gallons).

Figure 2 shows a system 10 in accordance with the present invention with a coiled tubing module 20 and a blowout preventer module 22 , each including a pressure- compensated reservoir 12 in fluid communication with one or a bank of accumulators 14 , each of which is in fluid communication with an hydraulic power unit (16 or 18) of a subsea module 30 on a seafloor 6 in a closedloop system. The pressure-compensated reservoir 12 and accumulators 14 may be any of the embodiments of the apparatus described with reference to Figures 3 to 6 or any other in accordance with the present invention. The hydraulic power unit 16 selectively operates a subsea coiled tubing system of the module 20 and the hydraulic power unit 18 selectively operates a subsea blowout preventer ("BOP") system of the module 22. Fluid flows from the units 16, 18 to the accumulator (s) 14, to device 8 (e.g., BOP; coil tubing apparatus) to be operated by the hydraulic power fluid, and then back to the pressure- compensated reservoir 12 in lines 36, 38 respectively. The pressure-compensated reservoir 12 has a reservoir

charged at the surface to balance the pressure to be encountered at a depth at which the system will be used.

A power/communications umbilical 24 from a reel 32 on a floating surface vessel 28 supplies power to the subsea module 30 via a junction box 39 (which may be an intermediate floating body) and umbilicals 26, 28. The pressure of the seawater 4 is applied to a movable piston in the pressure-compensated reservoir 12

Control systems 2 control the module's functions. A control system 11 remote from the underwater structures is in communication with the control systems 2.

Figure 3 shows a first embodiment 40 of an apparatus in accordance with the present invention. A hollow body 42 contains an amount of hydraulic fluid 43 in an interior chamber 44. Via a flow channel 45, hydraulic fluid under pressure is supplied for operation of an apparatus 46 (e.g. a motor, accumulator (s) , BOP control system, or any of the devices 8, Figure 2) . This fluid flows back to the chamber 44 via a channel 47 in a closed loop system.

A piston 50 closes off an opening defined by a circumferential lip 48 of the hollow body 42. The piston 50 is sealingly mounted with a seal 52 for movement within the chamber 44. The seal 52 is arranged in a circumferential recess in the piston 50. Seawater 4 external the body 42 exerts pressure on an outer surface 54 of the piston 50.

A piston rod 60 is connected at one end to an interior portion 56 of the piston 50. Another end 58 of the piston rod 60 is sealingly movable within an interior 72 of a piston rod chamber 70. A seal 62 seals a piston- rod/piston-rod-chamber interface . The seal 62 is arranged in a circumferential recess in the piston rod chamber 70.

Gas 81 under pressure in a vessel 80 provides pressure against a compressible bladder 82 which contains hydraulic fluid 84 which provides pressure against the piston rod end 58 to counter the pressure of the sea water 4 against the outer surface 54 of the piston 50. Thus , with a chamber initially charged to a pressure equal to the sea water pressure, the pressure in the chamber 44 is always greater than the pressure of the sea water 4; e.g., in one aspect between 10 to 20 psi greater and, in one particular aspect, 15 psi greater. In one aspect the bladder 82 is deleted and the gas itself provides pressure against the piston rod end 58 (see, e.g. a vessel 80b, Figure 7B, like the vessel 80, Figure 4, with gas 81c therein that acts on the piston rod end 58) . Alternatively, the bladder is deleted and gas 81a, Figure 7A expands and contracts above hydraulic fluid 84a in a vessel 80a, like the vessel 80, Figure 4. The hydraulic fluid 84a acts on the piston rod end 58. In certain embodiments, an apparatus as in Figure 3 (and other systems in accordance with the present invention) can handle sea water pressures up to 414 bars (6000 psi) .

Optionally, as shown in Figure 5, a secondary pressure compensator 90 provides pressure on the hydraulic fluid 43 in the chamber 44; e.g. for movement of the apparatus 40 from a water surface to a location beneath the water surface so that, as the apparatus 40 is moved down in a body of water, a minimum desired pressure

(e.g. 10 to 20 psi) is applied to the hydraulic fluid 43 to provide a desired overpressure so that sea water cannot flow into the apparatus 40 at any depth prior to removing fluid from the reservoir. The secondary pressure compensator 90 can be like any suitable known apparatus in accordance with the present invention,

including, but not limited to, a well-known system with an enclosure 91 in which is movably mounted a piston 92 with a surface 93 exposed to the sea water 94 through an opening 95 through the enclosure 91. Once the piston 92 strokes out (contacts the interior of enclosure 91 - left end as viewed in Figure 5) the piston 50 can be moved by the pressurized gas 84. Like parts in Figures 3 and 5 have like identifying numerals .

Figure 4 shows an apparatus in accordance with the present invention 40 (as disclosed in Figure 3) with an optional spring 51 which provides an initial force to over-pressure the operational hydraulic fluid prior to reaching an operating depth. Once at depth, desired overpressurization is provided by the pneumatic fluid in the vessel 80 or any other means in accordance with the present invention. After removing a certain amount of fluid (e.g. 2 litres (0.5 gal)) from the reservoir, the spring reaches its free length and no longer exerts a force . Figure 6 shows a system 100 in accordance with the present invention with a pressure-compensated reservoir 110 in accordance with the present invention (like any disclosed herein in accordance with the present invention) . A pump 102 driven by a motor 112 (e.g. electric, pneumatic, or hydraulic) selectively and controllably pumps hydraulic fluid from the reservoir system 110 (as any described herein in accordance with the present invention) to fluid accumulators 104 from which the fluid is supplied, on demand, to operate subsea equipment, e.g. a subsea BOP system 106. A valve (or valves) 108 control the flow of fluid to and from the BOP. As shown the system 100 is a closed loop system with all fluid pumped from the reservoir system 110 flowing

back from the BOP system 106 to the reservoir system 110 for further recirculation and use. A control system 114 controls the items 102, 110, 112, and 108. Instead of the BOP system 106, any other device or apparatus to be operated can be used in the system 100.