WO2018164657A1

WO2018164657A1 - Compact flow control module

Info

Publication number: WO2018164657A1
Application number: PCT/US2017/020876
Authority: WO
Inventors: Richard M. Murphy; Saverio PLAZZAI
Original assignee: Fmc Technologies, Inc.
Priority date: 2017-03-06
Filing date: 2017-03-06
Publication date: 2018-09-13

Abstract

A compact flow control module assembly including a multi-piece body having a first body portion (124) having an inlet flow bore (119) and an outlet flow bore (112) and a second body portion (128) having a first flow bore (127), a second flow bore (126), a choke bore (106), and a transition flow bore (122) fluidly connecting the first flow bore, the choke bore, and the second flow bore, The second body portion (128) is removably attached to the first body portion (124) such that the inlet flow bore (119) of the first body portion (124) aligns with the first flow bore (127) of the second body portion (128) and the outlet flow bore (112) of the first body portion (124) aligns with the second flow bore (126) of the second body portion (128). Furthermore, a choke (109) is removably attached to the second body portion (128). Additionally, a connector (110) is disposed on the first body portion (124), opposite the second body portion (128) and configured for connection to a subsea device.

Description

COMPACT FLOW CONTROL MODULE

BACKGROUND

[0001] Flow control modules may be useful in the process of extracting and managing wells that are drilled into the earth to retrieve one or more subterranean natural resources, including oil and gas. Flow control modules may be utilized both offshore and onshore. In offshore environments, flow control modules are particularly useful in directing and managing the flow of fluids (e.g. oil and/or gas) from one or more subsea wells, including satellite wells. A flow control module is a structure having a set of pipes and components through which fluid, such as oil and gas, may flow. Further, flow control modules may include a number of flow control devices, including chokes, and may also include a number of instruments or devices for measuring and obtaining pertinent data about the fluid flowing through the one or more pipes located in the flow control modules.

[0002] When used in a marine environment, a subsea flow control module may be landed and locked adjacent to a subsea tree or other subsea structures. As part of field architecture and planning, the location of subsea trees around one or more wells involves the planning for flow control modules that assist in routing the fluids produced from the wells to another subsea structure or to a riser pipeline for further processing.

[0003] Flow lines are often used to interconnect a flow control module to another subsea structure as part of a subsea oil and gas field layout for fluid communication. Such flow lines may generally be rigid or flexible hoses or pipes that are provided with subsea mateable connectors at either end. Such flexible hoses or pipes are known in the art as jumpers or spools, and may be used to connect several wells and other subsea equipment together.

SUMMARY

[0004] In one aspect, the embodiments disclosed herein relate to a compact flow control module assembly including a multi-piece body having a first body portion having an inlet flow bore and an outlet flow bore; and a second body portion, having a first flow bore, a second flow bore, a choke bore, and a transition flow bore fluidly connecting the first flow bore, the choke bore, and the second flow bore; wherein the second body portion is removably attached to the first body portion such that the iniet flow bore of the first body portion aligns with the first flow bore of the second body portion and the outlet flow bore of the first body portion aligns with the second flow bore of the second body portion; a connector disposed on the first body portion, opposite the second body portion, the connector being in fluid communication with the inlet flow bore and the outlet flow bore, and configured for connection to a subsca device; and a choke removably attached to the second body portion, the choke including an actuator configured to manipulate a choke mechanism disposed in the choke bore to regulate a flow of fluid from the inlet flow bore to the outlet flow bore.

[0005] In one aspect, the embodiments disclosed herein relate to a method of regulating flow to or from a subsea tree including connecting a compact flow control module with a connector to a flow passage of a subsea tree, wherein the compact flow control module have a first body portion having an inlet flow bore and an outlet flow bore, a second body portion having a first flow bore, a second flow bore, a choke bore, and a transition flow bore fluidly connecting the first flow bore and the choke bore, wherein the second body portion is coupled to the first body portion such that the inlet flow bore of the first body portion aligns with the first flow bore of the second body portion and the outlet flow bore of the first body portion aligns with the second flow bore of the second body portion, wherein the connector is in in fluid communication with the inlet flow bore of the first body portion and the outlet flow bore of the first body portion, and a choke body having a choke coupled to the second body portion, wherein the choke is in fluid communication with the choke bore; directing a fluid from the flow passage of the subsea tree to the inlet flow bore of the first body portion; actuating the choke to manipulate a choke mechanism disposed in the choke bore to regulate the flow of the fluid from the inlet flow bore to the outlet flow bore; and directing the fluid from the outlet flow bore of the first body portion to a second flow passage.

[0006] In one aspect, the embodiments disclosed herein relate to a method for manufacturing a flow control module including forging and / or machining a first body portion having two parallel bores in the first body, wherein one bore is an inlet flow bore and the other bore is an outlet flow bore; forging and / or machining a second body portion having two second parallel bores in the second body, wherein one bore is a first flow bore and the other bore is a second flow bore, drilling a transition bore perpendicular to the two second parallel bores in the second body portion, wherein the transition bore connects the two second parallel bores, and drilling a choke bore to be fluidly connected with the transition bore and the two second parallel bores; and attaching the second body to the first body and aligning the two parallel bores of the first body to the two second parallel bores of the second body.

[0007] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

BRIEF DESCRIPTION OF DRAWINGS

[0008] Figure 1 is a perspective view of a compact flow control module assembly coupled to a subsea tree in accordance with one or more embodiments of the present disclosure.

[0009] Figure 2 is a perspective frontal view of a compact flow control module assembly in accordance with one or more embodiments of the present disclosure.

[0010] Figure 3 is a cross-sectional view of the compact flow control module assembly of Figure 2 in accordance with one or more embodiments of the present disclosure.

[0011] Figure 4 is a cross-sectional view of the compact flow control module assembly in accordance with one or more embodiments of the present disclosure

[0012] Figure 5 is a side view of a compact flow control module assembly in accordance with one or more embodiments of the present disclosure.

[0013] Figure 6 is a cross-sectional view of the compact flow control module assembly of Figure 5 in accordance with one or more embodiments of the present disclosure.

[0014] Figure 7 is a close up view of the compact flow control module assembly of Figure 6 in accordance with one or more embodiments of the present disclosure.

[0015] Figure 8 is a side view of a compact flow control module assembly in accordance with one or more embodiments of the present disclosure. DETAILED DESCRIPTION

[0016] In one aspect, embodiments disclosed herein relate to flow control modules. A flow control module may also be interchangeably referred to as a flow control module assembly in the present disclosure. As used herein, the term "coupled" or "coupled to" or "connected" or "connected to" may indicate establishing either a direct or indirect connection, and is not limited to either unless expressly referenced as such. Wherever possible, like or identical reference numerals are used in the figures to identify common or the same elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale for purposes of clarification.

[0017] Compact flow control modules, according to embodiments herein, are apparatuses that include multiple flow bores, may include no or minimal welded flow loops, within the multiple components that are arranged in a certain layout and contained within a frame or frame housing. The reduction or elimination of welded flow loops significantly reduces the complexity, design, and weight of the module. The flow bores included in flow control modules may be used to direct fluid produced from or injected into a subsea well. As used herein, fluids may refer to liquids, gases, and/or mixtures thereof. In addition, one or more flow meters may be integrated with one or more of the flow bores of a flow control module. Furthermore, one or more chokes may be coupled to one of the flow bores of a flow control module. As known in the art, a choke may be an apparatus used to control pressure of fluid flowing through the choke and also may control a back pressure of a corresponding downhole well. Other instruments and devices, including without limitation, sensors and various valves may be incorporated within a flow control module.

[0018] Conventional flow control modules in the oil and gas industry are typically very large and heavy. Conventional flow control modules may include an extensive layout and arrangement of pipes that weigh several tons each. In some instances, a pipe used to direct fluid into another pipe may be ten inches in diameter and may include complicated bends or changes in orientation. Such flow control modules may be both heavier in weight and may also be more expensive to manufacture because of the higher number of parts and components. For example, in order to connect conventional flow control modules to a flow line, such as a well jumper (i.e., a pipe with a connector on each end) additional pipe work is required to be connected from conventional flow control modules to the well jumper. This additional pipework needed to connect a flow control module to a well jumper adds to the weight, installation costs, and overall cost of flow control systems, such as a flow control module.

[0019] Subsea flow lines are often used for the transportation of crude oil and gas from other subsea structures. Examples of subsea structures that may be interconnected or connected to one of the flow lines mentioned above include without limitation subsea wells, manifolds, sleds, Christmas trees or subsea trees, as well as Pipe Line End Terminations (PLETs), and/or Pipe Line End Manifolds (PLEMs). Examples of subsea flow lines include without limitation jumpers and spools. Further, subsea flow lines may include flexible or rigid flow tines, including rigid jumpers, rigid flow lines with flexible tails and flow line risers. Achieving a successful tie-in and connection of subsea flow lines is an important part of a subsea field development. Additional challenges further exist in a subsea environment for connection from one structure to another while both minimizing costs and providing flexibility for future changes to the overall layout of a field or well.

[0020] Accordingly, one or more embodiments in the present disclosure may be used to overcome such challenges as well as provide additional advantages over conventional flow control modules, as will be apparent to one of ordinary skill. In one or more embodiments, a compact flow control module assembly may be lighter in weight and lower in cost as compared with conventional flow control modules due, in part, to integrating a flow meter with one or more of the flow bores and to a reduced number of parts and pipes necessary for a compact flow control module. Additionally, the compact flow control module may comprise components that are forged and/or machined thus requiring no welding, relaxing control tolerances and improving manufacture (i.e. reduced cost and reduced time to manufacture). Furthermore, the compact flow control module has no need for flow loops and has a plurality of inlets and outlets to reduce the number of flow lines and welded flow loops to various other subsea equipment. Overall the compact flow control module may minimize product engineering, risk associated with flow loops manufacture, reduction of assembly time, hardware cost reduction, and weight and envelope reduction.

10021] Further, according to embodiments of the present disclosure, a flow control module may be directly connected to a flow line such as a well production line or similar flow line instead of requiring additional pipework to connect the compact flow control module to the flow line, thus reducing cost and weight of such a compact flow control module.

[0022] Further, in one or more embodiments, a compact flow control module assembly may include more than one inlets or outlets ISO, such as two, three, or more inlets or outlets 150 (see Figures 3-7). In addition, a flow control module assembly may be arranged in series to distribute and manage fluid flow over a wider area in some instances and to connect to multiple subsea equipment thru the plurality of inlets or outlets ISO.

[0023] Turning to Figure 1 , Figure 1 shows a perspective view of a compact flow control module assembly 106 in accordance with one or more embodiments of the present disclosure coupled to a subsea tree. In one or more embodiments, subsea tree 104 may be coupled to a downhole well or a well head (not shown). As known in the art, a subsea tree, such as subsea tree 104 may be a structure useful for producing fluid or injecting fluid into a downhole well, and is often a complex configuration of actuated valves and other components having various functions relevant to the downhole well. It is noted that subsea tree 104 in one or more embodiments may be configured as a horizontal or vertical subsea tree. Subsea tree 104 may include subsea tree frame 105, which surrounds or encases the vertical body of subsea tree 104. Subsea tree 104 is a separate subsea structure from flow control module 106. As known to those of ordinary skill in the art, a blowout preventer (BOP) (not shown) may be coupled to a top hub 102 of subsea tree 104.

[0024] In one or more embodiments, subsea tree 104 may include a production wing block 114 incorporated into the main body of the tree. Fluids from subsea tree 104 may flow to production wing block 114, including in some embodiments, flowing up a vertical borehole (not shown) of subsea tree 104. Further, production wing block 114 may include a production wing valve (not shown). A wing valve is a valve that may be selectively closed or opened to control the flow of fluid from a body of subsea tree 104 and through a flow passage of production wing block 114.

10025] In one or more embodiments, compact flow control module 106 may be used to direct fluid flowing from subsea tree 104 to another subsea structure or distribution point for storage and/or processing.

[0026] A subsea structure may refer without limitation to a subsea tree, a manifold, a

PLEM, or a PLET. A manifold (not shown) is a subsea structure, as known in the art, which may be an arrangement of piping or valves designed to collect the flow from multiple wells into a single location for export and to provide control, distribution and monitoring of the fluid flow. In other embodiments, the fluid flowing from flow control module 106 may be directed to a PLEM or a PLET.

[0027] In one or more embodiments, subsea tree 104 is connected to flow control module 106. In one or more embodiments, flow bore connector 110 is used to connect production wing block 114 or the tree main body with flow control module 106. Flow bore connector 110 may be any type of connector known in the art, including without limitation a collet connector, a clamp connector, or a flanged connector. Flow bore connector 110 may be oriented horizontally, vertically, or at any angle in between.

[0028] In one or more embodiments, the flow bore connector 1 10 is a vertical connector that connects with an inlet flow bore 119 (see Figures. 3, 4, and 6) of the compact flow control module 106, whereby the flow bore connector 110 is oriented for a vertical connection, such as a collet connector, a clamp connector, or flanged connector. By connecting the compact flow control module 106 directly to the production wing block 114, an intermediate flow loop (including welded pipe, flanges, and elbows) is not needed. However, a flow loop (not shown) may be used to additionally connect the production wing block 114 to the compact flow control module 106. According to embodiments of the present disclosure, a vertical connection (or in some instances an angled connection) to a production wing block located on subsea tree 104 and to a well jumper (not shown) may naturally protect critical sealing surfaces of those connections from dropped object impact. The compact flow control module 106 may be coupled to the tree frame 105 and supported by the production wing block 114. In other embodiments, the compact flow control module 106 may be supported by another structure mounted to a conductor housing. Additionally, in one or more embodiments, compact flow control module 106 may include a direct connection to production wing block 114 of subsea tree 104.

[0029] In accordance with one or more embodiments, compact flow control module 106 may include a connector such as a flow line jumper connector 116. The connector may facilitate a direct connection to the inlet flow bore 119 or the outlet flow bore 112 of the compact flow control module 106, as shown in see Figures. 3, 4, and 6. For example, a flow line, such as a jumper, jumper spool, or umbilical, may be directly connected to compact flow control module 106 at flow bore connector 1 10. Thus, the flow bore connector 1 10 connects to one end of a jumper, jumper spool, or umbilical, and the other end of the jumper, jumper spool, or umbilical may connect to another subsea structure, such as a manifold, a subsea tree, PLET, PLEM, in-line tees, riser bases, etc. In one or more embodiments, the connection may include, for example, a collet- or clamp-based connector. In certain embodiments, the connection may be part of an ROV-operated connection system that may be used for the horizontal or vertical connection of rigid or flexible flow lines, such as without limitation jumpers, spools, and umbilicals towards other subsea structures, such as manifolds, subsea trees, PLETs, PLEMs, in-line tees, riser bases, etc. Having a horizontal connection, as the flow line jumper connector 116, may advantageously allow flow control module 106 to not "hinge over" to connect to a flow line. In accordance with embodiments disclosed herein, the flow control module is run with the flow line jumper and is rotated approximately 90 degrees to allow the connection to the tree to be made up.

[0030] It is noted that the ability to directly connect from flow bore connector 110 to a flow line, such as a jumper, spool, or umbilical, without inclusion of or with a reduced number of additional pipes and adaptors, may enable flow control module 106 to be lighter in weight. Specifically, a flow line jumper connector 116 connects directly to the flow bore connector 110 so that the flow path of fluid exiting the flow control module does not reenter the tree assembly. Further, compact flow control module 106 may reduce the manufacturing and installation costs for compact flow control module 106

[0031] As seen by Figure 3, in one or more embodiments, the compact flow control module 106 includes the hub 100 having a multi-piece body such as a first body portion 124 and a second body portion 128. Additionally, the inlet flow bore 119 and an outlet flow bore 112 is integrated in the first body portion 124 located in the hub 100 of the compact flow module 106. One of ordinary skill in the art will appreciate that these elements are not limited to any specific orientation. The inlet flow bore 1 19 provides an entrance into compact flow control module 106 and outlet flow bore 112 provides an exit out of compact flow control module 106. Furthermore, a first flow bore 127 and a second flow bore 126 is integrated in the second body portion 128 with a transition flow bore 122 allowing for a fluid pathway between the first flow bore 127 and the second flow bore 126. Additionally, a choke bore 106 (as shown in Figure 7) is integrated within the second body portion 128 to be in fluid communication with the transition bore 122 and second flow bore 126. Accordingly, in one or more embodiments, the second body portion 128 is removably attached to the first body portion 124 on the opposite side of the flow bore connector 110. One skilled in the art will appreciate how the second body portion 128 can attached to the first body portion 124 using various methods as known in the art, including without limitation mechanical fasteners 152, welding, adhesives, etc. According to one or more embodiments, a fluid (not shown) flowing from subsea tree 104 (see Figure 1) may flow into the inlet flow bore 119 of compact flow control module 106, through the first flow bore 127 to the transition flow bore 122 and be directed out of flow control module 106 through the second flow bore 126 and the outlet flow bore 1 12 of compact flow control module 106. As shown in FIGS. 3, 4, and 6, the outlet flow bore 112 is integrated into the first body portion 124 of the hub 100 of the flow control module 106; in other embodiments, the hub 100 may include multiple outlets. Furthermore, each outlet may include one or more bores for flowing hydrocarbons or injection fluids.

[0032] Still referring to Figure 3, in one or more embodiments, compact flow control module 106 may further include a choke body 108 disposed on the second body portion 128 of the hub 100. Choke body 108 may include a choke 109 which may control pressure by controlling the size of an opening located in the choke through which a fluid passes. In one or more embodiments, the choke 109 may be in fluid communication with at least one of the plurality of flow bores of compact flow control module 106, such as the transition flow bore 122. In accordance with one embodiment, choke 109 may be disposed on the second body portion 128 of the hub 100 vertically or horizontally, as shown in Figures 3-8. [0033] One or more seals and retention mechanisms (such as a clamp or crown or bonnet) may be used to hold choke 109 in place. Further, one or more actuators, such as choke actuator 1 17 may be used to actuate or operate choke 109 or a choke mechanism. As illustrated in Figures 3-8, the choke actuator 117 may be disposed on top of the choke 109 of the flow control module 106 and may include one or more actuating mechanisms. [0034] In one or more embodiments, choke 109 may be either a fixed choke or adjustable choke. A fixed (also known as positive) choke conventionally has a fixed aperture (orifice) used to control the rate of flow of fluids. An adjustable (or variable) choke has a variable aperture (orifice) installed to restrict the flow and control the rate of flow of fluids. Choke 109 may be a variable choke, such that the choke may include a mechanism that allows changing the size of the opening to control both the flow rate of the fluid passing through choke 109 and a pressure associated with the fluid. Choke 109 may operate such that the larger the opening through the choke, the higher the flow rate. A larger opening in the choke creates a smaller pressure drop across the choke, and hence, a higher flow rate. Likewise, a smaller opening in the choke results in a higher pressure drop and a lower flow rate. In one or more embodiments, choke 109 may be an adjustable choke, a fixed or positive type choke, or any other type of choke known in the art [0035] Those of ordinary skill in the art will appreciate that choke 109 may be actuated via choke actuator 1 17 which may include one or more mechanisms including electric and hydraulic actuators. For example, choke 109 disposed in choke body 108 may be mechanically adjusted by a diver or a remotely operated vehicle (ROV), or may be adjusted remotely from a surface control console.

[0036] In accordance with one or more embodiments, choke 109 may incorporate any choke trim suitable for the desired or optimal performance and control of the fluid expected to flow into and out of choke 109. Choke trim as understood in the art may be a pressure-controlling component of a choke and controls the flow of fluids. Choke trim design types include, without limitation, needle and seat, multiple orifice, fixed bean, plug and cage, and external sleeve trims. Sizing of the choke 109 may also depend on a myriad of factors unique to the type of fluid flowing through choke 109. Thus, choke body 108 may include any type of choke as understood in the art and be of any size useful for the specific flow parameters of the subsea tree 104. Additionally, those of ordinary skill in the art will appreciate how the choke 109 or choke mechanisms may be replaced or repaired. In one or more embodiments, the replacement or repair may be achieved by removing the choke body 108 from the second body portion 128 and / or removing the second body portion 128 from the first body portion 124. Once removed, repairs may be done to the choke 109 or choke mechanisms. Additionally, if need be, the choke 109 or choke mechanisms may be all together replaced with new parts. After the repairs or replacement is completed, the choke body 108 and /or second body portion 128 is reattached to the compact flow module 106 within its respective position.

[0037] Referring to Figure 2, compact flow control module 106 may be attached to a frame 138 made up of a plurality of frame support members, such as one or more side support members 137. Frame 138 generally contains the components and pipework of compact flow control module 106. In one or more embodiments, compact low control module 106 is retrievable such that frame 138 and the entirety of the components located within compact flow control module 106 may be retrieved to the surface for maintenance or replacement. Accordingly, frame 138 may include a lop end 142 and a bottom end or base 140. Further, side support members 137 may be connected to top end 142 and base 140 to form frame 138. Various fasteners and attaching mechanisms as known in the art may be used to connect the frame support members together including without limitation brackets, bolts, screws, etc. In other embodiments, frame 138 may be integrally formed of any type of material, including metals, composites, etc.

[0038] Furthermore, the components of the compact flow control module 106, may be attached to one or more frame support members of frame 138 using various methods as known in the art, including without limitation mechanical fasteners, welding, integrally forming, adhesives, etc. Frame 138 may act as the housing that supports and/or encases one or more components of flow control module 106, including an opening to access the choke actuator 117. Additionally, the flow bore connector 110 of the hub 100 is seen near the bottom end or base 140 of the frame 138.

[0039] Referring back to Figure 3, which shows a cross sectional view of the flow control module assembly of Figure 2, in accordance with one or more embodiments of the present disclosure. As shown, compact flow control module 106 has the hub 100 with the first body portion 124 and the second body portion 128. The first body portion 124 includes the inlet flow bore 119 and the outlet flow bore 112 being parallel vertical flow bores. Fluid flowing from the inlet flow bore 119 (from, e.g., subsea tree 104) may flow through the conduit connected to the inlet flow bore 119 and up in the vertical flow path. Furthermore, a plurality of seals 153 can be in between the first body portion 124 and the second body portion 128 to ensure there is a complete seal between the bodies (124, 128) and preventing flow from escaping the flow bores. Once the second body portion 128 is attached to the first body 124 portion, the inlet flow bore 119 of the first body portion 124 aligns with the first inlet flow bore 127 of the second body portion 128 and the outlet flow bore 112 of the first body portion 124 aligns with second flow bore 126 of the second body portion 128. Additionally, one skilled in the art would appreciate how the first body portion 124 and the second body portion 128 are each forged or machined from one piece of material suitable for subsea conditions (i.e. metals, composites, or structural insulating materials). This is achieved by forging or machining, by means know to those skilled in the art, the first body portion 124 and the second body 128 portion to the determined dimensions based on the required flow module performance and subsea conditions.

[0040] In one or more embodiments, a flow meter or other desired equipment is integrated into either or both the first body portions 124 and the second body portion 128 of the hub 100. Then the parallel bores are drilled into the first body portion 124 and the second body portion 128 to create the flow bores (119, 112, 127, and 126). In this manner, the need for extensive flow loops and flow lines in the compact flow control module 106 can be eliminated. By eliminating the need for extensive flow loops and flow lines, the compact flow module may only have 3 to 4 turns, such as 90 degree bends, from the inlet flow line to outlet flow line. In contrast, conventional flow modules have extensive flow loops and flow lines with multiple turns that create a more tortuous flow path with a higher pressure loss. Advantageously, the compact flow module 106 reduces the pressure loss through the parallel flow bores by eliminating the need for extensive flow loops and flow lines. [0041] In one or more embodiments, a flow meter (not shown), which is integrated into the first body portion 124 of the hub 100 of the compact flow control module 106, may be fluidly connected to the inlet flow bore 119 and the outlet flow bore 112. Thus, the flow meter's bore shares the inlet flow bore 119 and the outlet flow bore 1 12. A flow meter as known by those in the art may be used to measure one or more properties or conditions of flow of a fluid. Additionally, in one or more embodiments, the flow meter may be coupled to the first body portion 124. In one or more embodiments, the flow meter may be a multi-phase flow meter. In other embodiments, the flow meter may be a wet gas flow meter or a single-phase flow meter. In other embodiments, the flow meter may be removed (i.e., the inlet flow bore 1 19 and the outlet flow bore 112 may not include a flow meter) and/or configured to include virtual metering, in which the flow is not measured directly but is determined, calculated, or otherwise extrapolated from indirect measurements such as pressure and temperature measurements between flow meter tabs 144. In such embodiments, the flow control module may be said to include a "virtual meter." [0042] In accordance with embodiments of the present disclosure, the flow meter may be "inverted" (as compared to conventional flow meters) and configured for a top-down flow regime (not shown), whereby fluid flows down through the outlet flow bore 112and through the flow meter (not show). Such an orientation reduces or eliminates settling of the liquid phase of the fluid which may interfere with sensor measurements if the meter is horizontally oriented and allows a reduction in size and weight of the equipment when compared to a conventionally oriented meter with a "bottom up" flow direction. [0043] Further, compact flow control module 106 may include a number of additional instruments and devices useful in monitoring a fluid flowing through compact flow control module 106. Such instruments and devices may include chemical meters, pressure and/or temperature sensors, erosion probes, densitometers, or other instruments/devices known in the art. [0044] In one or more embodiments, a choke valve 120 (shown in Figures 3 and 6) may be incorporated into the flow passage. A choke valve as known to one of ordinary skill in the art may be used as a control valve in a fluid handling system that stops the flow of fluid to a given location, usually for maintenance or safety purposes. An isolation valve (not shown) may further be used to provide flow logic (selecting one flow path versus another), and to connect external equipment to a system. A transition flow bore 122 may be aligned with the choke valve 120 to direct fluid through the transition flow bore 122 as needed, for example, for maintenance or safety purposes. Furthermore, the choke valve 120 may be disposed in the first flow bore 127 or second flow bore 126.

[0045] As shown in Figure 1 subsea tree 104 may be coupled to compact flow control module 106. Accordingly, in one or more embodiments, subsea tree 104 may be adapted for use as an injection subsea tree. Additionally, arrows 101 in Figure 3 show a flow path for fluids traveling in the compact flow control module 106 after being injected into the subsea tree 104. However, it is noted, that subsea tree 104 may be configured for use with production services and compact flow control module 106 may be adapted for use for production services as well, which is further discussed below.

[0046] In accordance with one or more embodiments, fluids flowing down into the subsea tree 104 (not shown) may flow upwardly through the compact flow control module 106. As known to those of ordinary skill in the art, compact flow control module 106 may include one or more master valves (not shown) and/or swab valves (not shown) as well as additional components to regulate the flow of fluids through the inlet flow bore 119.

[0047] In accordance with one embodiment, not shown, a fluid may flow through an injection wing valve located in injection wing block (as shown by the production wing block 114 in Figure 1). Flow bore connector 110 connects an injection wing block of subsea tree 104 (see Figure 1) to the inlet flow bore 119 of compact flow control module 106. Fluid may proceed to flow through the inlet flow bore 119 of the first body portion 124 and to the first flow bore 127 of the second body portion 128 of compact flow control module 106. Fluid may flow through the transition flow bore 122. Fluid may then flow through choke 109, which is actuated by choke actuator 117, thereby regulating a pressure of the flowing fluid and then proceed to the second outlet flow bore 126 of the second body 128. The fluid may proceed to flow to the outlet flow bore 112 of the compact flow control module 106 and to any connected subsea structure, including one or more flow lines. (0048] As noted above, subsea tree 104 (see Figure 1) may be used for production services where the fluid is from a well or reservoir. Accordingly, a compact flow control module 106 may also be configured for well production services. In such instances, choke body 108 may be located at an upper end of a vertical flow passage (e.g., the second flow bore 126 in Figure 3) located in the compact flow control module 106. In one or more embodiments, a flow meter may be positioned within the inlet flow bore 119 and configured for a more traditional bottom-up flow regime. Furthermore, one skilled in the art would appreciate how the inlet flow bore 119 may be configured to have a constricted section 151 to create a venturi effect. Additional, the outlet flow bore 112 may also have a constricted section (not shown) to create a venturi effect.

[0049] Figure 5, in one or more embodiments, illustrates a side view of the compact flow module 106 without the frame 138. The hub 100 has the flow bore connector 110 connected to a bottom of the first body portion 124 with the second body portion 128 disposed on a top of the first body portion 124. Additionally, the first body portion 124 may have a plurality of inlets/outlets 150 drilled to be in fluid communication with the flow bores (as seen in Figures 3, 4, and 6) of the first body portion 124. One skilled in the art will appreciate how the plurality of inlets/outlets 150 may connect the compact flow module 106 to other various devices. As seen by Figure 6, in one or more embodiments, Figure 6 illustrates a sectional view of the compact flow control module 106 seen in Figure 5 without the frame 138.

[0050] As shown in Figure 6, in one or more embodiments, illustrates a cross-sectional view of Figure 5 and similar to Figure 3 but without the frame 138. The compact flow control module 106 includes the hub 100 having a multi-piece body such as a first body portion 124 and a second body portion 128. Additionally, the inlet flow bore 119 and an outlet flow bore 112 is integrated in the first body portion 124 located in the hub 100 of the compact flow module 106. One of ordinary skill in the art will appreciate that these elements are not limited to any specific orientation. The inlet flow bore 1 19 provides an entrance into compact flow control module 106 and outlet flow bore 112 provides an exit out of compact flow control module 106. Furthermore, a first flow bore 127 and a second flow bore 126 is integrated in the second body portion 128 with a transition flow bore 122 allowing for a fluid pathway between the first flow bore 127 and the second flow bore 126, Additionally, a choke bore 106 (as shown in Figure 7) is integrated within the second body portion 128 to be in fluid communication with the transition bore 122 and second flow bore 126. Accordingly, in one or more embodiments, the second body portion 128 is removably attached to the first body portion 124 on the opposite side of the flow bore connector 110. One skilled in the art will appreciate how the second body portion 128 can attached to the first body portion 124 using various methods as known in the art, including without limitation mechanical fasteners 152, welding, adhesives, etc. According to one or more embodiments, a fluid (not shown) flowing from subsea tree 104 (see Figure 1) may flow into the inlet flow bore 1 19 of compact flow control module 106, through the first flow bore 127 to the transition flow bore 122 and be directed out of flow control module 106 through the second flow bore 126 and the outlet flow bore 112 of compact flow control module 106. As shown in FIGS. 3, 4, and 6, the outlet flow bore 112 is integrated into the first body portion 124 of the hub 100 of the flow control module 106; in other embodiments, the hub 100 may include multiple outlets. Furthermore, each outlet may include one or more bores for flowing hydrocarbons or injection fluids.

[0051] Furthermore, compact flow control module 106 may further include a choke body 108 disposed on the second body portion 128 of the hub 100. Choke body 108 may include a choke 109 which may control pressure by controlling the size of an opening located in the choke through which a fluid passes. In one or more embodiments, the choke 109 may be in fluid communication with at least one of the plurality of flow bores of compact flow control module 106, such as the transition flow bore 122. In accordance with one embodiment, choke 109 may be disposed on the second body portion 128 of the hub 100 vertically or horizontally. One or more seals and retention mechanisms (such as a clamp or crown or bonnet) may be used to hold choke 109 in place. Further, one or more actuators, such as choke actuator 117 may be used to actuate or operate choke 109. As illustrated in Figures 3-8, the choke actuator 117 may be disposed on top of the choke 109 of the flow control module 106 and may include one or more actuating mechanisms.

(0052) Figure 7, in one or more embodiments, illustrates a close up view of Figure 6 including the second body portion 128 attached to the first body portion 124 on the opposite side of a first end 161 proximate to the flow bore connector 110. On the opposite of the first end 161, the first body portion 124 may include a second female connector end 1S6 having an inner diameter and depth. The inner diameter and depth of the second female connector end 156 is adapted to receive a lower section 157 of the second body portion 128. Additionally, the lower section 157 has an outer diameter and a length to fit within the inner diameter and depth of the second female connector end 156. Furthermore, the second body portion 128 may include a flanged middle section 158 above the lower section 157 and below an upper body section 159 of second body portion 128. In one or embodiments, the flanged middle section 158 has an outer diameter larger than the outer diameter of the lower section 157 and the upper body section 159.

|0053] Further seen by Figure 7, in one or embodiments, the first body portion 124 and / or the second body portion 128 may have a first groove 162 encompassing the first flow bore 127 / inlet flow bore 1 19 interface. Additionally, the first body portion 124 and / or the second body portion 128 may have a second groove 163 encompassing the second flow bore 126 / outlet flow bore 112 interface. Furthermore, a plurality of seals 153 may be within the first groove 162 and the second groove 163 in between the first body portion 124 and the second body portion 128 to ensure there is a complete seal between the bodies (124, 128) and preventing flow from escaping the flow bores.

[0054] Now referring to Figure 8, in one or more embodiments, illustrates a compact flow control module 106 with the hub 100. The hub 100 has the second body 128 coupled to the first body 124 by the coupling devices 152. Furthermore, the choke body 108, with a choke actuator 117, is disposed on a side of the second body 128 and a flow meter (not shown) is integrated into the first body 124.

[0055] In accordance with one or more embodiments, subsea tree 104, and compact flow control module 106 may be landed together or substantially simultaneously onto the subsea wellhead (not shown). In other embodiments, subsea tree 104 may be landed first and then compact flow control module 106 may be landed and coupled to subsea tree 104.

|00S6] Advantageously, compact flow control module 106 may be separately landed independent from a flow line, such as a jumper, spool, or umbilical. Subsequently, according to one or more embodiments, a flow line, such as a jumper, spool, or umbilical, may be connected to the outlet flow bore 112 of the first body 124 of the hub 100 of the compact flow control module 106. Compact flow control module 106 may be retrievable to the surface in order to conduct repairs, inspection, or replacement of any components of compact flow control module 106 by disconnecting flow bore connector 110 located between tree frame 105 and compact flow control module 106.

[0057] Government regulations typically require at least two barriers (e.g., valves that may be selectively closed and regulated) be included in a subsea tree, such as subsea tree 104, to protect the environment, particularly the marine environment, from fluids flowing up through a subsea tree from a reservoir. In accordance with one or more embodiments, subsea tree 104 may include a number of valves, including a master valve and a production wing valve, which may act as the necessary "barriers" required to protect the marine environment when compact flow control module 106 is removed.

[0058] According to one or more embodiments, subsea tree 104 may include passageways for hydraulic control fluid for a surface controlled subsurface safety valve (SCSSV) to isolate the wellbore fluids. Further, subsea tree 104 may include in one or more embodiments a production master valve (PMV) and a production wing valve (PWV). When these valves (SCSSV, PMV, and PWV) are closed, in one or more embodiments, compact flow control module 106 may be retrieved or removed from subsea tree 104. Access to a main bore (not shown) of subsea tree 104 may be provided after removal of the compact flow control module 106. The outlet on production wing block 1 14 may facilitate such main bore access of subsea tree 104 without requiring extensive well intervention. The main bore and the valves of subsea tree 104 may be visually inspected and/or cleaned through the outlet provided in production wing block 114 once the compact flow control module 106 is removed via flow bore connector 110. For example, an ROV based borescope may be used to inspect a main bore and the valves located on subsea tree 104. Further, a washout tool or similar may be used to clean the main bore and the valves on subsea tree 104. Typical subsea flow control module/assemblies do not provide the ability to visually inspect or provide access to a main bore of a subsea tree or valves located a main bore of a subsea tree unless the entire subsea tree is retrieved to the surface and the tree is partially disassembled. In accordance with one or more embodiments disclosed herein, the compact flow control module 106 may be separately removed and access provided to a main bore of a subsea tree as well as to one or more valves without having to entirely retrieve the subsea tree to the surface.

[0059] In addition to the benefits described above, a lighter weight flow control module, such as the compact flow control module 106 may further beneficially enable a lighter weight tree assembly that may reduce cost of the overall subsea tree system. A lighter weight of a tree and tree system may increase the range of vessels capable of installing a corresponding tree, thereby reducing the reliance on a limited number of multi service vessels (MSVs). It is noted that the compact flow control module 106 may be used for onshore systems and surface trees as well.

[0060] In one or more embodiments, the First body portion 124 and the second body portion 128 of the hub 100 of the compact flow control module 106 may be each manufactured from one solid piece of material. Those skilled in the art would appreciate how the material can be any material suitable for subsea conditions, for example, metals, ceramics, and/or composites. Additionally, coatings may be added to the hub 100 for thermal insulation and to prevent corrosion. The first body portion 124 and the second body portion 128 from the hub 100 may be forged and/or machined into the size and shape needed for based on required application of the compact flow control module 106.Thc first body portion 124 is forged and/or machined to include the first end 161 in which the flow bore connector 110 may be connected to. On an end opposite of the first end 161, the second female connector end 156 is forged and/or machined to have inner diameter and depth. Additionally, the first body portion 124 is forged to integrate two parallel flow bores within the body, such as the inlet flow bore 119 and the outlet flow bore 112. Furthermore, after the two parallel flow bores are formed within the first body portion 124, manufacturing processes well known in the art may be used to ensure proper dimensions and cleanliness of the two parallel flow bores are achieved. Alternatively, in one or embodiments, the first body portion 124 may being forged and/or machined without any flow bores, and then have two parallel flow bores are drilled, such as the inlet flow bore 119 and the outlet flow bore 112 from the first end 161 to the second female connector end 1S6. .

[0061] In addition to the above mentioned manufacturing, the second body portion 128 is forged and/or machined to include the lower section 157 with an outer diameter and length adapted to fit within the second female connector end 156. Additionally, the second body portion 128 may be forged and/or machined to include a flanged middle section 158 and an upper body secdon 159. In one or embodiments, the flanged middle section 158 has an outer diameter larger than the outer diameter of the lower section 157 and the upper body section 159. Additionally, the second body portion 128 is forged to integrate flow bores within the body, such as the first flow bore 127 and the second flow bore 126. Alternatively, in one or embodiments, the second body portion 128 may being forged and/or machined without any flow bores, and then the first flow bore 127 and the second flow bore 126 are drilled from the lower section to a point in the upper section 159. One skilled in the art will appreciate how the first flow bore 127 and the second flow bore 126 may be forged / drilled all the way through the upper body section 159 and have a fill material (like fill material 154) emplaced to seal the bores upper end. Additionally, the transition flow bore 122 is drilled into the second body portion 128 to fluidly connect the first flow bore 127 and the second flow bore 126. If the transition bore 122 is drill from a side of the second body portion 128 a fill material 154 may be emplaced to seal of the transition flow bore 122 from outside sources. Additionally, one of the flow bores may be drilled to have a constricted section 151 to create a venturi effect Those skilled in the art would appreciate how the venturi effect may alternatively be created by emplacing a fill material in the flow bores. Furthermore, a plurality of transition flow bores, choke bores, inlets and outlets are drilled into the hub. Once the bores are drilled, the bores may be further machined or the fill material may be added to achieve the desired shape of the flow bore. Furthermore, the choke bore 160 is drilled into the second body portion 128 to be in fluid communication with the first flow bore 127, the second flow bore 126, and the transition flow bore 122. With choke bore 160 drilled, the choke body 108 may be coupled to the second body portion 128 such that the choke 109 is in fluid communication with the choke bore 160. Additionally, the first body portion 124 and / or the second body portion 128 may have the first groove 162 forged and / or machined within the area encompassing the first flow bore 127 / inlet flow bore 119 interface. Further, the first body portion 124 and / or the second body portion 128 may have the second groove 163 forged and / or machined within the area encompassing the second flow bore 126 / outlet flow bore 112 interface. [0062] As described above, the compact flow control module 106 may be placed in fluid communication with various subsea devices. Following formation of the inlet and outlet bores, as described above, coupling devices known in the art, such as flanges or other types of pipe connection devices, may be added to the openings of the flow bores, inlets and outlets to allow for easy access and coupling to the compact flow control module 106. Additionally, valves or caps know in the art may be added (such as choke and isolations valves) within the flow bores to control the flow of the fluid within the compact flow control module 106. Furthermore, the hub 100 may have a plurality of connectors added and/or machined/welded to make for easy connection to the frame 138.

[0063] While the present disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments may be devised which do not depart from the scope of the disclosure as described herein. Accordingly, the scope of the disclosure should be limited only by the attached claims.

Claims

CLAIMS What is claimed:

1. A compact flow control module assembly, comprising:

a multi-piece body comprising:

a first body portion having an inlet flow bore and an outlet flow bore; and a second body portion, having a first flow bore, a second flow bore, a choke bore, and a transition flow bore fluidly connecting the first flow bore, the choke bore, and the second flow bore;

wherein the second body portion is removably attached to the first body portion such that the inlet flow bore of the first body portion aligns with the first flow bore of the second body portion and the outlet flow bore of the first body portion aligns with the second flow bore of the second body portion;

a connector disposed on the first body portion, opposite the second body portion, the connector being in fluid communication with the inlet flow bore and the outlet flow bore, and configured for connection to a subsea device; and

a choke removably attached to the second body portion, the choke including an actuator configured to manipulate a choke mechanism disposed in the choke bore to regulate a flow of fluid from the inlet flow bore to the outlet flow bore.

2. The assembly of claim 1, wherein at least one of the first body portion and the second body portion comprises a first groove encompassing the first flow bore / inlet flow bore interface and a second groove encompassing the second flow bore / outlet flow bore interface.

3. The assembly of claim 2, further comprising a seal ring disposed in each of the first groove and the second groove,

4. The assembly of claim 1 , wherein:

the second body portion comprises:

an upper body section;

a flanged middle section; and a lower section having an outer diameter and a length, defined as the distance from a bottom of the flanged middle section to an end of the lower section;

the first body portion comprises:

a first end proximate the connector; and

a second female connector end configured to receive the lower section of the second body portion, the second female connector end having an inner diameter and depth similar to the outer diameter and length, respectively, of the lower section of the second body portion.

5. The assembly of claim 4, wherein the flanged middle section of second body portion having an outer diameter larger than the outer diameter of the lower section of the second portion.

6. The assembly of claim 4, wherein the flanged middle section of second body portion engages with an end of the second female connector end of the first body portion.

7. The assembly of claim 1, further comprising a flow meter coupled to the first body portion and in fluid communication with at least one of the inlet flow bore and the outlet flow bore.

8. The assembly of claim 1, further comprising at least one of the bores of the first body portion and/or the second body portion comprises a venturi.

9. The assembly of claim 1, further comprising a fill material to seal an end of the transition flow bore from the outside atmosphere.

10. The assembly of claim 1, wherein the second body portion is removably attached to the first body portion with a mechanical fasteners, welding, and / or adhesives.

1 1. The assembly of claim 1, wherein the choke is removably attached to the second body portion with a mechanical fasteners, welding, and / or adhesives and the choke is repairable or replaceable.

12. The assembly of claim 1, further comprising at least one sensor in fluid communication with at least one of the inlet flow bore, the outlet flow bore, first flow bore, and/or the second flow bore.

13. A method of regulating flow to or from a subsea tree, comprising:

connecting a compact flow control module with a connector to a flow passage of a subsea tree, wherein the compact flow control module comprises:

a first body portion having an inlet flow bore and an outlet flow bore, a second body portion having a first flow bore, a second flow bore, a choke bore, and a transition flow bore fluidly connecting the first flow bore and the choke bore,

wherein the second body portion is coupled to the first body portion such that the inlet flow bore of the first body portion aligns with the first flow bore of the second body portion and the outlet flow bore of the first body portion aligns with the second flow bore of the second body portion,

wherein the connector is in in fluid communication with the inlet flow bore of the first body portion and the outlet flow bore of the first body portion, and

a choke body having a choke coupled to the second body portion, wherein the choke is in fluid communication with the choke bore;

directing a fluid from the flow passage of the subsea tree to the inlet flow bore of the first body portion;

actuating the choke to manipulate a choke mechanism disposed in the choke bore to regulate the flow of the fluid from the inlet flow bore to the outlet flow bore; and directing the fluid from the outlet flow bore of the first body portion to a second flow passage.

14. The method of claim 13, measuring the fluid flow rate with a flow meter in fluid communication with at least one of the inlet flow bore of the first body portion and / or the outlet flow bore of the first body portion.

15. The method of claim 13, further comprising coupling a flow loop from the first body portion to a production or injection wing outlet of the subsea tree or to a spool that is connected to the production or injection wing of the subsea tree.

16. The method of claim 13, further comprising constricting the fluid via a venturi in at least one of the bores of the first body portion and / or second body portion.

17. A method for manufacturing a flow control module, comprising:

forging and / or machining a first body portion comprising:

two parallel bores in the first body, wherein one bore is an inlet flow bore and the other bore is an outlet flow bore;

forging and / or machining a second body portion comprising:

two second parallel bores in the second body, wherein one bore is a first flow bore and the other bore is a second flow bore, drilling a transition bore perpendicular to the two second parallel bores in the second body portion, wherein the transition bore connects the two second parallel bores, and drilling a choke bore to be fluidly connected with the transition bore and the two second parallel bores; and attaching the second body to the first body and aligning the two parallel bores of the first body to the two second parallel bores of the second body.

18. The method of claim 17, further comprising emplacing a fill material to enclose the transition bore in the second body portion.

19. The method of claim 17, further comprising forging and / or machining a first groove and a second groove in at least one of the first body portion and the second body portion encompassing the first flow bore / inlet flow bore interface and encompassing the second flow bore / outlet flow bore interface, respectively.

20. The method of claim 19, further comprising adding seals in each of the first groove and the second groove.

21. The method of claim 17, further comprising coupling a choke to the second body to be in fluid communication with the choke bore, the transition bore, and the two second parallel bores.

22. The method of claim 21, further comprising using a mechanical fasteners, welding, and/or adhesives to removably attach the choke to the second body portion.

23. The method of claim 17, further comprising at least one of the bores of the first body portion and/or the second body portion comprises a venturi.

24. The method of claim 23, wherein creating the venturi by adding a fill material or drilling, wherein drilling further comprises:

drilling a first and second innermost diameter of the venturi, drilling a first and second outermost diameter of the venturi, and drilling a transition diameter to connect the first and second innermost / outermost diameter of the venturi.

25. The method of claim 17, further comprising coupling a flow meter to first body portion to be in fluid communication with the one of the two parallel bores of the first body portion.

26. The method of claim 17, further comprising attaching at least one sensor to be in fluid communication with the two parallel bores, and / or the transition bore, choke bore, and/or the two second parallel bore.

27. The method of claim 17, wherein:

forging and / or machining the second body portion to have:

an upper body section;

a flanged middle section; and

a lower section having an outer diameter and a length, defined as the distance from a bottom of the flanged middle section to an end of the lower section;

forging and / or machining the first body portion to have:

a first end proximate the connector; and

a second female connector end configured to receive the lower section of the second body portion, the second female connector end having an inner diameter and depth similar to the outer diameter and length, respectively, of (he lower section of the second body portion.

28. The method of claim 27, further comprising inserting a lower section of the second body portion into a second female connector end of the first body portion.

29. The method of claim 28, further comprising using a mechanical fasteners, welding, and/or adhesives to removably attach the second body portion to the first body portion.