The present invention relates to an underwater buoy installation system.
Offshore flexible riser systems with flow lines are used routinely for transferring fluids between a well on the sea bed and a vessel floating on the surface of the sea. Along the flow line, typically, a plurality of buoys are attached, giving the flow line a flow profile in which the lowest part of the flow line extends relatively steeply upwards from the anchoring point at the sea bed and wherein the upper part of the flow line extends at a more flat angle towards the vessel, such that it allows a relatively large degree of lateral movement of the vessel relatively to the anchoring point at the bottom.
In order to minimize influence on the routine working conditions, the buoys are designed for long term stability and tightness. However, occasionally, the buoys have to be exchanged. This can be a difficult operation under sea level, especially, if the buoys are located in an area underneath the vessel where they are inaccessible by crane-based exchange equipment carried by another vessel. Rough sea conditions may additionally complicate the operation of exchange of buoys. Disconnection of the flow line from the vessel is a possibility, which, however, is a complicated and expensive solution.
For this reason, it would be desirable to provide a system for exchange of buoys that does not disturb the general operation of the flow line.
Buoys for the above described systems, generally have static buoyancy. However, prior art discloses also systems with variable buoyancy, for example as disclosed in U.S. Pat. No. 3,436,776, U.S. Pat. No. 4,860,487, U.S. Pat. No. 7,311,469. A flexible underwater buoyancy system for an underwater ROV (remotely operated vehicle) is disclosed in US2007/186837.
Norwegian patent document NO334758 discloses a remotely controlled underwater vehicle with gripper system for installing sleeves on underwater pipes. The vehicle is limited to pipes that are in horizontal orientation on the seabed, why this system is not suitable for riser lines.
It is an objective of the invention to provide a general improvement in the art. Especially, it is an objective to provide an improved method and system for removal and attachment of buoys on an underwater construction, for example flexible underwater line, especially riser line. Particularly, the exchange of buoys shall not disturb the operation of the subsea riser line. This objective is achieved with an underwater buoy installation and de-installation system and method as described in the following.
The system comprises an underwater vehicle configured for underwater operation and transport of buoys under sea level. The vehicle is equipped with a controlled propulsion and manoeuvring system, for example including water jet thrusters. The vehicle also has a gripper system for gripping buoys for the transport and installation as well as de-installation.
For example, the vehicle comprises a frame to which the gripper system is mounted via an orientation adjustment mechanism that is used for adjusting the gripper orientation and position in a controlled way relatively to the vehicle frame when installing a buoy onto a flexible underwater line or for de-installing the buoy therefrom. In comparison to the aforementioned Norwegian patent NO334758, the orientation of the gripper is adjustable relatively to the frame, and the gripper can be brought into the optimal orientation for operation on a riser.
Advantageously, in order to control the gripper system, the vehicle comprises an illumination system and a camera system that illuminates and records the gripper and the area around the gripper.
The vehicle comprises a controller system for the manoeuvring and operation of the various operative elements, including the gripper system and the propulsion and steering system. The term controller system, is not limited to a single unit but also includes a plurality of controller units, typically interoperating controller units.
For example, the underwater manoeuvring and operation is controlled by a computer and a controller system in cooperation, the controller system receiving command data from the computer. The term computer is not limited to a single unit but also includes a plurality of computer units, typically interoperating computer units.
In some embodiments, the vehicle is configured for autonomous operation. In this embodiment, the computer is programmed for performing a sequence of operations, including manoeuvring the vehicle toward a location where buoys have to be installed or deinstalled and for performing the installation or de-installation itself. The computer receives data from various monitors, including but not limited to the camera system, sonar system, depth meters, orientation data and operational data from the propulsion system. The computer evaluates these received data according to the programming for, upon evaluation, give corresponding commands to the propulsion and steering system and the gripper system to execute the necessary process automatically and autonomously.
In other embodiments, the vehicle is a remotely operated vehicle, ROV. In this case, the vehicle is connected to a surface control vessel via a connection line, typically called umbilical. A control centre is provided on the control vessel for remotely controlling manoeuvring and operation of the vehicle. The manoeuvring and operation of the vehicle is potentially done manually by a control person in the control centre on the control vessel. The person receives information from various monitoring units on the vehicle, including the camera system, and is accordingly steering the vehicle to the correct location and is also performing the gripping and releasing of buoys. Commands for propulsion and steering and further operation of the vehicle, including the gripper system, are transmitted from the control centre to the vehicle through a signal transmission line in the umbilical.
In some embodiments, the manoeuvring and operation is assisted by a computer either as part of the control centre on the control vessel or on the vehicle. For example, a person on the control vessel is instructing the computer to transmit the corresponding steering and/or operational commands in digital form to the controller on the vehicle. The use of a computer as an additional control mechanism is providing assistance to the person and reduces the risk for accidents when a person gives commands for the manoeuvring and operation.
For example, the computer is located in the control centre on the control vessel, and the controller is located on the vehicle, and exchange of data between the computer and the controller is done via a digital data transmission line in the umbilical extending from the computer to the controller. Manoeuvre and operation of the vehicle is controlled by a person with assistance from the computer in the control centre on the control vessel.
In order to control and facilitate manoeuvring of the vehicle under water, the vehicle comprises a buoyancy adjustment system for continuously adjusting the buoyancy of the vehicle during underwater operation. This is important not only when manoeuvring the vehicle toward the buoys but also, once a buoy is gripped or released, adding or reducing substantial buoyancy to the vehicle, for example the equivalent buoyancy of 1000 litre. Typically, before releasing of the buoy from the gripper, the buoyance of the gripper is increased by the buoyancy adjustment system to a level corresponding to the buoyancy of the buoy. Once the buoyancy is adjusted, the buoy can be released without affecting the proper floating of the vehicle.
For example, the buoyancy adjustment system comprises a plurality of water tanks, wherein each water tank is divided into a first compartment for water and a second compartment for gas, the two compartments being mutually separated by a flexible membrane, such that filling of pressurised gas into the second compartment exerts pressure on the membrane and thereby presses water out of the first compartment. This way, buoyancy of the vehicle is increased. Oppositely, release of gas from the tank allows more water to flow into the tank, which reduces buoyancy of the tank. In a practical embodiment, the flexible membrane is an inflatable bladder inside the tank.
A tank or, rather, a plurality of tanks, is attached to a buoy gripper remotely from the frame. The latter allows specific buoyancy adjustment of the gripper in dependence on whether a buoy is gripped by the gripper or not. Also, the buoyancy can be adjusted to the specific buoyancy of the buoy in the gripper. Optionally, tanks for adjusting the buoyancy of the frame of the vehicle are also attached to the frame.
Typically, the underwater vehicle with the gripper is provided as a customization of a multi-purpose standard gripper-free underwater vehicle, for example an ROV. Such multi-purpose standard gripper-free underwater vehicle comprises a buoyancy system to provide a largely floating vehicle. The term “largely floating” is used here with the meaning of the weight or buoyancy being less than 10%, for example less than 5%, of the total above-water weight of the vehicle in question. This implies a slight deviation from neutral buoyancy. For example, an ROV with a weight of more than 1000 kg, for example 3000-4000 kg, would typically have a buoyancy or weight in water of less than 50 kg, for example as low as only 20 kg or lower, due to an integrated static buoyancy system. Such static buoyancy system is typically provided by integrated lightweight foam-filled tanks in the gripper-free vehicle. As the gripper system is being attached to the gripper-free underwater vehicle, for example by a special latch system, and the gripper system is used for gripping buoys that have a large and variable buoyancy, the specialised gripper system itself is advantageously provided with an adjustable buoyancy adjustment system in order to adjust the buoyancy of the gripper system in the case of holding a buoy in the gripper or when no buoy is in the gripper. Also, it should be recalled that such buoys can have various buoyancy, especially if the skin of the buoy is punctured, and the buoy is partially filled with water.
For example, such customization implies an assembly kit of a gripper and a gripper-free underwater vehicle. The assembly can be done on board of a ship. Alternatively, the assembly is advantageously done under water in order to reduce the necessary capacity of a crane ship that is lifting the components into the water. In this case, the gripper-free underwater vehicle with propulsion and steering system is submerged under sea level for the assembly with the gripper system, which is also submerged in the water separately from the vehicle. The buoyancy of the gripper system is adjusted to largely neutral buoyancy of the gripper system before it is mounted onto the gripper-free vehicle while submerged in water. The result is an underwater vehicle with a gripper system having a buoyancy adjustment system.
A gas system delivers pressurised gas to the tanks on the gripper. For monitoring the pressure in the gas system, a pressure meter is provided, feeding data for the pressure to the control vessel. An example of a robust and simple structure is found by a pressure metre in functional connection with a pressure display that is displaying the actual gas pressure in the gas system. The camera system is used to image the pressure display and transmitting the corresponding digital image data via the umbilical to the control vessel for display thereof.
For gripping and releasing buoys, the gripper system with a gripper extends from the vehicle frame via an orientation adjustment mechanism, for example a turn and tilt mechanism, that is used for adjusting the gripper orientation and position in a controlled way when installing a buoy onto a flexible underwater line or for de-installing the buoy therefrom. The orientation adjustment mechanism is functionally connected to the controller, which is electronically connected to the control vessel from which it receives control commands, including commands for adjusting the orientation of the gripper and for gripping and releasing a buoy.
Advantageously, the gripper comprises two hinged jaws for gripping a buoy. Optionally, each jaw has a holding mechanism for engaging with one half of a buoy. By opening the jaws, the two halves of the buoy are pulled apart. This is used for releasing the buoy from the underwater construction, for example flexible underwater line, or for attaching the buoy thereto. An example of a holding mechanism involves a movable pin that is movable towards and away from the buoy when the buoy is abutting the jaws. The pin engages with a cooperating receiver element in the buoy for fastening one half of the buoy to one jaw and the other half to the other jaw. In case that the buoy is not provided with a cooperating receiver, the pin may be used to destructively penetrate the buoy during de-installation.
For example, during installation of a buoy, the holding mechanism is activated to engage each one of the two jaws with one of the two halves of the buoy, after which the two halves of the buoy are pulled apart by opening the jaws. While the two halves are pulled apart, the vehicle is navigated to the specific necessary installation position of the buoy and the two jaws closed in order to bring the two halves of the buoy together around a part of the construction for thereby fixing the buoy to that part of the construction. After fixation, the holding mechanism is disengaged from the buoy and the gripper is opened without pulling the two halves of the buoy apart, and the buoy is thereby released from the gripper.
In some embodiments, the orientation adjustment mechanism is implemented as part of a coupling between the frame and the gripper. For example, the coupling comprising a tilt hinge and a tilt actuator for tilting the gripper relatively to the frame about the tilt hinge. In normal orientation of the vehicle, the tilt mechanism can be arranged for lifting and lowering the gripper. A further hinged mechanism can optionally be included for moving the gripper from side to side. Typically, in addition, a rotational axle is provided, for example normal to a rotational direction of the tilt hinge, for rotation of the gripper relatively to the frame. With such orientation adjustment mechanism, the buoy can be precisely oriented for controlled attachment and detachments
The system as explained is, especially, useful for installation and/or de-installation of buoys that are located underneath a ship or platform at sea level, as the vehicle can be manoeuvred to the buoys underneath the ship. For example, the buoys are located on a flexible underwater line, such as a riser.
For example, in order for a buoy installation, the vehicle would be navigated with the buoy to the underwater construction and stop there in close proximity to the construction. The specific location for installation of the buoy on the underwater construction would be located, and the specific necessary orientation and position of the buoy for installing would be determined. Typically, this is done by using the camera system, although also sonar systems can be used alternatively or in addition. Correspondingly, the gripper would then be adjusted in order for the actual orientation of the buoy in the gripper to match the specific necessary orientation of the buoy. The vehicle would be navigated the last distance with the buoy in the gripper to match the specific necessary final position of the buoy, and the buoy would be installed at the construction in the specific necessary orientation and position. During the navigation the last distance just prior to installation, it may be necessary to fine-adjust the buoy orientation, especially, if the vehicle orientation under water changes during the final navigation. Similarly, a de-installation process comprises the manoeuvring of the vehicle to the construction, adjustment of the gripper to match the orientation of the buoy and then gripping around the buoy for finalising the de-installation process.
The invention will be explained in more detail with reference to the drawing, where
With reference to
Alternatively, the vehicle 10 is operating autonomously and not connected to the control vessel 13. In this case, a computer of the vehicle 10 is programmed to steer the vehicle 10 to a certain underwater location and perform the necessary operation in accordance with the programming and supported by evaluation of the video recording taken continuously by the camera system of the vehicle 10.
In the following, the operation of the vehicle 10 is explained with respect to control signals received by the vehicle through the umbilical 14, but it is understood that a similar operation could be performed autonomously by the computer on board of the vehicle 10 instead of the control centre 15 on the control vessel 13, where human control, command, and intervention typically takes place.
As best seen in
Such buoys 9 have buoyancy in the order of 500-1500 kg, which implies that the vehicle 10 must comprise a correspondingly heavy underwater weight in order to perform a controlled take up and delivery of such buoys 9. On the other hand, manoeuvring of the vehicle 10 under water without a buoy 9 in the gripper 24 should not be hampered due to an unnecessarily overheavy vehicle 10. For this reason, the vehicle 10 is equipped with a buoyancy adjustment system 19 where a plurality of tanks 20 are controllably filled with an amount of water and gas in varying volume ratios, dependent on the desired buoyancy. The tanks 20 are provided on the gripper 24 in order to adjust the buoyancy of the gripper 24 in dependent on a buoy 9 with weight or buoyancy being held in the gripper 24.
The system as illustrated in
Number | Date | Country | Kind |
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PA 2015 70301 | May 2015 | DK | national |
Filing Document | Filing Date | Country | Kind |
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PCT/DK2016/050136 | 5/20/2016 | WO | 00 |