A free standing riser system and a method for installing the same relate to a riser coupled at its lower-end to a wellhead and supported in an erect, substantially vertical position by a buoy assembly that encloses the upper-end of the riser. The system also includes a subsea intervention unit, with three connections, interlinked to a Floating Production Unit (FPU) through a flexible jumper. The system can be used for testing subsea petroleum production and can be applied to Early Production Systems (EPS) or to Long Duration Tests (LDT) and can also be utilized as a completion riser. The application refers also to the method of installation of such system.
One of the well-known production systems utilizes a dynamically positioned offshore vessel fitted with a derrick and a riser constructed of drill pipe threaded joints and the riser's stability is provided by a tension applied to the top-end of the riser by a vessel tensioning system, which is located beneath the derrick. This production system has high operational costs because it utilizes a vessel that is not easily available.
The use of free standing riser is also known in production as well as in completion systems. For example, U.S. Pat. No. 4,234,047 (hereinafter the '047 reference) describes the use of a free standing drilling riser utilizing inflatable buoys installed in the upper-end of the riser. This system permits a quick disconnection of the floating vessel and the riser, which remains buoyantly in place on the sea bed, in a vertical position. Although the specification of the '047 reference does not explicitly address this technical aspect, the use of a rig vessel and a compensator are necessary for the handling of the upper section of the riser, as may be seen in the figures accompanying this reference.
A free standing riser including various annular chambers that control buoyancy is described in U.S. Pat. No. 4,646,840 (hereinafter the '840 reference). However, only anchored vessels may be used with this system since there is no swivel device for the riser. Thus, the arrangement described in the '840 reference provides little practicability for lowering a WCT utilizing the same production riser.
U.S. Pat. No. 4,762,180 describes a configuration with a wellhead, a riser, a riser tensioning buoy, and a WCT on top of the buoy, in that order. This configuration is not suitable for a Long Duration Test LDT since, after the referenced test, the resulting configuration does not include a typical arrangement of the equipment, namely a wellhead, a subsea WCT, a flowline supported at the seabed, and finally a riser in ascendant catenary to the FPU, in that order.
U.S. Pat. No. 5,046,896 (hereinafter the '896 reference) describes a riser with air filled buoys, instead of rigid buoys. The use of these air filled rigid buoys, although not directly addressed in the specification of the '896 reference, also requires a rig vessel and a compensator for handling the top section of the riser.
It is emphasized that, in all the free standing riser systems mentioned above, the technologies therein described require that the vessel be fitted with a derrick and compensator for handling the upper section of the riser (i.e., the section above the point of disconnection).
U.S. Pat. No. 6,082,391 and U.S. Pat. No. 6,321,844 describe a system for the conveyance of petroleum from the seabed in deep water to a floating structure at the surface, in which at least one rigid and straight riser is vertically positioned. This hybrid riser has a central rigid tubular structure and a cylindrical block of syntactic material that surrounds the rigid tubular structure. The cylindrical block provides both buoyancy and thermal insulation to the riser. A floating reservoir is provided above the riser. Multiple rigid pipes for receiving petroleum from the seabed are inserted in the syntactic material. Flexible pipes connect the rigid pipes to the floating structure. Thus, the rigid riser does not provide for passage through the floating reservoir. In addition, the riser, which includes multiple pipes and an insulation system, must be constructed and assembled at a dry location (i.e., on land). Once installed, its reutilization at a different water depth can be troublesome and quite limited, since the method of fabrication is by means of welding the joints.
The system 200 in
Hence, in spite of the technological advances in the area, there is a continuing need for a free standing riser system including a riser formed of interconnected joints and being coupled at its lower-end to a subsea equipment, the riser being fitted with a subsea intervention unit. Such a system would provide easy access and maintenance of the well, allow easy installation and retrieval, and allow the system to be adapted to different water depths.
A first aspect of the invention is a free standing riser system for testing and operating a subsea petroleum production from a wellhead on a seabed to a Floating Production Unit (FPU). The system includes a free standing riser including a terminal, a subsea intervention unit, and an umbilical line. The riser includes interconnected joints linked to one another, a lower-end being coupled to a WCT and wellhead and an upper-end enclosed in a buoy assembly, the riser being maintained in an erect, substantially vertical position. The subsea intervention unit is provided above a riser terminal, and includes three connections, one connection to the terminal, one connection to a flexible jumper that is interconnected to the FPU, and one connection that provides a vertical conveyance to an intervention rig, for well maintenance.
The subsea intervention unit allows the subsea petroleum production to be conveyed to both the FPU and the intervention rig; and the umbilical line controls, monitors and transmits electrical and hydraulic energy, the umbilical line linking the FPU to the wellhead and being supported by the riser or provided in a free catenary mode.
An upper-end of the riser is enclosed in a buoy assembly with control devices for variable buoyancy, the buoy assembly serving to maintain the riser in an erect, substantially vertical position.
The subsea intervention unit includes an internal mandrel providing second and third connections, wherein the mandrel provides a conveyance throughout a Y-shaped divider, the Y-shaped divider within the mandrel including a first extension for vertical conveyance to the intervention rig and a second extension for connection with a production flow line, and the first extension includes an intervention valve, and the second extension includes a production valve.
An upper funnel guide fits to the mandrel, and a curved pipe segment can be joined to the second extension, the curved pipe segment being connected to the flexible jumper.
The subsea intervention unit also includes a connector providing the first connection with the terminal of the riser, wherein the mandrel is linked to the connector, and the connector is provided with a lower funnel guide.
The connector includes a metal sealing ring adapted to fit within a recess of complementary shape located in a mandrel of the terminal of the riser, the mandrel of the terminal including an isolation valve, the valve isolating the riser to allow removal of the subsea intervention unit.
The invention refers to a free standing riser to be used in Early Production System or in Long Duration Test, where the riser is also utilized for deployment of the WCT, providing significant savings in time
Second and third aspects of the invention are installation methods of the free standing riser system.
The above and other aspects of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which:
The following description relates in detail to exemplary embodiments which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout. The following terms have the meaning described below:
A Long Duration Test (LDT) is a test of a well wherein the production is collected by the FPU during a period of from 2 to 6 months and periodically transported to a storage terminal located on land.
An Early Production System (EPS) is a provisional system installed to operate a few producing wells until the main production system is operational.
The free standing riser system 100 of the exemplary embodiment eliminates the need for a physical link to any vessel in order to provide this structural stability or to assure its coupling to the subsea equipment. The system is performed so that the riser 50 is enclosed by the buoy assembly 60.
The upper-end of the riser 50 is linked to an FPU by a flexible jumper 90, which conveys the oil produced by the wellhead 10 to this FPU.
The riser 50 is formed of interlinked joints joined by threads or a mechanical connector, and is connected at its lower-end to the WCT 20. An upper-end of the riser 50 is enclosed by the buoy assembly 60, which applies a vertical upward force that maintains the riser 50 in the erect, substancial vertical position.
The buoy assembly 60 may include buoys of various types, such as inflatable buoys, rigid solid buoys, rigid air filled buoys, or other types of buoys. The buoy assembly 60 may be a combination of similar buoys or of different types of buoys.
The buoy assembly 60 should permit variation in the total buoyancy force applied to the riser 50 since the buoy assembly is preferably installed and retrieved without a buoyancy load acting on the buoys (i.e., in a flooded or uninflated state). That is, the buoys should be deballasted or inflated to the necessary buoyancy only after installation of the riser system 100 and coupling on the seabed. In addition, the number of buoys installed will vary according to the water depth at which the riser 50 is installed.
In this exemplary embodiment, the preferred type of buoy 60 is an inflatable buoy because this type of buoy is easily manipulated due to its low weight and dimensions when uninflated, and furthermore, because the buoy may be inflated below the moon pool of the rig, where space is limited.
The functions of controlling, monitoring and transmitting of electrical and hydraulic energy are accomplished with the aid of an umbilical line 80. The umbilical line 80 may be supported by the riser 50, as shown in
As illustrated in
The first connection of the subsea intervention unit 700 includes a first extension of a Y-shaped divider that provides a vertical conveyance of the production fluid and intervention tools from a passage 715 within the subsea intervention unit 700 to an intervention rig 95. The upper guide funnel 710 is fitted on the mandrel 711, and an intervention valve 712 is positioned within the first extension of the Y-shaped divider.
The second connection of the subsea intervention unit 700 includes a second extension of the Y-shaped divider that is connected to a curved segment 714. A production valve 713 is positioned within the second extension of the Y-shaped divider. The curved segment 714 is shaped as a gooseneck and is connected to a flexible jumper 90 through a connection structure, such as a flange 720. The flexible jumper 90 is connected to the FPU.
The third connection of the subsea intervention unit 700 includes a lower part of the Y-shaped divider and the connector 717 which links the subsea intervention unit 700 to the terminal 730 at the upper-end of the riser 50. The inverted funnel guide 718 is fitted to the connector 717 and facilitates coupling to a terminal 730. The central part of the connector 717 has a metallic sealing ring 719, which provides a connection with a recess 731 within a mandrel 732 of the terminal 730, and as such provides the connection between the terminal 730 and the subsea intervention unit 700.
As shown in
In addition, the subsea intervention unit 700 permits the retrieval and maintenance of the jumper 90, inasmuch as the jumper is connected to the subsea intervention unit 700. The valve 734 within the terminal 730, when closed, permits uncoupling the subsea intervention unit 700 from the terminal 730, allowing maintenance.
In a manner distinct from the state of the art, the free standing riser system 100 if formed by threaded riser joints and is directly connected to the subsea wellhead, without the need of a vessel with a derrick.
In a manner distinct from the state of the art, the subsea intervention unit 700, which is coupled to the upper-end of the riser 50 permits an intervention (i.e., workover) in a production well through the interior of the riser 50 without the need to retrieve the free standing riser system 100 and the flexible jumper 90.
The FPU may be a Floating Production Storage and Offloading (FPSO). This vessel, which may be moored or may be of the Dynamic Positioning (DP) type, does not necessarily require a derrick. In case of the DP type vessel, an extra component, a swivel, is required to avoid the torsion of the flexible jumper 90 and riser 50 because the DP vessel may rotate (weathervane) along its own vertical axis during continuous operation. The swivel may be installed on the upper end of the riser 50 or at the entrance of the FPU. The entrance of the FPU is the preferred position since the maintenance and inspection of the swivel are facilitated at this position, and the swivel operates under lower external pressure.
The preferred use of the free standing riser system 100 is as a production riser. However, alternatively, this system also may be used as a completion riser, without the buoy assembly 60.
The system may either be used for producing naturally flowing wells or wells that require artificial lift pumping systems. If the riser system 100 is used for production through pumping, the production of the oil is accomplished through a subsea pumping module coupled to the WCT, with this subsea pumping module installed and retrieved via cable, as described in Applicant's Brazilian Patent application PI 0301255-7.
The advantages of the free standing riser system 100 include the following.
1) It is possible to deploy a WCT 20 utilizing the riser 50 itself.
2) riser 50 connected to the WCT 20 and to the buoy assembly 60
3) The subsea intervention unit 700 permits intervention and maintenance procedure on the well, thereby eliminating the need for retrieving any components of the riser system 100 during the procedure.
4) The riser 50 enclosed by the buoy assembly 60 simplifies the fabrication, assembly and installation of the free standing riser system 100.
5) The characteristics of the free standing riser system 100 make it appropriate for use in water depths up to 3,000 meters.
In this way, the free standing riser system 100 of the exemplary embodiment presents the following aspects which distinguish it from the prior art.
1) It eliminates the need for constructing a foundation 210 and spools 211 interlinking the wellhead to the base of the riser 50, such as those found in the conventional system of
2) It utilizes mechanical connectors and may be installed by a rig during the deployment operation of a WCT 20, as discussed below.
3) The subsea intervention unit 700, which permits intervention in the well while eliminating the need for removing the entire riser system 100, is provided at the upper-end of the riser 50, and permits the retrieval of the jumper 90 for maintenance of the same. On the contrary, the well-known systems would not permit the easy disconnection of the jumper 90.
4) The free standing riser system 100 makes it unnecessary to use an FPU with a DP system and a derrick for performing Long Duration Tests or Early Production System procedures.
5) The passage of a riser 50 enclosed by a buoy assembly 60, as discussed below, permits easy conveyance to the upper-end of the riser 50, with consequent advantages of direct and vertical access to the well.
Two exemplary methods of installing the free standing riser system 100 are contemplated. The first exemplary embodiment is shown in
According to the first exemplary embodiment, generally shown in
a) Hoisting the buoy assembly 60, by a crane G, as shown in
b) Transporting the barge 802 and the buoy assembly 60 with the aid of a tug 803, as shown in
c) Connecting the buoy assembly 60 to a installation platform 804, which is used for lowering the riser 50, with a cable 805, as shown in
d) Carrying out a partial controlled submersion of one of the ends of the transport barge 802 and sliding the buoy assembly 60 from the deck of the transport barge 802, while the cable 806 is pulled by the tug 803.
e) Separating and removing the transport barge 802 from the location. After that, the free floating buoy assembly 60 will be connected to the installation platform 804 by the cable 805 and connected to the tug 803 by the cable 806, as shown in
f) Carrying out the process of keel hauling (i.e., a cargo transfer) the buoy assembly 60 under the installation platform 804 by appropriately maneuvering the cables 805 and 806 and an auxiliary cable 807 linked to the tug 803. The auxiliary cable 807 controls an anchor weight 808, connected to the lower end of the buoy assembly 60, as shown in
g) Bringing the upper-end of the buoy assembly 60 to the moon pool region of the installation platform 804, and transferring the weight of the buoy assembly 60 to tensioning system steel cables 809 of the platform 804, as shown in
h) After the disconnection of the cable 805, connecting and lowering the joints 810 of the riser 50 within the buoy assembly 60 until the required length of the riser 50 is reached, and connecting the upper-end of the riser 50 to the buoy assembly 60, as shown in
i) Lowering the buoy assembly 60 to the operational depth by a service pipe 811 of the installation platform 804, and then making a connection 812 between the lower-end of the riser 50 and the wellhead 10 on the seabed, as shown in
j) Injecting air into the chambers of the buoy assembly 60 and dewatering the chambers using a remote operated vehicle (ROV) 813 in order to effect a positive buoyancy in the buoy assembly 60, the air volume required for riser 50 stability having been determined.
k) Disconnecting the service pipe 811 utilized for the lowering of the buoy assembly 60 and removing the installation platform 804 from the location.
l) With the aid of a flexible line installation vessel 831, installing the production flexible jumper 90 and the subsea intervention unit 700, which is coupled to the upper-end of the riser 50 and the buoy assembly 60, as shown in
m) Moving the flexible line installation vessel 831 towards the FPU while unwinding a storage spool B of the flexible production jumper 90, as shown in
n) Transferring the end of the production flexible jumper 90 to the FPU, utilizing auxiliary cables 841 and 842, to accomplish the pull-in operation, as shown in
o) Testing the free standing riser system 100; and
p) Operating the free standing riser system 100.
The second exemplary embodiment, shown on
a) Assembling a WCT 20, a BOP preventer 30 and a connection device 40 on a temporary support unit 901, as shown in
b) Connecting and lowering the riser joints 810 until the required length of the riser for the installation of a first buoy of the buoy assembly 60 is reached; maneuvering the first buoy in the moon pool region 902 of the installation platform 804 in order to enclose the riser joints 810 within the first buoy through the opening 903, so that the first buoy is attached to the riser joints 810, as shown in
c) Connecting additional riser joints 810 and repeating this operation for the remaining buoys of the buoy assembly 60.
d) Lowering the buoy assembly 60 to an operational depth through a service pipe 811 of the installation platform 804, and then connecting the WCT 20 at the lower-end of the riser 50 to the wellhead 10 on the seabed, as shown in
e) Injecting air into the buoy assembly 60 and dewatering the buoy assembly with the aid of the ROV 813 in order to produce a positive buoyancy to the buoy assembly 60, the air volume required for riser 50 stability having been determined, as also shown in
f) Disconnecting the service pipe 811 utilized to lower the buoy assembly 60, and removing the installation platform 804 from the location.
g) Installing the production flexible jumper 90 and the subsea intervention unit 700 with the aid of a flexible line installation vessel 831, as discussed above with respect to the first embodiment as shown in
h) Moving the flexible line installation vessel 831 towards the FPU while unwinding a storage spool B of the flexible production jumper 90, as discussed above with respect to the first embodiment and shown in
i) Transferring the upper-end of the production flexible jumper 90 to the FPU, utilizing auxiliary cables 841 and 842, as discussed above with respect to the first embodiment and shown in
j) Testing the free standing riser system 100; and
k) Operating the free standing riser system (100).
In both embodiments of the method of installing the free standing riser system 100 the test can be either an Early Production System (EPS) or, a Long Duration Test (LDT).
While this invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
This application is a Continuation of U.S. application Ser. No. 11/218,926 filed Sep. 1, 2005, which was published as US 2007/0044972, the disclosure of which is incorporated herein by reference.
Number | Date | Country | |
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Parent | 11218926 | Sep 2005 | US |
Child | 12100960 | US |