Patent Grant
9359829
The present invention relates to a riser assembly and method of providing a riser assembly. In particular, but not exclusively, the present invention relates to a riser assembly suitable for use in the oil and gas industry, to help prevent unwanted movement of buoyancy modules after installation.
Traditionally flexible pipe is utilised to transport production fluids, such as oil and/or gas and/or water, from one location to another. Flexible pipe is particularly useful in connecting a sub-sea location (which may be deep underwater, say 1000 meters or more) to a sea level location. The pipe may have an internal diameter of typically up to around 0.6 meters. Flexible pipe is generally formed as an assembly of a flexible pipe body and one or more end fittings. The pipe body is typically formed as a combination of layered materials that form a pressure-containing conduit. The pipe structure allows large deflections without causing bending stresses that impair the pipe's functionality over its lifetime. The pipe body is generally built up as a combined structure including metallic and polymer layers.
In known flexible pipe design the pipe includes one or more tensile armour layers. The primary load on such a layer is tension. In high pressure applications, the tensile armour layer experiences high tension loads from the internal pressure end cap load as well as weight. This can cause failure in the flexible pipe since such conditions are experienced over prolonged periods of time.
One technique which has been attempted in the past to in some way alleviate the above-mentioned problem is the addition of buoyancy aids at predetermined locations along the length of a riser. The buoyancy aids provide an upwards lift to counteract the weight of the riser, effectively taking a portion of the weight of the riser, at various points along its length. Employment of buoyancy aids involves a relatively lower installation cost compared to some other configurations, such as a mid-water arch structure, and also allows a relatively faster installation time. Examples of known riser configurations using buoyancy aids to support the riser's middle section are shown in
Wave riser configurations as shown in
However, in some applications, the buoyancy modules may react to changes in riser assembly weight, for example caused by marine growth (shellfish and other sea life and/or sea debris attaching to the riser). Alternatively or additionally, the riser assembly and/or the buoyancy modules may experience a gradual (or sudden) change in content density due to movement or general day to day wear for example. This may cause the amount of buoyancy support or net buoyancy (and therefore the relative height above the sea bed) of the riser to change. Any change in the amount of buoyancy support may have an adverse effect on the tension relief provided to the flexible pipe, which could ultimately decrease the lifetime of a riser.
Furthermore, such changes in weight could lead to an undesirable situation where the riser assembly diverts completely from its designated configuration by either popping up to the water's surface or sinking to the sea bed. This is particularly applicable to shallow water applications (less than 1000 feet (304.8 meters)), since any change in buoyancy has a more pronounced effect on the height change at shallow depths. Interference with any neighbouring riser assemblies or vessel structures could become a problem.
WO2009/063163, incorporated herein by reference, discloses a flexible pipe including weight chains secured to a number of buoyancy modules on the pipe. The chains hang from the buoyancy modules, extending downwards to the sea bed and having an end portion lying on the sea bed. The weight associated with each length of chain counteracts the buoyancy provided by the respective buoyancy module to which it is secured. That is, when the density of a riser section decreases and the pipe begins to rise towards the water surface, the amount of chain suspended between the buoyancy module and the seabed is increased (i.e. heavier), thus offsetting the pipe's tendency to rise upwards. When the density of a riser section increases and the pipe begins to descend towards the sea bed, the amount of chain suspended between the buoyancy module and the seabed is decreased (i.e. lighter), again offsetting the pipe's tendency to descend down to the sea bed.
It would be useful to provide an alternative to the assembly described in WO2009/063163.
In addition, particularly in shallow water applications, it would be useful to be able to ensure a certain minimum clearance distance between a so-called sag bend and the seabed, and also between a so-called hog bend and the sea surface and/or a vessel or structure at the surface. A sag bend 208 is a U-shaped bend in a riser and a hog bend 210 is an inverted U-shaped bend in a riser (as indicated in
It is an aim of embodiments of the present invention to provide a riser assembly and method for manufacturing a riser assembly suitable for operating in shallow water.
It is an aim of embodiments of the present invention to provide a riser assembly to which buoyancy modules can be secured or are included integrally so as to provide the advantages of a buoyed riser, without the disadvantages associated with variations in riser weight.
It is an aim of embodiments of the present invention to provide a riser assembly that has relatively low installation costs and short installation time, compared to known riser assembles.
According to a first aspect of the present invention there is provided a riser assembly for transporting fluids from a sub-sea location, comprising:
According to a second aspect of the present invention there is provided a riser assembly for transporting fluids from a sub-sea location, comprising:
According to a third aspect of the present invention there is provided a method of providing a riser assembly for transporting fluids from a sub-sea location, comprising:
According to a fourth aspect of the present invention there is provided a method of providing a riser assembly for transporting fluids from a sub-sea location, comprising:
Certain embodiments of the invention provide the advantage that a riser assembly is provided that is less sensitive to changing riser weight or changing riser buoyancy than some known configurations. For example, a weight element provided at least partially in the sag bend portion of the riser may be used to offset a relatively larger initial buoyancy of a riser section at an adjacent hog bend portion. In time, as the weight of the riser changes, for example the weight increasing due to the occurrence of marine growth and such like, much of the riser will sink down towards the sea bed. The change in overall configuration of the riser will mean that the weight element will effectively move to the more vertical portion (the suspended section) of the riser, rather than being located in the sag bend. Of course the weight element will not move relative to the riser. However, the amount of flexible pipe being suspended will increase, and pipe previously part of the sag bend will become part of the suspended section. As such, the weight of the weight element will be taken by the floating facility and not by the buoyancy modules.
Certain embodiments of the invention provide the advantage that a riser assembly is provided that can automatically offset variations in riser weight or riser buoyancy.
Certain embodiments of the invention provide the advantage that a riser assembly is provided that can be installed relatively quickly and at relatively low cost compared to known configurations.
Certain embodiments of the invention provide the advantage that a riser assembly is provided that is designed to ensure a certain minimum clearance distance between a sag bend and the seabed, and also between a hog bend and the sea surface or surface vessel or structure. This helps to ensure that the riser does not pop up to the water's surface, or collide with the floating facility from which it is suspended, or sink down to hit the sea bed, any of which could cause damage to the riser assembly.
Embodiments of the invention are further described hereinafter with reference to the accompanying drawings, in which:
In the drawings like reference numerals refer to like parts.
Throughout this description, reference will be made to a flexible pipe. It will be understood that a flexible pipe is an assembly of a portion of a pipe body and one or more end fittings in each of which a respective end of the pipe body is terminated.
As illustrated in
The internal pressure sheath 102 acts as a fluid retaining layer and comprises a polymer layer that ensures internal fluid integrity. It is to be understood that this layer may itself comprise a number of sub-layers. It will be appreciated that when the optional carcass layer is utilised the internal pressure sheath is often referred to by those skilled in the art as a barrier layer. In operation without such a carcass (so-called smooth bore operation) the internal pressure sheath may be referred to as a liner.
An optional pressure armour layer 103 is a structural layer with a lay angle close to 90° that increases the resistance of the flexible pipe to internal and external pressure and mechanical crushing loads. The layer also structurally supports the internal pressure sheath, and typically consists of an interlocked construction.
The flexible pipe body also includes an optional first tensile armour layer 105 and optional second tensile armour layer 106. Each tensile armour layer is a structural layer with a lay angle typically between 10° and 55°. Each layer is used to sustain tensile loads and internal pressure. The tensile armour layers are often counter-wound in pairs.
The flexible pipe body shown also includes optional layers of tape 104 which help contain underlying layers and to some extent prevent abrasion between adjacent layers.
The flexible pipe body also typically includes optional layers of insulation 107 and an outer sheath 108, which comprises a polymer layer used to protect the pipe against penetration of seawater and other external environments, corrosion, abrasion and mechanical damage.
Each flexible pipe comprises at least one portion, sometimes referred to as a segment or section of pipe body 100 together with an end fitting located at at least one end of the flexible pipe. An end fitting provides a mechanical device which forms the transition between the flexible pipe body and a connector. The different pipe layers as shown, for example, in
It will be appreciated that there are different types of riser, as is well-known by those skilled in the art. Embodiments of the present invention may be used with any type of riser, such as a freely suspended (free, catenary riser), a riser restrained to some extent (buoys, chains), totally restrained riser or enclosed in a tube (I or J tubes).
In addition, the riser assembly 400 includes a weight element, which in this example is a ballast module 406 attached to the riser in the sag bend portion 410. Here the ballast module is positioned at the lowermost point of the sag bend portion of the riser (closest to the sea bed). The ballast module 406 is used to add extra weight to the sag bend portion, and at the time of installation, will somewhat offset the upwards lift (positive buoyancy) provided by the buoyancy modules 404. The ballast module 406 may be any suitable weighted component or components, and could be integrally formed with the riser rather than attached to the riser. For example, the ballast module could be a weight block, or a metal chain. The length, weight and number of ballast modules can be predetermined based upon assessment of the riser dimensions and environmental factors at the site of use. These parameters should be determined based upon the largest potential change, for example in the riser contents. There could be two or more ballast modules. The ballast module may be made from stainless steel, and may have a mass of around 400 kg in air, and length around 0.4 meters, internal diameter 0.3 meters and outside diameter 0.5 meters. Of course the specific dimensions and mass of the ballast module will depend upon factors such as the riser length, shape, dimensions, and position and amount of buoyancy modules. This can be determined by a skilled person to suit the particular application.
As illustrated in
During the working lifetime of the riser assembly, the weight of the riser may change, for example the weight of the riser assembly increasing due to the occurrence of marine growth and such like on the assembly. In this case, most of the riser will sink down towards the sea bed, as depicted by the dashed line configuration of the riser assembly 416 of
As such, the riser assembly is able to offset additional weight caused by marine growth. The general shape of the riser assembly is only changed by a relatively small degree compared to its initial deployment position. In addition, the height of the sag bend and hog bend above the sea bed are unchanged or only changed by a relatively small degree compared to their initial deployment position. It is to be noted that the before and after positions shown in
Alternatively, or additionally, the buoyancy modules may experience a gradual or sudden change in content density due to movement of the riser assembly or general day to day wear. Or indeed the flexible pipe itself may experience a buoyancy change during service life from variation in content density (for example between states of being empty to being flooded, or carrying different fluids). This may cause the amount of buoyancy support (and therefore the relative height above the sea bed) of the riser to change. Again, with the ballast module 406 provided initially in the sag bend, a reduction of buoyancy in the buoyancy elements 404 would lead to the vertical section of the riser effectively lengthening, and the relative position of the ballast module 406 shifting towards the more vertical section of the riser. The buoyancy modules would then be freed from the weight of the ballast and able to provide more upward buoyancy to counteract the effect of net buoyancy loss or riser content variation, as described above.
It is to be noted that movement of the vessel 412 will not generally depose the ballast module 406 from its position at the sag bend portion 410, since any movement of the vessel (whether it be to a near or far position from the touch-down point of the riser) will be accompanied by movement of the riser assembly as a whole. The buoyancy modules and ballast module will work together to automatically adjust the height of the hog bend in the same manner as discussed above.
The riser assembly provides a reasonable degree of excursion from the touchdown point (where the riser touches the sea bed) in a neat and relatively easy to install configuration.
In manufacture of the riser assembly, the method may include providing a riser comprising at least one segment of flexible pipe, the riser having a first end for connection to a floating facility and a further end; providing at least one buoyancy element for enabling a portion of the riser to form a hog bend configuration and an adjacent portion of the riser to form a sag bend configuration; and providing a weight element between the first end of the riser and the at least one buoyancy element, such that in an initial deployment position, the weight element is provided at least partially in the sag bend portion of the riser. A flow diagram illustrating the method is shown in
The necessary elements of the riser assembly may be provided either in the factory at the point of manufacturing the flexible pipe, or the buoyancy element and/or weight element may be added to the pipe later, aptly prior to or at the time of deployment of the riser.
A further embodiment of the present invention is shown in
A tethering element is useful in helping to prevent the riser assembly from knocking against the sea floor with strong currents, for example, which may damage the riser. A tethering element may be used to apply a certain degree of tension to the lower portion of the riser. This may help to maintain the hog bend portion of the riser a predetermined distance from the water surface (and the sea bed).
A flow diagram illustrating a method of producing a riser assembly is shown in
A yet further embodiment of the present invention is shown in
The riser assembly 600 further includes weight chains 605 consisting of a length of interlocked links secured to a number of the buoyancy modules 604. Of course in other embodiments there could be more or less weight chains, and the chains could be connected directly to the flexible pipe or another part of the riser, rather than the buoyancy modules. A weight chain 605 may be secured to each buoyancy module secured to the riser or may be selectively secured to only one or more of the buoyancy modules.
The weight chains act as a self-adjusting mechanism to the riser assembly 600. The weight associated with the mass of chain in the length of chain counteracts the buoyancy provided by the buoyancy module to which the weight chain is secured and the inherent buoyancy of the flexible pipe. As such the elevation of the hog bend portion of the riser above sea level should be stabilized.
A section of the weight chain 506 hangs freely downwardly from the buoyancy module towards the sea bed 614. A further portion of the weight chain rests upon the surface of the sea bed 614. In this way a part of the weight chain is laid on the sea bed. It will be appreciated that as conditions experienced by the flexible pipe change, such as when the density of content within the flexible pipe changes the result will be a tendency for the buoyancy modules and flexible pipe to move upwardly away from the sea bed or downwardly towards the sea bed. As such movement occurs more or less chain will rest upon the sea bed. For example, when the riser content density reduces the buoyancy will be balanced by the additional chain weight as it is lifted from the sea bed. When the riser content density increases the buoyancy will be balanced by reduced chain weight as the additional chain is laid on the sea bed. In this way the support provided to the flexible pipe is automatically and continually adjusted so as to maintain the flexible pipe in a desired configuration or at least in a configuration within predetermined threshold limits.
With the ballast module 606 also attached to the riser 602, this helps the self-adjusting mechanism further, by helping to automatically offset any changes in buoyancy/height changes in the buoyancy modules (in the manner discussed above regarding
In an alternative embodiment, the riser assembly 600 could additionally include a tethering element for tethering a lower portion of the riser to the sea bed, to help prevent the riser assembly from knocking against the sea floor with strong currents, for example, which may damage the riser.
The weight chains 705 help to stabilize the elevation of the first hog bend 708, as discussed above. The weight chains also stabilize the elevation of the hog bend when the configuration of the riser assembly is altered due to changes in the surface vessel position from a near to far or far to near position, for example. That is, if the vessel 712 moves from a position close to the sea bed touching portion of the riser to a position far from the sea bed touching portion of the riser, then the riser will extend out more horizontally, which may affect the positions of the buoyancy modules. However, the action of the weight chains will automatically adjust and compensate for any change in height of the buoyancy elements.
The ballast modules 706 act as a means of pre-storing additional weight into the riser system, also helping to counteract changes in riser weight.
The buoyancy modules at the second hog bend 709 help to offset the riser weight and minimise any tension in the riser.
The tether element 707 helps to prevent the riser assembly from knocking against the sea floor with strong currents, for example, which may damage the riser, and helps to maintain the second hog bend portion 709 of the riser a predetermined distance from the water surface (and the sea bed).
The configuration of
The riser assembly can accommodate severe environmental loading, large surface vessel excursions, and large variations in riser weight due to changes in content density and marine growth, etc.
Various modifications to the detailed designs as described above are possible. For example, the number of ballast modules and/or number of buoyancy modules could be any number, depending on the specific requirements of different uses and situations. The ballast module(s) and/or buoyancy module(s) could be attached to or integrated with the riser.
It can be seen that the addition of a weight element to a riser configuration can be applied to various riser configurations, either alone or in combination with other measures (as a supplementary measure) to help control the riser configuration. The invention is therefore suitable for many different applications.
The present invention may be used for a single waved configuration of a riser, or a double waved configuration, or a triple waved configuration.
Although the riser has been described above as having an approximately vertical portion suspended from the vessel or floating facility, this portion need not be generally vertical. The suspended portion of the riser may be at any angle, with the angle moving closer to the vertical as the weight of the riser increases.
Although the invention has been described above with a riser extending between a floating facility (such as a vessel) and the sea bed, the riser could alternatively extend between fixed or floating platforms at different heights above the sea bed.
As an alternative to a weight chain extending from the buoyancy module to the sea bed, a top section of a weight chain may be replaced or provided by an alternative flexible filament such as a synthetic rope, wire, cable or the like. A weight chain or other weighted, flexible element may be secured at a lower end region of the filament so that again a portion of the weight chain rests upon the sea bed.
It will be clear to a person skilled in the art that features described in relation to any of the embodiments described above can be applicable interchangeably between the different embodiments. The embodiments described above are examples to illustrate various features of the invention.
Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.
Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/GB2012/052584 | 10/18/2012 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2013/061033 | 5/2/2013 | WO | A |
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| Number | Date | Country | |
|---|---|---|---|
| 20140262316 A1 | Sep 2014 | US |
| Number | Date | Country | |
|---|---|---|---|
| 61552316 | Oct 2011 | US |
