Patent Grant
9725966
The present invention relates to a riser system, and in particular to a riser system comprising a primary riser conduit and one or more auxiliary conduits extending adjacent the riser conduit.
In the oil and gas industry subsea wellbores are drilled from surface vessels, such as drill ships, semi-submersible rigs, jack-up rigs and the like, as is well known in the art. Typically, a drilling riser is provided which extends between the wellhead and a surface vessel to provide a contained passage for equipment and fluids. To this extent the drilling riser normally includes a large bore central riser pipe which accommodates the drilling equipment and certain fluids, such as drilling fluids and wellbore fluids, and a number of auxiliary conduits which extend alongside the central riser pipe and provide communication of control fluids, well kill fluids, choke fluids, hydraulic power fluid and the like. Such auxiliary lines may terminate at the wellhead, for example at a Blow Out Preventer (BOP) or the like.
The drilling riser is typically formed from a number of individual sections or joints which are secured together in end-to-end relation. Each individual section includes the required auxiliary lines arranged around a length of riser pipe, wherein the ends of the riser pipe and auxiliary lines are terminated at opposing flange connectors. During deployment, the individual sections are secured together via the flange connectors. This arrangement permits the riser pipes and auxiliary lines to be connected and sealed together at a single location to speed up the deployment process.
Known drilling risers are of a metallic construction, typically formed from steel. However, it has been proposed in the art, for example from WO 2010/129191 to provide auxiliary lines composed of aluminium.
During use a drilling riser will be subject to various forces. For example, the drilling riser may be subject to bending loads, for example due to deviation of the drilling vessel relative to the wellhead. As the auxiliary lines are offset from the riser bending axis this can result in significant strains being applied within said lines. Further, such bending may result in the auxiliary lines being subject to different levels of strain. For example, an auxiliary line on one side of the riser pipe may be subject to tension during bending of the riser, whereas an auxiliary line on an opposing side may be subject to compression. Excessive bending may result in tensile forces exceeding yield limits, and compressive forces causing buckling within the effected auxiliary line, the result of which may be permanent plastic deformation and/or catastrophic failure. Such deformation or failure may make disassembly difficult, and may prevent subsequent use of the deformed lines. Additionally, these significant differential strains may expose the flange connectors to adverse load conditions.
Furthermore, the drilling riser must be capable of supporting very large tensile forces, primarily applied by its own weight. As the industry moves to deeper waters such global tension requirements are becoming significant. Also, deeper environments place the drilling riser under increasing hoop forces due to large hydrostatic pressures. To accommodate the applied tensile and hoop forces the riser pipe sections must be of very thick wall construction, increasing the weight of the system. System weight will also increase in greater water depths due to the use of longer riser pipe and auxiliary lines. In some situations the design requirements of the riser may result in a system having a weight which exceeds the operational deckload of conventional drilling vessels.
In certain circumstances a rigid connection may be provided between the central riser pipe and the auxiliary lines, such as is disclosed in, for example, U.S. 2001/0017466, U.S. 2011/0073315 and U.S. 2011/0300609. Under static conditions this arrangement might permit acceptable loads to be transferred between the central riser pipe and the auxiliary lines via the rigid connection. However, under dynamic conditions, which is a very important design consideration, it might be possible for the auxiliary lines to become overloaded due to operational forces. For example, different dimensions of the central riser pipe and auxiliary lines may establish a disproportionate effect on the auxiliary lines due to transient loading, such as increasing axial tension and/or compression. Furthermore, the components of known risers are typically formed from metallic components which exhibit relatively large axial stiffness, and as such the reaction of such metallic components to appreciable dynamic loadings might be undesired. For example, the high axial stiffness of such metallic components may result in yield limits being approached or exceeded with relatively low strain levels. That is, an auxiliary line may approach or exceed failure loads during relatively small deformation events. To address such issues it is often the case that safety measures are introduced which permits relative movement between the central riser pipe and auxiliary lines to be achieved, for example during exposure to elevated loads and deformations.
Furthermore, the assembly of known risers having a rigid connection between a central metallic riser pipe and metallic auxiliary lines may be problematic. For example, it is known to fit metallic auxiliary lines between flanges formed integrally at either end of a central metallic riser pipe. However, due to the tolerances in the dimensions of the metallic auxiliary lines and/or the central metallic riser pipe, misalignment between the metallic auxiliary lines and the central metallic riser pipe may occur. This may, for example, necessitate the use of shims, spacers or similar to compensate for mismatches in axial length between the metallic auxiliary lines and the space between the flanges at either end of the central metallic riser pipe. Consequently, the assembly of known risers having a rigid connection between a central metallic riser pipe and metallic auxiliary lines may be complex and time-consuming.
An aspect of the present invention may relate to a riser system configured to be secured between a surface vessel and a subsea location, said system comprising:
a primary conduit; and
an auxiliary conduit extending adjacent the primary conduit and comprising a composite material formed of at least a matrix and one or more reinforcing elements embedded within the matrix,
wherein the primary and auxiliary conduits are connected together at an axial location along the riser system via a connecting portion.
The riser system may comprise or define a drilling riser system. The primary conduit may be configured to accommodate drilling equipment and certain fluids, such as drilling fluids. The auxiliary conduit may be configured to accommodate fluid communication of certain fluids, such as control fluids, well kill fluids or the like between the surface vessel and subsea location.
Both the primary and secondary conduits may be secured relative to a surface vessel.
The riser system may be configured to be secured to a subsea wellhead, for example to a Blow Out Preventer (BOP), a Lower Marine Riser Package (LMRP) or the like.
The primary and auxiliary conduits may be rigidly connected together at or via the connecting portion. Such a rigid connection may prevent or restrict relative movement of the auxiliary and primary conduits in at least one plane or direction at the connecting portion. The auxiliary conduit may be radially secured relative to the primary conduit at or via the connecting portion. That is, relative radial movement of the primary and auxiliary conduits at the connecting portion may be prevented or restricted. The auxiliary conduit may be axially secured relative to the primary conduit at or via the connecting portion. That is, relative axial movement of the primary and auxiliary conduits at the connecting portion may be prevented or restricted.
In some embodiments, rigidly connecting the primary and auxiliary conduits may be such that deflection or deformation of the primary conduit may result in load transference to the auxiliary conduit across the connecting portion which may cause deflection or deformation of the auxiliary conduit. However, forming the auxiliary conduit from a composite material may permit increased levels of strain to be accommodated for reduced levels of stress than conventional metallic conduits such that said auxiliary conduit may be suitably compliant during such periods of deformation, preventing or minimising failure, such as tensile failure, buckling or the like. Thus, additional measures for accommodating deformations in the auxiliary conduits of known riser systems, such as sliding seal assemblies, may not be required.
The composite material may exhibit a higher strain rate to specific stress than an equivalent metallic component. As will be appreciated by those of skill in the art, an equivalent metallic component may be one which defines the same pressure rating as the composite auxiliary conduit. Accordingly, the composite material may permit the auxiliary conduit to satisfactorily accommodate deformation, for example significant deformation, such as may be caused by tensile forces, compressive forces, bending forces, torsional forces and the like.
The composite material may be configured to withstand or permit axial and/or bending strains of up to 6%, up to 4%, up to 2% or up to 1%.
Such permitted strains for the composite material may be significantly larger than a maximum permitted strain for a conventional material such as steel, aluminium or the like. Accordingly, an auxiliary conduit comprising such a composite material may provide a compliant conduit by virtue of the properties of the composite material alone. Thus, the response of the auxiliary conduit to dynamic loading, for example, and events of excessive deformation may become of less concern to a riser designer and operator.
Forming the auxiliary conduit from a composite material may assist to minimise the weight of the system, for example relative to all metal riser systems known in the art. Such weight savings may assist in deployment and retrieval, and may assist to keep the global weight of the riser system within the deckload limits of an associated vessel.
The riser system may be configured such that the auxiliary conduit at least partially supports the weight of the primary conduit. This arrangement may be permitted via the connecting portion. Such an arrangement may generate axial strain within the auxiliary component. However, forming the auxiliary conduit from a composite material may permit increased levels of strain to be accommodated such that said auxiliary conduit may appropriately provide support to the primary conduit. Furthermore, load sharing between the primary and auxiliary conduits may permit the primary conduit to be reduced in size due to a lower requirement to be self-supporting, providing a number of benefits such as weight reduction, cost reduction and the like. Further, in some situations, for example where extremely large pressures and hoop strains must be accommodated, the primary conduit may be increased in size, and thus weight, while the auxiliary conduit contributes to supporting this additional weight.
Load sharing between the primary and auxiliary conduits may be achieved via the connecting portion. For example, the auxiliary conduit may be configured to at least partially support the weight of the primary conduit through the connecting portion.
The auxiliary conduit may be pre-tensioned, for example against or relative to the connecting portion. Such pretension may permit the auxiliary conduit to at least partially support the weight of the primary conduit. The pre-tension may permit the auxiliary conduit to at least partially support the weight of the primary conduits at all times during use. Furthermore, such pre-tension may assist to accommodate increased levels of compression within the auxiliary conduit, which may, for example, be present during bending of the riser system.
Establishing pre-tension within the auxiliary conduit may result in said conduit being exposed to tensile forces at the moment of assembly of the riser system. That is, even when the auxiliary member is under static loading conditions such tensile forces will be present. Accordingly, any axial extension deformation or strain affecting the auxiliary conduit during dynamic loading will result in further tension being applied within the auxiliary conduit. However, due to the composite construction of the auxiliary conduit this eventuality is accepted due to the composite material exhibiting a higher strain rate to specific stress than, for example, an equivalent metallic component. It is understood that in conventional riser arrangements, such as where metallic auxiliary lines are utilised, pre-tensioning is intentionally avoided or minimised where additional tension is expected during use. For example, as metallic components are generally axially stiff, an initial level of pre-tension may minimise the available accommodation of axial extension deformation during dynamic conditions, as stress will increase significantly for very little increase in axial strain.
Establishing pre-tension within the auxiliary conduit, for example against or relative to the connecting portion, may establish pre-compression within the primary conduit. Such pre-compression may permit the primary conduit to support greater levels of tension, such as may be caused by the weight of the riser system and any service loadings. Further, permitting a greater tensile capacity within the primary conduit by virtue of establishing pre-compression may permit a smaller or thinner walled primary conduit to be utilised, contributing towards a weight and material reduction.
In some embodiments the primary and auxiliary conduits may be compliantly connected together at or via the connecting portion. This arrangement may permit a degree of floating of the auxiliary conduit relative to the primary conduit at least in one direction or plane. This may, for example, assist to minimise load transference, which in some embodiments may not be desirable in one or more directions or planes. Such a compliant connection may permit relative movement of the auxiliary and primary conduits in at least one plane or direction at the connecting portion. The auxiliary conduit may be permitted to move radially relative to the primary conduit at the connecting portion. That is, relative radial movement of the primary and auxiliary conduits at the connecting portion may be permitted. The auxiliary conduit may be permitted to move axially relative to the primary conduit at the connecting portion. That is, relative axial movement of the primary and auxiliary conduits at the connecting portion may be permitted.
The primary and secondary conduits may be rigidly connected together in one plane or direction, and compliantly connected together in another plane or direction at or via the connecting portion. For example, the auxiliary conduit may be radially secured relative to the primary conduit at or via the connecting portion, and also may be permitted to move axially relative to the primary conduit at the connecting portion. Such an arrangement may retain the auxiliary conduit within a desired proximity of the primary conduit, while permitting a degree of independent axial movement, or floating, of the auxiliary conduit.
The riser system may comprise a plurality of connecting portions permitting the auxiliary component to be connected relative to the primary conduit at multiple points along the length of the riser system. At least one of the individual connecting portions may define a rigid connection between the primary and auxiliary conduits. Such rigid connection may define one or more load transfer points to permit transference of load between the primary conduit and the auxiliary conduit. At least one of the individual connecting portions may define a compliant connection between the primary and auxiliary conduits.
The auxiliary conduit may be pre-tensioned between two axially spaced connecting portions.
The connecting portion may comprise or be defined by a flanged connection. The connecting portion may comprise a pair of flange components secured together to define a flanged connection.
The riser system may comprise a plurality of auxiliary conduits. The auxiliary conduits may be circumferentially distributed about the primary conduit. Two or more of the plurality of auxiliary conduits may be configured similarly. Two or more of the plurality of auxiliary conduits may be configured differently.
The riser system may comprise a plurality of auxiliary conduits which are evenly circumferentially distributed about the primary conduit. Such an arrangement may be beneficial in embodiments in which the auxiliary conduits are to some degree pre-tensioned relative to the primary conduit. That is, the even distribution of pre-tensioned auxiliary conduits may permit an even global load being applied to the primary conduit. This may prevent or minimise any bending of the primary conduit by such pretension.
The riser system may comprise at least two diametrically opposed auxiliary conduits. Such an arrangement may also be beneficial in embodiments in which the auxiliary conduits are to some degree pre-tensioned relative to the primary conduit. That is, the diametric orientation of the pre-tensioned auxiliary conduits may permit an even global load being applied to the primary conduit to prevent or minimise any bending or the like of the primary conduit by such pretension.
In some embodiments a plurality of auxiliary conduits may be pre-tensioned to different degrees. This may permit a desired uneven loading to be applied to the primary conduit. For example to cause the conduit to adopt a desired shape, to control deformation of the primary conduit, to encourage an expected and repeatable deformation of the primary conduit, or the like.
The primary conduit may be of a larger diameter than the auxiliary conduit. The auxiliary conduit may extend externally of the primary conduit. The auxiliary conduit may extend internally of the primary conduit.
The primary conduit may comprise a metal or metal alloy.
The primary conduit may comprise a composite material formed of at least a matrix and one or more reinforcing elements embedded within the matrix. The primary and auxiliary conduits may comprise a similar composite material construction.
The matrix of one or both of the primary and auxiliary conduits may comprise a polymer material. The matrix of one or both of the primary and auxiliary conduits may comprise a thermoplastic material. The matrix of one or both of the primary and auxiliary conduits may comprise a thermoset material. The matrix of one or both of the primary and auxiliary conduits may comprise a polyaryl ether ketone, a polyaryl ketone, a polyether ketone (PEK), a polyether ether ketone (PEEK), a polycarbonate or the like, or any suitable combination thereof. The matrix of one or both of the primary and auxiliary conduits may comprise a polymeric resin, such as an epoxy resin or the like.
The reinforcing elements of one or both of the primary and auxiliary conduits may comprise continuous or elongate elements. The reinforcing elements of one or both of the primary and auxiliary conduits may comprise any one or combination of polymeric fibres, for example aramid fibres, or non-polymeric fibres, for example carbon, glass or basalt elements or the like. The reinforcing elements of one or both of the primary and auxiliary conduits may comprise fibres, strands, filaments, nanotubes or the like. The reinforcing elements of one or both of the primary and auxiliary conduits may comprise discontinuous elements.
The matrix and the reinforcing elements of one or both of the primary and auxiliary conduits may comprise similar or identical materials. For example, the reinforcing elements may comprise the same material as the matrix, albeit in a fibrous, drawn, elongate form or the like.
The connecting portion may comprise a metal or metal alloy.
The connecting portion may comprise a composite material formed of at least a matrix and one or more reinforcing elements embedded within the matrix. The connecting portion and auxiliary conduit may comprise a similar composite material construction.
The riser system may comprise a continuous auxiliary conduit along the length of the riser system. For example, the auxiliary conduit may be provided as a unitary component. In such an arrangement the auxiliary conduit may be deployed from a spool, directly as it is manufactured, or the like.
The riser system may comprise a modular auxiliary conduit. The auxiliary conduit may comprise a plurality of discrete auxiliary conduit sections secured together in end-to-end relation along the length of the riser system. Such a modular arrangement may assist in deployment and/or retrieval of the riser system, for example.
Adjacent discrete auxiliary conduit sections may be secured relative to each other in end-to-end relation to define a continuous auxiliary conduit. Adjacent discrete auxiliary conduit sections may be secured relative to each other in the region of the connecting portion. Adjacent discrete auxiliary conduit sections may be secured relative to each other at least in part by the connecting portion.
Adjacent discrete auxiliary conduit sections may be secured relative to each other at a region which is remote from the connecting portion.
A discrete auxiliary conduit section may be installed within the system by being axially inserted into or through one or more connecting portions.
A discrete auxiliary conduit section may be deformed, for example by longitudinal bending, to define a reduced axial envelope and then located between two connecting portions and subsequently relaxed to become secured or located between said connecting portions. In such an arrangement the composite material of the auxiliary conduit section may permit such longitudinal bending to be achieved without causing damage or creating significant stress within the conduit, and also permit substantially complete elastic recovery when relaxed during insertion between the connecting portions.
Adjacent discrete auxiliary conduits may be rigidly secured together. Adjacent discrete auxiliary conduit sections may be rigidly secured together in at least one plane or direction. Adjacent discrete auxiliary conduit sections may be rigidly secured together in an axial direction. That is, relative axial movement of adjacent auxiliary conduit sections may be restricted or prevented at the region of connection therebetween.
Adjacent discrete auxiliary conduit sections may be compliantly secured together, for example in at least one plane or direction. Adjacent discrete auxiliary conduit sections may be compliantly secured together in an axial direction. That is, relative axial movement of adjacent auxiliary conduit sections may be permitted at the region of connection therebetween. Such a compliant connect may minimise the transference of load between different auxiliary conduit sections.
The riser system may comprise an interface assembly.
The interface assembly may be configured to facilitate connection between the auxiliary and primary conduits at the connecting portion.
The interface assembly may be configured to permit adjacent discrete auxiliary conduit sections to be secured relative to each other at or remotely from the connecting portion. The interface assembly may provide a rigid connection. The interface assembly may provide a compliant connection.
The interface assembly may be provided separately from the connecting portion. The interface assembly may be configured to be secured relative to the connecting portion. Such an arrangement may permit connection of the primary and auxiliary conduits to be achieved via both the connecting portion and the interface assembly. The interface assembly may be configured to be rigidly secured relative to the connecting portion. The interface assembly may be secured relative to the connecting portion by, for example, bolting, interference fitting, clamping, threaded connection or the like. The interface assembly may be configured to be compliantly secured relative to the connecting portion.
The interface assembly may comprise a unitary component to which adjacent discrete auxiliary conduit sections are secured.
The interface assembly may comprise separate components which are respectively secured or otherwise associated with adjacent auxiliary conduit sections and secured or connected relative to each other to provide connection between said auxiliary conduit sections. The separate components may be directly secured relative to each other. The separate components may be indirectly secured relative to each other. The separate components may be indirectly secured relative to each other via the connecting portion.
The interface assembly may permit connection between at least one discrete auxiliary conduit section and the connecting portion.
At least a portion of the interface assembly may be defined by or form part of the connecting portion. For example, the connecting portion may include one or more components to which one or adjacent discrete auxiliary conduit sections may be secured. The connecting portion may entirely define the interface assembly.
At least a portion of the interface assembly may be defined by or form part of one or both adjacent auxiliary conduit sections. For example, an end region of one or both adjacent auxiliary conduit portions may define at least a portion of the interface assembly.
The interface assembly may comprise a telescoping arrangement. For example, a discrete auxiliary conduit section may be secured to the interface assembly in a telescoping manner. Such a telescoping arrangement may provide an axially compliant connection. The interface assembly may comprise a spigot portion configured to be engaged internally or externally of an auxiliary conduit section in a telescoping manner. A sealing arrangement, such as one or more sliding seals, o-rings or the like may be provided between the spigot portion and the auxiliary conduit section. The spigot portion may be provided on a component which is separate from either of adjacent auxiliary conduit sections. The spigot portion may be defined by or be provided on one of a pair of adjacent auxiliary conduit sections. In such an arrangement, an end region of one auxiliary conduit section may be received within the end region of an adjacent auxiliary conduit section.
Adjacent discrete auxiliary conduit sections may be mechanically secured relative to the interface assembly. Adjacent discrete auxiliary conduit sections may be fluidly coupled to the interface assembly.
The interface assembly may permit an end region of one discrete auxiliary conduit section to directly engage an end region of an adjacent discrete auxiliary conduit section. Such engagement may occur at the location of the connecting portion. For example, adjacent discrete auxiliary conduits may extend through or into the connecting portion to be engaged with each other.
The interface assembly may permit end regions of adjacent discrete auxiliary conduits to terminate remotely from each other, for example at separate regions of the connecting portion. In such an arrangement the connecting portion may be interposed between respective end regions of adjacent discrete auxiliary conduits. The connecting portion may define an interface conduit portion, for example provided by a bore, sleeve or the like, configured to provide fluid communication between said adjacent discrete auxiliary conduits.
The interface assembly may comprise a releasable arrangement configured to permit release and optionally reconnection of an auxiliary conduit or discrete auxiliary conduit section. The interface assembly may comprise or define a releasable connector, such as a stab-in type connector, collet-type connector or the like.
The interface assembly may be configured to establish tension within an associated auxiliary conduit or discrete auxiliary conduit section. For example, the interface assembly may provide a degree of adjustment to apply tension within an associated auxiliary conduit or discrete auxiliary conduit section. Such adjustment may be provided by a threaded arrangement or the like.
The use of an auxiliary conduit comprising a composite material may simplify the assembly of the riser system because such an auxiliary conduit may accommodate greater deformation than an equivalent metallic component. The use of such an auxiliary conduit may avoid any requirement to use shims, spacers or the like to accommodate any misalignment between the primary conduit, the auxiliary conduit and/or the connecting portion. The use of such an auxiliary conduit may, in particular, avoid any requirement to use shims, spacers or the like to accommodate any axial separation between the connecting portion and an end of the auxiliary conduit. The use of such an auxiliary conduit may, therefore, simplify the assembly of the riser system. The auxiliary conduit may comprise an interface portion configured to mechanically engage the interface assembly. A discrete auxiliary conduit section may comprise an interface portion configured to mechanically engage the interface assembly. In some embodiments the interface portion may form part of the interface assembly. In some embodiments the interface portion may be provided separately from the interface assembly. The interface portion may facilitate securing of the auxiliary conduit, and/or discrete auxiliary conduit section to the interface assembly via mechanical fasteners, such as bolts or the like. In such an arrangement the interface portion may comprise one or more holes for receiving one or more mechanical fasteners.
The interface portion of the auxiliary conduit or discrete auxiliary conduit section may define a thread configured for threaded engagement with the interface assembly.
The interface portion of the auxiliary conduit or discrete auxiliary conduit section may define a profile configured to engage a corresponding profile formed on or within the interface assembly. The profiled interface pardon may comprise a wedge shaped profile, for example. The profiled interface portion may comprise a region of increased outer diameter relative to the auxiliary conduit portion.
The interface portion may define a profile configured to be captivated by the interface assembly.
The interface portion may be integrally formed with the auxiliary conduit or discrete auxiliary conduit section. Alternatively, the interface portion may be separately formed and subsequently secured to the auxiliary conduit or discrete auxiliary conduit section.
The interface pardon may comprise a composite material formed of at least a matrix and one or more reinforcing elements embedded within the matrix. The interface portion may be formed integrally with or may comprise an end region of the auxiliary conduit or discrete auxiliary conduit section. The interface portion may permit an end face of the auxiliary conduit or discrete auxiliary conduit section to extend through the conduit connecting portion and engage, for example directly or indirectly, an end face of a further auxiliary conduit or discrete auxiliary conduit section.
The interface portion may comprise a flange.
The riser system may comprise a plurality of interface assemblies axially distributed along said system. Axially adjacent interface assemblies may be configured to establish tension within an auxiliary conduit or a discrete auxiliary conduit section which extends therebetween.
The riser system may comprise a continuous primary conduit along the length of the riser system. For example, the primary conduit may be provided as a unitary component. In such an arrangement the primary conduit may be deployed from a spool, directly as it is manufactured, or the like.
The riser system may comprise a modular primary conduit. The primary conduit may comprise a plurality of discrete primary conduit sections secured together in end-to-end relation along the length of the riser system. Individual discrete primary conduit sections may be secured together at or via the connecting portion. In other embodiments individual discrete primary conduit sections may be secured together remotely from the connecting portion.
The riser system may comprise a plurality of riser joint sections coupled together in end-to-end relation. Each riser joint section may comprise a section of primary conduit and a section of auxiliary conduit coupled together via one or more corresponding connecting portions. In one embodiment each riser joint section may comprise a connecting portion at each end, wherein the associated primary and auxiliary conduit sections extend between the respective connecting portions. Adjacent riser joint sections may be secured together via respective connecting portions.
The connecting portion may be integrally formed with the primary conduit. In an alternative embodiment the connecting portion may be separately formed and subsequently secured to the primary conduit, for example via mechanical fasteners, a stab-in type connector, welding, melding or the like.
The connecting portion may be integrally formed with the auxiliary conduit. In an alternative embodiment the connecting portion may be separately formed and subsequently secured to the auxiliary conduit, for example via mechanical fasteners, a stab-in type connector, welding, melding or the like.
At least the auxiliary conduit may comprise a variation along its length. For example, at least one axial portion of the auxiliary conduit may vary relative to a different axial portion. Such an arrangement may permit the auxiliary conduit to be more appropriate tailored to a specific use.
At least the auxiliary conduit may comprise a variation in axial load carrying capacity or specification along its length. For example, an upper region of the auxiliary conduit may be configured to accommodate greater axial load than a lower region of the auxiliary conduit. This may permit the upper region of the auxiliary conduit to be more suited to a requirement to carry a greater proportion of the system weight that the lower region. Such variation in axial load carrying capacity may be achieved by a variation in wall thickness, a variation in material, a variation in the make-up of the composite material or the like. Such a variation may be achieved along the length of a single conduit or conduit section. Such a variation may be achieved between different or individual conduit sections.
At least the auxiliary conduit may comprise a wall comprising the composite material, wherein the wall comprises or defines a local variation in construction to provide a local variation in a property of the auxiliary conduit.
Such a local variation in a property of the auxiliary conduit may permit tailoring of a response of the auxiliary conduit to given load conditions.
The local variation in construction may comprise at least one of a circumferential variation, a radial variation and an axial variation in the riser material and/or the auxiliary conduit geometry.
The local variation in construction may comprise a local variation in the composite material.
The local variation in construction may comprise a variation in the matrix material. The local variation in construction may comprise a variation in a material property of the matrix material such as the strength, stiffness, Young's modulus, density, thermal expansion coefficient, thermal conductivity, or the like.
The local variation in construction may comprise a variation in the reinforcing elements. The local variation in construction may comprise a variation in a material property of the reinforcing elements such as the strength, stiffness, Young's modulus, density, distribution, configuration, orientation, pre-stress, thermal expansion coefficient, thermal conductivity or the like. The local variation in construction may comprise a variation in an alignment angle of the reinforcing elements within the composite material. In such an arrangement the alignment angle of the reinforcing elements may be defined relative to the longitudinal axis of the auxiliary conduit. For example, an element provided at a 0 degree alignment angle will run entirely longitudinally of the auxiliary conduit, and an element provided at a 90 degree alignment angle will run entirely circumferentially of the auxiliary conduit, with elements at intermediate alignment angles running both circumferentially and longitudinally of the auxiliary conduit, for example in a spiral or helical pattern.
The local variation in the alignment angle may include elements having an alignment angle of between, for example, 0 and 90 degrees, between 0 and 45 degrees or between 0 and 20 degrees.
At least one portion of the auxiliary conduit wall may comprise a local variation in reinforcing element pre-stress. In this arrangement the reinforcing element pre-stress may be considered to be a pre-stress, such as a tensile pre-stress and/or compressive pre-stress applied to a reinforcing element during manufacture of the auxiliary conduit, and which pre-stress is at least partially or residually retained within the manufactured auxiliary conduit. A local variation in reinforcing element pre-stress may permit a desired characteristic of the auxiliary conduit to be achieved, such as a desired bending characteristic. This may assist to position or manipulate the auxiliary conduit, for example during installation, retrieval, coiling or the like. Further, this local variation in reinforcing element pre-stress may assist to shift a neutral position of strain within the auxiliary conduit wall, which may assist to provide more level strain distribution when the auxiliary conduit is in use, and/or for example is stored, such as in a coiled configuration.
In embodiments where the primary conduit comprises a composite material, similar constructional variations to those described above in relation to the auxiliary conduit may also apply to the primary conduit.
A further aspect of the present invention may relate to a method of forming a riser system to be secured between a surface vessel and a subsea location, comprising:
providing a primary conduit;
extending an auxiliary conduit adjacent the primary conduit, wherein the auxiliary conduit comprises a composite material formed of at least a matrix and one or more reinforcing elements embedded within the matrix; and
connecting the primary and auxiliary conduits together at an axial location along the riser system via a connecting portion.
The method may comprise tensioning the auxiliary conduit.
Such a method may simplify the assembly of the riser system because an auxiliary conduit comprising a composite material may accommodate greater deformation than an equivalent metallic component.
Such a method may avoid any requirement to use shims, spacers or the like to accommodate any misalignment between the primary conduit, the auxiliary conduit and/or the connecting portion. Such a method may, in particular, avoid any requirement to use shims, spacers or the like to accommodate any axial separation between the connecting portion and an end of the auxiliary conduit. Such a method may, therefore, simplify the assembly of the riser system.
A further aspect of the present invention may relate to a riser system joint for use in forming a riser system, comprising:
a section of primary conduit;
a section of auxiliary conduit extending adjacent the primary conduit and comprising a composite material formed of at least a matrix and one or more reinforcing elements embedded within the matrix; and
at least one connecting portion for connecting together the primary and auxiliary conduits.
The riser joint may comprise a connecting portion at opposing ends of the riser joint, wherein the primary conduit and auxiliary conduit extend between said connecting portions.
Another aspect of the present invention may relate to a riser system comprising a plurality of riser system joints according to any other aspect defined herein.
A connecting portion may be located at one end of the riser system joint.
A connecting portion may be provided at opposite ends of the joint.
At least the auxiliary conduit may be pre-tensioned between the end connecting portions. This arrangement may permit the auxiliary conduit to share loading applied by or through the primary conduit when in use, for example when installed to form part of a riser system.
Another aspect of the present invention may relate to a conduit system comprising:
a primary conduit; and
an auxiliary conduit extending adjacent the primary conduit and comprising a composite material formed of at least a matrix and one or more reinforcing elements embedded within the matrix,
wherein the primary and auxiliary conduits are connected together at an axial location along the conduit system via a connecting portion.
A further aspect of the present invention may relate to a riser system configured to be secured between a surface vessel and a subsea location, said system comprising:
a primary conduit; and
an auxiliary conduit extending adjacent the primary conduit and comprising a composite material formed of at least a matrix and one or more reinforcing elements embedded within the matrix.
Another aspect of the present invention may relate to a compliant connector or interface assembly for connecting first and second conduits in end-to-end relation, comprising:
a retaining portion configured to be retained relative to a separate structure;
first and second tubular portions arranged on opposing sides of the retaining portion and each configured to be received within, or receive, an end region of a respective one of first and second conduits,
wherein at least one of the first and second tubular portions is configured to permit relative axial movement with a respective conduit.
Such relative axial movement may be in the form of a telescoping movement.
Both of the first and second tubular portions may be configured to permit relative axial movement with the respective conduits.
The compliant connector of interface assembly may be provided for use in connecting together adjacent discrete conduits of a riser system, such as the riser system defined above.
The retaining portion may be configured to be secured relative to a connecting portion, such as a flanged connecting portion of a riser system.
Another aspect of the present invention may relate to a method of forming a riser system, comprising:
providing a primary conduit having first and second axially separated connecting portions;
deforming an auxiliary conduit to define a reduced axial envelope length which is less than the axial separation of the connecting portions, wherein the auxiliary conduit comprises a composite material formed of at least a matrix and one or more reinforcing elements embedded within the matrix;
locating the deformed auxiliary conduit intermediate the connecting portions;
and relaxing deformation of the auxiliary conduit to permit said conduit to be retained between said connecting portions.
The method may comprise installing multiple auxiliary conduit sections between multiple adjacent connecting portions.
The method may comprise connecting together multiple conduit sections in end-to-end relation, for example using an interface assembly or the like.
It should be understood that features presented in accordance with one aspect may be provided in combination with or in accordance with any other aspect.
These and other aspects of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
A riser system, generally identified by reference numeral 10, in accordance with an embodiment of the present invention is illustrated in
Reference is now additionally made to
The riser system 10 is formed from a plurality of individual riser joints 22 which are secured together in end-to-end relation via the connecting portions 20. Each joint 22 includes a discrete primary conduit section 16a and a plurality of discrete auxiliary conduit sections 18a. Opposite ends of each joint 22 include a respective flange component 20a, 20b to which the primary conduit section 16a and auxiliary conduit sections 18a are rigidly secured. As will be described below, such a rigid connection between the conduit sections 16a, 18a results in load transference therebetween. In some circumstances this may permit the auxiliary conduits 18 to support some of the weight of the primary conduit 16.
With particular reference to
Each adjacent auxiliary conduit section 18a is connected together at the connecting portion via respective interface assemblies 23, wherein in the present embodiment the interface assemblies 23 provide a rigid connection between respective pairs of adjacent auxiliary conduit sections 18a. Example embodiments of such interface assemblies 23 will be described later below. In the present embodiment such interface assemblies 23 are provided at the region of the connecting assembly 20. However, in other embodiments an interface assembly may be provided remotely from the connecting portion 20, such that connection of at least two discrete auxiliary conduits need not exist at a connecting portion 20.
In the present invention at least one and in some embodiments all of the auxiliary conduits 18 comprise or are formed from a composite material of at least a matrix and one or more reinforcing elements embedded within the matrix. As will be described in detail below, composing the auxiliary conduits 18 of a composite material provides significant advantages over known arrangements, for example in arrangements in which metallic auxiliary lines are utilised.
In the present embodiment the primary conduit 16 may be formed of a metallic material. However, in other embodiments the primary conduit 10 may be formed of a composite material. Also, in the present embodiment the connecting portions 20 may be formed of a metallic material. However, in other embodiments at least one of the connecting portions 20 may be formed of a composite material.
The riser system 10 will be subject to various operational loads during use, which are illustrated with respect to
Also during use the joint 22 may be subject to bending, as illustrated in
The present invention may permit such strains during load transference between the primary and auxiliary conduits 16, 18 to be accommodated by forming the auxiliary conduit from a composite material. That is, the use of a composite material may permit increased levels of strain to be accommodated such that the auxiliary conduits may be suitably compliant during such periods of deformation, preventing or minimising failure, such as tensile failure, buckling or the like. More specifically, the composite material may exhibit a higher strain rate to specific stress than an equivalent metallic component. Accordingly, the composite material may permit the auxiliary conduits 18 to satisfactorily accommodate deformation, such as may be caused by tensile forces, compressive forces, bending forces, torsional forces and the like. The composite material of the auxiliary conduits 18 may be configured to withstand or permit axial and/or bending strains of up to 6%, up to 4%, up to 2% or up to 1%. Such maximum permitted strains for the composite material may be significantly larger than a maximum permitted strain for a conventional material such as steel, aluminium or the like. Accordingly, an auxiliary conduit 18 comprising such a composite material may provide a compliant conduit by virtue of the properties of the composite material alone. This may reduce or eliminate the requirement for additional measures to protect the auxiliary conduits from excessive strains.
The composite material of the auxiliary conduits 18 may provide an inherent increase in elastic recovery properties. Accordingly, any deformation, such as buckling, while under load may only be temporary. This may assist in maintaining the auxiliary conduits in a non-deformed state when in a no-load condition, which may assist in handling, disassembly and re-use of the auxiliary conduits, for example.
Increasing water depths will also expose the riser system 10 to increasing pressures, such as hydrostatic pressures, which will typically be manifested as hoop strain within the conduits 16, 18 of the riser system 10. The requirement to accommodate pressure originating loading, and axial loading such as tension and compression, may necessitate the use of very thick-walled conduits, which in turn may add significantly to the weight of the entire system. In some cases such design requirements may result in the operational capacity of the vessel 12 (
Further, differential strain applied to different auxiliary members 18 may place significant loading, particularly bending, on the connecting portions 20. Providing auxiliary conduits 18 composed of composite material may allow a larger strain rate to specific stress within the auxiliary conduits, permitting greater axial extension of said conduits and thus assisting to protect the connecting portions 20.
Furthermore, forming the auxiliary conduits 18 from a composite material may assist to minimise the weight of the system, for example relative to all metal riser systems known in the art. This may permit thicker-walled conduit sections to be utilised without exceeding weight limits, such as may be dictated by the surface vessel 12.
As described above and illustrated in the drawings, in the exemplary embodiment the primary and auxiliary conduit sections 16a, 18a of a riser joint 22 are rigidly secured between respective flange components 20a, 20b. In the present exemplary embodiment one or more of the auxiliary conduit sections 18a are connected to the respective flange components 20a, 20b (via appropriate interface assemblies 23 or components thereof) such that a pretension is applied within the auxiliary conduit section 18a. Such a pre-tension arrangement is illustrated with respect to
As suggested above, any additional axial extension deformation or strain affecting the auxiliary conduit sections 18a, for example due to the global weight of the assembled riser 10 or during dynamic loading, will result in further tension being applied within the auxiliary conduit section 18a. However, due to the composite construction of the auxiliary conduit sections 18a this eventuality is accepted due to the composite material exhibiting a higher strain rate to specific stress than, for example, an equivalent metallic component. It is understood that in conventional riser arrangements, such as where metallic auxiliary lines are utilised, pre-tensioning is intentionally avoided or minimised where additional tension is expected during use. For example, as metallic components are generally axially stiff, an initial level of pre-tension may minimise the available accommodation of axial extension deformation during dynamic conditions, as stress will increase significantly for very little increase in axial strain.
The pre-tension within the auxiliary conduits 18a may effectively permit the auxiliary conduits 18 to share some of the axial loading within the riser system 10 with the primary conduit 16. That is, pre-tensioned auxiliary conduits 18 may function to support at least a portion of the weight of the primary conduit 16. Such an arrangement may permit the primary conduit 16 to be reduced in size, providing a number of benefits such as weight reduction, cost reduction and the like.
Pre-tension within the auxiliary conduit sections 18a may be selected such that load sharing with the primary conduit is achieved at all times during use. As such, even in the event of dynamic loading the primary conduit 16 will always be structurally assisted in accommodating the applied loads.
Providing a pre-tension within one or more of the auxiliary conduits 18 may also provide protection to the auxiliary conduit 18 during compression thereof. That is, an deformation which would normally result in compression will be initially absorbed by relaxation of the pretension and corresponding strain.
Providing a pre-tension may also provide benefits during bending of the riser system, such as illustrated in
In the riser system 10 first illustrated in
In other embodiments such variation may be achieved by a variation in the construction of the composite material.
Further, other conditions may be accommodated. For example, it will be recognised that lower auxiliary conduit regions will be subject to larger local pressure forces due to increased water depths. As such, lower regions of an auxiliary conduit may be configured to resist larger hoop forces than upper regions.
The primary conduit of a riser system may also include similar constructional variations to be more closely tailored to specific conditions.
As noted above, each adjacent auxiliary conduit section 18a is connected relative to each other at the connecting portion via respective interface assemblies 23. There are a number of possible arrangements of such interface assemblies 23, some of which will be described below.
One such exemplary interface assembly or arrangement 23 is shown in
In this embodiment the end region of the lower auxiliary conduit section 18a extends through flange component 20b. A wedge or conical profiled portion 24 is defined on the end of the auxiliary conduit section 18a which is received within a corresponding profile 26 formed within flange component 20b. As such, the flange component 20b and connecting portion 20 define integral parts of the interface assembly 23. In the illustrated embodiment the wedge profiled portion 24 is integrally formed with the end of the conduit 18a. In this way, the auxiliary conduit section 18a may be robustly secured at the connecting portion 20. Further, this arrangement can permit the auxiliary conduit section 18a to transmit a load, such as a tensile load, between respective flange components 20a, 20b of a riser joint 22.
As the wedge portion 24 is to be captivated by the profile 26 formed in the lower connecting portion 20b, the lower conduit section 18a will be installed by being inserted through the connecting portion 20b from above. The opposite end of the auxiliary conduit 18a may be secured to a lower connecting portion 20 (not shown in
Although not illustrated, a sealing arrangement may be provided between the flange components 20a, 20b and/or the conduit sections 18a. Also, in some embodiments the composite material of the auxiliary conduit sections 18a may permit inherent compliance upon engagement together to provide appropriate sealing.
In the embodiment shown in
As in the embodiment shown in
An alternative interface assembly 223 is shown in
In the embodiment shown in
The embodiment shown in
The interface assembly 323 includes an interface component 40 which is secured to the flange component 320a, for example by a threaded connection, interference fit, welding, integrally forming or the like. The end of an associated auxiliary conduit section 318a includes a profiled region 324. The assembly 323 further includes a collar 42 which defines a captive profile 44 at one end for captivating the end profile 324 of the auxiliary conduit section 318a, and a thread 46 at an opposite end for threadably engaging with the interface component 40. Accordingly, the collar 42 may be used to secure the conduit section 318a to the interface component 40. Furthermore, the threaded connection between the collar 42 and interface component 40 may permit a degree of tension, such as pre-tension, to be established within the auxiliary conduit section 318a.
In an alternative embodiment the functionality of the interface component 40 and collar 42 shown in
A further alternative embodiment of an interface assembly 523 is illustrated in
It should be understood that a combination of interface assemblies may be utilised. For example, an interface assembly similar to that shown in
The embodiments described above provide a rigid connection between the primary and auxiliary conduits within a riser system. Such a rigid connection may provide advantages such as permitting the auxiliary conduits to load share with the primary conduit, to allow the auxiliary conduits to be pre-tensioned and the like. However, in other embodiments such a connection may be compliant. For example, while a general connection, or at least an association, may exist between primary and auxiliary conduits, this may permit relative movement of said conduits in one or more planes or directions, as will be demonstrated below, initially with reference to
The riser system includes a primary conduit 616 and a plurality of auxiliary conduits 618 which run axially alongside the primary conduit. As illustrated by arrows 70 the auxiliary conduits 618 are permitted to move axially, or float, relative to the primary conduit 616.
The riser system 610 is formed from a plurality of riser joints 622 which are secured together in end to end relation at a connecting portion 620. Each riser joint 622 includes a discrete primary conduit section 616a and a plurality of discrete auxiliary conduit sections 618a, wherein each conduit section 616a, 618a extends between opposing flange components 620a, 620b. Opposing flange components 620a, 620b of adjacent riser joints 622 are connected together to define respective connecting portions 620. A clamping arrangement 72 is provided intermediate individual flange components 620a, 620b of each riser joint 622 and functions to clamp or retain the auxiliary conduit sections 618a within proximity to the primary conduit section 616a.
A form of connection or interface assembly 623 is provided between adjacent auxiliary conduit sections 618a generally in the region of the connecting portions, wherein the interface assemblies 623 permit relative axial movement of adjacent and connected auxiliary conduit sections 618a. Many different forms of such an interface assembly is possible within the scope of the present invention and some example embodiments are presented below.
Such an example interface assembly 623 is illustrated in
Each tubular spigot portion 76 is received within the end of a respective auxiliary conduit section 618a with sealing being achieved via seals 80. The arrangement is such that a telescoping movement, illustrated by arrows 82, between the auxiliary conduit sections 618a and respective spigot portions 76 is permitted, providing a degree of relative axial movement between the adjacent conduit sections 618a.
In the embodiment illustrated in
In other embodiments the use of a separate interface component, such as illustrated in
In a similar manner to that described above with reference to
In various embodiments described above, such as with reference to
Referring initially to
Alternatively, as shown in
It should be understood that the embodiments described herein are merely exemplary and that various modifications may be made thereto. For example, the riser system is not limited for use as a drilling riser system. Furthermore, the principles of the invention need not only be applied to riser systems, and may be utilised within conduit systems which comprise multiple individual conduits running alongside each other.
Furthermore, in the embodiments described above the auxiliary conduits are established by a number of discrete conduit sections joined together at the connecting portions. However, in other embodiments a continuous length of auxiliary conduit may be provided. In such an arrangement the continuous conduit may extend through a connecting portion, for example through a suitably dimensioned throughbore or the like.
Many different embodiments of connection or interface between auxiliary conduit sections has been presented. However, any suitable combination of such embodiments may also be possible. For example, one end of an auxiliary conduit section may be associated with one type or form of connection or interface, whereas an opposite end may be associated with a different type or form of connection or interface.
| Number | Date | Country | Kind |
|---|---|---|---|
| 1112469.0 | Jul 2011 | GB | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/GB2012/051317 | 6/11/2012 | WO | 00 | 10/8/2015 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2012/168742 | 12/13/2012 | WO | A |
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| Number | Date | Country | |
|---|---|---|---|
| 20160138345 A1 | May 2016 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13158100 | Jun 2011 | US |
| Child | 14124812 | US |
