Not Applicable
The present invention generally relates to offshore oil and gas production. More specifically, it relates to the connection of subsea risers to floating vessels, particularly Floating Production, Storage and Offloading (FPSO) vessels.
A Floating Production, Storage and Offloading (FPSO) unit is a floating vessel used by the offshore oil and gas industry for the production and processing of hydrocarbons, and for the storage of oil. A FPSO vessel may be designed to receive hydrocarbons produced by itself or from nearby platforms or subsea template, process them, and store oil until it can be offloaded onto a tanker or, less frequently, transported through a pipeline. FPSOs are preferred in frontier offshore regions as they are easy to install, and do not require a local pipeline infrastructure to export oil. FPSOs may be a conversion of an oil tanker or may be a vessel built specially for the application. A vessel used only to store oil (without processing it) is referred to as a Floating Storage and Offloading vessel (FSO).
Oil produced from offshore production platforms may be transported to the mainland either by pipeline or by tanker. When a tanker is chosen to transport the oil, it is necessary to accumulate oil in some form of storage tank, such that the oil tanker is not continuously occupied during oil production, and is only needed once sufficient oil has been produced to fill the tanker.
Floating production, storage and offloading vessels are particularly effective in remote or deep water locations, where seabed pipelines are not cost-effective. FPSOs eliminate the need to lay expensive long-distance pipelines from the processing facility to an onshore terminal. This may provide an economically attractive solution for smaller oil fields, which may be exhausted in a few years and do not justify the expense of installing a pipeline. Furthermore, once the field is depleted, the FPSO may be moved to a new location.
FPSO vessels may include a turret mooring system wherein subsea risers are in fluid communication with processing equipment on the FPSO vessel via a swivel stack and the vessel may weathervane about the turret. Alternatively, if metocean conditions permit, an FPSO vessel may be spread-moored. Subsea risers may be terminated along the port or starboard bow, port or starboard beam, port or starboard quarter, or stern of a spread-moored FPSO vessel.
A steel catenary riser (SCR) is a common method of connecting a subsea pipeline to a deepwater floating or fixed oil production platform. SCRs are used to transfer fluids like oil, gas, injection water, etc. between the platforms and the pipelines.
A steel catenary riser (SCR) is a steel pipe hung in a catenary configuration from a floating vessel in deep water to transmit flow to or from the sea floor.
In the offshore industry the word catenary may be used as an adjective or noun with a meaning wider than is its historical meaning in mathematics. Thus, an SCR that uses a rigid, steel pipe that has a considerable bending stiffness may be described as a catenary. That is because, in the scale of depth of the ocean, the bending stiffness of a rigid pipe has little effect on the shape of the suspended span of an SCR. The shape assumed by the SCR is controlled mainly by weight, buoyancy and hydrodynamic forces due to currents and waves. Thus, in spite of using conventional, rigid steel pipe, the shape of an SCR may be closely approximated with the use of ideal catenary equations, used historically to describe the shape of a chain suspended between points in space. A chain line has by definition a zero bending stiffness and those described with the ideal catenary equations use infinitesimally short links.
The rigid pipe of the SCR forms a catenary between its hang-off point on the floating or rigid platform, and the seabed. A free-hanging SCR assumes a shape roughly similar to the letter ‘J’. A catenary of a lazy wave SCR consists of at least three catenary segments. The top- and the seabed-segments of the catenary have negative submerged weight, and their curvatures ‘bulge’ towards the seabed. The middle segment has buoyant material attached along its entire length, so that the ensemble of the steel pipe and the buoyancy is positively buoyant. Accordingly, the curvature of the buoyant segment ‘bulges’ upwards (inverted catenary), and its shape may also be well-approximated with the same ideal catenary equations. The positively and negatively buoyant segments are tangent to each other at the points where they join. The overall catenary shape of the SCR has, at those locations, points of inflection. Lazy wave SCRs were first installed on a turret moored FPSO offshore Brazil in 2009 (although lazy wave configuration flexible risers were in wide use for several decades beforehand).
The SCR pipe and a short segment of pipe lying on the seabed use “dynamic pipe,”—steel pipe having slightly greater wall thickness than the nominal pipeline wall thickness, in order to sustain dynamic bending and material fatigue encountered in the touch-down zone of the SCR. Beyond that the SCR is typically extended with a rigid pipeline, but the use of a flexible pipeline is also feasible. The risers are typically 8-12 inches in diameter and operate at a pressure of 2000-10,000 psi. Designs beyond those ranges of pipe sizes and operating pressures are also feasible.
A riser top interface for a floating, offshore vessel (e.g. a spread-moored FPSO) has an upper funnel and a co-axial, lower funnel spaced apart from the upper funnel. Tension loads on the riser are reacted at the upper funnel while lateral and bending loads are reacted at the lower funnel. A riser top interface according to the invention may be used with flexible risers or steel catenary risers. The steel catenary risers may be equipped with a flex joint or a tapered stress joint proximate the lower funnel.
The invention may best be understood by reference to the exemplary embodiments illustrated in the drawing figures wherein the following reference numbers are used to indicate the associated elements:
The present invention was developed to simplify the connection of a steel catenary riser (SCR) to a floating, offshore vessel (such as a spread-moored FPSO, tension leg platform, semi-submersible, spar-type vessel or the like) having a hull (10). The invention employs two separate funnels (17 and 18), one below water (18) and one above water (17). The lower funnel (18) reacts the lateral and bending loads and the upper funnel (17) reacts the tension loads. The upper funnel (17) allows personnel access for connection of the tension support and for valve and piping connections to be made without requiring divers. The SCR (12) requires a special top joint that spans between the two coaxial, spaced-apart funnels (17 and 18).
Two SCR versions are illustrated as exemplars: a pipe-in-pipe version (see
The upper support may be a split flange (16) that fits a profile (42) on the top joint and bolts to the upper guide funnel (17). The lower support may have radial dog segments (62) for diver or ROV actuation to support lateral and bending loads.
Elastomeric flex joints (34) may be used for FPSO applications, but tapered stress joints (74), either titanium or steel, may also be adapted for use with the two funnel configuration of the invention.
In an embodiment, a flexible riser (14) is fitted in the lower guide funnel (18). This may be accomplished by flanging a flexible riser pull-in support (20′) in place of the SCR clamp configuration. Thus, the capability to convert from SCR to flexible hang-off may be provided on the same location.
SCR pull-in has been done on FPSOs with traditional hang-off baskets and with specialized hang-off assemblies. Turret and disconnectable systems of the prior art use a pull-in tube with a hang-off clamp to support lateral and bending loads. The arrangement of the present invention uses a similar style hang-off clamp at the lower funnel and similar hang-flange at the upper funnel, to the turret arrangement pull-in tube.
SCR lazy wave risers may be an effective solution in deep water applications. However, with the hang-off porch below the water surface, the connection and pull-in operation are heavily dependent on diver intervention. Diver intervention increases the time and cost of the operation.
The present invention reduces the scope of diver work required and moves many of the connection steps above the water, allowing workers better access. The piping spool is also difficult to install using the apparatus and methods of the prior art due to size, handling access, and diver connections required.
Some SCR basket-type systems place the flex bearing above water level for connection and partially during use. This has been shown to reduce the elastomer life by raising the temperature of the elastomer. Also, repeated travel into and out of the water may increase corrosion in equipment. By keeping the lower funnel below the water surface, the benefit of seawater cooling may be maintained and corrosion protection of the cathodic protection system may be maintained.
Referring now to
The novel SCR upper section illustrated in
Practice of the invention provides the following benefits:
Dry make up for top-of-riser testing and plumbing connections.
Large separation of funnels (guide funnels) reduces pull-in forces.
Provides the flexibility to adapt from an SCR hang-off receptacle to a flexible riser support.
Guide provided by outer pipe or segmented guides enables pull in between split funnels.
Reduces diver intervention for significant cost savings.
The time to complete a pull-in operation may also be reduced, lowering the cost of the installation spread. It is estimated that between one and three days may be saved per riser.
A single, long funnel may trap gas in the event of a leak thereby creating a potential explosion hazard. This is not possible with the separate, short funnels employed in the practice of the present invention. Although a single, long tube might make pull-in simpler, it would also add significant weight.
The flex joint (34) may be positioned beneath the water surface to maintain cooling of the flex element and allow cathodic protection.
Riser lateral and bending moments are transferred to the lower funnel, minimizing movement at the upper end of the riser top joint.
The riser top interface is always above water, so diver connections are not required. Test plug and end connection removal are simplified inasmuch as flooding of the riser is no longer a concern.
The twin funnel design reduces weight and cost of the interface in comparison to a single, long funnel or I-tube.
The lower connection may be either diver made up or ROV made up. Total required diver intervention is greatly reduced over previous systems.
A flanged or welded interface may be used for the lower connector. Using a flanged interface permits future adaption to a flexible riser, if required.
The upper riser joint may be pipe-in-pipe construction, providing additional accidental damage protection and thermal insulation to the risers. Alternatively, a single pipe with guide bumpers may be used.
Connection time may be reduced by several days, compared to the systems of the prior art.
Operating expenses are reduced because flange connections are accessible above the water surface.
Riser loads are spread over the hull (10) of the floating vessel.
A work platform may be provided around the top of the upper funnel.
A standardized interface may be provided at the bottom of the lower funnel (18) to accommodate different types of risers.
In an embodiment, an offshore, floating vessel having a nominal, fully loaded waterline comprises a first, upper funnel 17 mounted to and extending outboard from a side of the vessel on an upper porch 66 above the waterline of the vessel, a second, lower funnel 18 mounted to a lower porch 68 and extending outboard from the side of the vessel in spaced-apart, co-axial relation to the first funnel 17 at a location below the waterline of the vessel, wherein the first, upper funnel 17 is configured to support the upper end of a subsea riser 12, and the second, lower funnel 18 comprises means for reacting lateral and bending loads on the subsea riser supported in the upper funnel 17.
The offshore, floating vessel may further comprise a winch 54 positioned above the first, upper funnel 17 and having a winch line wound on a winch drum configured to wind the winch line co-axially with the upper and lower funnels.
The offshore, floating vessel may further comprise a split flange 16 configured to transfer tension loads on the subsea riser to the upper funnel 17.
In an embodiment, the second, lower funnel 18 is mounted farther outboard from the side of the vessel than the first, upper funnel 17.
In an embodiment, the upper funnel 17 and the lower funnel 18 have a longitudinal axis that is inclined from the vertical between about 8 to about 12 degrees.
In an embodiment, the means for reacting lateral and bending loads on a riser comprises a centralizer 20 attached to a lower end of the lower funnel 18. The centralizer may comprise retractable dogs 62 configured to bear against an outside surface of a subsea riser that passes through the lower funnel 18. The retractable dogs may be mechanically or hydraulically actuated.
The offshore, floating vessel may be a spread-moored FPSO vessel, a semi-submersible vessel, a spar-type vessel, a tension leg platform (TLP), or any similar such vessel having a hull 10.
In certain embodiments, the subsea riser is a steel catenary riser (SCR) 12 or a steel lazy wave riser (SLWR). The SCR may comprise a flex joint 34 below and proximate the lower funnel 18, or a tapered stress joint 74 below and proximate the lower funnel 18.
In yet other embodiments, the subsea riser is a flexible riser 14. The flexible riser may comprise a bend stiffener [bend restrictor] 70 below and proximate the lower funnel 18 and a pull head 72 configured to pull the riser 14 through the lower funnel 18 with the bend stiffener 70 attached to the lower funnel 18.
A steel catenary riser (SCR) 12 according to the invention may comprise a first flange 36 on a first, upper end of the SCR sized and configured to connect a pull head 32 to the SCR, a second, tension load-bearing flange 42 below and proximate the first flange, an outer pipe 40 surrounding an upper portion of the SCR below the tension load-bearing flange 42, and a plurality of spacers 38 holding the outer pipe 40 in spaced-apart relation to a central fluid conduit of the SCR and forming an annulus 44 between the outer pipe 40 and the central fluid conduit of the SCR.
Such an SCR may further comprise a radially enlarged portion 52 below and proximate a lower end of the portion surrounded by the outer pipe 40. The SCR may further comprise a flex joint 34 below and proximate the radially enlarged portion 52 or a tapered stress joint 74 below and proximate the radially enlarged portion.
A steel catenary riser (SCR) according to the invention may comprise a port 46 in the outer pipe 40 in fluid communication with the annulus 44 between the outer pipe 40 and the central fluid conduit of the SCR for connecting control line tubing for monitoring the pressure and/or content of fluid within the annulus.
In another embodiment, a steel catenary riser (SCR) 12 comprises a first flange 36 on a first, upper end of the SCR sized and configured to connect a pull head 32 to the SCR, a second, tension load-bearing flange 42 below and proximate the first flange, a radially enlarged portion below and spaced apart from the second flange 42, and a plurality of bumpers 30 on an outer wall of the SCR between the second flange and the radially enlarged portion 52.
A method of attaching a subsea riser (12 or 14) to an offshore floating vessel having a nominal, fully loaded waterline may comprise pulling an upper end of the riser through a first, upper funnel 17 mounted to and extending outboard from a side of the vessel at a location above the waterline of the vessel and a second, lower funnel 18 mounted to and extending outboard from the side of the vessel in spaced-apart, co-axial relation to the first funnel at a location below the waterline of the vessel, attaching the upper end of the subsea riser to the upper funnel 17 such that tension loads on the riser are reacted to the upper funnel 17, and attaching the riser to the second, lower funnel 18 such that lateral and bending loads on the riser are reacted to the lower funnel 18. Pulling the riser through the upper and lower funnels may be performed with a winch 54 positioned above the upper funnel 17 and having a winch line wound on a winch drum configured to wind the winch line co-axially with the upper and lower funnels. This may obviate the need for lateral steering winches and associated sheaves and minimize the pull-in load by reducing friction and side loads.
The foregoing presents particular embodiments of a system embodying the principles of the invention. Those skilled in the art will be able to devise alternatives and variations which, even if not explicitly disclosed herein, embody those principles and are thus within the scope of the invention. Although particular embodiments of the present invention have been shown and described, they are not intended to limit what this patent covers. One skilled in the art will understand that various changes and modifications may be made without departing from the scope of the present invention as literally and equivalently covered by the following claims.
This application claims the benefit of U.S. Provisional Patent Application No. 62/469,161 filed on Mar. 9, 2017, and U.S. Provisional Patent Application No. 62/473,053 filed on Mar. 17, 2017, the contents of which are hereby incorporated by reference in their entireties.
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Invitation to Pay Additional Fees received in PCT Application No. PCT/IB2018/051569, mailed Jun. 7, 2018. |
Number | Date | Country | |
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20180258711 A1 | Sep 2018 | US |
Number | Date | Country | |
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