The present invention relates to a subsea vessel comprising a liner connected to at least one flange, and where a load bearing structure of the vessel is of a composite material. The invention further relates to a method of manufacturing said subsea vessel.
A Subsea Separation System is designed to separate multiphase fluids on the seabed, sending topside the oil and/or gas streams and reinjecting the undesirable phases like water, carbon dioxide, etc. This separation reduces the topside facilities for separation and treatment of these phases, enabling the increase of the oil production in the field. One of the main components on this kind of system is a separation vessel, which consists essentially in a pressure vessel in which this fluid segregation, by gravitational or cyclonic means, occurs. For example, considering the operational conditions for pre-salt fields, a pressure vessel for this purpose must be long and have a large diameter in order to withstand the elevated production volume, and also be capable to operate under elevated pressure and temperature conditions, in a water depth up to 2500 meters.
A material commonly considered for such kind of pressure vessels construction is steel, since it is a consolidate material in the oil and gas industry with a significantly large knowhow accumulated over the years with equipment engineering, manufacturing and usage. To withstand the required operational conditions for such application, however, a metallic pressure vessel must have a considerably thick wall, which may end up resulting in a product that is costly, heavy and very challenging in terms of sourcing, manufacturing and installation.
It is therefore an objective of the invention to provide an alternative pressure vessel which is lighter without compromising on the strength.
The present invention is set forth and characterized in the independent claims, while the dependent claims describe other characteristics of the invention.
The invention relates to a composite vessel, which aims to provide an alternative solution for the large conventional metallic pressure vessel, focusing on weight reduction and/or also gain in lead-time and installation costs. This can be possible since composite material presents higher specific strength compared to other materials and relies on an additive manufacturing process.
It is described a cylindrical subsea vessel for separation of a flow, the vessel comprising first and second longitudinal ends, wherein the subsea vessel comprises:
The liner and the at least one flange can be made of metal, i.e., the liner can be a metallic liner and the flange can be a metallic flange. Alternatively, the liner and the at least one flange may be a Polyether ether ketone (PEEK) liner or thermoplastic liner suitable for harsh environment. In any case, it may be an advantage that the liner and flange are of the same material or, at least of two materials with similar electric potential, such that they do not degrade each other. The at least one flange can be a hub or other connection interface.
The liner and the at least one flange may form a closed inner volume of the subsea vessel. The only opening(s) into and out of the vessel is via the through-going opening(s) in the flange(s). The liner and the flange(s) perform the functions of containing the processing fluids or the flow as well as protecting chemically the composite material(s) from abrasive or hazardous processing fluids able to degrade the composite material(s).
Since the liner acts as a fluid container, it may be necessary just to have a thin shell, suitable for direct contact with the production fluid, to protect the inner volume, avoiding adding unnecessary weight and cost. However, the liner may also have some load bearing capacity. In any case, although no structural function may be assigned to the liner, a minimum geometrical stability is needed for the liner.
The at least one flange is preferably connected to the liner forming a fluid-tight connection therebetween. Such fluid-tight connection may be obtained by welding, gluing etc, dependent on the materials of the liner and the flange. Once connected, the liner and the at least one flange form a closed inner volume of the subsea vessel. The only access into the inner volume being through the at least one through-going opening in the at least one flange.
The liner and flange(s) form a chemical protection between any fluid within the inner volume and the composite material on the outside of the liner and flange. In order to protect the flange(s), it may have weld overlaid cladding placed on the flange surfaces exposed to the fluid inside the vessel.
The vessel may comprise two flanges, the flanges preferably being connected to the first and second longitudinal ends of the vessel. The preferred option if using two flanges in total is to arrange one flange in each of the longitudinal ends of the subsea vessel.
Alternatively, the vessel may comprise only one flange. If the vessel comprises only one flange, the one flange may comprise a first and a second through-going opening, wherein the first through-going opening forms a fluid inlet and the second through-going opening forms a fluid outlet into and out of the inner volume of the vessel.
In the embodiment of only one flange, an inlet pipe for directing fluid into the subsea vessel may extend from the one flange towards an opposite longitudinal end of the subsea vessel. Thus, in the event the subsea vessel is a separator, instead of having inlet and outlet into and out of the subsea vessel at the opposite ends, the inlet pipe and outlet from the subsea vessel are arranged in the same one flange. The retention time for the fluid in the vessel will be similar to arranging the inlet and outlet at the opposite longitudinal ends provided that the subsea vessels are of the same size and that an outlet of the inlet pipe is at the same position as would be the case if the outlet where in a flange in the opposite end. Preferably, all through-going openings for inlet and/or outlet of fluid into and out of the inner volume of the vessel are arranged in the at least one flange connected to the at least one longitudinal end of the vessel. Arranging all of the through-going openings into and out of the flange(s) ensures that the strength of the subsea vessel is optimized as there are no portions of the composite material that is weakened, i.e., the composite material is continuous without any hole(s) therethrough.
The load bearing structure may carry a majority of, and possibly all, loads. However, other layers of the vessel may carry some of the loads. Then the load bearing structure not necessarily have to carry all loads. The composite material of the load bearing structure may comprise a Carbon Fiber Reinforced Polymer (CFRP). The CFRP may be seen as the core part of the vessel and may be responsible to sustain the majority of loads imposed to the product during its life. The CFRP is a layup of non-twisted continuous fibers, such as for example polyacrylonitrile (PAN) carbon fibers impregnated with polymer which, once winded forming an optimal layup, grant to the vessel and adequate mechanical performance and load bearing capacity. Such polymer may be epoxy, polyester, vinyl ester resin or phenolic.
Alternatively, the composite material of the load bearing structure can be fiberglass, basalt, aramid or other (natural or synthetic) fiber reinforced material. The vessel may further comprise a coating outside the composite material.
The coating may be a thermoplastic coating, thermosetting coating or paint. A thermoplastic coating, i.e., a thermoplastic polymeric external coating, is responsible to act as an absorption barrier and protect the internal layers from minor impacts, direct sunlight, and from the surrounding environment.
The liner may be a metallic liner, the vessel may comprise a galvanic coupling protection for the metallic liner. The galvanic coupling protection may be arranged between the metallic liner and the load bearing structure.
The galvanic coupling protection may be a Glass Fiber Reinforced Polymer (GFRP). The GFRP may be a composite layup of non-twisted continuous glass fiber roving impregnated with polymer, placed between the load bearing material and the liner and flanges, in order to avoid metal parts contact with the carbon fiber layers, aiming to inhibit the formation of a galvanic coupling that could potentially result in galvanic corrosion. Such polymer may be epoxy, polyester or phenolic.
Instead of a Glass Fiber Reinforced Polymer, the galvanic coupling protection may be a basalt, aramid, other (natural or synthetic) fiber, polymeric or ceramic electrical insulation material.
The subsea vessel may further comprise a glass fiber reinforced polymer (GFRP) composite protective shell over the carbon fiber, made from a layup of non-twisted continuous glass fiber roving impregnated with polymer, made to provide protection against impacts and minor damages, as well as to provide additional galvanic insulation between the load bearing structure and external metallic parts. If present, this external protective shell serves as base for external protective polymeric coating. Instead of a fiberglass composite protective shell, basalt, aramid, other natural fibers or polymeric material may be used.
The subsea vessel may further comprise a particulate removal system inside the inner volume. The particulate removal system may comprise:
The particle movement device can be jet nozzles or a spray device suitable for putting sedimented (i.e., gravity separated) particles from the flow towards the particle removal device. Alternatively, the particle movement device can be a screw pump, such as an Archimedes' screw.
The particle removal device may comprise suction means for sucking particles out of the inner volume and up and out through the outlet in the flange. The particle removal device can comprise a fine particulate pipe with an opening at or close to the bottom of the vessel and a second opening outside of the inner volume through the flange. The opening of the pipe inside the inner volume may be conical with the relatively larger cross section of the cone directed against the particles/sediments. This may provide a more efficient suction of the particles than using a pipe with a constant cross section.
The subsea vessel can be a gravitational separation vessel. Gravitational separation vessels are designed to separate the multiphase fluids on the seabed and then send the oil and gas streams with a minimum amount of water either together or using separate lines to the surface for further treatment. Subsea separation key benefit is to reduce capital and operating costs by reducing surface processing needs. The gravitational separation vessels are relatively large structures and can be in the size of 0.5 meter (or more) in diameter, and range from 2 to 25 meters in length. Preferably, the gravitational separation vessel is at least 1.5 meters in diameter and more than 10 meters long. The gravitational separation vessel is preferably of sufficient length for gravitational separation to occur. The degree of separation in a gravitational separator is dependent on the retention time. The retention time in a separator is determined by dividing the liquid volume inside the vessel by the liquid flow rate. The retention time usually varies between 30 seconds and 3 minutes.
As an alternative to gravitational separation vessel, the subsea vessel can be a cyclonic separation vessel comprising cyclonic means for separation.
The subsea vessel can be a slug flow vessel. The term “slug flow” usually refers to heavier, slower moving fluid. Such flow is characterized by the intermittent sequence of liquid slugs followed by longer gas bubbles flowing through a pipe. In order to prevent that such slugs damage subsea equipment, the flow may be guided through the subsea vessel. The flow exiting the subsea vessel is steady, e.g., a laminar flow without liquid slugs.
The subsea vessel can be a mixing or buffering vessel.
The subsea vessel can be a dump vessel.
It is further described a cylindrical subsea vessel having first and second longitudinal ends;
The structure is designed for taking up any expected internal and external loads, and/or any pressure differences between an outside of the vessel and the inner volume of the vessel.
In this embodiment, the vessel can be formed without a liner and the composite material is chosen based on the expected production fluid composition. This may be important in order to prevent that the production fluid react with the composite material thereby degrading or eating away the vessel.
The invention further relates to a method of manufacturing a cylindrical subsea vessel having first and second longitudinal ends, comprising the steps of:
The liner and the at least one flange may chemically separate the inner volume from outer composite layer(s).
As indicated above, the composite material may be a layup of non-twisted continuous fibers, such as for example polyacrylonitrile (PAN) carbon fibers impregnated with polymer which, once winded forming an optimal layup, grant to the vessel and adequate mechanical performance and load bearing capacity. Such polymer may be epoxy, polyester or phenolic.
The fluid-tight connection may be formed by welding. However, other alternative connections providing a fluid-tight connection are also possible, such as gluing. The method may further comprise a step of:
A mandrill may be used instead of the liner in the manufacturing. Mandrill may form part of the finished vessel or it may be removed after the vessel has been made. The liner and the flange(s) may also act as a mandrill for a filament winding manufacturing process. In order to perform this function, the liner and flange(s) may have a minimum geometrical stability, or be supported with additional support. As an alternative to filament winding, automated fiber placement, automated tape layup, resin transfer molding (RTM), vacuum assisted resin transfer molding (VARTM), fiber braiding or bladder molding may be used as processing method.
The method may further comprise, after the step of forming the fluid-tight connection, a step of:
The method may further comprise, prior to forming the load bearing structure, the steps of:
The elastomeric sealing layer may be a sheet of elastomeric material which is placed over the flanges and liner, aiming to provide a water-tight interface between the liner and the composite layers.
Instead of an elastomeric sealing layer, a polymeric material may be used.
The method may further comprise, prior to adding the external coating, a step of:
The relative terms “upper”, “lower”, “below”, “above”, “higher” etc. shall be understood in their normal sense and as seen in a cartesian coordinate system. When mentioned in relation to a well, “upper” or “above” shall be understood as a position closer to the surface of the well (relative to another component), contrary to the terms “lower” or “below” which shall be understood as a position further away from the surface of the well (relative another component).
A product with such characteristics is well aligned with the Oil and Gas industry demand, since it seeks the reduction in overall costs, weight and time for first oil production.
The following drawings are appended to facilitate the understanding of the invention. The drawings show embodiments of the invention, which will now be described by way of example only, where:
In the following, embodiments of the invention will be discussed in more detail with reference to the appended drawings. It should be understood, however, that the drawings are not intended to limit the invention to the subject-matter depicted in the drawings.
As disclosed in the
Further, as disclosed in
The elevation of the inlets of the gas pipe 20 and the fluid production pipe 21 are chosen based on expected well flow composition etc., and can be varied.
It is further disclosed a fine particulate outlet 6. The fine particulate outlet 6 is connected to a fine particulate pipe 22 inside the subsea vessel 1. The fine particulate outlet and fine particulate pipe form part of a particulate removal system 13.
The particulate removal system 13 (which is better illustrated in
The particle removal device 16 is conically with the relatively larger cross section of the cone directed downwards towards the sedimented particles/sediments (which due to their relative higher density than the fluids, will collect at the bottom of the subsea vessel 1). This may provide a more efficient suction of the particles or sediments than using a pipe with a constant cross section.
If used as a gravitational separator, the internals encompass all the devices in the multiphase separation process, such as inlet diverter, sand removal system, weir plates, internal piping, demisters, etc. These components are preferably modular and comply with the same boundary conditions as established for the liner 2 and flange(s) 8.
In the preceding description, various aspects of the subsea vessel according to the invention have been described with reference to the illustrative embodiment. For purposes of explanation, specific numbers, systems and configurations were set forth in order to provide a thorough understanding of the subsea vessel and its workings. However, this description is not intended to be construed in a limiting sense. Various modifications and variations of the illustrative embodiment, as well as other embodiments of the subsea vessel, which are apparent to persons skilled in the art to which the disclosed subject matter pertains, are deemed to lie within the scope of the present invention as defined in the attached claims.
Number | Date | Country | Kind |
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PCT/IB2020/059678 | Oct 2020 | WO | international |
Filing Document | Filing Date | Country | Kind |
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PCT/IB2020/062071 | 12/16/2020 | WO |