Patent Application
20130146301
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1. Field of the Invention
The present invention relates to subsea structure flowline connection systems. More particularly, the present invention the relates to systems whereby a fly-in connector is joined to subsea structures so as to establish a flow communication therewith. More particularly, the present invention the relates to a flowline connector assembly for use with large bore connections between the fly-in connector and the flowline connector.
2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98.
Flowlines are used to interconnect pieces of subsea oil-field equipment for fluid communication. They generally take the form of somewhat flexible armoured hoses or pipes, provided with subsea matable connectors at either end. Typically, they are installed by being lowered into place from a pipe-laying vessel, with the final positioning and make-up of the end connectors carried out by divers or by an ROV. Short ROV-installable hoses and pipes are used to interconnect adjacent pieces of subsea equipment.
Examples of subsea equipment that may be interconnected using flowlines include subsea Christmas trees, manifolds, capping stacks, blowout preventors or any other subsea structures that require hydraulic connections. This equipment is located on the seabed.
When there are several different pieces of equipment to be interconnected, installation of the necessary pipes and flowlines can be time-consuming. An end of each flowline is generally lowered vertically to the seabed from a pipe-laying vessel. The flowline is then laid out horizontally between the points to be interconnected. The flowline ends must then be retrieved from the seabed bed by an ROV. The end connectors are aligned with the subsea equipment for make-up of the required fluid-tight connections.
A known type of flowline has a first part mounted to a piece of subsea equipment, such as a wellhead, and a mating second part fitted to the end of a flowline. In use, the second part is lowered towards the sea bed and is stabbed from above into the first. A pivot arrangement then guides the second part and attached flowline so as to hinge over into a generally horizontal position, in which the flowline may be laid away along the sea bed, and in which the connector first and second mating parts are axially aligned for make-up of a fluid-tight connection between them.
In order to connect various flowlines to items of equipment on the ocean floor, special connectors known as “flying leads” are often employed. The flying leads connect the ends of lines to subsea equipment, such as connecting to a control pod on a manifold or subsea tree at one end to an umbilical termination assembly at the other end. In shallow water, flying leads are connected to subsea equipment by divers. In deeper waters, one or more remotely-operated vehicles (ROV) are utilized.
Different configurations of flying leads are presently available. Two types of flying leads for interconnecting the elements of a subsea production system are hydraulic flying leads or steel flying leads. Both types of leads may house lines for monitoring, control and, when necessary, chemical injection in the subsea system. Each type of lead has benefits and limitations.
The hydraulic flying leads commonly are made up of thermoplastic hoses of various sizes and configurations. In known arrangement, a nylon “type 11” internal pressure sheath is utilized as the inner layer. A reinforcement layer is provided around the internal pressure sheath. A polyurethane outer sheath is bonded thereto so as to provide waterproofing. End fittings are provided on each end of the thermoplastic hoses. The end fittings are typically crimped or swaged onto the hose. Connected to the end fittings on each of the ends of the hoses is a multiple quick-connect junction plate. This plate provides the connection plate between the subsea equipment and communication lines. It is usually installed using ROV unit subsea.
Steel flying leads presently being used define a collection of separate steel tubes bundled within a flexible vented plastic tube. Typically, a “Cobra” type end connection containing multiple quick-connect junction plate connections is provided at each end of the tubes. The individual tubes are routed into the respective end connections and welded into socket fitting in the opposing junction plate connections. These plates are usually installed by means of ROV units.
One of the problems with the existing systems is that, while they are effective for small bores of less than two inches, they are extremely difficult to install with respect to large bore applications (of greater than two inches). In these large bore applications, the large pressures involve tend to create greater separation pressures. As such, they would generally be ineffective in supporting the connection under the effect of great pressures. As such, a need has developed so as to provide a subsea flowline connection assembly which can be used for large bore applications and which can withstand the great pressures involved in such applications.
In the past, various patents have issued relating to subsea flowline connection assemblies. For example, U.S. Pat. No. 4,661,016, issued on Apr. 28, 1987 to Baugh et al., describes a subsea flowline connector for remotely connecting and releasing a first flowline to a complementary second flowline at a submerged location without the use of divers. Seals in the connector may be remotely replaced without the need to bring the connector to the surface. A bundle of control/supply lines are remotely connected to respective submerged lines at the same time as the flowline is connected.
U.S. Pat. No. 4,728,125, issued on Mar. 1, 1988 to B. J. Reneau, describes a grip-and-seal mechanically-locking flowline connector. In particular, flowlines have separately actuated gripping and sealing assemblies which are actuated by hydraulic pressure but are held in actuated positions using internally mounted mechanical-type mechanisms.
U.S. Pat. No. 5,468,023, issued on Nov. 21, 1995 to Galle et al., teaches a flowline connector which remotely connects subsea flowlines without the use of a diver. The flowline connector has a frame which supports a seal carrier plate assembly. Springs allow axial movement of the carrier plate assembly during engagement of mating hubs of flowlines. A metal seal carried by the carrier plate assembly engages conical seats in the hubs of the two flowlines. An elastomeric test seal located radially outward of the metal seal seals between flat faces of the hubs of the flowlines.
U.S. Pat. No. 5,593,249, issued on Jan. 14, 1997 to Cox et al., provides a diverless flowline connection system for connecting a flowline to a subsea wellhead or other subsea structure. The diverless flowline connection system is used with an ROV. The diverless flowline connection system includes a frame assembly having clamping arms for mounting the frame assembly to the flowline. A pair of winches are mounted to the frame assembly. Each winch includes a winch line for attachment to the wellhead to which the flowline is to be connected. Each winch is independently controlled so that the lateral position of the flowline may be variously adjusted by controlling each of the winches.
U.S. Pat. No. 5,730,551, issued on Mar. 24, 1998 to Skeels et al., discloses a subsea connector system and method using a skid on the sea floor for coupling a subsea conduit carried by the skid to a subsea conduit on a fixed subsea structure. A lift line device has an upper lift line connected by a spreader bar to a pair of lower guide lines which are directed from a vertical position to a generally horizontal position by J-tubes. The ends of the guide lines have anchor members thereon which are anchored to guides on the subsea facility. Upon raising of the upper lift line, the skid moves in a combined pulling and lifting motion to engage a side of the subsea facility for being guided into a docked position with aligned guides on the subsea facility. An ROV secures the skid into a releasably locked position by insertion of retainer pins into aligned openings of the skid. The coupling on the end of flowline conduit is coupled onto an aligned conduit on the subsea facility.
U.S. Pat. No. 5,794,701, issued on Aug. 18, 1998 to Cunningham et al., teaches a subsea connection usable with subsea wellheads. A female receptacle end is provided on the wellhead which has connections to an umbilical or a flowline. The male end has an orientation lug for rough orientation. Once rough orientation is made, the male end is advanced into the female end and the shaft rotated by a ROV for alignment of lugs with a detent. Once the lugs advance past the detent, they are rotated so that a segment of the shaft on the male end of the connection can no longer turn. Further rotational movements by the ROV on another portion of the shaft advances a plate which makes up the connection.
U.S. Pat. No. 5,807,027, issued on Sep. 15, 1998 to I. Ostergaard, shows a system for pull-in and interconnection of two pipelines in subsea position. A first pipeline is initially freely suspended. A second pipeline is mounted on a bottom-based manifold frame. The end section of the first pipeline is provided with a socket-like termination with a front end, which is provided with means for coupling of the terminator to complementary pipe coupling means on the second pipeline. The terminator is provided with a laterally-directed, longitudinally-shaped anchor member. The manifold frame is provided with receiving means for receipt and fixation of the anchor element. The anchor element and the receiving means are dimensioned and positioned such that when the anchor element is placed in position in the receiving means, the coupling means of the terminator will be positioned straight in front of the complementary coupling means on the second pipeline.
U.S. Pat. No. 6,481,504, issued on Nov. 19, 2002 to N. Gatherar, provides a flowline connector having a first connector portion for mounting on a first piece of subsea equipment and a second connector portion attached to the end portion of a flowline. Each connector portion has a respective guide inter-engageable by lowering the second connector portion, on the end portion of the flowline, into the first connector portion. The guides allow the second connector portion to pivot relative to the first connector portion to bring the first connector portion and the second connector portion into axial alignment for make-up of a fluid-tight connection therebetween.
U.S. Pat. No. 6,805,382, issued on Oct. 19, 2004 to C. E. Jennings, describes a one-stroke soft-land flowline connector. A frame is used to land on a base and soft land a connector receptacle on the end of a flowline to a mandrel protruding from the base. After the frame lands on the base, the frame and the receptacle are pushed toward the base so as to cause frame latching members to latch the frame to the base. The frame holds the base and the receptacle above the mandrel. The frame and receptacle are pushed further towards the base and the connector receptacle abuts the mandrel. The connector receptacle moves relative to the frame as the frame is pushed closer to the base. This causes an actuator on the frame to move dogs on the receptacle to engage the mandrel and lock the receptacle to the mandrel.
U.S. Pat. No. 6,098,715, issued on Aug. 8, 2000 to Seixas et al., provides a flowline connection system having a pivotally-mounted funnel which is a permanent part of a subsea structure. The funnel is rotatably mounted so as to rotate from a vertical position to a horizontal position. Retractable pins engage a slot in the funnel to lock the funnel in a vertical position. This allows the funnel to rotate to the horizontal position to engage a hub connector. A flowline end termination stabs into the funnel while the funnel is in the vertical position. The flowline termination body has a flange connector on one end that connects to a flexible flowline.
U.S. Pat. No. 6,902,199, issued on Jun. 7, 2005 to Colyer et al., provides an ROV-activated subsea connector so as to connect a subsea flowline to a subsea connector hub. The connector has a frame with a tubular mandrel located within it. The mandrel connects to the flowline and has a forward end that engages the connector end. The mandrel moves axially relative to the frame between retracted and extended positions. A lock member on the forward end of the mandrel will engage the profile of the connector hub. An actuator mounted to the mandrel causes the lock member to move into engagement with the connector hub after the mandrel has been moved into engagement with the connector hub.
U.S. Pat. No. 7,112,009, issued on Sep. 26, 2006 to C. Mackinnon, provides an apparatus for substantially horizontal connection of a conduit to a subsea structure. A frame connectable to and supportable by the subsea structure. The frame has a docking device operable to allow a horizontal connection device to dock with the frame such that the frame is capable of bearing at least part of an operational load associated with the horizontal connection of the conduit to the subsea structure.
U.S. Patent Publication No. 2007/0227740, published on Oct. 4, 2007 to Fontenette et al., discloses a flying lead connector and method for making subsea connections. The flying lead arrangement is configured to provide fluid communication between a first item of subsea equipment and a second item of subsea equipment. The flying lead includes a first substantially rigid end kit disposed at a first end of the flying lead and a second substantially rigid end kit disposed at a second end of the flying lead. A substantially rigid midsection is defined between the first end kit and the second end kit. At least one fluid communication line is disposed within the midsection so as to provide fluid communication between the items of subsea equipment.
U.S. Patent Publication No. 2009/0283274, published on Nov. 19, 2009 to M. R. Lugo, discloses a connector assembly for connecting a hot stab to a hydraulic hose. The hot stab has a fluid conduit connector thereon. A hydraulic hose has a connector assembly at an end thereof suitable for joining to the fluid conduit connector of the hot stab. A sleeve is affixed to the hot stab and to the hydraulic hose so as to extend over and surround the fluid conduit connector and the connector assembly. A jam nut is affixed to the tubular portion of the fluid conduit connector. The sleeve is threadedly connected to the threaded exterior surface of the jam nut.
It is an object of the present invention to provide a subsea flowline connection system which is particularly configured to withstand the high pressures associated with large bore applications.
It is another object of the present invention to provide a subsea flowline connection system which facilitates the ability of an ROV to join the fly-in connector to the flowline connector of the subsea structure.
It is still another object of the present invention to provide a subsea flowline connection system which allows the large pressures from the flowline of the subsea structure to be distributed over structural surfaces of the fly-in connector.
It is still another object of the present invention to provide a subsea flowline connection system which effects a secure and strong seal between the fly-in connector and the flowline connector.
These and other objects and advantages of the present invention will become apparent from a reading of the attached specification and appended claims.
The present invention is a subsea flowline connection assembly having a flowline therein, a junction plate affixed to the subsea structure so as to support a flowline connector thereon, a receptacle affixed to or adjacent to the junction plate, and a fly-in connector assembly having a connector thereon. The receptacle has an interior opening to the flowline connector of the junction plate. The connector of the fly-in connector assembly is engaged with the flowline connector of the junction plate. The fly-in connector assembly has a flow passageway in communication with the connector of the fly-in connector assembly.
The flowline connector has a male connector at an end thereof. The connector of the flowline connector assembly has a female connector overlying the male connector in liquid-tight sealing relationship. The male connector defines a sealing surface with the female connector. The sealing surface has a metal seal at an end thereof. The sealing surface also has a first elastomeric seal extending around the male connector. The sealing surface further has a second elastomeric seal extending around the male connector in spaced relationship to the first elastomeric seal. A hole extends through a wall of the female connector. This hole has an opening at the sealing surface between the first elastomeric seal and the second elastomeric seal.
The fly-in connector has an actuator coupled to the connector thereof. The actuator has an end effector suitable for allowing an ROV to rotate the end effector and the actuator so as to move the connector of the fly-in connector assembly toward the flowline connector. The actuator is a threaded member arranged in threaded relationship with the fly-in connector assembly.
The receptacle includes a first plate and a second plate in spaced relation to the first plate. Each of the first and second plates has an end positioned against or adjacent to the junction plate. Each of the first and second plates has a slot formed adjacent an opposite end thereof. The fly-in connector assembly has a first insert member and second insert member formed on opposite sides thereof. The first insert member is received in the slot of the first plate. The second insert member is received in the slot of the second plate. Each of the first and second insert members has a wing shape tapering such that a wide end is joined to the fly-in connector assembly and such that a narrow end is away from the fly-in connector assembly. The wing shape has a flat surface at an end thereof. The slot has a bearing surface thereon. The flat surface bears against the bearing surface. The slot of the first and second plates has a bottom surface. Each of the first and second insert members has a bottom abutting the bottom surface of the slots. The slot also has walls spaced from each other for a distance greater than a width of the insert member.
Each of the first and second plates is directly affixed to the subsea structure. The junction plate has a slot formed therein adjacent the flowline connector. The fly-in connector assembly has a key extending outwardly therefrom. This key is received by the slot.
The flow passageway comprising a conduit extending downwardly and outwardly from the fly-in connector assembly. The fly-in connector assembly also has a brace affixed thereto. This brace is affixed to the conduit.
This foregoing section intends to be a summary of the preferred embodiment of the present invention. As such, the language used in this section is not intended to limiting of the various embodiments and configurations that are possible within scope of the present invention. The present invention should be defined by the claims herein and not by the foregoing section.
Referring to
In
The receptacle 20 is directly bolted by flange plates 28 and 30 to the subsea structure 12. The receptacle 20 can also be directly affixed to the junction plate 16. In any circumstances, the receptacle 20 will be positioned at least adjacent to the junction plate 16 and positioned around the flowline connector 18. The direct affixing of the receptacle 20 through the use of flange plates 28 and 30 allows the structure of the receptacle 20 to be directly supported by the subsea structure 12. As such, this will avoid any undesired bending moment imparted to the junction plate 16 and/or to the flowline 14 or the flowline connector 18.
The receptacle 20 includes a first plate 32 and a second plate 34 arranged in generally spaced parallel relationship on opposite sides of the flowline connector 18. As such, these plates 32 and 34 will define an interior opening to the flowline connector 18. As will be described hereinafter, each of the plates 32 and 34 has a slot formed at an end thereof opposite the junction plate 16 that can be used for the receipt of the fly-in connector assembly 22.
The fly-in connector assembly 22 has the connector 24 at one end thereof. The flow passageway 26 is in nature of a conduit that will communicate with an interior of the fly-in connector assembly 22 adjacent to the connector 24. A brace 36 extends so as to be engaged with the body of the fly-in connector assembly 22 and with the flow passageway 26. As such, the flow passageway 26 is rigidly support by the fly-in connector assembly 22.
The fly-in connector assembly 22 has a key 28 extending radially outwardly therefrom. This key 38 can be engaged with a slot 40 in the junction plate 16 adjacent to the flowline connector 18. The fly-in connector assembly 22 also includes a torque bucket 42 at an end thereof opposite the connector 24. An end effector 44 is positioned within the torque bucket 42. The end effector 44 can be utilized by an ROV so as to carry out the necessary function of connecting the connector 24 to the flowline connector 18, to be described hereinafter.
In use, the fly-in connector assembly 22 can be lowered by winch and line to the seabed adjacent to the subsea structure 12. An ROV can grasp the fly-in connector assembly 22 so as to move the fly-in connector assembly 22 to a position, such as illustrated in
The receptacle 20 has a slot 52 formed at an end thereof opposite the junction plate 16. The plate 34 has a slot 54 formed at an end thereof opposite the junction plate 16. Slot 54 has a bottom surface 56 at a lower end thereof. Each of the slots 52 and 54 opens at an upper end thereof so as to provide an area whereby the wing-shaped surfaces of the fly-in connector assembly 22 can be received therein.
The fly-in connector assembly 22 is illustrated as in a position slightly above the receptacle 20. The connector 24 of the fly-in connector assembly 22 is located at one end thereof. The torque bucket 42 is positioned at an opposite end thereof. The flow passageway 26 is a conduit that extends downwardly and outwardly from the body of the fly-in connector assembly 22. Ultimately, the flow passageway 26 has another connector 58 formed therein so as to allow the flow passageway 26 to be joined to another conduit in a conventional manner.
The fly-in connector assembly 22 includes a first insert member 60 and second insert member 62 extending outwardly therefrom. Each of the insert members 60 and 62 has a generally wing shape. This wing shape has a wide end adjacent to the fly-in connector assembly 22 and a narrow end away from the fly-in connector assembly 22. Generally, the width of each of the inserts members 60 and 62 will be less than the width of the respective slots 52 and 54 of the receptacle 20. The key 38 is illustrated as extending upwardly from the top of the fly-in connector assembly 22. Also, the brace 36 extends downwardly so as to be rigidly secured to the flow passageway 26.
In
Importantly,
In
When a strong mechanical connection is established between the connector 24 and the flowline connector 18, the strong hydraulic forces passing through the interior 86 of the flowline connector 80 and through the interior of the connector 24 will be resisted by the mechanical connection between the threaded surfaces 72 and 74 of the actuator 70. The bearing surfaces 82 of the insert member 62 against the flat surface 80 of the slot 54 provide a secondary bearing surface for the hydraulic connection. As such, the hydraulic forces are effectively resisted by the strong mechanical connections between these surfaces.
The flow passageway 26 of the fly-in connector assembly 22 will open to the interior 88 of the connector 24. As such, it will be in fluid communication with the flowline 86 of the flowline connector 80.
A sealing surface 90 is defined between the exterior of the male flowline connector 18 and the female connector 24. Various seals can be placed in association with the sealing surface 90 so as to provide a strong sealing relationship therebetween. The nature of this sealing surface is described hereinafter in
A first elastomeric seal 98 is received within a notch 100 formed on the inner wall of the female connector 24. This elastomeric seal 98 is in the nature of an O-ring seal. This O-ring elastomeric seal 98 will extend around the outer diameter of the male flowline connector 18. As such, the elastomeric seal 98 will provide a secondary liquid-tight seal at the sealing surface 90. A second elastomeric seal 102 is received within an notch 104 formed on the inner wall of the female connector 24. This second elastomeric seal 102 will extend around the outer surface of the male flowline connector 18. The elastomeric seal 102 is in generally spaced relationship to the first elastomeric seal 98. The second elastomeric seal 102 will provide a tertiary seal as to prevent the release of any hydraulic fluids through the sealing surface 90. A hole 106 is formed through the wall of the female connector 24. Hole 106 opens to the sealing surface 90 and is positioned between the first elastomeric seal 98 and the second elastomeric seal 102. Hole 106 can allow well fluids to escape therethrough if the pressure of the well fluids is beyond the ability of the seals 92 and 98 to withstand. These fluids can be diverted outwardly of the hole 106.
The foregoing disclosure and description of the invention is illustrative and explanatory thereof. Various changes in the details of the illustrated construction can be made within the scope of the appended claims without departing from the true spirit of the invention. The present invention should only be limited by the following claims and their legal equivalents.
