This disclosure relates to methods and systems for displacement sensing and monitoring. More specifically, this disclosure relates to sensing and monitoring displacement on a structural component of subsea systems such a subsea pipeline networks to transport production fluid from a subsurface wellhead to surface facilities.
Pipe installations are subject to fatigue and potential damage which greatly benefit from permanently installed sensors for monitoring the status of these structures. Such monitoring aids in mitigating the risks associated with a possible loss of integrity. When monitoring such structures, it is often desirable to install the monitoring instrumentation intimately with the structures. One such monitoring objective is to measure the structural strain developed by the monitored system under a load.
Sensor technologies which could be used for such monitoring include: Linear Variable Differential Transformer (LVDT), Wheatstone bridges, and Fiber Optic with Bragg Grating. Generally, the strain sensors are mounted on a frame or on collars that constitute an interface between the structural element being monitored and the sensor itself. These interfaces allow for recovering and reinstalling the sensors onto the structural element for maintenance or repair. The sensor could also be directly bonded to the assets, which often makes it difficult or impossible to maintain or repair the sensor in case of sensor failure.
One example of such pipe installations relates to subsea applications wherein the structures are generally exposed to severe environmental conditions. Subsea hydrocarbon production systems using sea surface facilities of any sort require petroleum fluids to flow from the seabed to the surface through pipes called risers. The sea surface rises and falls with waves and tides, and the facilities are moved vertically, laterally and rotationally by various forces. The risers can either be steel pipes relying on their intrinsic flexibility or a range of flexible composite materials that are designed to resist the internal conveyance of fluids and the external forces imposed by all foreseen conditions. In another example, single line offset risers (SLHR) consist of a column of rigid pipe firmly attached to a foundation on the seabed and supported near the mean water level by a buoyancy can or tank. It is vital that these risers do not leak petroleum fluids to the environment, and do not suffer mechanical failures, which would require production to be stopped, causing severe loss of revenue. It might thus be beneficial to monitor integrity of such installations to mitigate risks associated with possible failure.
A typical field of application for subsea is a subsea oil and gas field architecture that integrates a pipeline network to transport the production fluid from the wellhead to the surface facilities. As part of this pipeline network the riser pipe structure is provided close to the surface process facilities to lift the fluid from the seabed to the surface. In deep and ultra deep water examples, operators have often adopted the hybrid free-standing riser concept which comprises: a seabed riser anchor base; a vertical single or bundled riser pipe(s) anchored to the seabed; a buoyancy tank providing an uplift tension to vertical riser pipe(s); a flexible pipe connecting the top of the vertical riser to the surface process facilities (FPSO); and a flexible joint connecting the buoyancy tank to the vertical riser. Accidental flooding of the buoyancy tank could create a potential hazard to the riser system and expose the field to catastrophic failure if a sufficient uplift tension is not applied to the vertical pipe system. In some applications, the buoyancy tank is made up of several independent compartments to limit the amount of water that could accidentally fill the tank. In order to further mitigate risks, subsea operators often request to install instrumentation to monitor possible accidental flooding of the buoyancy tank.
Generally, operators request that the tension generated by the buoyancy tank be monitored by means of an integrity monitoring system equipped with gages able to measure the pipe strain as shown. Such a system, well suited for detecting a sudden event, is more limited in the case of a slow water intrusion inside the tank, for example, due to corrosion. Readings collected from the tension collar may drift and the instrument cannot be recalibrated subsea. As a result, it is difficult to differentiate real water ingress from the data drift. Further, in some cases it is desirable to provide a secondary and independent monitoring system for redundancy and increased security.
According to some embodiments a method is described for sensing displacement on a subsea structural system. The method includes sensing displacement between a first location on structural element of the subsea structural system and a second location on the structural element, the sensing being based at least in part on a sensing element having a crystalline material substrate. According to some embodiments the crystalline material is sapphire or quartz, and one or more sensor instruments are formed on the substrate so as to detect bending of the sensing element.
According to some embodiments, the subsea structural system is a subsea riser system configured to lift a production fluid from a subsurface wellhead to a surface facility. In some examples, the subsea riser system includes an uplift system, such as buoyancy tank, configured to provide uplift tension on components of the subsea riser system, and the structural element is under tension due to the uplift tension and the sensing of displacement is used to monitor the integrity of the uplift system. According to some embodiments, the sensed displacement is used to determine one or more other properties associated with the structural element such as: force; tension; strain or torque.
According to some embodiments, an alert signal is automatically transmitted to a surface facility when a predetermined threshold value relating to the structural element is met. According to some embodiments the sensing system including the sensing element can be installed on the structural element using an ROV unit.
According to some embodiments, a system for sensing displacement on a subsea structural system is described. The displacement sensing system includes: an elongated frame having a first end and a second end; a first anchoring system mounted to the first end of the frame and configured to fixedly anchor the displacement sensing system to a structural element of the subsea structural system at a first location; a second anchoring system configured to fixedly anchor the displacement sensing system to the structural element at a second location; and a sensing element having a crystalline material substrate with a major longitudinal axis, first and second ends, and at least one sensor instrument formed on the crystalline material substrate configured to sense bending of the sensing element substrate. The sensing element is mounted and configured such that displacement between the first and second locations can be sensed as bending of the sensing element. According to some embodiments the sensor instruments are two independent strain bridge resistors formed on the crystalline material substrate, which can be configured to operate in opposite modes. According to some embodiments, the first and second anchoring systems comprise one or more spikes configured to penetrate the structural element upon installation of the displacement sensing system on the structural element. One or more flexible non-sensing blades can be mounted in parallel with the sensing element to increase physical robustness.
According to some embodiments, a method is described for sensing displacement on a subsea structural system. The method includes: sensing bending of an elongated sensing element having a major longitudinal axis and at least one sensor instrument configured to sense bending of the sensing element; and sensing displacement in a sensed displacement direction between first and second locations on a structural element of the subsea structural system. The displacement sensing is based on the sensed bending of the elongated sensing element. The sensing element is configured and mounted such that the major longitudinal axis is non-parallel to the sensed displacement direction, and such that displacement between the first and second locations is directly transmitted to bending of the sensing element. According to some embodiments, the major longitudinal axis of the sensing element is approximately perpendicular to the sensed displacement direction. According to some embodiments the sensing element is made of a crystalline substrate, and according to some other embodiments the sensing element is made of a polycrystalline material such as a metal or of an amorphous material.
According to some embodiments, a system is described for sensing displacement on a subsea structural system. The displacement sensing system includes: an elongated frame having a first end and a second end; a first anchoring system mounted to the first end of the frame and configured to fixedly anchor the displacement sensing system to a structural element of the subsea structural system at a first location; a second anchoring system configured to fixedly anchor the displacement sensing system to the structural element at a second location; and a sensing element having a major longitudinal axis, first and second ends, and at least one sensor instrument formed thereon configured to sense bending of the sensing element. The sensing element is mounted and configured such that displacement along a sensed displacement direction between the first and second locations can be sensed as bending of the sensing element and such that the major longitudinal axis is non-parallel to the sensed displacement direction. According to some embodiments, the major longitudinal axis of the sensing element is perpendicular, or approximately perpendicular to the sensed displacement direction. According some embodiments, the first end of the sensing element is fixed in rigid relationship with the second end of the frame, and the second end of the sensing element is fixed in rigid relationship with the second anchoring system. According to some other embodiments, one end of the sensing element is fixed and the other end is movably attached, such as by contacting rounded bearing surfaces.
The subject disclosure is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of embodiments of the subject disclosure, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein:
The particulars shown herein are by way of example, and for purposes of illustrative discussion of the embodiments of the subject disclosure only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the subject disclosure. In this regard, no attempt is made to show structural details of the subject disclosure in more detail than is necessary for the fundamental understanding of the subject disclosure, the description taken with the drawings making apparent to those skilled in the art how the several forms of the subject disclosure may be embodied in practice. Further, like reference numbers and designations in the various drawings indicate like elements.
According to some embodiments, a sensor apparatus and method for displacement measurement are described. The measurement is made by bending an instrumented blade equipped with one or several sensing means. The system includes an anchor means that can lock the sensor extremity to the structure being monitored so that any structural deformation or deflexion is directly transmitted to the sensor by bending the instrumented blade. Depending on the interface frame between the sensor with the structural element being monitored, this system can be configured to measure pulling force, torque, bending moments, strain, elongation, internal pipe pressure, and/or any load deformation experienced by a structure. This measurement apparatus can be either ab initio installed for continuous or discrete monitoring and/or can be retrofitted to existing facilities.
Accidental flooding of the buoyancy tank 132 could create a potential hazard to the riser system 130 and expose the field to a risk of catastrophic failure if a sufficient uplift tension is not applied to the vertical pipe system 136. In order to mitigate this risk, instrumentation can be installed to monitor possible accidental flooding of the buoyancy tank 132. Additionally, the buoyancy tank 132, can divided into independent compartments (e.g. vertically stacked or longitudinally) to limit the amount of water that could accidentally fill in the tank.
When buoyancy means, such as buoyancy tank 132, are immersed at depth greater than the conventional depth of human intervention (i.e. greater than 100 meters) the use of Remotely Operated Vehicles (ROVs) allows operations around submersed devices, such as sensor deployment and telemetry plugging.
According to some embodiments, a displacement sensor system 150 is anchored to a structural component of the riser pipe network 130. In the example shown, the displacement sensor system 150 is anchored to section of pipe 250 just below tank 132 just above the flexible joint 138. According to some embodiments, internal or external power means (for example batteries) supply power used by the sensor electronics for signal measurement, and for internal telemetry to relay the information to a piloting system. Although the displacement sensor system 150 is shown anchored to a section of pipe 250 below the buoyancy tank 132 in
In a subsea production system example such as shown in
One typical known approach of monitoring the tension force is by installing a conventional strain measurement system on the pipe section 250 that connects the buoyancy tank to the riser. The strain of the connecting section may be measured by a known technique such as a strain gauge, an optical fiber based strain gauge (FBG), or a LVDT transducer. Ideally, the measured strain should be a proportional representation of the tension force. However, it has been found that the stability of such strain sensors and the possible slip of the clamps that couple the sensors to the structure under monitoring can cause errors and long-term drift in the baseline of the measurement system, often in such magnitudes that can mask significant accumulation of flood water in the tank.
According to some embodiments, an improved strain gauge sensor system 150 provides increased stability and accuracy. One feature of the system 150 is its ability to work under flexion (the measured displacement is perpendicular to the blade). When compared to conventional strain sensor, this configuration provides low stiffness, large amplitude and high sensitivity.
According to some embodiments, the described displacement sensor system includes bending an instrumented blade equipped with one or several sensing means. Examples of the sensing means include one or more Wheatstone bridges that are bonded to the blade. The system further comprises anchor means. The anchor means may include at least one penetrating spike or any other device that can firmly lock the sensor extremity to the structure so that any structural deformation of deflexion is directly transmitted to the sensor by bending the instrumented blade. Depending on the interface frame of the sensor with the structural element, this system can be configured to measure properties such as: pulling force, torque, bending moments, strain, elongation, internal pipe pressure, or any load deformation experienced by a structure.
The anchoring point 340 on the displacement sensor 150 is directly connected to at least one bending sensing blade 300 operating within the elastic domain. The blade 300 is configured to work under flexion. Therefore, as represented in
Providing two flexible blades 332 and 334 has been found to avoid bending of the anchoring point itself to minimize drift in the measurement. The instrumented blade 330 can be instrumented with strain resistors (not shown). According to some embodiments, the sensor blade 300 is a high performance sapphire strain blade, mounted in parallel of the two flexible blades 332 and 334.
According to this configuration, the sensor blade 330 being directly coupled to the anchoring point 340 and linked to the monitored structure 250, has been found to provide several advantages: (1) the mechanical transmission chain of the structure skin movement between the anchoring points and the sensing element are substantially reduced; (2) high sensitivity to small displacements can be provided; (3) the installation is independent of the distance between the anchoring points; as a result the sensor module is very compact and might be easily integrated on any interface frame or collar with the structure to monitor; (4) the distance between the upper and lower anchoring points can be maximized; and (5) sensor packaging can be simplified.
According to some embodiments, the sensor system 150 is integrated with an interface frame other than frame 610 (shown in
While the present invention has been described in connection with a number of embodiments, and implementations, the present invention is not so limited, but rather covers various modifications, and equivalent arrangements, which fall within the purview of the appended claims.
Number | Date | Country | Kind |
---|---|---|---|
12290250 | Jul 2012 | EP | regional |
12189912 | Oct 2012 | EP | regional |
This patent application claims the benefit of U.S. Prov. Ser. No. 61/675,739 filed Jul. 25, 2012; U.S. Prov. Ser. No. 61/729,983 filed Nov. 26, 2012; and U.S. Prov. Ser. No. 61/762,576 filed Feb. 8, 2013, each of which is incorporated by reference herein.
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/IB2013/056078 | 7/24/2013 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2014/016784 | 1/30/2014 | WO | A |
Number | Name | Date | Kind |
---|---|---|---|
3853000 | Barnett et al. | Dec 1974 | A |
4505018 | Regalbuto | Mar 1985 | A |
5065631 | Ashpitel | Nov 1991 | A |
5099700 | Morin et al. | Mar 1992 | A |
20080303382 | Edwards, Jr. | Dec 2008 | A1 |
20110259115 | Roberts et al. | Oct 2011 | A1 |
Number | Date | Country | |
---|---|---|---|
20150211968 A1 | Jul 2015 | US |
Number | Date | Country | |
---|---|---|---|
61762576 | Feb 2013 | US | |
61729983 | Nov 2012 | US | |
61675739 | Jul 2012 | US |