Installing Subsea Risers

Abstract

An end fitting for a subsea riser comprises an engagement head to be engaged with a subsea foundation in a vertically downward longitudinal direction. A structure of the end fitting surrounds a longitudinally extending flow axis and is arranged to bear a tensile load on a load path extending longitudinally from the engagement head parallel to the flow axis. The structure includes a pivot joint assembly having a first part attached to or integral with the engagement head and a second part pivotable relative to the first part about a centre of rotation substantially aligned with the flow axis. The structure can be fixed to the engagement head or removably attached to the engagement head. The engagement head supports an upwardly facing connector hub that is offset laterally from the flow axis. A connector pipe in fluid communication with the connector hub extends from the flow axis to the connector hub. A counterweight is opposed to the connector hub and the connector pipe about the flow axis.

Claims

1. An end fitting for a subsea riser, the end fitting comprising: an engagement head that is arranged to be engaged with a subsea foundation in a longitudinal engagement direction; a structure surrounding a longitudinally extending flow axis, which structure is arranged to bear a tensile load on a load path that extends longitudinally from the engagement head in parallel to the flow axis, wherein the structure includes a pivot joint assembly having a first part that is attached to or integral with the engagement head and a second part that is pivotable relative to the first part about a centre of rotation that is substantially aligned with the flow axis; a connector hub that is offset laterally from the flow axis; a connector pipe in fluid communication with the connector hub, which pipe extends from the flow axis to the connector hub; and a counterweight that is opposed to the connector hub and the connector pipe about the flow axis; wherein the engagement head is configured to support the connector hub, the connector pipe and the counterweight.

2. The end fitting of claim 1, wherein the connector hub faces in a direction opposed to the engagement direction.

3. The end fitting of claim 1, wherein the connector hub faces in a direction substantially parallel to the flow axis.

4. The end fitting of claim 1, wherein the connector pipe is substantially U-shaped, defining a first limb that is aligned with the connector hub and a second limb that is aligned with the flow axis.

5. The end fitting of claim 1, wherein the connector hub and the counterweight are located within a substantially matching pair of funnel formations.

6. The end fitting of claim 5, wherein the pair of funnel formations is substantially bisected by a central plane that contains the flow axis.

7. The end fitting of claim 1, attached to a riser conduit that is coaxial with the flow axis.

8. The end fitting of claim 7, wherein the riser conduit extends along the flow axis through the structure.

9. The end fitting of claim 1, wherein the structure is removably connectable to the engagement head.

10. The end fitting of claim 9, wherein the structure is connectable to the engagement head by a subsea connector comprising complementary connector elements that surround the flow axis when inter-engaged.

11. The end fitting of claim 10, wherein the engagement head and the structure comprise complementary guide parts that are spaced laterally from the flow axis and that are inter-engageable along an alignment axis that extends parallel to the flow axis.

12. The end fitting of claim 11, wherein the guide parts have complementary helical orientation formations that are arranged to move one of the connector elements into alignment with the other of the connector elements on the flow axis.

13. The end fitting of claim 1, wherein the first and second parts of the pivot joint assembly are joined by a universal joint or a flexible joint.

14. A subsea riser comprising an end fitting of claim 1.

15. The riser of claim 14, comprising a riser conduit of composite pipe or flexible pipe.

16. The riser of claim 14, when engaged with the subsea foundation and with the flow axis of the end fitting in a substantially vertical orientation.

17. An engagement head for a subsea riser, the engagement head being arranged to be engaged with a subsea foundation in a longitudinal engagement direction and comprising: a connector hub that is offset laterally from a central longitudinally extending flow axis; a connector pipe in fluid communication with the connector hub, which pipe extends from the flow axis to the connector hub; and a counterweight that is opposed to the connector hub and the connector pipe about the flow axis; further comprising a pivot joint assembly having a first part that is attachable to or integral with the engagement head and a second part that is pivotable relative to the first part about a centre of rotation that is substantially aligned with the flow axis.

18. The engagement head of claim 17, wherein the connector hub and the counterweight are disposed substantially symmetrically about the flow axis.

19. The engagement head of claim 17, wherein the connector hub and the counterweight are located within respective funnel formations.

20. A method of installing a subsea riser, comprising: lowering the riser toward a seabed foundation with at least a bottom end portion of the riser in a substantially vertical orientation; in an engagement head at a bottom end of the riser, counterbalancing the weight of a connector hub that is offset laterally from a flow axis extending substantially vertically through the engagement head and the weight of a connector pipe that extends from the flow axis to the connector hub; suspending the engagement head while allowing a conduit of the riser to pivot relative to the engagement head away from alignment with the flow axis that extends through the engagement head; and mechanically engaging the engagement head with the seabed foundation.

21. The method of claim 20, comprising moving the engagement head into engagement with the seabed foundation in a substantially vertical engagement direction.

22. The method of claim 20, comprising counterbalancing hydrodynamic forces that act on a guide funnel around the connector hub while lowering the riser, which forces are offset laterally from the flow axis that extends through the engagement head.

23. A method of installing a subsea riser, comprising: lowering an engagement head while counterbalancing the weight of a connector hub that is offset laterally from a flow axis extending substantially vertically through the engagement head and the weight of a connector pipe that extends from the flow axis to the connector hub; mechanically engaging the engagement head with the seabed foundation; coupling a riser conduit to the engagement head engaged with the foundation; and allowing the riser conduit to pivot relative to the engagement head away from alignment with the flow axis that extends through the engagement head.

24. The method of claim 23, comprising guiding the riser conduit onto the flow axis that extends through the engagement head by inter-engaging complementary guide parts of the engagement head and of the riser conduit.

25. The method of claim 20, comprising supporting the connector hub in a substantially vertical orientation when the engagement head is engaged with the foundation.

26. The method of claim 23, comprising supporting the connector hub in a substantially vertical orientation when the engagement head is engaged with the foundation.

Description

[0049] In order that the invention may be more readily understood, reference will now be made, by way of example, to the accompanying drawings in which:

[0050] FIG. 1 is a side view of a riser system of a subsea installation for the production of oil and gas;

[0051] FIG. 2 is a schematic part-sectional side view of one of the risers of the system shown in FIG. 1, showing details of a bottom connector of the invention;

[0052] FIG. 3 corresponds to FIG. 2 and shows the bottom connector in the water column approaching a subsea foundation to which the bottom connector is shown attached in FIG. 2; and

[0053] FIG. 4 is a schematic part-sectional side view of a variant of the bottom connector shown in FIGS. 2 and 3.

[0054] FIG. 1 shows part of a riser system 10 of a subsea installation for the production of oil and gas. The riser system 10 extends from the seabed 12 to the surface 14, where it connects to a surface installation that is exemplified here as an FPSO 16. The FPSO 16 is held in position at the surface 14 by conventional spread moorings 18.

[0055] In practice, the riser system 10 will comprise multiple risers 20 but only two of those risers 20 are shown in the simplified view of FIG. 1, opposed symmetrically about a vertical central plane that intersects the FPSO 16. Each riser 20 comprises a conduit 22 of lightweight, buoyant pipe such as TCP and has a bottom connector 24 of the invention at its base that connects the riser 20 to the seabed 12 via a respective foundation 26. FIG. 1 also omits subsea flowlines that, in practice, will extend across the seabed 12 to connect with the base of each riser 20 through its bottom connector 24.

[0056] To allow for heave of the FPSO 16, buoyancy 28 is added at an intermediate location along the length of each riser 20 to confer a curved compliant shape on the riser 20. In this example, the risers 20 have a CVAR configuration. Other riser configurations such as a Steep Wave configuration are possible, or any other configuration in which a riser is connected to the seabed 12 under tension through a bottom connector 24.

[0057] The bottom connector 24 of a riser configuration like CVAR is at a bottom end portion of the riser 20 whose orientation is upright and typically is substantially vertical. In this respect, it will be noted that the bottom end portions of the risers 20 in FIG. 1 are upright but are pulled away from a perfectly vertical axis by their asymmetric shape and by tension between the upthrust of the FPSO 16 and the buoyancy 28 acting against the reaction force of their foundations 26.

[0058] It is known to construct risers with configurations like these from rigid steel pipe. However, where a riser 20 is of a lightweight pipe such as TCP, aligning and coupling the bottom connector 24 with the foundation 26 becomes more challenging. Alignment is particularly problematic where, as here, the bottom connector 24 has asymmetric pipework to simplify fluid coupling to a subsea flowline that extends across the seabed 12 from a subsea well or other subsea installation.

[0059] Turning next to FIG. 2, this shows one of the risers 20 of FIG. 1 and is not to scale. A first embodiment of a bottom connector 24 of the invention is shown at the base of the riser 20.

[0060] A series of buoyancy modules 28 attached to the riser 20 imparts the desired compliant shape to the riser 20. Upper buoyancy modules 28 of the series are typically smaller than lower buoyancy modules 28 of the series as shown.

[0061] At its base, the bottom connector 24 connects the riser 20 to a pre-installed permanent subsea foundation shown in dashed lines, exemplified here as a suction pile 26. Most of the suction pile 26 is embedded in the seabed 12 but a minor upper portion of the suction pile 26 protrudes above the seabed 12 and is surrounded by a horizontally-projecting mudmat 30 that sits on the seabed 12.

[0062] The suction pile 26 is also surmounted by an integral hollow guide base 32 that serves as a close-fitting complementary interface with the bottom connector 24. The guide base 32 comprises an upwardly-opening tubular socket 34 and a downwardly-tapering guide formation 36 that flares upwardly and outwardly from the top of the socket 34.

[0063] The bottom connector 24 comprises an engagement head 38 that hangs beneath a pivot joint assembly 40 to engage within the socket 34 of the guide base 32. The engagement head 38 and the pivot joint assembly 40 are aligned on, and are substantially symmetrical about, a common central longitudinal axis 42. The riser conduit 22 extends within the pivot joint assembly 40 along the central longitudinal axis 42 between an upper end of the bottom connector 24 and the engagement head 38.

[0064] The engagement head 38 tapers downwardly to cooperate with the similarly-inclined guide formation 36 of the foundation 26. The cooperation between those parts aligns the engagement head 38 with the socket 34 on a common axis, in particular the central longitudinal axis 42, as the bottom connector 24 is lowered substantially vertically toward engagement with the foundation 26. Correct azimuthal orientation between the engagement head 38 and the socket 34 is assured by orientation pins 44 that project laterally from the engagement head 38 to engage with complementary upwardly-opening guide slots of the socket 34.

[0065] When the engagement head 38 is fully engaged within the socket 34 on the correct azimuth, a lock pin 46 at the downward extremity of the engagement head 38 is engaged with a complementary recess 48 at the base of the socket 34. This locks the bottom connector 24 and hence the riser 20 to the suction pile 26.

[0066] On its upper side, the engagement head 38 has matching frusto-conical funnels 50, 52 that are diametrically opposed to each other about, and with equal spacing from, the central longitudinal axis 42. The funnels 50, 52 flare and open upwardly.

[0067] A first funnel 50 serves as a guide to facilitate subsea fluid coupling with an upwardly-facing API connector hub 54 at the base of the funnel 50. The connector hub 54 is at the free end of an upwardly-extending limb of a steel U-shaped pipe 56 within the engagement head 38. Advantageously, the connector hub 54 provides for direct connection to a subsea flowline without requiring an intermediate jumper pipe to connect to the flowline. In this example, the connector hub 54 is on a substantially vertical axis when the engagement head 38 is engaged with the socket 34.

[0068] The U-shaped pipe 56 is in fluid communication with the riser conduit 22. The connector hub 54 and most of the U-shaped pipe 56 are offset laterally from the central longitudinal axis 42, although an upwardly-extending limb of the U-shaped pipe 56 opposed to the connector hub 54 lies on the central longitudinal axis 42.

[0069] The other, second funnel 52 serves as a receptacle for a complementarily-shaped counterweight 58 to counterbalance the laterally-offset weight of the connector hub 54 and the U-shaped pipe 56 about the central longitudinal axis 42. Also, by virtue of being of similar size and shape to the first funnel 50, the second funnel 52 is a dummy counterpart of the first funnel 50. This balances the first funnel 50 hydrodynamically as the engagement head 38 moves through the water column toward the foundation 26 and as ocean currents flow past the engagement head 38.

[0070] With reference now also to FIG. 3, the counterweighted dummy second funnel 52 ensures that the engagement head 38 hangs substantially vertically from the pivot joint assembly 40 in a fully-balanced manner, despite any deflection of the remainder of the riser conduit 22 above the pivot joint assembly 40. This orientation promotes simple and reliable engagement between the engagement head 38 and the guide base 32. Thereafter, the pivot joint assembly 40 allows the remainder of the riser 20 to sway about the foundation 26 in response to ocean currents.

[0071] The pivot joint assembly 40 comprises upper and lower steel tubes 60, 62 that surround the riser conduit 22 and are joined end-to-end by a gimbal joint 64. The upper tube 60 is surmounted by a steel flange 66 that anchors a taper joint 68. The taper joint 68 tapers upwardly from the flange 66 and surrounds and is attached to, or is integral with, the riser conduit 22. The lower tube 62 is rigidly attached to the engagement head 38 by a steel end fitting 70 of the riser conduit 22 that is joined to the U-shaped pipe 56 at a welded joint 72. Tensile loads between the riser 20 and the suction pile 26 are carried by the upper and lower tubes 60, 62 and the gimbal joint 64 on a load path that bypasses the riser conduit 22 extending within the pivot joint assembly 40.

[0072] The gimbal joint 64 defines multiple pivot axes that extend orthogonally through the central longitudinal axis 42 to define a centre of rotation 74, enabling the base of the riser 20 to pivot freely relative to the suction pile 26 as the remainder of the riser conduit 22 deflects in response to ocean currents. The base of the riser 20 is free to pivot within an inverted conical volume 76 whose apex is at the centre of rotation 74.

[0073] Various universal joint arrangements are possible for the gimbal joint 64, such as a simple Hooke-type joint in which U-shaped yokes or forks are offset angularly by 90° about the central longitudinal axis 42. In that well-known arrangement, the forks are connected by a cross-shaped link that can pivot relative to the forks and that defines mutually-orthogonal pivot axes about which the respective forks can pivot. The riser conduit 22 can extend through a central opening in the link or can be diverted, curved or kinked to extend around the link, between the link and the forks. The latter option is preferred as a diversion lengthens the riser conduit 22 locally and allows for the riser conduit 22 to be shaped with a stress-relieving formation that promotes flexing of the riser conduit 22 around the centre of rotation 74.

[0074] By way of example, the upper and lower tubes 60, 62 may be about 6 m long so that the pivot joint assembly 40 is about 12 m long overall. The engagement head 38 may be about 3 m long from the tip of the lock pin 46 at the bottom to the top of the connector hub 54 positioned within the first funnel 50.

[0075] FIG. 4 shows a second embodiment of the bottom connector 24 that has several features in common with the first embodiment of the bottom connector 24 shown in FIGS. 2 and 3. Like numerals are therefore used for like features.

[0076] In the variant shown in FIG. 4, the pivot joint assembly 40 and the remainder of the riser 20 are separably coupled to the engagement head 38. This allows the engagement head 38 to be pre-installed in the guide base 32 atop the suction pile 26 and for the pivot joint assembly 40 and the remainder of the riser 20 to be coupled to the engagement head 38 in a subsequent operation. That operation is shown in progress in FIG. 4. Conversely, it is also possible to separate the pivot joint assembly 40 and the remainder of the riser 20 from the engagement head 38 while leaving the engagement head 38 coupled mechanically with the guide base 32 on the seabed 12.

[0077] The variant of FIG. 4 also differs from the arrangement shown in FIGS. 2 and 3 in that the pivot joint assembly 40 comprises a flexible joint 78 instead of a gimbal joint. The flexible joint 78 also defines a centre of rotation 74 and so allows the base of the riser 20 to pivot freely relative to the suction pile 26 within an inverted conical volume 76 as the remainder of the riser conduit 22 deflects in response to ocean currents.

[0078] A flange 80 under the flexible joint 78 joins a subsea connector 82 to the flexible joint. In this example, the connector 82 is a downwardly-opening female connector 82 that complements an upwardly-facing male connector 84 extending along the central longitudinal axis 42 atop the engagement head 38. The male connector 84 engages within the female connector 82 when the pivot joint assembly 40 is lowered onto the engagement head 38. The male and female connectors 80, 82 thereby serve as a re-entry interface that effects fluid communication between the connector hub 54 and the riser conduit 22 via the U-shaped pipe 56.

[0079] Alignment of the female connector 82 with the male connector 84 on the central longitudinal axis 42 is assured by an orientation system that comprises an upwardly-extending guide post 86 on the engagement head 38. The guide post 86 is offset laterally to one side of, and extends parallel to, the central longitudinal axis 42. A complementary re-entry funnel 88 attached to the female connector 82 is, correspondingly, offset laterally to one side of, and extends parallel to, the central longitudinal axis 42. In particular, the guide post 86 and the re-entry funnel 88 are offset laterally to the same extent relative to the central longitudinal axis 42. The re-entry funnel 88 flares downwardly to admit the top of the guide post 86 as the pivot joint assembly 40 is lowered onto the engagement head 38.

[0080] Further lowering of the re-entry funnel 88 along the guide post 86 engages a helical orientation formation 90 of the guide post with a complementary formation within the re-entry funnel. This turns the re-entry funnel 88 about the guide post 86, swinging the female connector 82 about the guide post 86 into axial alignment with the male connector 84 on the central longitudinal axis 42, until the re-entry funnel 88 engages with a key 92 at the bottom of the orientation formation 90. With axial alignment between the male and female connectors 82, 84 thereby assured, the re-entry funnel 88 slides down the guide post 86 as the pivot joint assembly 40 is lowered fully onto the engagement head 38 until the male and female connectors 82, 84 are fully engaged. Once the inter-engaged male and female connectors 82, 84 are sealed to each other, they define a flow path extending between them that is in fluid communication with the connector hub 54, via the U-shaped pipe 56, and with the riser conduit 22.

[0081] Many other variations are possible within the inventive concept. For example, a bottom connector of the invention may be used with other lightweight pipes such as unbonded flexible pipe. A length of bonded or unbonded flexible pipe may extend along the bottom connector and in particular through or around the centre of rotation where the parts of the connector can pivot relative to each other.