Offloading Hydrocarbons from Subsea Fields
20210148173 · 2021-05-20
Inventors
Cpc classification
B63B22/021
PERFORMING OPERATIONS; TRANSPORTING
B63B2022/028
PERFORMING OPERATIONS; TRANSPORTING
E21B17/017
FIXED CONSTRUCTIONS
International classification
Abstract
A subsea hydrocarbon export system includes a riser tower having a riser column extending from a seabed location to a sub-surface buoy that supports the riser column in an upright orientation. A subsea connector is operable underwater to couple the riser column temporarily to a hose suspended from a surface shuttle tanker vessel for an export operation and to release the hose after the export operation.
Claims
1-46. (canceled)
47. A subsea hydrocarbon export system, comprising: a riser tower having a column extending from a seabed location to a sub-surface buoy that supports the column in an upright orientation, wherein the column communicates with a subsea tank for storing hydrocarbon fluids and with a subsea processing system for processing hydrocarbon fluids; and a subsea connector that is operable underwater to couple the column temporarily to a hose suspended from a surface shuttle tanker vessel for an export operation and to release the hose after the export operation; wherein the subsea connector comprises an upwardly-facing socket at an upper extremity of the column for receiving a plug connector of the hose.
48. The system of claim 47, wherein the subsea tank serves as a foundation for the riser tower.
49. The system of claim 47, further comprising a subsea pump for pumping hydrocarbon fluids up the column to the subsea connector.
50. The system of claim 47, wherein the column extends through the buoy.
51. The system of claim 47, wherein the buoy surrounds an upper end portion of the column.
52. The system of claim 51, wherein the buoy comprises shell elements assembled together around the upper end portion of the column.
53. The system of claim 47 wherein the column comprises a connection between a major lower section and a minor upper section, the buoy being attached to the upper section of the column.
54. The system of claim 47, comprising at least one laterally-projecting male formation on the column, which formation is engaged with a female interlocking formation of the buoy.
55. The system of claim 54, wherein the male formation surrounds the column.
56. The system of claim 54, wherein the male formation is formed integrally with the column.
57. The system of claim 47, wherein the buoy comprises a sleeve fixed to and surrounding the column.
58. The system of claim 57, further comprising an upper cross-member extending laterally from the sleeve, which cross-member supports one or more lifting points.
59. The system of claim 58, wherein the upper cross-member also supports one or more attachment points for the attachment of at least one clump weight.
60. The system of claim 58, wherein one or more buoyant elements of the buoy bear against an underside of the upper cross-member to apply buoyant upthrust to the upper cross-member in use.
61. The system of claim 57, further comprising a lower cross-member extending laterally from the sleeve.
62. The system of claim 61, wherein the lower cross-member supports one or more attachment points for the attachment of at least one clump weight.
63. The system of claim 61, wherein one or more buoyant elements of the buoy rest upon the lower cross-member.
64. The system of claim 47, wherein a bend restrictor is attached to the buoy and extends along and around the column under the buoy.
65. The system of claim 47, further comprising at least one clump weight releasably attached to the buoy.
66. The system of claim 65, wherein the or each clump weight comprises a chain.
67. The system of claim 65, wherein the or each clump weight is a rigid structure attachable to the buoy.
68. The system of claim 47, wherein the buoy comprises one or more external tubes or sockets that open upwardly to receive at least one clump weight.
69. The system of claim 47, wherein the buoy comprises non-floodable buoyancy.
70. The system of claim 69, wherein the buoy comprises rigid buoyant foam or macrospheres.
71. The system of claim 47, wherein the hose is a bonded polymer composite hose.
72. The system of claim 47, wherein the hose is longitudinally flexible and comprises a rigid guide structure at a distal end of the hose.
73. The system of claim 47, wherein the column is of pipe that can be wound onto a reel or carousel onboard an installation vessel, without substantial plastic deformation of the pipe.
74. The system of claim 47, wherein the column is of bonded polymer composite pipe.
75. The system of claim 47, wherein the column is of material that is substantially neutrally buoyant in sea water.
76. The system of claim 47, wherein the hose is connected to the column at a depth of between 30 m and 200 m underwater.
77. A method of exporting hydrocarbon fluids from a seabed location, the method comprising: sailing a shuttle tanker vessel to a surface export location above a column that extends from the seabed location and communicates with a subsea tank for storing the hydrocarbon fluids to a sub-surface buoy, which buoy supports the column in an upright orientation; suspending a hose from the vessel to reach the column; operating a subsea connector underwater to couple the hose temporarily to the column for an export operation by inserting a plug connector of the hose into an upwardly-facing socket at an upper extremity of the column; during the export operation, causing hydrocarbon fluids to flow from the seabed location up the column and along the coupled hose to the vessel; and on completion of the export operation, releasing the hose from the column by removing the plug connector of the hose from the upwardly-facing socket, lifting the hose to the vessel and sailing the vessel away from the surface export location.
78. The method of claim 77, comprising storing the hydrocarbon fluids at the seabed location before the export operation.
79. The method of claim 77, comprising processing the hydrocarbon fluids at the seabed location before or during the export operation.
80. The method of claim 77, comprising pumping the hydrocarbon fluids at the seabed location during the export operation to flow up the column.
81. A method of installing a subsea hydrocarbon export system, the method comprising: lowering a major lower section of a column into water beneath an installation vessel; suspending the lower section from the installation vessel; positioning a buoy and a minor upper section of the column over the suspended lower section; joining the upper section to the lower section to complete the column; and lowering the buoy and the completed column into the water beneath the installation vessel to anchor a lower end of the column to a subsea facility comprising a subsea tank for storing hydrocarbon fluids at a seabed location, the buoy then being at a sub-surface location.
82. The method of claim 81, comprising unwinding the lower section of the column from shipboard storage while launching the lower section into the water.
83. The method of claim 81, comprising raising the buoy and the upper section from a stowed position on the installation vessel into an upright orientation when positioning them over the suspended lower section.
84. The method of claim 81, comprising: adding ballast to the buoy before lowering the buoy and the completed column into the water beneath the installation vessel; and removing the added ballast from the buoy after anchoring the lower end of the column at the seabed location.
85. The method of claim 84, comprising attaching one or more clump weights to the buoy to add the ballast and then removing the or each clump weight from the buoy to remove the added ballast.
86. The method of claim 85, comprising attaching the or each clump weight to the buoy at a level beneath a mid-point of the buoy.
87. The method of claim 86, comprising attaching the or each clump weight to a lower end region of the buoy.
88. The method of claim 85, comprising attaching the or each clump weight to an upper end region of the buoy.
89. The method of claim 85, comprising inserting at least part of a clump weight into an upwardly-opening external tube or socket on the buoy.
Description
[0051] 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:
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[0076] Referring firstly to
[0077] For this purpose, a riser tower 20 extends upwardly from the subsea facility 12 to an upper end beneath the surface 18. The riser tower 20 comprises a composite riser pipe 22 that is kept upright and under tension by a buoy 24 at or near to its upper end.
[0078] Conveniently, in this example, the riser tower 20 is anchored by the weight of the subsea facility 12. However, other well-known foundation arrangements such as weights or piles could be used to anchor the riser tower 20 to the seabed 14 instead.
[0079] The upper end of the riser pipe 22 includes interface features for mating with, and fluid connection to, a flexible hose 26 that hangs under the surface 18 from the tanker 16. When the hose 26 is engaged with the riser pipe 22 in this way, fluid communication is effected between the subsea facility 12 and the tanker 16 via the riser pipe 22 and the hose 26.
[0080] The interface features shown here at the upper end of the riser pipe 22 comprise an upwardly-facing socket 28 that receives a plug connector 30 on the free end of the hose 26. However, it would be possible to have alternative interface features, such as a plug connector on the upper end of the riser pipe 22 that mates with a socket at the end of the hose 26.
[0081] In this example, the buoy 24 surrounds a short upper section 22U of the riser pipe 22 that implements the interface features at the upper end of the riser pipe 22. A flange connection 32 joins the upper section 22U end-to-end to a much longer lower section 22L of the riser pipe 22. The lower section 22L may extend from the connection 32 all the way down through the water column to the subsea facility 12.
[0082] Within the buoy 24, the upper section 22U of the riser pipe 22 is surrounded by a fixed tubular sleeve 34 in concentric, telescopic relation. The buoy 24 further comprises a tubular buoyant body 36 that surrounds the sleeve 34. The buoyant body 36 may comprise one or more hollow chambers, may be formed of rigid buoyant material such as syntactic foam or may comprise a mass of rigid buoyant macrospheres, depending upon the hydrostatic pressure expected at the operational depth
[0083] The buoyant body 36 bears against an upper cross-member 38 that is fixed to the sleeve 34 above the buoy 24. Consequently, buoyant upthrust of the buoyant body 36 exerted via the upper cross-member 38 and the sleeve 34 imparts tension in the riser pipe 22. The sleeve 34 and the upper cross-member 38 are suitably of steel and so are apt to be welded together.
[0084] In this example, the buoyant body 36 comprises shells 40 of part-circular cross-section that are brought together and fixed together as an annulus, for example by clamping under tension applied to external straps, closely to encircle the sleeve 34 and the upper section 22U of the riser pipe 22 within the sleeve 34. In this example, there are two sets of shells 40 stacked one above the other. There could be only one such set of shells 40 or more than two such sets of shells 40.
[0085] In addition to the upper cross-member 36, the shells 40 are located against axial movement along the riser pipe 22 by engagement of locating formations on an inner side of each shell 40 with complementary locating formations on an outer side of the sleeve 34. The locating formations are exemplified here by male formations on the sleeve 34 that engage with female formations of the shells 40. Specifically, axially-spaced collars 42 encircle the sleeve 34 to engage with grooves on an inner side of each shell 40.
[0086] The collars 42 may be attached to the sleeve 34 by welding, clamping and/or by bonding. Alternatively the sleeve 34 could be omitted. In that case, the collars 42 may be clamped or bonded directly to the riser pipe 22 or could be formed integrally with the riser pipe 22 by locally thickening the wall of the riser pipe 22 to increase its external diameter.
[0087] An optional bend restrictor 44 surrounds the upper section 22U of the riser pipe 22 immediately beneath the buoy 24. Conveniently, the bend restrictor 44 is attached to the underside of the buoy 24 and tapers downwardly as shown here. However, as will be explained, other bend restrictor arrangements are possible.
[0088] With reference to
[0094] Reference is now made to
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[0096] The upwardly-facing socket 28 at the upper end of the riser pipe 22 is shown in
[0097] The enlarged view of
[0098] The further enlarged sectional view of
[0099] The socket 28 is defined by a tubular steel funnel 54 fixed to the top of the sleeve 34. The funnel 54 is stiffened by radial webs 56 and is surrounded by a tubular upper housing 58. The funnel 54 and the plug connector 30 have complementary frusto-conical mating surfaces that guide those parts into mutual alignment as the plug connector 30 moves downwardly.
[0100] The upper section 22U of the riser pipe 22 is shown here extending concentrically within the sleeve 34 and protruding from the sleeve 34 into the funnel 54. The protruding end of the riser pipe 22 is surrounded by a steel collar 60. When the plug connector 30 engages within the funnel 54, the collar 60 is received in a complementary recess 62 in a distal end face of the plug connector 30.
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[0103] The lower cross-member 66 provides a connection point for the attachment of clump weights as will be explained later with reference to
[0104] The lower cross-member 66 may also have another function, namely to provide an attachment point for the bend restrictor 44. In this respect,
[0105] Turning next to
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[0109] Once the riser tower 20 has been anchored to the subsea facility 12 or to another foundation on the seabed 14, the chains 88 are removed so that the buoyant upthrust of the buoy 24 can apply the necessary tension to the riser pipe 22. Depending upon the water depth, divers or an ROV may be used to attach the chains 88 to suitable lifting lines and to release the chains 88 at the appropriate time for recovery to the surface. The lower end of the chain 88 is lifted and then the upper end of the chain 88 is disconnected from the hanging padeyes 70 below the buoy 24.
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[0111] Moving on now to
[0112] The installation vessel 96 has a working deck 98 that supports a carousel 100 on which the major lower section 22L of the riser pipe 22 can be wound or spooled. In this respect, it will be noted that the composite riser pipe 22 has some flexibility to be bent elastically along its length if a sufficiently large minimum bend radius is observed. In principle, a reel with a horizontal axis could be used instead of a carousel to carry the lower section 22L of the riser pipe 22.
[0113] The lower section 22L of the riser pipe 22 is unspooled from the carousel 100 through a spooler 102 on the working deck 98 beside the carousel 100 and then is overboarded into the sea along a chute 104. At this stage, a tensioner 106 upstream of the chute 104 carries the weight load of the launched portion of the lower section 22L.
[0114] Once the lower section 22L of the riser pipe 22 has been fully unspooled from the carousel 100 and lowered into the sea, its weight load is transferred to a crane 108 on the working deck 98. As best shown in
[0115] The working deck 98 supports a frame 114 that in turn supports the upper section 22U of the riser pipe 22 surrounded by the buoy 24. The frame 114 is shown here in a horizontal stowed position but can be pivoted about a horizontal axis into a vertical installation position. This pivoting movement upends the upper section 22U and the buoy 24 and brings them into alignment with the vertical axis of the lower section 22L hung off from the hang-off structure 112 below. It also brings a bottom flange part 116 of the upper section 22U into alignment with the top flange part 110 of the lower section 22L. The top and bottom flange parts 110, 116 can then be bolted together.
[0116] When united in this way, the top flange part 110 of the lower section 22L and the bottom flange part 116 of the upper section 22U together form the aforementioned flange connection 32 between the upper and lower sections 22U, 22L. This completes the full length of the riser pipe 22.
[0117] The crane 108 can now take the load of the riser tower 20 comprising the riser pipe 22 and the buoy 24 by attaching lifting lines to the lifting padeyes 48 shown in preceding figures. Clump weights are attached to the buoy 24 using the hanging padeyes 70 also shown in the preceding figures. This added ballast overcomes the buoyancy of the buoy 24 and allows the crane 108 to lower the riser tower 20 to the required depth. When the bottom end of the riser pipe 22 has been anchored to the subsea facility 12 or other subsea foundation, the clump weights can be removed from the buoy 24 and recovered to the surface by the crane 108.
[0118] Reference is now made to
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[0120] In
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[0122] Also, clump weights exemplified here by chains 88 have been attached to the lower end of the buoy 24.
[0123] The added ballast of the chains 88 overcomes the buoyancy of the buoy 24 and allows the crane 108 to lower the riser tower 20 to the required depth in the water as shown in
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[0125] In
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[0127] Whilst the solid clump weights 122 allow for the addition of ample ballast,
[0128] The chains 88 shown in
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[0130] Finally,
[0131] A frame 130 at the bottom of the buoy 24 supports an array of upwardly-opening buckets or sockets 132 that are equi-angulary spaced around the central vertical axis of the buoy 24.
[0132] Part-circular solid clump weights 128 are assembled together as a lifting ring or flange that encircles the buoy 24. In this case, there are two semi-circular clump weights 128.
[0133] Each clump weight 128 has attachment points 134 on its upper side to allow lifting lines 136 to be attached. Each clump weight 128 also has angularity-spaced pins 138 on its underside that are spaced to align with and engage into the sockets 132. In this example, there are four sockets 132 and therefore each of the two clump weights 128 has two pins 138.
[0134] On each clump weight 128, one pin 138 is preferably longer than the other pin 138 as shown. This allows the longer pin 138 to be engaged with its socket 132 first and then to serve as a pivot that helps to guide the shorter pin 138 into an adjacent socket 132.
[0135] The clump weights 128 can be installed onto the frame 130 of the buoy 24 or removed from the frame 130 together as shown in
[0136] As in some preceding embodiments, locating the clump weights 128 near the bottom end of the buoy 24 improves stability by lowering the centre of gravity or centre of buoyancy and by decreasing rotational moments.