MODULAR SUBSEA EQUIPMENT, SUBSEA DISTRIBUTION EQUIPMENT, SUBSEA DISTRIBUTION EQUIPMENT ASSEMBLY AND REPAIR

Abstract

The present invention deals with the modularization of SDA components, as well as the assembly, installation, and repair thereof. The blocks (10) have a metallic structure (11) and panels (13) that allow the configuration for several equipment, in such a way that both the hydraulic instrumentation and the electrical instrumentation are also modularized. Modularization, according to the present invention, allows the configuration assembly of equipment (40) and (50) on the vessel (85), thus reducing costs in relation to installations of the art. In addition, the equipment is already installed with the umbilicals connected, which allows the modularization to be carried out using the crane (83) of the vessel (85) or even a buoy (95).

Claims

1. MODULAR SUBSEA EQUIPMENT, characterized in that it comprises: a structure (10) comprising a metallic structure (11), wherein the metallic structure (11) includes panels (13) on its lateral, lower and upper surface and the block (10) further comprises at one end a panel (16), said panel (16) having a hole (15) for installing the umbilical connector; a pipe mat (19) located inside the block (10), wherein the pipe mat (19) comprises parallel pipes (20), wherein the parallel pipes (20) have connectors (21), in which said connectors (21) connect to pipes of the MQCs (14) and Logic Caps (28) and (29) that are located on the surface of the structure (10); an electrical control of the electrical instrumentation is modularized inside the structure (10), which has QUADs comprising junction boxes, electrical connectors (32) and Field Assembled Cable Termination (FACTs) (31), wherein the electrical connectors (32) connect to the inlet and oulet umbilicals.

2. EQUIPMENT, according to claim 1, characterized in that the structure (10) comprises an eye (12) or a flange gasket (55 and 56).

3. EQUIPMENT, according to claim 1, characterized in that the panel has a hole (15) or not.

4. SUBSEA DISTRIBUTION EQUIPMENT comprising a modular equipment described in claims 1-3, characterized in that it comprises blocks (42) and (43), wherein block (42) has, at its end, a STI (44) which is connected to an umbilical cable (35), block (43) has, at its end, a STI (45) which is connected to an umbilical cable (36), said blocks (42) and (43) are connected by a UTAJ (46); said blocks (42) and (43) having a pin (66) on the their lower portion, the subsea distribution equipment (40) further comprising a foundation (47), said foundation (47) comprising a funnel (66).

5. SUBSEA DISTRIBUTION EQUIPMENT comprising a modular equipment described in claims 1-3, characterized in that it comprises blocks (51) and (52), wherein block (51) has, at its end, a STI (53) which is connected to a umbilical cable (35), block (52) has, at its end, a STI (54) which is connected to an umbilical cable (36), block (51) comprises, at the end opposite the STI (53), a female connector (55) and the block (52) comprises a male connector (56), said blocks (51) and (52) are connected by the female connector (55) and the male connector (56), said blocks (51) and (51) are connected to a foundation (57) by screwed gaskets (58).

6. SUBSEA DISTRIBUTION EQUIPMENT ASSEMBLY comprising an equipment described in claim 4, characterized in that it is performed on the deck of the vessel (85) and comprises the following steps: a) transporting the block (43) from the spool using a gutter (81), tensioners (82) and a crane (83) of the vessel (85), wherein said block (43) is transported to the hang-off collar (96) of the vessel (85); said block (43) being connected to the umbilical cable (35); b) after the block (43) arrives at the hang-off collar (96), transporting the block (42) and then installing the eye joint (90), and the transport of the block (42) is performed; c) the eye joint (90) being installed, the eyes (12) of the blocks (42) and (43) are aligned and brought together so that the eyes (12) are connected through the eye joint (90); d) installing the foundation (47), wherein the foundation (47) is lifted by the crane (83) and trolley (84) of the PSL; after the verticalization and stabilization of the foundation (47), the crane cable is disconnected; then the crane and trolley (85) move to the moon pool center (92); e) connecting the foundation (47) to the blocks (42) and (43), wherein the foundation (47) has a pin (71) and the blocks have, on their lower portion, a connector (72) to connect to the pin (71); and the foundation (57) further comprising gaskets (73) to be fastened by screws (49) after connecting the trolley (84); f) then installing a temporary UTAJ (46) between the blocks (42) and (43).

7. SUBSEA DISTRIBUTION EQUIPMENT ASSEMBLY comprising equipment described in claim 5, characterized in that it is performed on the vessel's deck and comprises the following steps: a) transporting the block (52) from the spool using the gutter (81), tensioners (82) and the crane (83) of the vessel (85), wherein said block (52) is transported to the hang-off collar (96) of the vessel (85); said block (43) being connected to the umbilical cable (35); b) transporting the block (51) through the gutter (81) and the tensioners (82) and lifting using the crane (83) of the PLS, the umbilical cable (36) that is connected to the block (51) being supported by the moon pool tugger winches and Chinese fingers; c) performing the connection of blocks (52) and (54) in such a way that the male connector (55) of the block (51) is connected to the female connector (56) of the block (52), then performing all electrical and hydraulic connections between the blocks; d) after the connection made in the previous step, the foundation (57) is lifted by the crane (83) and trolley (84) of the PSL, after the verticalization and stabilization of the foundation (57), the crane (83) and the trolley (84) of the PSL move to the moon pool center; e) connecting the foundation (57) to the blocks (51) and (52), at that moment, the trolley (84) of the PSL releases the foundation (57), then the Electrical Flying Leads are installed in the SDA (50).

8. REPAIR characterized in that it repairs the SDA (40) and comprises the following steps: a) removing the UTAJ (46) for installing the recovery tool (100) in the block (42), and subsequently unlocking the foundation (47), b) unlocking the pin (66) of the block (42); c) lifting the block (42) using the umbilical (36) and/or the crane (83) of the vessel (85); d) rotating the block (42); e) disconnecting the hook of the crane (83) and elevating it to the surface; e) moving downwards the recovered block (42), wherein the recovery tool (100) is connected to the eye of the block (42); f) rotating the block (42); g) checking the position of the block (42) and the ROV (not shown) in relation to the foundation (47) and, after said checking, housing the pin (66) in the funnel (67) of the foundation (47); h) performing the payment of the crane cable and the umbilical cable (36), i) locking the pin (66) and unlocking the recovery tool (100).

Description

DESCRIPTION OF THE FIGURES

[0010] The present invention can be well understood from the accompanying illustrative figures, which in a schematic and non-limiting way of the invention represent:

[0011] FIG. 1Perspective view of the SDA of the state of the art;

[0012] FIG. 2Schematic of a subsea installation of the state of the art;

[0013] FIG. 3Perspective view of the SDA components of the state of the art;

[0014] FIG. 4Perspective view of the structure of the present invention;

[0015] FIG. 5Perspective view of the panel and the MQC of the present invention;

[0016] FIG. 6Perspective view of the block used by SDA in line with the eye joint of the present invention;

[0017] FIG. 7Perspective view of the block used by SDA in line with the flange gasket of the present invention;

[0018] FIG. 8-16Assembly sequence using the hydraulic modularization of the present invention;

[0019] FIG. 17-18Assembly sequence of the block in the hydraulic modularization disclosed by the present invention;

[0020] FIG. 19Top view of the block with the hydraulic modularization of the present invention;

[0021] FIG. 20Detail of the MQC couplers of the present invention;

[0022] FIG. 21Side view of the block with the hydraulic modularization of the present invention;

[0023] FIG. 22Perspective view of the block with the MQC of the present invention;

[0024] FIG. 23Side view of the block with the MQCs of the present invention

[0025] FIG. 24Perspective view of the block with the hydraulic modularization and electrical modularization;

[0026] FIG. 25Perspective view of the SDA of the present invention;

[0027] FIG. 26Side view of the SDA of the present invention;

[0028] FIG. 27Perspective view of the SDA of the present invention;

[0029] FIG. 28Perspective view of the SDA block of the present invention;

[0030] FIG. 29View of the male and female connectors according to the present invention;

[0031] FIGS. 30-34Assembly sequence of the SDA in line with eye joint according to the present invention;

[0032] FIGS. 35-42Assembly sequence of the SDA in line with flange gasket according to the present invention;

[0033] FIG. 43Schematic of the SDA installation using a crane according to the present invention;

[0034] FIG. 44Schematic view of the installation of the equipment using a buoy according to the present invention;

[0035] FIG. 45Sequence of the process of replacing the temporary UTAJ with the permanent UTAJ according to the present invention.

[0036] FIG. 46Removal sequence of a block for repairing the SDA in line with eye joint according to the present invention;

[0037] FIG. 47Installation sequence of a block for repairing the SDA in line with eye joint according to the present invention; and

[0038] FIG. 48Schematic of a subsea installation according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0039] As can be seen in FIG. 4, the present invention deals with the modularization of the structure, hydraulic instrumentation and electrical instrumentation of an SDA, in blocks, as well as the assembly, installation and recovery of the modules.

Structure

[0040] As can be seen in FIG. 4, block (10) comprises a metallic structure (11), wherein the metallic structure (11) serves as a structure for the installation of panels (13), illustrated by FIG. 5, around the surface thereof; the structure (10) further comprising a panel (16) located at its end, wherein said panel (16) has a hole (15) for the umbilical connector to be installed.

[0041] Still referring to FIG. 5, the panel (13) may have or not a hole for the installation of multi-quick connectors (14) or not have any hole, serving only to seal the inside of the structure (11), therefore, the panel format (13) varies according to the type of electro-hydraulic function and the control logic required for each field of production or injection of oil and gas.

[0042] In a first embodiment of the structure (10), as can be seen in FIG. 6, the structure (10) presents at the end opposite the end having the hole (15), a panel with an eye (12).

[0043] In a second embodiment, illustrated by FIG. 7 of the present invention, the structure (10) has panels (16) along its length, both on the side and on the upper portion and lower portion, the side panels having holes (16) for the installation of MQC (14) and, on the upper portion, there are also holes for the installation of MQC (14).

[0044] It is important to note that the panel format (13) varies according to the type of electro-hydraulic function and the control logic required for each field of production or injection of oil and gas.

[0045] It is noted that the block (10) allows several configurations, given the possibility of installing specific panels according to the needs of the subsea equipment design.

Hydraulic Instrumentation

[0046] As previously mentioned, the present invention also comprises the modularization of hydraulic instrumentation, said hydraulic instrumentation, illustrated by FIGS. 8 and 9, being formed by a first layer, which is a pipe mat (19), wherein the said pipe mat (19) is located inside the structure (11). The pipe mat (19) comprises parallel tubes (20), wherein said parallel tubes (20) are composed of connectors (21) along their extension. The connectors (21) allow the installation of multi-quick connectors (MQC) (14), wherein said MQCs (14), as previously mentioned, are located on the panels (13). As can be observed, pipes for an UTAJ (22) are located at the end of the mat (19).

[0047] Next, the sequence of a hydraulic configuration according to the present invention will be illustrated, wherein FIGS. 8-16 illustrate the assembly sequence of a hydraulic configuration. FIGS. 8 and 9 illustrate the first layer comprising the pipe mat (19) and the UTAJ (22). FIG. 10 illustrates the installation of the pipes of a MQC distribution module (23), wherein said MQC distribution module (23) is connected to the connectors (21) of the pipe mat (19). The MQC distribution module (23) can be connected to a Christmas tree, for example.

[0048] FIG. 11 illustrates the installation of a distribution module (24), wherein the pipes of the distribution module (24) are connected to the mat connectors (19), the distribution module (24) can be connected to a manifold, for example. FIG. 12 illustrates the installation of a distribution module (25) and FIG. 13 illustrates the installation of a distribution module (26), the distribution modules (25) and (26) being connected to the pipe mat (19).

[0049] After the assembly of the distribution modules (23-26), the couplers (27) are installed in the UTAJ (22), illustrated by FIG. 14. After this step, the assembly of the pipes for the second Logic Cap (28) and the first Logic Cap (29), illustrated by FIGS. 15 and 16, is carried out, wherein the first Logic Cap (29) and the second Logic Cap (28) are connected to the pipe mat (19). The assembly where said distribution module (25) in which said MQC (23) can be connected to a distribution module (24), illustrates the installation of pipes of a MQC (22) at the end of the pipe mat (19).

[0050] After the assembling of the Logic Caps (28) and (29), the MQC distribution modules (23-26) and the couplers (26) of the UTAJ (22) and the couplers (29) of the Logic Caps (28) and (29), the structure (10) is installed in the hydraulic configuration (30) illustrated by FIGS. 17 and 18, wherein the hydraulic configuration (30) is the configuration previously shown by FIGS. 9-16.

[0051] As can be seen in FIG. 19, the metallic structure (11) does not come into contact with the pipes of the MQC distribution modules (23-26). After the installation of the structure (10), couplers (31) are installed, as can be seen in FIGS. 20 and 21, wherein panels (13) with the MQC (14) are subsequently installed, as shown in FIGS. 22 and 24.

[0052] [Note that the pipe mat (19) allows configuring several arrangements according to the desired use. The pipe mat (19) connects with the inlet umbilicals, outlet umbilicals, as well as the MQC and Logic caps (LC), in order for the block to obtain a maximum number of functions. If there is a need for a smaller number of functions, the reduction in the number of tubbings (20), fittings, couplers and MQC will be sufficient to adapt the block (10) to the system.

Electrical Instrumentation

[0053] As can be seen in FIG. 24, the electrical instrumentation is modularized inside the structure (10), so that each structure (10) has the same electrical scheme. Therefore, it is defined a maximum number of QUADs that the structure (10) bears. These QUADs comprise the following components: junction boxes, electrical connectors (32) and Field Assembled Cable Termination (FACTs) (31). FIG. 24 illustrates the location of the FACTs (31) and the electrical connectors (32). These components are connected to the inlet and outlet umbilicals. Thus, if there is a need to bear fewer QUADs, it will be necessary only to remove the electrical connectors, FACTs and modify the junction box.

Embodiments

[0054] Using the modularization proposed above, two embodiments for two SDAs (40) and (50), according to the present invention, are provided.

[0055] As can be seen in FIG. 25, the first embodiment consists of an SDA in line (40) with an eye joint (49). The SDA (40) comprises two blocks (42) and (43), wherein said blocks (42) and (43) will be used as Subsea Umbilical Termination (SUT), wherein the block (42) comprises a structure (10), MQC (14) and Logic Caps (28) and (29) and UTAJ (22), at its end, the block (42) comprises a Subsea Termination Interface (STI) (44), wherein said STI is connected to the umbilical cable (35), at its other end, the block (42) comprises an eye joint (49), the block (42) further comprising a pin (66) in its lower portion, wherein said pin (66) can be seen in FIG. 26. The block (43) comprises MQCs (14) and UTAJ (46), at one of its ends, the block (43) comprises an STI (45) that connects to an umbilical cable (36). At its other end, the block (43) comprises an eye joint (49).

[0056] The two blocks (42) and (43) are mounted on a foundation (47), where said foundation (47) comprises a funnel (67), as can be seen in FIG. 26, wherein the funnels (67) serve to house the pins (66) of the blocks (42) and (43). The eyes (49) of the blocks (42) and (43) are used to connect said blocks (42) and (43). In addition, UTAJ (46) links blocks (42) and (43).

[0057] It is important to mention that the UTAJ (46) is temporary, after the installation of the SDA (40) on the seabed, a permanent UTAJ (49) is installed, as will be illustrated in FIG. 45, and the process of replacing temporary UTAJ (46) with permanent UTAJ (49) will be demonstrated below.

[0058] In a second embodiment, illustrated by FIG. 27, an SDA (50) is disclosed using the concepts presented herein by the present invention, wherein the SDA (50) comprises two blocks (51) and (52) that will be used as subsea umbilical termination (SUT), wherein the block (51) comprises a structure (10), MQCs (14), and Logic Caps (28) and (29). At its end, the block (51) comprises a STI (53), illustrated by FIGS. 27 and 28, which connects to an umbilical cable (35). The block (52) comprises a structure (10) and MQCs (14) and, at its end, the block (52) comprises a STI (54) to be connected to the umbilical cable (36). The connection between blocks (51) and (52) is made through a flange gasket, where block (51) comprises a male connector (55) and block (52) comprises a female connector (56), as seen in FIG. 29. Blocks (51) and (52) are connected to a foundation (57), with this connection being made by screws, as can be seen in FIG. 30.

[0059] These embodiments of SDA (40) and (50) have a lower weight compared to the SDA (01) of the art, wherein SDA (01) weights 28,000 kgf, while the SDA (40) weights 12,000 kgf and the SDA (50) weights 9,000 kgf.

Assembly

[0060] Among the factors that are important for the assembly of the SDA (40) and (50), the limitations of the tower, the gutter, A&R, the tensioners' opening, deflectors, and the sizes of the work floor of a vessel should be highlighted. SDAs (40) and (50) allow their assembly to be carried out on smaller vessels, in order to reduce the cost of renting vessels, since SDAs (40) and (50) have fewer components and consequently less weight. In addition, the SDAs (40) and (50) disclosed herein further are smaller.

[0061] Therefore, the present invention allows the assembly of the SDAs using the structure of the existing vessel in order to reduce assembly and installation costs of the SDA. Later, the assembly of the SDA (40) and (50) on a vessel (85) will be disclosed. The assembly is carried out on the deck of the vessel (85) and comprises the following steps, which are illustrated by FIGS. 30-34:

[0062] a) As can be seen in FIG. 30, block (43) is transported from the spool using the gutter (81), tensioners (82) and the crane (83) of the vessel (85), wherein said block (43) is transported to the hang-off collar (96) of the vessel (85); said block (43) being connected to the umbilical cable (35);

[0063] b) After the block (43) arrives at the hang-off collar (96), block (42) is transported and then the eye joint (90) is installed, and the block (42) is transported, as shown in FIG. 31;

[0064] c) After installing the eye joint (90), the eyes (12) of the blocks (42) and (43) are aligned and brought together, so that the eyes (12) are connected through the eye joint (90); as seen in FIG. 32;

[0065] d) After the blocks (43) and (42) are connected by the eye joint (90), the foundation (47) is installed, wherein the foundation (47) is lifted by the crane (83) and trolley (84) of the PSL. After the verticalization and stabilization of the foundation (47), the cable of the crane (83) is disconnected; then the crane and the trolley (85) move to the moon pool center (92); as can be seen in FIGS. 33 and 34;

[0066] e) The foundation (47) is connected to the blocks (42) and (43), wherein the foundation (47) has a pin (71) and the blocks, on its lower portion, have a connector (72) to connect to that pin (71); and the foundation (57) also comprises gaskets (73) to be fastened by screws (49) after connecting the trolley (84); the foundation (47) is released,

[0067] f) then, a temporary UTAJ is installed (46) between blocks (42) and (43).

[0068] Similarly, the assembly of the SDA (50) follows the subsequent steps, illustrated by FIG. 35-42:

[0069] a) As can be seen in FIG. 36, block (52) is transported from the spool using the gutter (81), tensioners (82) and the crane (83) of the vessel (85), wherein said block (52) is transported to the hang-off collar (96) of the vessel (85); said block (43) being connected to the umbilical cable (35);

[0070] b) Subsequently, as can be seen in FIG. 35, block (51) is transported through the gutter (81) and tensioners (82) and lifted using the crane (83) of the PLS, the umbilical cable (36) that is connected to the block (51) is supported by the moon pool tugger winches and the Chinese fingers;

[0071] c) The connection between blocks (52) and (54) is made in such a way that the male connector (55) of the block (51) is connected to the female connector (56) of the block (52), as can be seen in FIGS. 36-38, subsequently all electrical and hydraulic connections between blocks (51) and (52) are made;

[0072] d) After the connection made in the previous step, the foundation (57) is lifted by the crane (83) and trolley (84) of the PSL. After the verticalization and stabilization of the foundation (57), the crane (83) of the PSL and the trolley of the PSL (684 travels to the moon pool center) are removed. As can be seen in FIGS. 39 and 40;

[0073] e) the foundation (57) is connected to the SUDs (51) and (52), at that moment, the trolley (84) of the PSL releases the foundation (57), then the Electrical Flying Leads are installed in the SDA (50), as can be seen in FIG. 41.

Installation

[0074] After assembling the SDA (40) and (50), the installation can be done in two ways, using the crane (83) of the vessel (85) or using a buoy (95). In the case of the crane (83) of the vessel (85), the SDA (40 or 50) is lifted by the Snatch block's Master Link and launched overboard. Since the SDA (40 or 50) is launched vertically, the vessel (85) remains motionless so that the SDA (40 and 50) moves in a horizontal direction. After the SDA (40 and 50) reach the seabed, the cables of the crane (83) are removed. The process is illustrated by FIG. 43

[0075] In the case of the installation with the buoy (95), the SDA (40 and 50) has on its upper surface a buoy (95) to slow down the lowering of the equipment to the seabed. Due to the fact that the SDA (40 and 50) are launched vertically, the vessel (85) moves so that the equipment (40, 50) when moving downwards, gradually changes its direction to horizontal direction. After the equipment (40, 50) arrives at the seabed, the buoy (95) is removed. The process is illustrated by FIG. 44.

[0076] Furthermore, after the SDA (40), reaches the seabed, the process of replacing the temporary UTAJ (46) with a permanent UTAJ (49) takes place. As can be seen in FIG. 45, after step (I), in which the SDA (40) lies on the seabed, the temporary UTAJ (46) is removed (step (II)). After removing said UTAJ (43), the gasket (90) is removed (step (III)) consists of removing. As we can see in the following steps (IV) and (V), permanent UTAJ (48) is installed.

[0077] Additionally, the installation of the SDA (40 and 50) of the present invention occurs in a more efficient way in relation to SDA (state of the art) (01), FIG. 1, since the SDA (01) comprises a foundation (09), SUT (02), SDAJ (03), LC (05), HDU (06), EDU (07). For the installation of the SDA (01), the stop and go process is used, which consists of the installation of each component of the SDA (01) individually on the seabed, which demands time and a higher installation cost. For the installation of the SDA (01), it will be initially necessary to install the foundation (09), and later, the installation of the SUT (02), SDAJ (03), LC (05), HDU (06), EDU (07), and finally, the connection of the components, as can be seen in FIG. 1. Since the present invention is mounted on the vessel (85), it is not necessary to install components separately in the marine environment.

SUT Recovery and Reinstallation

[0078] In case of any problem due to hydraulic or electrical failure, the present invention presents a method of recovering and reinstalling the blocks (42) and/or (43), wherein the recovery method, in an exemplary embodiment of recovery, comprises the following steps I-IV, illustrated by FIG. 46:

[0079] a) In step I, after removing the UTAJ (46), the recovery tool (100) is installed in the block (42) and unlocks the foundation (47);

[0080] b) In step II, the pin (66) of the block (42) is unlocked;

[0081] c) In step III, the block (42) is lifted using the umbilical (36) and/or the crane (83) of the vessel;

[0082] d) In step IV, the block (42) rotates;

[0083] e) In step V, the hook of the crane (83) is disconnected and the elevation to the surface takes place.

[0084] After removing the block (42), the procedure for reinstalling the block (42) already recovered or even the installation of a new block (42) is performed, illustrated in FIG. 47, wherein the method comprises the following VI-X steps:

[0085] a) In step VI, the recovered block (42) moves downwards, wherein the recovery tool (100) is connected to the eye of the block (42); the foundation, in step VII, the block (42) rotates;

[0086] b) In step VIII, the position of the block (42) and the ROV (not shown) are checked in relation to the foundation (47), after said checking, the pin (66) is housed in the funnel (67) of the foundation (47);

[0087] c) In step IX, payment of the crane cable and the umbilical cable (36) is performed;

[0088] d) In step X, the pin (66) is locked and the recovery tool (100) is unlocked.

[0089] The present invention allows a simplification of the subsea field configuration, illustrated by FIG. 2. As can be seen in FIG. 48, the SDA (40) is used to connect the topside (A) to the subsea equipment, Christmas trees (B) and manifold (C), the SDA (40) is connected by electrical and/or hydraulic jumper (D). This configuration provides a reduction in umbilicals when compared to the configuration of the art illustrated by FIG. 2.

[0090] Among the numerous advantages that the modularization of subsea systems, object of the present invention, provides, those skilled in the art have noted the: [0091] reduction of design and manufacturing costs; [0092] reduction of the weight and size of the final structure; [0093] ease in transport the final structure; [0094] reduction of the number of parts of the structure; and [0095] reduction of the amount of welding that the structure requires.