Spreader Structures for Lifting Loads

Abstract

A modular spreader structure (10) for use in offshore lifts comprises a plurality of elongate tubular elements (26, 22) made primarily of composite material. Primary tubular elements (26) each comprise an axial coupler formation (28) for end-to-end coupling with a complementary axial coupler formation of another primary tubular element, aligned on a common longitudinal axis. The adjoining primary tubular elements are interengageable by longitudinal overlap between male and female axial coupler formations. Secondary tubular elements (22) each comprise a node connector (30) that is configured for attachment to the structure at an orientation inclined relative to the common longitudinal axis of the primary tubular elements. In particular, the secondary tubular elements can be attached to an outer surface of one of the primary tubular elements.

Claims

1. A modular spreader structure for use in offshore lifts, the structure comprising a plurality of elongate primary tubular elements made primarily of composite material, wherein each primary tubular element comprises an axial coupler formation for end-to-end coupling with a complementary axial coupler formation of another primary tubular element of the structure aligned on a common longitudinal axis.

2. The structure of claim 1, wherein the axial coupler formation of at least one of the tubular elements comprises a male formation.

3. The structure of claim 2, wherein the male formation tapers distally.

4. The structure of claim 2 or claim 3, wherein the male formation is surrounded by a distally-facing shoulder.

5. The structure of any of claims 2 to 4, wherein the axial coupler formation of at least one of the primary tubular elements comprises a complementary female formation.

6. The structure of claim 5, wherein the female formation tapers proximally.

7. The structure of claim 5 or claim 6, wherein the female formation is surrounded by a distally-facing flange.

8. The structure of any preceding claim, wherein the axial coupler formation of each primary tubular element extends distally from a radially-enlarged portion of the tubular element that has locally-increased wall thickness.

9. The structure of any preceding claim, wherein adjoining primary tubular elements are interengageable by longitudinal overlap between their axial coupler formations.

10. The structure of claim 9, further comprising at least one locking pin extending through mutually-aligned transverse bores in the axial coupler formations.

11. The structure of claim 10, further comprising an alignment key in at least one of the axial coupler formations, cooperable with an opposed notch in another of the axial coupler formations.

12. The structure of any preceding claim, wherein the axial coupler formations are covered by a protective cover or liner of a stiffer material than the composite material.

13. The structure of claim 12, wherein the protective cover or liner is of steel.

14. The structure of any preceding claim, wherein at least one of the primary tubular elements comprises an external stopper formation.

15. The structure of claim 14, wherein the stopper formation is a ridge extending circumferentially around said primary tubular element.

16. The structure of any preceding claim, further comprising at least one secondary elongate tubular element made primarily of composite material, the secondary tubular element having a node connector that is configured to attach the secondary tubular element to the structure at an orientation inclined relative to the common longitudinal axis of the primary tubular elements.

17. The structure of any preceding claim, wherein the node connector is configured to attach the secondary tubular element to an outer surface of one of the primary tubular elements.

18. The structure of claim 17, wherein the node connector comprises at least one jaw with a distal end face that has curvature complementary to the outer surface of said primary tubular element.

19. The structure of claim 18, wherein the distal end face of the or each jaw is curved about an axis of curvature that is substantially aligned with a central longitudinal axis of the secondary tubular element.

20. The structure of claim 19, wherein the axis of curvature is substantially orthogonal to the central longitudinal axis of the secondary tubular element.

21. The structure of any of claims 18 to 20, wherein the or each jaw is made from a composite material that is integral with the composite material of the secondary tubular element.

22. The structure of claim 21, wherein the or each jaw further comprises an insert of a stiffer material than the composite material of the jaw.

23. The structure of any of claims 18 to 22, wherein the distal end face of the or each jaw comprises a recess that is engageable with an external stopper formation of at least one of the primary tubular elements.

24. The structure of any of claims 18 to 22, wherein at least two external stopper formations are spaced apart longitudinally along a primary tubular element and the node connector is engageable with that primary tubular element between those external stopper formations.

25. The structure of any of claims 16 to 24, wherein the node connector is joined to the secondary tubular element by additional axial coupler formations.

26. The structure of any preceding claim, wherein no part of the structure is of more than 12 m in length when disassembled.

27. The structure of any preceding claim, further comprising attachment points for suspending the structure from a lifting point and for suspending a load from the structure.

28. A method of assembling a spreader structure, made primarily of composite material, for use in an offshore lift, the method comprising interengaging elongate primary tubular elements end-to-end in mutual alignment on a common longitudinal axis by virtue of longitudinal overlap between axial coupler formations of the primary tubular elements.

29. The method of claim 28, comprising locking together the primary tubular elements by extending at least one locking pin through mutually-aligned transverse bores in the overlapping axial coupler formations.

30. The method of claim 28 or claim 29, further comprising attaching at least one elongate secondary tubular element to the primary tubular elements at an orientation that is inclined relative to the common longitudinal axis of the primary tubular elements.

31. The method of claim 30, comprising attaching the or each secondary tubular element to an outer surface of at least one of the primary tubular elements.

32. The method of claim 31, comprising engaging or abutting the or each secondary tubular element with at least one stopper formation on the outer surface of at least one of the primary tubular elements.

33. The method of any of claims 28 to 32, further comprising disassembling the spreader structure and reassembling the spreader structure at a different installation site or in a different configuration.

34. The method of claim 33, comprising placing the tubular elements into a standard shipping container for storage or transportation after disassembly of the spreader structure.

Description

[0044] 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:

[0045] FIG. 1 is a perspective view of a spreader structure of the invention in use supporting a jumper pipe;

[0046] FIG. 2 is a perspective view in longitudinal section of an axial coupler interface between adjoining tubular elements of the spreader structure shown in FIG. 1, in the process of assembly;

[0047] FIG. 3 is a longitudinal sectional view of the interface shown in FIG. 2, when assembled;

[0048] FIG. 4 is an exploded part-sectional side view of a node connector joining perpendicular tubes of the spreader structure shown in FIG. 1;

[0049] FIG. 5 is a part-sectional side view of a variant of the node connector shown in FIG. 4;

[0050] FIG. 6 is an exploded top view of another variant of the node connector, showing a stopper arrangement; and

[0051] FIG. 7 is a top view of another node connector, showing a variant of the stopper arrangement shown in FIG. 6.

[0052] Referring firstly to FIG. 1 of the drawings, a spreader structure 10 of the invention is shown here suspended by upper slings 12 that radiate outwardly and downwardly from a lifting point 14 such as a hook of a crane (not shown). The spreader structure 10 supports a jumper pipe 16 via a set of lower slings 18. The upper and lower slings 12, 18 are represented here schematically by dotted lines.

[0053] In this example, the spreader structure 10 comprises an elongate, substantially straight and substantially horizontal spreader bar 20. The spreader structure 10 further comprises outrigger tubes 22 that extend in opposite directions orthogonally and substantially horizontally from respective junctions that are close to respective ends of the spreader bar 20. The outrigger tubes 22 provide additional support to the heavy and bulky end connectors 24 of the jumper pipe 16, which depart from the otherwise substantially upright plane of the central portion of the jumper pipe 16.

[0054] Conveniently, at least some of the upper and lower slings 12, 18 are attached to the spreader structure at junctions between the spreader bar 20 and the outrigger tubes 22.

[0055] The spreader bar 20 comprises a longitudinal series of tubular sections or elements 26 that are joined together end-to-end. Here, the spreader bar 20 is an assembly that comprises a series of four elongate tubular elements 26, each element 26 being 12 m in length for example.

[0056] The tubular elements 26 of the spreader bar 20 and the outrigger tubes 22 are each made primarily of a fibre-reinforced polymer composite material, preferably comprising a matrix of thermoplastics. More generally, the tubular elements 26 and the outrigger tubes 22 may be made of an elastomeric or polymeric matrix, embedding unidirectional or multidirectional reinforcements.

[0057] The interface defining the joint between each successive pair of tubular elements 26 is defined by an axial coupler 28 as exemplified in FIGS. 2 and 3. The interface defining the junction between each outrigger tube 22 and the spreader bar 20 is defined by a node connector 30 like those exemplified in FIGS. 4 to 7.

[0058] Turning next, then, to FIGS. 2 and 3, the axial coupler 28 comprises radially-enlarged facing end portions 32 of the polymer composite tubular elements 26. The local wall thickness of the tubular elements 26 is increased at these end portions 32 and then decreases distally to form complementary, tapering axially-engageable male and female formations.

[0059] One of the facing end portions 32 is a male coupler that comprises a distally-tapering, frusto-conical protrusion or spigot 34. The spigot 34 is concentric with a surrounding circumferential shoulder 36 that lies in a plane orthogonal to the central longitudinal axis 38 of the tubular element 26.

[0060] The other of the facing end portions 32 is a female coupler that comprises a proximally-tapering, frusto-conical recess or socket 40 whose shape corresponds to and complements the spigot 34 of the male coupler. The socket 40 is concentric with a surrounding circumferential flange 42 that lies in a plane orthogonal to the central longitudinal axis 38 of the tubular element 26.

[0061] The spigot 34 and the surrounding shoulder 36 are faced by a steel cover layer 44. Similarly, the socket 40 and the surrounding flange 42 are faced by a complementary steel liner layer 46. The cover layer 44 and the liner layer 46 are each bonded to the underlying polymer composite material of the tubular elements 26 so as to reinforce and protect that material.

[0062] When the spigot 34 of the male coupler is fully inserted into the socket 40 of the female coupler as shown in FIG. 3, the cover layer 44 of the spigot 34 engages closely against and within the liner layer 46 of the socket 40. Similarly, the shoulder 36 of the male coupler bears against the flange 42 of the female coupler via the cover layer 44 and the liner layer 46.

[0063] Once fully inter-engaged in this way, the male and female couplers are preferably locked together by a transverse pin 48 as also shown in FIG. 3. The pin 48 extends through longitudinally- and angularly-aligned holes 50 that penetrate the tapering tubular walls of the spigot 34 and the socket 40 and also extend through the associated cover and liner layers 44, 46.

[0064] Longitudinal alignment of the holes 50 is assured by abutment between the shoulder 36 and the flange 42 upon full engagement between the male and female couplers. Conversely, angular alignment between the holes 50 is assured by alignment of, and engagement between, a key formation 52 projecting from the shoulder 36 of the male coupler and a complementary notch 54 in the opposed flange 42 of the female coupler.

[0065] Moving on to FIGS. 4 to 7, these drawings show various node connectors 30 of the invention. The simplest of these node connectors 30 is shown in FIG. 4 and comprises a jaw formation 56 at an end of an outrigger tube 22. The jaw formation 56 is of thermoplastic composite material and is conveniently formed integrally with the composite wall of the outrigger tube 22. The concave-curved distal end face 58 of the jaw formation 56 is faced by, or reinforced with, an embedded steel insert layer 60 to protect or strengthen the composite material.

[0066] The distal end face 58 of the jaw formation 56 is part-circular in longitudinal section, with a substantially constant radius of curvature. The radius of curvature is centred on an axis of curvature 62 that is orthogonal to, and intersected by, the central longitudinal axis of the outrigger tube 22. The radius of curvature of the distal end face 58 corresponds to the outer radius of the spreader bar 20. Thus, when the outrigger tube 22 is assembled with the spreader bar 20 such that the central longitudinal axis 38 of the spreader bar 20 lies on the axis of curvature 62 of the distal end face, a tubular element 26 of the spreader bar 20 is received snugly in the jaw formation 56.

[0067] The jaw formation 56 is held in engagement with the spreader bar 20 by an oppositely-curved jaw element 64 of steel. Thus, the jaw formation 56 and the jaw element 64 cooperate with each other in the manner of half-shells. The jaw element 64 is suitably bolted to the jaw formation 56 via washers 66 and may thereby deform resiliently to apply clamping force to the spreader bar 20.

[0068] In the variant of FIG. 5, the jaw formation 56 of the node connector 30 is not integral with an outrigger tube 22 but is instead coupled to an end of an outrigger tube 22 by an axial coupler 28 like that of FIGS. 2 and 3, shown here in a partially-engaged state. Like numerals are used for like features of the axial coupler 28, and so need not be described further here.

[0069] Frictional engagement between the spreader bar 20 and the jaw formation 56 of a node connector 30 may be sufficient to keep an outrigger tube 22 in fixed relation to the spreader bar 20. However, the spreader bar 20 and the jaw formation 56 may additionally, or instead, be connected to each other by mechanical engagement. FIGS. 6 and 7 show arrangements for the node connector 30 that effect mechanical engagement between these parts.

[0070] In FIG. 6, the spreader bar 20 is encircled by a circumferential stopper ridge 68 that is received in complementary grooves 70 provided in the concave faces of the jaw formation 56 and the opposed jaw element 64. The stopper ridge 68 may be formed integrally with a tubular element 26 of the spreader bar 20 by locally increasing the wall thickness of the tubular element 26, or may be bonded or otherwise attached to the tubular element 26.

[0071] When the spreader bar 20 is clamped between the jaw formation 56 and the jaw element 64, engagement between the stopper ridge 68 and the grooves 70 prevents the node connector 30 and the outrigger tube 22 sliding along the spreader bar 20. Moreover, the spreader bar 20 has one or more key formations 72, conveniently formed integrally with the stopper ridge 68, that engage with one or more complementary recesses 74 of the jaw formation 56 and/or the jaw element 64. Engagement of the or each key formation 72 with the or each recess 74 prevents the node connector 30 and the outrigger tube 22 pivoting or swinging about the spreader bar 20.

[0072] Finally, in FIG. 7, the spreader bar 20 is encircled by a pair of circumferential stopper ridges 68 that are spaced apart longitudinally. The jaw formation 56 and the jaw element 64 are clamped together around the spreader bar 20 in the space between the stopper ridges 68. The stopper ridges 68 thereby prevent the node connector 30 and the outrigger tube 22 sliding beyond them along the spreader bar 20.

[0073] Many variations are possible within the inventive concept. For example, the jaw formations 56 of the node connectors 30 shown in FIGS. 6 and 7 need not be integral with the outrigger tube 22 but may instead be coupled to an end of an outrigger tube 22 by an axial coupler 28 like that of FIGS. 2 and 3.

[0074] The principles of the invention may be used to construct spreader structures of various shapes or sizes, including box-section or triangulated lattices that may comprise diagonal braces. Consequently, it is not essential that adjoining tubular members of the spreader structure are in mutually orthogonal relation. It would instead be possible for adjoining members of the structure to be at angles of greater or less than 90° relative to each other. Thus, the axis of curvature of a jaw formation may lie at any required angle relative to the central longitudinal axis of a tubular member that carries the jaw formation.

[0075] The cover layer, liner layer and insert layer need not be of steel but could instead be of other metals or of other suitably robust materials.

[0076] The length of at least some of the tubular members of the spreader structure may be adjustable, for example by a telescoping action.

[0077] At least some of the tubular members of a spreader structure such as a spreader bar or an outrigger tube may support lift clamps. Each lift clamp may, for example, comprise a sleeve that encircles the supporting member and may have a frictionless design so as to pivot freely around that member. In that case, unwanted sliding of a lift clamp along a member of the spreader structure may be resisted by stopper arrangements like those shown in FIGS. 6 and 7.

[0078] Whilst the drawings show the outrigger tubes as being of substantially the same outer diameter as the tubular elements of the spreader bar, the outrigger tubes and the tubular elements could instead have different outer diameters.