Flexible Connection Apparatus

The present invention discloses an apparatus in a fluid-carrying system for accommodating relative movement between a compliant offshore structure and the sea floor. More particularly, the present invention relates to a helical flowline in a fluid-carrying system which is capable of flexing to accommodate relative movement between a compliant offshore structure and a subsea well.

The offshore production of oil and gas requires the use of fluid-carrying systems to convey production fluids from a subsea well to the water surface. Such fluid-carrying systems typically include a rigid, substantially vertical conductor pipe which is cemented at its lower end to the subsea well. The upper end of the conductor pipe is connected to a wellhead which is typically located on the deck of an offshore production platform. Tubing, which is located inside the conductor pipe, conveys production fluids from the subsea well to the wellhead. At the upper end of the wellhead, valves in a "Christmas Tree" are manipulated to regulate the pressure and flow rate of the production fluids. A flowline conveys production fluids from the Christmas Tree to a manifold on the deck of the offshore platform. The manifold routes the production fluids to treating and separation equipment which processes the production fluids. The flowline is rigidly anchored to the deck of the offshore platform or is rigidly connected to the manifold. Such rigid connection completes the fluid-carrying system between the subsea well and the offshore platform.

While rigid offshore production platforms are typically used to support a fluid-carrying system in water less than 1000 feet deep, compliant offshore platforms such as guyed towers or tension leg platforms have been designed for greater water depths. Such compliant offshore platforms are less massive than are rigid offshore platforms and "comply" with loading forces induced by wind, waves, and ocean currents. When acted upon by such forces, a compliant offshore platform will be displaced from its equilibrium position above a subsea well. Such displacement may be vertical as well as horizontal. As the displacing force subsides, the compliant offshore platform will return to its equilibrium position above the subsea well.

A fluid-carrying system supported by a compliant offshore platform must be sufficiently flexible to compensate for movement of the compliant offshore platform from its equilibrium position. Fluid-carrying systems typically compensate for such movement by using a flexible flowline, such as an elastomeric hose, between the wellhead and the deck of the offshore platform. However, a flexible flowline manufactured from an elastomeric hose is subject to certain limitations. For example, "sour" production fluids frequently contain chemical compounds such as hydrogen sulfide and carbon dioxide which deteriorate the materials used in an elastomeric hose. Thus, an elastomeric hose carrying sour production fluids must be periodically replaced. In addition, the pressure of the production fluids may exceed 5000 psi. An elastomeric hose must be reinforced in order to handle such fluid pressures without failing. Such reinforcement reduces the flexibility of an elastomeric hose and correspondingly increases the minimum bending radius of the hose. An elastomeric hose with a greater bending radius will therefore require more deck space than will a hose with a lesser bending radius. Consequently, the use of elastomeric hoses will reduce the number of wells that can be produced by an offshore platform.

In addition to elastomeric hoses, slip joints have been used in a fluid-carrying system to compensate for movement of a compliant offshore platform from its equilibrium position. Such joints typically have an inner pipe which slidably moves within an outer pipe. The annulus between the inner and outer pipe is sealed with elastomeric seals to prevent production fluid from leaking into the ambiance. However, slip joints are undesirable in a fluid-carrying system between a wellhead and an offshore platform. Slip joints sized to accommodate the movement of an offshore platform are long and therefore require a great deal of vertical space between the decks of the offshore platform. Such space is typically limited by the dimensions of the offshore platform. Additionally, slip joints in a fluid-carrying system are undesirable when conveying a sour production fluid. The elastomeric seals used in such slip joints are subject to deterioration induced by compounds in the sour production fluid and will leak. Furthermore, the movement of the inner and outer pipes of the slip joint will abrade the elastomeric seal as the inner pipe reciprocates within the outer pipe. Such abrasion reduces sealing effectiveness as the elastomeric seals become worn. Finally, a slip joint is limited because it moves linearly and does not accommodate lateral movement of the offshore platform about the subsea well. This lateral movement of the offshore platform can be so severe as to damage the slip joint.

To avoid certain limitations of flexible hoses and slip joints, various combinations of in-line swivels and concentric swivels have been used to accommodate relative movement in a fluid-carrying system. However, swivels rely on elastomeric seals to seal the moving elements of the swivel. Such seals are subject to deterioration induced by a sour production fluid as previously described. Furthermore, swivel connections are limited to a particular range of movement and do not flex beyond such operating range. If a severe storm should displace an offshore platform to an extraordinary distance from its equilibrium position, the pipe connecting the swivels in a fluid-carrying system would not plastically deform but would rupture. Such rupture would release the pressurized production fluid into the ambiance.

A need, therefore, exists for a flexible apparatus in a fluid-carrying system to accommodate movement of a compliant offshore structure about a subsea well. Such flexible apparatus should be capable of conveying a sour production fluid which is produced at high pressures. The flexible apparatus should also accommodate, without leakage, cyclic as well as extreme displacements of a compliant offshore platform from its equilibrium position.

The present invention provides an apparatus for transporting a fluid between a compliant offshore structure and the sea floor while accommodating movement of the offshore structure. A riser means for transporting the fluid has a lower end and an upper end. The lower end of the riser means is connected to the sea floor. A first end of a helical flowline means is connected to the upper end of the riser means. A second end of the helical flowline means is connected to the offshore structure. The helical flowline means is capable of flexing to accommodate movement of the offshore structure.

In a preferred embodiment of the present invention, a wellhead means is connected between the upper end of a riser means and the first end of a helical flowline means. The second end of the helical flowline means may be connected to an offshore structure such that the centerline of the helical flowline means is substantially vertical. As the offshore structure is displaced relative to the sea floor, the helical flowline means would therefore flex to accommodate such movement. The helical flowline means may be located above the wellhead means to conserve deck space and to permit unrestricted access to the wellhead means.

In an alternative embodiment of the present invention, a first end of a helical flowline means is connected to a wellhead means. A second end of the helical flowline means is connected to an offshore structure such that the centerline of the helical flowline means is substantially horizontal rather than vertical. The helical flowline means accommodates relative motion of the offshore structure through bending deflection rather than through torsional deflection.

FIG. 1 illustrates an elevational view of three fluid-carrying systems supported by a compliant offshore structure.

FIG. 2 illustrates an isometric view of a helical flowline means connecting a wellhead to a deck of a compliant offshore structure.

FIGS. 3A and 3B illustrate profile and side views, respectively, of a bending flowline means connecting a wellhead to a deck of a compliant offshore structure.

FIG. 1 illustrates compliant structure 10 which may be used in the offshore production of oil and gas. Structure 10 may be a guyed tower, tension leg platform or other compliant structure. The major components of structure 10 are support legs 12, cellar deck 14, main deck 16 and upper deck 18. Structure 10 is anchored to the sea floor 20 with piles 22. As shown in FIG. 1, loading forces (F) induced by wind, waves and ocean currents will act on structure 10. Such loading forces (F) will displace the structure from its vertical equilibrium position. During typical conditions, a guyed tower may be displaced from the vertical equilibrium position by an angle of more than 5.degree. while a tension leg platform may be displaced by more than 10.degree.. During storm conditions, these displacement angles may be even greater.

Production fluids 24 are conveyed from subsea wells 26a, 26b, and 26c to treating and separation facilities 28 on main deck 16 by means of fluid-carrying systems 30a, 30b, and 30c. The fluid-carrying systems may also convey injection or other fluids from structure 10 to the subsea wells. Although three fluid-carrying systems are shown in FIG. 1, varying numbers of fluid-carrying systems may be associated with a particular structure. The following description of fluid-carrying system 30a will be applicable to systems 30b, 30c and any additional fluid-carrying system.

Fluid-carrying system 30a comprises rigid conductor pipe 32a, wellhead 34a, and helical flowline 36a. Conductor pipe 32a is rigidly cemented at its lower end to sea floor 20 and is rigidly connected at its upper end to wellhead 34a. The upper end of conductor pipe 32a preferably extends above the water surface. Guide means 38 connected to cellar deck 14 and to the cross-bracing of structure 10 provide a guide through which conductor pipe 32a can be threaded. The inside diameter of guide means 38 is sufficiently large to permit conductor pipe 32a to slide therethrough. Casing and tubing pipe (not shown) within conductor pipe 32a are in fluid communication with subsea well 26a and wellhead 34a so that fluids can be transported therebetween. Helical flowline 36a completes fluid-carrying system 30a by conveying fluids from wellhead 34a to treating and separation facilities 28. Control bundle 48 for remotely controlling valves (not shown) in wellhead 34a is attached to fluid-carrying system 30a so that it does not interfere with the use of the fluid-carrying system.

As compliant structure 10 is displaced from its vertical equilibrium position, there will be relative movement between wellhead 34a and main deck 16 because the conductor pipe 32a and structure 10 have differing deflectional properties. To accommodate this relative movement, helical flowline 36a is positioned between wellhead 34a and main deck 16. As shown in FIG. 2, helical flowline 36a includes tubing member 42 and helical coil 44. Tubing member 42 is rigidly connected at its first end to wellhead 34a and at its second end to the lower end of helical coil 44. Brace 40 firmly attaches tubing member 42 to wellhead 34a. The upper end of helical coil 44 is rigidly connected by mounting bracket 46 to main deck 16.

Helical coil 44 is illustrated as being positioned above wellhead 34a to conserve deck space and to provide free access to wellhead 34a. Helical coil 44 is preferably positioned so that its centerline is substantially vertical to permit the vertical movement of structure 10 to be accommodated through torsional deflection of helical coil 44. Additionally, helical coil 44 is preferably located with its centerline substantially coaxial with the centerline of wellhead 34a so that workover or wireline equipment (not shown) can be directly lowered through helical coil 44 and through wellhead 34a into the tubing pipe. To permit such operation, the inside diameter of helical coil 44 should be sufficiently large to permit the passage of the workover and wireline equipment therethrough.

Helical coil 44 should be manufactured from a material which combines optimal properties of strength, elasticity, and durability. Preferably, helical coil 44 is manufactured from a metal such as AISI 4130 steel which has been heat treated to a yield strength 80 KSI. Although helical coil 44 may be manufactured from various materials such as elastomers, plastics or other nonmetallic compounds, such materials are typically less strong than metals. Moreover, many nonmetallic materials are subject to deterioration induced by chemical compounds such as hydrogen sulfide or carbon dioxide which are found in a sour production fluid. As such materials deteriorate they must be periodically replaced to prevent failure of the fluid-carrying system. Finally, a metallic helical coil is less susceptible to fire damage because metals have a higher melting point than many non-metallic materials which are otherwise suitable in a helical coil.

The torsional deflection of helical coil 44 as it elongates or is compressed can be modeled by applying fundamental spring equations well-known in the art. The equations will depend upon the physical properties and configuration of a particular helical coil. For example, the stiffness of a helical coil can be varied by altering the yield strength of the material used. In addition, a helical coil manufactured from rectangular tubing will have a different moment of inertia than a helical coil manufactured from cylindrical tubing. Additionally, the size, shape, and number of turns in a helical coil will determine the dynamic response of the helical coil. For example, a conical helical coil will respond differently than a cylindrical helical coil to a particular displacement. Also, a reduction in the diameter of a helical coil will increase its stiffness while an increase in the diameter of a helical coil will reduce its stiffness. Moreover, an increase in the number of turns of a helical coil will reduce its stiffness while a reduction in the number of turns will increase its stiffness. Each helical coil can therefore be sized to accommodate the displacement anticipated in a given application.

A plurality of fluid-carrying systems, each having a helical coil, can be closely spaced together in an offshore structure. Preferably, when the structure is at its equilibrium postion, each helical coil is neither in compression nor in tension. The dynamic response of helical coils in a guyed tower is typical of such movement in compliant offshore structures. At equilibrium, the helical coils are preferably unstressed. As a loading force (F) displaces the guyed tower from its equilibrium position, the stress on each helical coil will vary according to the location of the helical coil in reference to the horizontal deck of the guyed tower. For example, certain helical coils, located along a vertical plane which intersects the center of the guyed tower but which is perpendicular to the displacing force, will remain unstressed. Other helical coils located at a distance from such vertical plane will be compressed or tensioned to compensate for movement of the guyed tower. The present invention automatically compensates for movement of a compliant offshore structure whether such movement compresses or elongates the helical coils.

If an offshore structure should be damaged due to a storm or accident, the helical flowline in the present invention will tend to plastically deform and thereby resist fracturing of the helical coil. Such fracturing could result in loss of fluids from the fluid-carrying system into the ambiance. If the displacement of the helical coil is compressive, the coils will "ground" against themselves and the helical coil will essentially accommodate the axial compressive force as a solid member. If the helical coil is elongated, the helical coil will tend to straighten. In either event, the helical flowline will accommodate an excessive deforming force through compressive or elongating deformation while resisting failure of the fluid-carrying system.

FIG. 3 illustrates and alternative embodiment of the present invention. Each element of the alternative embodiment is similar to a corresponding element in the preferred embodiment illustrated in FIGS. 1 and 2 except that bending coil 52 is substituted for helical coil 44. While helical coil 44 flexes due to torsional deflection, bending flowline 52 flexes due to bending deflection. Accordingly, the mathematical equations describing such bending deflection differ from those which describe torsional deflection. However, such bending equations are also well-known in the art and may be applied to varying configurations of bending coils.

The present invention is thus advantageous over flexible flowlines, slip joints, and swivel combinations in accommodating movement of a compliant offshore structure. Such movement is accommodated while fluids are conveyed between the offshore structure and the sea floor. The helical coils accommodate large displacements relative to spring size through elastic movement. In the event of excessive displacements due to a storm or accident, the helical flowline will resist failure by plastically deforming. The helical flowline in the present invention need not contain any sharp bends which are susceptible to pipe erosion due to hard particles such as sand in the production fluid. In addition, the helical coil amy comprise one piping member or a bundle of separate piping members. Because the present invention eliminates the need for elastomeric seals, the fluid-carrying system will resist corrosive fluids and will not leak.

Inasmuch as the present invention is subject to many variations, modifications, and changes in detail, it is intended that all subject matter discussed above or shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense.