CN115734914A - Unmanned vessel for offshore hydrocarbon production, storage and offloading - Google Patents

Abstract

A vessel for offshore hydrocarbon production, storage and offloading to be located on a body of water comprises a hull, a hydrocarbon processing plant and a mooring system. The vessel comprises a topsides structure holding hydrocarbon processing plants arranged longitudinally in at least three sections, with non-hydrocarbon processing modules installed in a first section, low pressure/low explosion risk hydrocarbon processing modules in a second section, and high pressure hydrocarbon gas and toxic compounds processing modules in a third section. The vessel is provided with one or more central processing and/or maintenance structures. The track is provided at a level above or at the top level of the section and is configured for holding the one or more structures and allowing the structures to travel on the track.

Description

Unmanned vessel for offshore hydrocarbon production, storage and offloading

Technical Field

The present invention relates to a vessel (vessel) for offshore hydrocarbon production, storage and offloading. The invention further relates to a method for manufacturing such a ship.

Background

While in the offshore industry unmanned wellhead facilities are very sophisticated and have 40 year track records, the smallest man-made facility to perform process elements (separation, dewatering or compression) offshore is far from the same. In particular, the operation of a floating installation such as a floating hydrocarbon production, storage and offloading platform or vessel still requires a large number of personnel, for example consisting of production personnel, maintenance personnel and support personnel. Typically, a vessel or platform (hereinafter referred to as an FPSO) is located off shore and personnel remain on the FPSO for a relatively long time. Thus, a relatively large portion of the FPSO is used in facilities to support personnel.

In addition, in the prior art, the treatment plant is arranged and laid out in such a way that it can be operated by a person, which may not be an optimal layout for hydrocarbon treatment.

It is an object of the present invention to overcome or alleviate the disadvantages of the prior art.

Disclosure of Invention

This object is achieved by a vessel for offshore hydrocarbon production, storage and offloading to be located on a body of water, the vessel comprising a hull, a hydrocarbon processing plant and a mooring system.

The vessel comprises a topsides structure holding hydrocarbon processing apparatus extending longitudinally from stern to bow and arranged in at least three sections, wherein non-hydrocarbon processing modules are mounted in a first section, low pressure/low explosion risk hydrocarbon processing modules are in a second section, and high pressure hydrocarbon gas and toxic compounds processing modules are in a third section, the second section being between the first and third sections, wherein,

the vessel is provided with one or more central processing and/or maintenance structures;

the track is disposed at a level above or at the top level of the section;

the track is configured for holding one or more central processing and/or maintenance structures and allowing the structures to travel on the track.

According to an embodiment, a vessel as described above is provided, wherein the track comprises a rail and/or a plate-like structure on which one or more structures can travel.

According to an embodiment, a vessel as described above is provided, wherein the track extends substantially along the length of the vessel.

According to an embodiment, a vessel as described above is provided, wherein the track is arranged along a side wall of the hull or a centre line of the vessel.

According to an embodiment, a vessel as described above is provided, wherein the central processing and/or maintenance structure is a maintenance structure equipped with a high capacity lifting device and the ability to deploy one or more robotic devices on the topsides structure.

According to an embodiment, a vessel as described above is provided, wherein the central processing and/or maintenance structure is a maintenance structure equipped with one or more robot arms on which the robotic devices are mounted.

According to an embodiment, a vessel as described above is provided, wherein the topside structure comprises one process deck or a plurality of process decks positioned at different levels above each other, and optionally between and along each process deck of the respective process modules, a service aisle is provided, wherein each service aisle is configured to be accessed by a robotic device.

According to an embodiment, there is provided the vessel described above, wherein each processing deck comprises a garage for holding the robotic device, and optionally the garage is provided with an elevator for allowing the robotic device to move between different levels of the processing deck.

The garage provides docking for the robotic device not in use and protects the robotic device from the offshore environment. Additionally, the garage has a space for storing tools and equipment spares used by the robotic equipment. Additionally, the garage may be provided with a power supply to which the robotic device may be connected for recovering its energy level.

The elevator provides that the robot device can be transferred from one treatment deck level to another. In this way, devices may be shared between various deck levels, if desired. In addition, the elevator may be controlled by the robotic device in such a way that the robotic device may autonomously move between the various deck levels.

According to an embodiment, a vessel as described above is provided, wherein on at least one process deck, a high energy rotary apparatus comprising at least a generator and a compressor is arranged on the outside of each process module adjacent to the hull side wall, the high energy apparatus being configured with a coupling for detachable coupling with other components of the process module and comprising a connector for a crane on the apparatus.

Such an arrangement allows for relatively easy access to the types of equipment that typically require relatively frequent maintenance and/or replacement that may exceed the service capabilities of the robotic equipment. By providing a connector for the crane on the device, the device can be removed or replaced by a crane on the vessel, but alternatively also by a crane on the support vessel.

According to an embodiment, a vessel as described above is provided, wherein on the at least one process deck the static equipment is arranged on the inner side of the process modules facing away from the hull side walls. This equipment generally requires less maintenance or replacement and therefore can be located further away from the support vessel. In addition, this type of equipment can be completely serviced by the robotic equipment.

According to an embodiment, there is provided the vessel described above, wherein the at least one processing deck comprises a longitudinally extending central corridor and the track is arranged above the central corridor.

According to an embodiment, there is provided the vessel described above, wherein the central corridor comprises at least one service aisle for one or more robotic devices deployed from one or more central processing and/or maintenance structures.

According to an embodiment, a vessel as described above is provided, wherein the hull is provided with a central vertical passage for arranging and accommodating a riser connecting between a subsea hydrocarbon well at the production location and the hydrocarbon processing plant, wherein optionally the third section is positioned adjacent to the bow and above the central passage.

The FPSO according to this embodiment is configured for spread mooring such that it will have a fixed orientation at a location above the offshore hydrocarbon field. In addition, a central passage is provided inside the hull to allow risers, pipelines, etc. to enter the vessel. This arrangement of risers allows the riser balcony to be removed to free up space for ship-to-ship access along the sides of the hull. This creates flexibility so that the support vessel can freely access the FPSO from either side for maintenance or other necessary intervention activities. Furthermore, arranging the treatment devices in three different zones having different operational tasks allows the hydrocarbon production process to become safer as the process flow substantially follows the zone arrangement.

According to an embodiment, the vessel further comprises a flare stack, wherein the flare stack is located at the stern adjacent to the first section of the treatment module; and/or comprises an auxiliary equipment module comprising at least a metering unit, at least one auxiliary generator and a pump unit, wherein the auxiliary equipment module is located between the stern and the first section of the treatment module; and/or further comprising an offloading device, preferably located at the stern, having a floating hose for coupling to the shuttle tanker, and wherein the offloading device comprises a docking station for docking the free end of the floating hose when the floating hose is not coupled to the shuttle tanker.

By positioning the flare stack between the stern and the first section, the flare is isolated from the second and third sections of the processing apparatus that have a relatively high risk of explosion when exposed to a fire. According to the prior art, the auxiliary equipment will be placed inside the hull. In this embodiment, by placing the apparatus on deck, relatively more hull volume is available for fluid storage of liquid chemicals used in the hydrocarbon production process.

According to requirements, the devices may be stacked, allowing for arranging devices of comparable risk within the same section.

In some embodiments, between and along each process deck of the respective process modules, a service aisle is provided, wherein each service aisle is configured to be accessed by robotic equipment. The service aisle that exists between and along the process modules allows maintenance processes to be carried out by the robot devices that are designed to interact with the process modules. According to the required maintenance, the robot device is provided with tools specifically for carrying out the maintenance.

According to an embodiment, there is provided the vessel described above, wherein the at least one process deck comprises a central corridor extending longitudinally and containing an area for one or more interconnected pipe racks between various equipment within the process modules on the process deck.

According to an embodiment, the vessel described above is provided, wherein the central corridor comprises at least one service corridor for robotic equipment.

In some embodiments, there is provided a vessel as described above, further comprising an offloading device, preferably located at the stern, having a floating hose coupled to the shuttle tanker, and wherein the offloading device comprises a docking station for docking a free end of the floating hose when the floating hose is not coupled to the shuttle tanker.

In some embodiments, a vessel as described above is provided, wherein the hull is configured for allowing access to the vessel by walking commuters via gangways at each hull side wall, preferably providing an outboard extending landing porch.

Drawings

The invention will be explained in more detail below with reference to the drawings, in which illustrative embodiments of the invention are shown. The drawings are intended for illustrative purposes only. The scope of the invention is only limited by the definitions given in the appended claims.

Fig. 1 shows a perspective view of a vessel according to an embodiment;

figure 2 shows a perspective view of the hull part of the vessel of figure 1;

fig. 3A, 3B show a perspective view and a top view, respectively, of the area of a process module on a ship, and

figure 4 shows a cross-sectional view of the area of the process module on the vessel.

Detailed Description

Fig. 1 shows a perspective view of a vessel 100 according to an embodiment.

According to an embodiment of the invention, an offshore hydrocarbon production, storage and offloading vessel 100 is provided for mooring at an offshore location above an oil and/or gas field. The vessel is moored in this position by spread mooring using mooring lines 110, which mooring lines 110 are attached to seabed anchors (or piles), not shown here. Alternatively, vessel 100 may be configured with a turret mooring system.

On board the vessel 100, hydrocarbon processing equipment is located on a topsides structure of a process deck including one or more process deck layers. The process deck comprises at least three sections 20, 21, 22, 23.

In the first section 20, non-hydrocarbon processing modules associated with processes that do not involve processing hydrocarbons are installed.

In the second section 21, a low pressure/low explosion risk hydrocarbon processing module is installed in connection with processing hydrocarbons from the feed during operation at a relatively low pressure and/or low explosion risk.

The process involving high pressure hydrocarbon gas and toxic compounds is operated in the third section 22 of the hydrocarbon processing module.

The first section, the second section and the third section are arranged longitudinally on the vessel. A second section 21 with a moderate risk of explosion is located between the first section 20 and the third section 22.

In an embodiment, the third high risk section 22 is located adjacent to and/or above the central passage. The low risk first section 21 is located adjacent the stern of the vessel.

Depending on the risks involved in the process running in the additional section, the additional section 23 may be installed in the topsides structure on the side of the third section or the first section.

For example, the additional section 23 may comprise a device for high pressure hydrocarbon entry. As shown in fig. 1, the additional section 23 is located adjacent to the third section 22.

According to an embodiment, spacers in the topsides structure are provided between the sections to protect the sections from each other.

The topsides structure may include one or more cranes (26, see fig. 2).

According to an embodiment, a rail 70 is provided at a level above the top level of the sections 20, 21, 22, 23 or at the top level of the sections 20, 21, 22, 23, which rail is configured for travel of one or more central handling and/or maintenance structures (not shown). The track may comprise a rail and/or a plate-like structure on which one or more central processing and/or maintenance structures may be moved.

In a preferred embodiment, the track 70 extends substantially along the length of the vessel. Depending on the layout of the freeboard structure of the sections, the tracks may be arranged, for example, along the sidewalls of the hull or along the centerline of the vessel.

In this way, the movable central processing and/or maintenance structure may be located at any position above the sections. The function of the one or more central processing and/or maintenance structures will be explained in more detail with reference to fig. 2 to 4.

Fig. 2 shows a longitudinal section of the vessel of fig. 1.

On the track 70, one or more central processing and/or maintenance structures are positioned. In the exemplary embodiment, two central processing and/or maintenance structures 71, 72 are provided. In this example, the first structure 71 is a maintenance structure equipped with a high capacity lifting device and the ability to deploy at least one robotic device. This central processing and/or maintenance structure 71 is configured to deploy a robot 73 at a certain location on the hull, for example at a certain location in one of the sections, where the robot can perform some operation such as maintenance.

Further, the second structures 72 are arranged at different positions on the track. The second central processing and/or maintenance structure 72 is equipped with one or more robotic arms 74. Thus, the second central processing and/or maintenance structure 72 is configured to perform local operations in one or more sections by means of the robotic arm 74. Similar to the first structure 71, the second structure 72 may be moved to a selected position on the track requiring operation of the robotic arm.

The robot and/or robotic arm is configured to operate autonomously or by remote control via a wired (electrical or optical) connection or by a wireless connection. In an embodiment, the wireless connection is provided by a satellite link.

According to an embodiment, a flare stack 28 comprising a flare tank is located at the stern 25 of the ship, remote from the second and third sections 21, 22, 23 having a relatively medium and higher risk of explosion.

Inside the hull, the vessel comprises storage tanks 30, 31, 32 for hydrocarbons and by-products.

According to an embodiment, the offloading system 33, 34 is arranged at the stern of the vessel. The offloading system comprises a pumping system 33 and at least a floating hose 34, which floating hose 24 is connected at one end to an offloading point on the vessel. The other free end, which is configured to float on the water surface, is arranged to be connected to a shuttle tanker (tanker) during the unloading process. When not in use, the free end of the floating hose may be connected to the vessel near the water line. The use of a permanently floating hose facilitates a relatively easy connection process with the tanker and reduces the duration of the offloading process.

Typically, the floating hose may have a length of at least 250 meters to allow for a safe distance between the vessel and the tanker.

Optionally, the hull 10 of the vessel is provided with a central vertical passage 27 through which risers from oil and/or gas fields enter and are connected to hydrocarbon processing equipment on the vessel to provide processed oil and gas from the field. In addition, other connections to subsea equipment (such as power or communication lines) may be arranged to enter the vessel through the central passage. With this alternative arrangement of risers and other lines in the central channel, there is no need for a riser balcony arrangement for connecting the marine risers to the side walls of the hull 10. By keeping the sidewalls free, the support vessel can moor directly to the vessel on each of the sidewalls. In this optional arrangement, vessel-to-vessel access will be improved. Inside the hull 10, a central channel 27 is arranged, which central channel 27 serves as a passage for risers connecting the subsea wells 120, 125 with hydrocarbon processing equipment on board the vessel. In addition, the central passage 27 may be used as a passage for other lines and conduits, such as power and communication lines and water injection lines. The central passage 27 may be a moon pool or may consist of a central section in the hull 10, with one or more pipes passing through the hull.

Fig. 3A, 3B show a perspective view and a top view, respectively, of a process module area 40 on a ship.

In fig. 3A, a topsides structure 20, 21, 22, 23 according to an embodiment is depicted. The topsides structure includes a plurality of process decks 42, 43, 44 located above each other at various levels from the top deck of the hull. On the process deck, the (hydrocarbon) process equipment 45, 46 is installed as explained above with reference to fig. 1. The number of layers of the treatment deck may vary from one to three or more, depending on the area required for the treatment facility.

In an embodiment, the rails 70 are arranged at the sides of the topmost deck 42 such that the rails extend along the length of the vessel and the central processing and/or maintenance structure 71, 72 can be moved along the sides.

On each layer 42, 43, 44 of the process deck, an infrastructure 50 is laid out to guide the robotic equipment 51, 52 deployed by the first structure 71 to a location on the deck, for example to service the process equipment 45, 46. As shown in fig. 3B, on the process deck, there is an infrastructure comprising an aisle 50 detectable by the robotic devices 51, 52. Additionally, the infrastructure may comprise a plurality of (electronic) beacons 53 detectable by the robotic device for navigation.

According to an embodiment, the lifting device of the first central processing and/or maintenance structure 71 is configured for transporting the robot to any of the levels 42, 43, 44 in the processing sections 20, 21, 22, 23 if the section is provided with a vertical upper pull-off 75 on each level.

The infrastructure has a layout that enables the robot to position itself to a predetermined position near the process module to perform a particular maintenance or repair on the module.

The robots 51, 52 may be configured with dedicated tools for specific maintenance tasks. Alternatively, the robot may be arranged to exchange tools depending on the actual maintenance task to be performed.

In the case of a robotic arm with a robot attached to the second structure 72, the second central processing and/or maintenance structure 72 may be moved along the rails 70 to the location of a target device on which the robotic tool 73 mounted on the robotic arm may act. The robotic arm is typically configured as a manipulator to position and align the robotic tool with the target device.

The topsides structure also includes one or more garages 54 to store robotic equipment on various levels of the process deck (see fig. 3A). The garage is included in a layout on the process deck so that the robotic device can reach the location of the garage.

According to an embodiment, the garages on the various levels of the processing deck are positioned above each other and configured with elevators to allow the robotic devices to travel from one level of the processing deck to another.

In an alternative embodiment, the garage and elevator are separate units.

According to an embodiment, on the process deck, one or more garages 54 may be arranged for storing and housing unused robotic equipment. Additionally, the garage may be used as a storage space and to exchange various tools used by the robotic device. Preferably, the one or more garages include one or more docking stations for providing energy to the robotic devices.

Fig. 4 shows a cross-sectional view of the process module area 40 on the vessel 100.

In fig. 4, the topsides structure is shown in a transverse direction across the vessel.

In this exemplary embodiment, the freeboard structure includes three layers of process decks 42, 43, 44. A corridor 55 is arranged along the centre line of the vessel 100, which corridor 55 comprises areas for interconnecting pipe racks 56 and longitudinal passages 57 for robots and transport equipment. On each side of the corridor, a treatment device 45, 46 is arranged on the treatment deck level. The track 70 is disposed above the corridor 55, allowing one or more movable central handling and/or maintenance structures 71, 72 to perform robotic maintenance on either side of the track. As described above, the structure 71 may be configured to deploy the robotic device at any of the layers 42, 43, 44 in the treatment section.

In some embodiments, the rails 70 have a width that allows the central processing and/or maintenance structures 71, 72 to pass each other.

According to an embodiment, the processing equipment is distributed between the side walls and corridor areas corresponding to the (estimated) maintenance requirements of the equipment. The processing equipment with higher requirements is arranged in an outer part 60 of the processing deck adjacent to the side walls and the other equipment is arranged in an inner part 61 closer to the corridor area. Further, the handling equipment in the outer part is configured to be removed by the support vessel using a crane. In this way, the equipment may be removed for maintenance or repair and replaced with another equipment delivered by a support vessel (not shown). Alternatively or additionally, the crane 26 may be located on the vessel 100.

Processing equipment with higher maintenance requirements includes dynamic equipment, such as rotating equipment: generators, pumps, etc. Equipment with lower maintenance requirements includes static equipment such as separators, scrubbers, storage tanks, valve equipment, and the like.

It will be appreciated that the offshore hydrocarbon production, storage and offloading vessel as described above may also be embodied as a circular FPSO type vessel configured for extended mooring at a production location and having a hull provided with a central passage for arranging and accommodating risers connected between a subsea hydrocarbon well at the production location and a hydrocarbon processing plant.

The circular FPSO is configured to have a topside structure holding a hydrocarbon processing plant segmented into at least three sections with non-hydrocarbon processing modules installed in a first section, low pressure/low explosion risk hydrocarbon processing modules in a second section and high pressure hydrocarbon gas and toxic compounds processing modules in a third section. Partition walls may be placed between the sections for protection.

In a similar manner as described above, the freeboard structure comprises one treatment deck or a plurality of treatment decks positioned at different levels above each other.

Between and along each process deck of the respective process modules, service aisles may be provided, wherein each service aisle is configured to be accessed by robotic equipment. Each processing deck may include a garage for holding robotic equipment, which may be connected to other processing decks by an elevator.

The invention has been described with reference to the preferred embodiments. Obvious modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims.

Claims (15)

1. Vessel for offshore hydrocarbon production, storage and offloading to be located on a body of water, comprising a hull of a vessel type, a hydrocarbon processing plant and a mooring system,

the vessel comprising a topsides structure holding the hydrocarbon processing apparatus extending longitudinally from stern to bow and arranged in at least three sections with non-hydrocarbon processing modules mounted in a first section, low pressure/low explosion risk hydrocarbon processing modules in a second section and high pressure hydrocarbon gas and toxic processing modules in a third section, the second section being located between the first and third sections, wherein the vessel is provided with one or more movable central processing and/or maintenance structures;

the rail is provided at a level above or at the top level of the sections,

the track is configured for holding the one or more central processing and/or maintenance structures and allowing the structures to travel on the track.

2. Vessel according to claim 1, wherein the track comprises a guide rail and/or a plate-like structure on which the one or more central processing and/or maintenance structures can travel.

3. Vessel according to claim 1 or 2, wherein the track extends substantially along the length of the vessel.

4. A vessel according to any of claims 1 to 3, wherein the track is arranged along a side wall of the hull or a centre line of the vessel.

5. Vessel according to any of the preceding claims, wherein the central processing and/or maintenance structure is a maintenance structure equipped with high capacity lifting equipment and the ability to deploy one or more robotic devices on the topsides structure.

6. Vessel according to any of the preceding claims 1 to 4, wherein the central processing and/or maintenance structure is a maintenance structure equipped with one or more robot arms on which robotic devices are mounted.

7. The vessel according to any of the preceding claims 1 to 6, wherein the topsides structure comprises one process deck or a plurality of process decks positioned at different levels above each other, and optionally, between and along each process deck of the respective process modules, a service aisle is provided, wherein each service aisle is configured to be accessed by a robotic device.

8. The vessel according to claim 7, wherein each processing deck comprises a garage for holding the robotic device, and optionally the garage is provided with a lift for allowing the robotic device to move between different levels of the processing deck.

9. Vessel according to any of the preceding claims, wherein on at least one process deck a high energy rotary apparatus comprising at least a generator and a compressor is arranged on the outside of each process module adjacent to the hull side wall, the high energy apparatus being configured with a coupling for detachable coupling with other components of the process module and comprising a connector for a crane on the apparatus.

10. Vessel according to any of the preceding claims, wherein on the at least one process deck static equipment is arranged on the inner side of the process modules facing away from the hull side walls.

11. Vessel according to any of the preceding claims, wherein the at least one processing deck comprises a longitudinally extending central corridor and the track is arranged above the central corridor.

12. The vessel according to claim 11, wherein the central corridor comprises at least one service corridor for one or more robotic devices deployed from the one or more central processing and/or maintenance structures.

13. Vessel according to any of the preceding claims, wherein the hull is provided with a central vertical passage for arranging and accommodating a riser connecting between a subsea hydrocarbon well at a production location and the hydrocarbon processing plant,

wherein optionally the third section is located adjacent the bow and above the central passage.

14. The vessel according to any one of claims 1 to 13, further comprising a flare stack, wherein the flare stack is located at the stern adjacent to the first section of the treatment module; and/or

Comprising an auxiliary equipment module comprising at least a metering unit, at least one auxiliary generator and a pump unit, wherein the auxiliary equipment module is located between the stern and the first section of the treatment module; and/or

Further comprising an offloading device, preferably located at the stern, having a floating hose for coupling to a shuttle tanker, and wherein the offloading device comprises a docking station for docking a free end of the floating hose when the floating hose is not coupled to the shuttle tanker.

15. Vessel according to claim 13 or 14, wherein power cables, control cables and communication cables enter the vessel through the central vertical passage.

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