WO2007011237A2 - Unmanned platform maintenance - Google Patents

Unmanned platform maintenance Download PDF

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Publication number
WO2007011237A2
WO2007011237A2 PCT/NO2006/000279 NO2006000279W WO2007011237A2 WO 2007011237 A2 WO2007011237 A2 WO 2007011237A2 NO 2006000279 W NO2006000279 W NO 2006000279W WO 2007011237 A2 WO2007011237 A2 WO 2007011237A2
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WO
WIPO (PCT)
Prior art keywords
equipment
module
deck
area
personnel
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Application number
PCT/NO2006/000279
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French (fr)
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WO2007011237A3 (en
Inventor
Finn WICHSTRØM
Jon Liverud
Original Assignee
Aker Kværner Engineering & Technology As
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Publication of WO2007011237A2 publication Critical patent/WO2007011237A2/en
Publication of WO2007011237A3 publication Critical patent/WO2007011237A3/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21BEARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/01Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells specially adapted for obtaining from underwater installations

Definitions

  • the present invention regards an arrangement in accordance with the preamble of the appended Claim 1 or 4.
  • the invention also regards a module in accordance with the preamble of the appended Claim 10.
  • the equipment is located on installations above the surface of the sea, or on shore.
  • the invention makes it possible to carry out the necessary work on the equipment without requiring the operators performing these operations to be present near the site of the operations.
  • the invention is instrumental in making it possible to process hydrocarbons without exposing any personnel to the risks involved in this process.
  • the invention also aims to improve the utilization of space on the platform deck and lighten the structure in order to make it possible to construct and operate the equipment in a more cost effective manner.
  • process equipment is currently arranged, and has been for over 100 years, is based on allowing personnel access to all process equipment, and requires the physical presence of people in those places where inspection, operation, maintenance and replacements are carried out. Although a certain degree of remote control has been achieved over time, it is still assumed that the process must be controlled by personnel present at the processing site.
  • a conventional arrangement is oriented relative to horizontal surfaces where personnel can move around, and everything is set up for manual handling of devices for inspection, operation, maintenance and replacement.
  • This type of arrangement is highly work preserving, i.e. it requires a lot of manpower in the areas where the equipment is located.
  • the operating costs are high because it requires the physical presence of personnel at the equipment to be inspected, maintained and replaced.
  • These operations require skilled personnel, and in many cases the rigging of lifting and transportation equipment.
  • These lifting devices inside the process plant will, in the case of conventional designs, require the presence of fixed points or rails above the equipment to be lifted. These fixed points or rails will either have rigidly mounted lifting devices or manual lifting devices are mounted prior to each operation.
  • the process area comprises several deck levels. These decks act as fixed access bases for operators of the equipment. During the construction, these decks may complicate and prolong the building process, because any equipment delivered behind schedule becomes difficult to install. The depth of the deck areas and the lack of free access from above to the areas in which the equipment is to be installed, can make the installation of this equipment expensive and time consuming.
  • the invention aims to provide:
  • This grid system will be used to identify the positioning of all instrumentation, components, pressure vessels, pipes and structures in said area, making it possible to locate these by use of electronic systems.
  • This grid system will also be used to ensure that the movement of the movable craft can be planned, either manually or electronically, so as to avoid collisions. In addition, lifting and hauling operations will be carried out in an optimal manner. Part of said system is covered by conventional equipment retrieval technology currently used for storage control. 3. All pipes and structural units will receive electronic coordinates, making it possible to manoeuvre devices for inspection and maintenance along these and to identify positions for observations and actions.
  • the access device itself to visit a series of individual components, visually logging (with a camera) the state of manual sight glasses and manometers.
  • the access device carries its own camera, lights, microphones, fire and gas detectors, noise or vibration detectors; and 5. an arrangement of process equipment oriented according to access areas in the vertical plane in order to favour access by mechanical equipment for gripping, retaining and transporting components or a collection of components. This can also be done in those locations where there is little clearance above the equipment.
  • a reduction in explosion loading on the process area through making it more open to explosion venting by having no fixed decks over the process equipment and by having open transportation areas between the racks in which process equipment and piping is installed.
  • one or more overhead travelling cranes as a mobile base for the equipment for personnel access to the process equipment, and for the devices that inspect and maintain the equipment, makes it possible to haul/manoeuvre even heavy equipment in both the vertical and horizontal planes. This provides a possibility for replacing even heavy assemblies of equipment, vessels and pipes, even with small clearances to other process equipment in the horizontal and vertical direction.
  • the crane or cranes may be manoeuvred past said wall and into the area that personnel can access for shorter or longer periods. This is expedient when it comes to changing equipment which is later to be used for inspection, operation, maintenance, lifting and hauling.
  • the same cranes may be manoeuvred so as to allow floating transport vessels to be positioned directly underneath them, the cranes carrying out the operations either singly or jointly in a coordinated fashion.
  • the lifting and hauling tool has been rendered independent of deck level and may be operated in a way that allows all required positions to be reached based on manual or automatic positional navigation (such as is presently used for storage control).
  • the plane or planes of reference are constructed in such a way as to allow several devices for inspection, operation, maintenance and replacement to be operated independently of each other, or their actions may be coordinated.
  • the lifting and hauling tool can be made powerful enough to carry out even heavy lifting in areas with little vertical clearance above the equipment to be lifted or hauled. This can also be done when manoeuvring heavier equipment than that which is considered normal today. Today it is normal to use expensive floating lifting vessels for heavy lift operations. Use of e.g.
  • a travelling gantry crane will allow practically all lifting operations into the area of the process equipment to be carried out without the use of floating cranes (which are currently expensive, i.e. approximately 1-3 MNOK/day). This also applies to those operations where a large proportion of the process equipment is to be replaced, e.g. to meet the requirements imposed through the nature of the reservoir and in export contracts.
  • Lifting, hauling, inspection and installation can be performed without the presence of any personnel near the areas of the actual physical activity. This allows a design of safety and working environment during operation of the process which would not be acceptable in an area where personnel are required to carry out these operations. This will lead to a reduction in costs related to conventional design, as radiation protection, escape routes, lighting, warning lights, loud speakers and general weather protection can be eliminated.
  • Non-destructive testing of material thickness in pipes, pressure vessels and structural steel is performed by said devices for inspection, operation, maintenance and replacement. These operations will take place independently of deck level and independently of the physical presence of personnel at the test site.
  • One of the advantages of this form of effective testing is that it opens up for more efficient corrosion and fire protection which requires less space and less maintenance.
  • a radiation shield for the gas flaring system is used to quickly depressurize the system to atmospheric pressure. This type of operation is carried out prior to allowing personnel access to the area. Using such a wall to split up the installation sets up two clearly divided regimes for inspection, operation, maintenance and replacement, and also for safety, working environment and personnel access to equipment.
  • a mechanical tool to carry out inspection, operation, maintenance and replacement of equipment will make it possible to utilize centrally located expertise — located in e.g. an operations centre on shore - to analyze and operate several platforms simultaneously. This can be done by mounting e.g. lighting, web cameras, microphones, fire and gas detectors etc. on this tool, or tools for gripping, screwing, lifting or pulling.
  • the object of the invention is also to arrange process equipment in such a way as to allow operation of the equipment without the presence of any personnel near the physical operations. Both inspections, operation, maintenance and replacements are performed by remote controlled tools, with the operator of these tools sitting in a completely different location from that of the physical site of operations.
  • One aspect of the invention is that the arrangement of all equipment to which access must be provided, is arranged in vertical planes at a sufficiently short distance from areas in which the access tool can move.
  • Mechanical devices for gripping, retaining and transporting equipment are made independent of deck level. • Mechanical devices can be placed in a more compact arrangement, as the space requirements are determined only by the access needs and operation of the mechanical tool.
  • this can be achieved if it is possible to get in with the mechanical tool from one or more planes of reference located above the equipment.
  • the invention regards a process module or modules that can be attached to an operative platform.
  • the object of this is to establish a solution for construction and modification of existing platforms which leads to a reduction in the weight, size and cost of process modules. It is equally important to reduce the number of interfaces between the original platform and the new process module(s). This can be achieved by processing the wellstream as far as possible in the new process module(s), requiring a minimum of support systems from the platform. Reducing the need for platform modifications, and also reducing the number of interfaces (piping, joints, instrumentation cabling, electronics cables), will reduce the scale and duration of any modification and installation work.
  • this may be done through complete separation in a new process module prior to bringing processed oil streams together.
  • the process may comprise only partial processing in such a module and final processing in the existing process plant.
  • the new concept will result in significantly improved financial conditions compared with conventional tie-in modules.
  • such a module may provide the following benefits:
  • the new tie-in process module is intended as a cantilever on an existing platform.
  • the new process module is based on maximum utilisation of compact process technology and equipment of a limited weight and with a limited requirement for space.
  • the new process module may among other things be implemented as follows:
  • the module is tall and narrow in order to limit the structural loading on the existing platform.
  • Access is via the access platform, which can travel in the vertical and horizontal planes for access along module levels and access to different heights.
  • the access platform is supported by a movable steel structure with a lifting tool (crane solution) which can move in the same plane.
  • a lifting tool crane solution
  • the module comprises no transport corridors or access routes, stairs or ladders, as all access takes place via the external access platform and remote controlled devices for inspection, operation, maintenance and replacement.
  • the equipment in the module can be constructed for easy loading or removal through modularised installation/loading solutions where the equipment can be skidded on separate rails in the modules during installation/loading and then locked in position.
  • Figure 1 shows an offshore production platform where part of the deck is equipped with process equipment arranged in accordance with the principles of the present invention
  • Figure 2 shows the deck area of Figure 1 laid out in accordance with the invention
  • Figure 3 is a side view of the deck area of Figure 2;
  • Figure 4 is a schematic diagram showing the layout of the deck area according to the invention.
  • Figure 5 shows a rack for equipment according to the invention
  • Figure 6 shows an attachment module provided with a rack
  • Figure 7 shows the attachment module of Figure 6 with an integrated lifting device
  • Figure 8 is a top view of the attachment module of Figure 8.
  • Figure 9 shows the process plant on the platform tied in to the process units in the attachment module.
  • Figure 1 shows an offshore platform comprising a support structure 1 which supports a main module deck 2.
  • One area 3 of the deck 2 is reserved for process equipment.
  • This deck area 3 is shut off from the rest of the deck 2 by a fire wall 4 which is to prevent any fires and explosions from spreading from the deck area 3 to other parts of the deck, and which is to act as a shield against radiation from the flare and as a noise barrier against that part of the installation to which personnel has access when the installation is operating and pressurized.
  • This wall will also serve as a physical barrier for personnel and makes it impossible to gain access to the process area during operation.
  • the other parts of the deck will among other things hold living quarters and day rooms.
  • a travelling gantry crane 5 is provided in the deck area 3, arranged to travel on rails 6 at the respective outer edges of the deck area 3.
  • the gantry crane 5 comprises two support frames 7 running respective rails, and a crossbeam 8 connecting the support frames 7.
  • the gantry crane 5 is arranged to travel across the entire deck area 3 and preferably also past the wall 4 to the manned part of the platform. This is useful when replacing equipment mounted to the crane and when transporting equipment to the pedestal crane 11, and also for carrying personnel past the wall 4 in a basket carried by the crane, as will be explained in greater detail below.
  • the rails 6 may also be extended past the aft end 9 of the platform, allowing the gantry crane 5 to travel outside the main module deck 2, for instance to lift items from a ship.
  • a knuckle boom crane may be used instead of a conventional crane 11, making it possible to operate with a great degree of precision in the deck area 3.
  • FIG 2 shows the deck area 3 in Figure 1. Also shown is the gantry crane 5.
  • Several racks 12 are provided in the deck area 3. These racks are constructed from simple steel girders joined to form rectangular frame structures.
  • the racks 12 are arranged to support various types of process equipment 13 such as separators, compressors, valves etc.
  • the racks 12 are arranged with a predetermined horizontal spacing so as to form corridors 14 between the racks 12.
  • the racks may also be arranged in stacks of two or more, as shown to the left in the figure, or they may include several levels for arranging process equipment.
  • Figure 3 is a side view of the deck area 3. This also shows the travelling gantry crane 5 and the racks 12.
  • the gantry crane is provided with a movable arm 16 carrying a personnel basket 17. This personnel basket is arranged to move along the corridors 15. The crew may enter the personnel basket 17 when the process plant has been shut down and depressurized. At this point, it will be situated in an appropriate location by the fire wall 4 which gives access for personnel. The personnel may then position the basket in the corridor 15 and at the location which provides access to the equipment for which maintenance is required.
  • the personnel basket 17 will not be used during operation of the process equipment. Any inspection, operation, maintenance and lifting/hauling operations can then be carried out by a remote controlled arm arranged in the gantry crane. Monitoring can be carried out by use of one or more cameras, lighting, fire and gas detectors.
  • the arm may be equipped with different tools, among other things tools capable of retrieving and installing entire process units, e.g. valves or assemblies of pipes, valves, instrumentation and pressure vessels.
  • the gantry crane 5 For replacement of large process units the most appropriate will be for the gantry crane 5 to grip the rack 12 in which the process unit is located, and then to transport it to the aft end 9 of the platform, lifting it over any racks on the outside.
  • Figure 4 is a schematic top view of the deck area 3, showing the racks 12 and the gantry crane 5. Also visible are rails 6. These extend outside the aft end 9 of the platform, thus forming a moon pool 18 aft of the platform area 3. Process units and racks may be lifted on board the platform via this, through use of the travelling gantry crane 5, directly to the designated location in deck area 3.
  • tie-in points The location of tie-in points is predetermined in order to facilitate connection and disconnection of process units. As a result of this, new process units may quickly be connected to the existing process plant. Connection can be carried out by personnel during a shut down of the plant, or it may be performed during operation of the plant, by remote controlled arms equipped with the appropriate tools.
  • FIG. 5 shows a rack according to the principles of the present invention.
  • the rack 12 comprises two levels, each of which holds a separator and associated equipment.
  • the rack may be a unit or consist of a unit for each level, where the upper unit is placed on top of the lower unit.
  • Each rack 12 includes a corridor 15 or free space on at least one long side of the rack /2.
  • the width of the corridors 15 may vary, as the width is adapted according to the equipment to be retrieved or installed via the respective corridor.
  • the equipment may be displaceably mounted on rails in the rack, which allows the equipment unit to be pulled out into the corridor 15 on these rails after being disconnected from adjacent process equipment. Then, after releasing any locking devices between the equipment and the rails, the unit may be lifted up and over the racks 12 to be transported to the moon pool 18. This order is reversed for installation of an equipment unit.
  • the racks 12 may include one or more defined slots for particular types of process units. This makes it possible to leave empty slots in which equipment may be retrofitted.
  • the only requirements for the retrofit unit are that it must not exceed the dimensions of the slot, and that support brackets and tie-in points are positioned according to a predetermined specification.
  • FIGS 6 -9 illustrate another aspect of the present invention, in which module 30 is attached to a platform 31.
  • the module 30 comprises a module deck 32 and a rack 33.
  • the rack 33 has three levels.
  • the module 30 is attached to the platform at the edge of the platform deck 34, and as a continuation of the process equipment area on the platform.
  • the module 30 is attached to the platform 31 by means of fasteners 35 between the module deck 32 and the platform deck 34. Further fasteners 36 between the rack 33 and the nearest rack 37 on the platform deck 34 provide module 30 stabilization.
  • the rack 33 will be permanently fixed to the module deck 32.
  • the module 30 also comprises a lifting device 38, best seen in Figures 7 and 8.
  • This comprises a cantilever beam 39 attached to the top of the rack 33. From the beam 39 there is suspended a telescopic arm 40, the lower end of which is provided with a basket 41. There are rollers 42 arranged in the bottom of the basket. Thus equipment units 43 to be retrieved from the rack 33 or installed in the rack 33 can be rolled in and out on this basket 41.
  • the module 30 may be installed through lifting it from a ship and attaching it to the platform deck 34. After the module has been attached to the platform 31, the process equipment in the module will be connected up to the process equipment on the platform.
  • Figure 9 shows exemplary process equipment in the module 30 (inside the dotted quadrangle) and part of the process equipment on the platform 31 (outside the dotted quadrangle). In this case the platform required more separator capacity due to tie-in of additional wells.
  • the additional wells are tied-in to the process equipment 44 in the module, and separated oil is transferred to the process equipment on the platform via line 45.
  • connection of the process equipment in the module to the process equipment on the platform takes place by use of remote controlled devices.
  • AU access to the process equipment in the module will take place via the lifting device 38, which operates outside the module 30.
  • the module is connected to a conventional process plant where personnel is allowed access also during operation, it will be appropriate for the module and its associated process equipment to be constructed so as also to allow personnel to access this during operation. If the module is connected to a process plant where personnel is not allowed access while the equipment is pressurized, it would be appropriate for personnel not to have access to the module either, as long as this equipment is in operation.

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Abstract

An arrangement of process equipment for treatment of hydrocarbons on an installation comprising a deck (2). The deck comprises a permanently unmanned, area (3) in which the process equipment (13) is located, and to which personnel has no access while the process equipment is pressurized and operating, and a manned area to which personnel normally has access. The permanently unmanned area (3) is separated from the manned area by a fire and explosion proof wall (4) which prevents personnel traffic into the permanently unmanned area (3) while the process equipment is pressurized and operating. The unmanned area (3) holds racks (12) that accommodate the process equipment (13). The racks (12) are located at one or more levels, and each rack has a corridor (14) on at least one side. Access to the process equipment in the racks is via a tool introduced into the corridor (14). There is also a description of a process module (30) for tie-in to an installation (31) for treatment of hydrocarbons. The module (30) is provided with connecting means (35) arranged to secure the module (30) at the edge of the platform deck (34).

Description

UNMANNED PLATFORM MAINTENANCE
The present invention regards an arrangement in accordance with the preamble of the appended Claim 1 or 4. The invention also regards a module in accordance with the preamble of the appended Claim 10.
It is an object of the invention to facilitate access to, inspection and maintenance of equipment for treatment of hydrocarbons without requiring the physical presence of any operators during the operation of this equipment. The equipment is located on installations above the surface of the sea, or on shore. The invention makes it possible to carry out the necessary work on the equipment without requiring the operators performing these operations to be present near the site of the operations. The invention is instrumental in making it possible to process hydrocarbons without exposing any personnel to the risks involved in this process.
The invention also aims to improve the utilization of space on the platform deck and lighten the structure in order to make it possible to construct and operate the equipment in a more cost effective manner.
The way process equipment is currently arranged, and has been for over 100 years, is based on allowing personnel access to all process equipment, and requires the physical presence of people in those places where inspection, operation, maintenance and replacements are carried out. Although a certain degree of remote control has been achieved over time, it is still assumed that the process must be controlled by personnel present at the processing site.
On installations being built today (both offshore and onshore), the arrangement of equipment is related to horizontal planes (i.e. decks and access routes). This is done to allow access for personnel and personnel-operated machines. This is a conventional way of thinking, and one which works, but it imposes conditions on the arrangement of all equipment, pipes, access and lifting and transportation routes.
This leads to high construction costs. Access to the entire process plant must be provided in the form of walkways and decks free of obstructions. Equipment must be placed at the correct working height for inspections, operation, maintenance and replacements. This places demands on the working environment in the form of correct lifting height, temperature, maximum wind strength etc. Moreover, the risk of explosions and fire must be taken into consideration. As the operation of conventional lifting and manoeuvring equipment requires a lot of space, the platform (and all the decks) will take up a lot of space. This equals a large volume, which in turn leads to a requirement for large structures and results in high construction costs.
A conventional arrangement is oriented relative to horizontal surfaces where personnel can move around, and everything is set up for manual handling of devices for inspection, operation, maintenance and replacement. This type of arrangement is highly work preserving, i.e. it requires a lot of manpower in the areas where the equipment is located. The operating costs are high because it requires the physical presence of personnel at the equipment to be inspected, maintained and replaced. These operations require skilled personnel, and in many cases the rigging of lifting and transportation equipment. These lifting devices inside the process plant will, in the case of conventional designs, require the presence of fixed points or rails above the equipment to be lifted. These fixed points or rails will either have rigidly mounted lifting devices or manual lifting devices are mounted prior to each operation. This is time consuming, and the personnel involved are exposed to the risks which the processing of hydrocarbons normally entails. In some cases it will be necessary to build scaffolding to provide an adequate platform from which the personnel can work. There may also be a requirement for temporary lifting equipment. AU these operations entail risks. Moreover, it is not common for the personnel carrying out the work to be subject to monitoring and quality assurance by other personnel or, for shorter periods, by skilled personnel located remote from the site of the operations.
Consequently the platform operating costs are high.
Today's technology will also result in problems when building and equipping the platform. The process area comprises several deck levels. These decks act as fixed access bases for operators of the equipment. During the construction, these decks may complicate and prolong the building process, because any equipment delivered behind schedule becomes difficult to install. The depth of the deck areas and the lack of free access from above to the areas in which the equipment is to be installed, can make the installation of this equipment expensive and time consuming.
In the case of offshore surface installations, the construction and operating costs will sometimes be such that subsea wells, possibly with simple processing equipment, become economically more viable. One of the disadvantages of subsea production equipment is the lower recovery rate from the reservoir, and substantial quantities of hydrocarbons may be left unrecovered and unsold.
In addition to the above primary objective, the invention aims to provide:
1. An arrangement of process equipment oriented according to access areas in the vertical plane in order to favour human access by movable crafts; and 2. that the entire area for the equipment to be inspected, operated, maintained and replaced will be covered by an electronic grid system with a high resolution, e.g. ± 1 cm. This grid system will be used to identify the positioning of all instrumentation, components, pressure vessels, pipes and structures in said area, making it possible to locate these by use of electronic systems. This grid system will also be used to ensure that the movement of the movable craft can be planned, either manually or electronically, so as to avoid collisions. In addition, lifting and hauling operations will be carried out in an optimal manner. Part of said system is covered by conventional equipment retrieval technology currently used for storage control. 3. All pipes and structural units will receive electronic coordinates, making it possible to manoeuvre devices for inspection and maintenance along these and to identify positions for observations and actions.
4. This will make it easy to find each one of the thousands of equipment units equipped with a tag number. One way of making use of this is for the access device itself to visit a series of individual components, visually logging (with a camera) the state of manual sight glasses and manometers. The access device carries its own camera, lights, microphones, fire and gas detectors, noise or vibration detectors; and 5. an arrangement of process equipment oriented according to access areas in the vertical plane in order to favour access by mechanical equipment for gripping, retaining and transporting components or a collection of components. This can also be done in those locations where there is little clearance above the equipment.
The various embodiments of the invention will also provide one or more of the following benefits:
1. A reduction in platform crew through remote control of the devices that perform the inspection, operation, maintenance and replacement of equipment.
2. Provides access to more and improved expertise in the areas of inspection, operation and maintenance of equipment.
3. A reduction in working time for personnel inside the process areas, through use of manually remote controlled tools for inspection and maintenance of equipment.
4. Arranging equipment in vertical planes instead of horizontal planes, and using manually remote controlled tools or automated tools to inspect and maintain equipment, makes the process easier and cheaper to procure, construct and operate. This reduction in costs is generally desirable for the entire area or areas in which the process is located.
5. An increase in overall personnel safety on the platform through physically eliminating work inside the process area.
6. An improved working environment for personnel working in the process area when the process has been shut down, as comfortable working heights, wind breaks, welding habitats can quickly and easily be constructed, even high above deck level.
7. An improvement in the efficiency of the work processes involved in the hauling of heavy equipment, especially during shutdowns.
8. A reduction in the duration of any fires in the process area by making the overall process area more compact.
9. A reduction in the decompression time for all process equipment located in the area in question, in order to reduce the fire water requirement, and passive fire protection for equipment, piping and structures. 10. Provides a process area in which the working environment is irrelevant when the process is operating.
11. A reduction in explosion loading on the process area, through making it more open to explosion venting by having no fixed decks over the process equipment and by having open transportation areas between the racks in which process equipment and piping is installed.
12. A reduction in the size of trans-shipment areas for process equipment, through allowing devices for inspection, operation, maintenance and replacement to bring equipment directly from the installed position in the process across to the means of transport away from the area (e.g. ship or truck).
13. A reduction in the size of the flare structure, through making the process area unmanned during normal operation and allowing higher radiation from the flare.
14. Using one or more overhead travelling cranes as a mobile base for the equipment for personnel access to the process equipment, and for the devices that inspect and maintain the equipment, makes it possible to haul/manoeuvre even heavy equipment in both the vertical and horizontal planes. This provides a possibility for replacing even heavy assemblies of equipment, vessels and pipes, even with small clearances to other process equipment in the horizontal and vertical direction. For handling of smaller equipment, the crane or cranes may be manoeuvred past said wall and into the area that personnel can access for shorter or longer periods. This is expedient when it comes to changing equipment which is later to be used for inspection, operation, maintenance, lifting and hauling. In the case of heavier lifting on the platform, the same cranes may be manoeuvred so as to allow floating transport vessels to be positioned directly underneath them, the cranes carrying out the operations either singly or jointly in a coordinated fashion.
15. It becomes possible quickly to access a piece of equipment and initiate inspection, operation, maintenance and replacement. Scaffolding will not be required for positioning. No manual on-site operations will be required to get lifting and hauling equipment into place when the process is in operation.
16. The lifting and hauling tool has been rendered independent of deck level and may be operated in a way that allows all required positions to be reached based on manual or automatic positional navigation (such as is presently used for storage control). Preferably the plane or planes of reference are constructed in such a way as to allow several devices for inspection, operation, maintenance and replacement to be operated independently of each other, or their actions may be coordinated. 17. The lifting and hauling tool can be made powerful enough to carry out even heavy lifting in areas with little vertical clearance above the equipment to be lifted or hauled. This can also be done when manoeuvring heavier equipment than that which is considered normal today. Today it is normal to use expensive floating lifting vessels for heavy lift operations. Use of e.g. a travelling gantry crane will allow practically all lifting operations into the area of the process equipment to be carried out without the use of floating cranes (which are currently expensive, i.e. approximately 1-3 MNOK/day). This also applies to those operations where a large proportion of the process equipment is to be replaced, e.g. to meet the requirements imposed through the nature of the reservoir and in export contracts.
18. Lifting, hauling, inspection and installation can be performed without the presence of any personnel near the areas of the actual physical activity. This allows a design of safety and working environment during operation of the process which would not be acceptable in an area where personnel are required to carry out these operations. This will lead to a reduction in costs related to conventional design, as radiation protection, escape routes, lighting, warning lights, loud speakers and general weather protection can be eliminated.
19. Non-destructive testing of material thickness in pipes, pressure vessels and structural steel is performed by said devices for inspection, operation, maintenance and replacement. These operations will take place independently of deck level and independently of the physical presence of personnel at the test site. One of the advantages of this form of effective testing is that it opens up for more efficient corrosion and fire protection which requires less space and less maintenance. 20. All transport of equipment after this has been gripped by the devices for inspection, operation, maintenance and replacement, will not necessarily go to intermediate storage on the installation. The equipment may be manoeuvred directly onboard the means of transport which is to remove the equipment from the area (e.g. ship or truck). 21. Installation of a wall between that part of the offshore or onshore installation where no personnel is allowed during operation of the plant, and the part where personnel is allowed for shorter or longer periods. This wall constitutes a physical barrier which physically shuts any personnel present on the installation during production off from this area in an operating situation. This wall will also serve as:
• An explosion and fire barrier. • A noise barrier for personnel, against equipment in the process area in which personnel are not allowed during production.
• A radiation shield for the gas flaring system. This flaring system is used to quickly depressurize the system to atmospheric pressure. This type of operation is carried out prior to allowing personnel access to the area. Using such a wall to split up the installation sets up two clearly divided regimes for inspection, operation, maintenance and replacement, and also for safety, working environment and personnel access to equipment.
Moreover, the use of a mechanical tool to carry out inspection, operation, maintenance and replacement of equipment will make it possible to utilize centrally located expertise — located in e.g. an operations centre on shore - to analyze and operate several platforms simultaneously. This can be done by mounting e.g. lighting, web cameras, microphones, fire and gas detectors etc. on this tool, or tools for gripping, screwing, lifting or pulling.
Thus the object of the invention is also to arrange process equipment in such a way as to allow operation of the equipment without the presence of any personnel near the physical operations. Both inspections, operation, maintenance and replacements are performed by remote controlled tools, with the operator of these tools sitting in a completely different location from that of the physical site of operations.
The above primary objective is achieved through the features that appear from the characterising part of the following independent claim Additional benefits can be achieved through the features that appear from the dependent claims.
One aspect of the invention is that the arrangement of all equipment to which access must be provided, is arranged in vertical planes at a sufficiently short distance from areas in which the access tool can move.
With the equipment to which access is required arranged in this manner, the following will be possible:
• Mechanical devices for personnel access can be made independent of stairs, ladders and walkways.
• Mechanical devices for gripping, retaining and transporting equipment are made independent of deck level. • Mechanical devices can be placed in a more compact arrangement, as the space requirements are determined only by the access needs and operation of the mechanical tool.
In practice, this can be achieved if it is possible to get in with the mechanical tool from one or more planes of reference located above the equipment. According to the invention, there is preferably one plane of reference across the entire process area in which the lifting device moves. It is possible to design the lifting device such that it can handle pieces of equipment in very confined spaces, even when there are very small clearance zones above the equipment or equipment assembly to be lifted or hauled. This could be realized e.g. through a hydraulically controlled gripping device suspended from one or more telescopic arms attached to a cross arm on a travelling gantry crane.
In a particular aspect the invention regards a process module or modules that can be attached to an operative platform. The object of this is to establish a solution for construction and modification of existing platforms which leads to a reduction in the weight, size and cost of process modules. It is equally important to reduce the number of interfaces between the original platform and the new process module(s). This can be achieved by processing the wellstream as far as possible in the new process module(s), requiring a minimum of support systems from the platform. Reducing the need for platform modifications, and also reducing the number of interfaces (piping, joints, instrumentation cabling, electronics cables), will reduce the scale and duration of any modification and installation work.
In terms of the process, this may be done through complete separation in a new process module prior to bringing processed oil streams together. Alternatively the process may comprise only partial processing in such a module and final processing in the existing process plant.
The new concept will result in significantly improved financial conditions compared with conventional tie-in modules.
In addition, such a module may provide the following benefits:
• Smaller and lighter modules are less expensive to build. • Robust separation with minimal use of the process and auxiliary systems on the platform.
• Small volumes of hydrocarbons in the new process module result in limited requirements for modifications in the platform safety systems, such as fire water and flare. • Fewer interfaces to the existing platform results in less modification work.
• Less modification work on the existing platforms means less down time and a smaller oil production loss.
The new tie-in process module is intended as a cantilever on an existing platform. The new process module is based on maximum utilisation of compact process technology and equipment of a limited weight and with a limited requirement for space. The new process module may among other things be implemented as follows:
• The module is tall and narrow in order to limit the structural loading on the existing platform. • Access is via the access platform, which can travel in the vertical and horizontal planes for access along module levels and access to different heights.
• The access platform is supported by a movable steel structure with a lifting tool (crane solution) which can move in the same plane. • Preferably the module comprises no transport corridors or access routes, stairs or ladders, as all access takes place via the external access platform and remote controlled devices for inspection, operation, maintenance and replacement.
• The equipment in the module can be constructed for easy loading or removal through modularised installation/loading solutions where the equipment can be skidded on separate rails in the modules during installation/loading and then locked in position.
The invention will now be explained in greater detail with reference to the accompanying drawings, in which:
Figure 1 shows an offshore production platform where part of the deck is equipped with process equipment arranged in accordance with the principles of the present invention;
Figure 2 shows the deck area of Figure 1 laid out in accordance with the invention;
Figure 3 is a side view of the deck area of Figure 2;
Figure 4 is a schematic diagram showing the layout of the deck area according to the invention;
Figure 5 shows a rack for equipment according to the invention;
Figure 6 shows an attachment module provided with a rack;
Figure 7 shows the attachment module of Figure 6 with an integrated lifting device;
Figure 8 is a top view of the attachment module of Figure 8; and
Figure 9 shows the process plant on the platform tied in to the process units in the attachment module.
Figure 1 shows an offshore platform comprising a support structure 1 which supports a main module deck 2. One area 3 of the deck 2 is reserved for process equipment. This deck area 3 is shut off from the rest of the deck 2 by a fire wall 4 which is to prevent any fires and explosions from spreading from the deck area 3 to other parts of the deck, and which is to act as a shield against radiation from the flare and as a noise barrier against that part of the installation to which personnel has access when the installation is operating and pressurized. This wall will also serve as a physical barrier for personnel and makes it impossible to gain access to the process area during operation. The other parts of the deck will among other things hold living quarters and day rooms.
In accordance with the present invention no arrangements have been made to allow personnel access to the deck area 3 unless all process equipment has been shut down and depressurized. Thus there are no passages in the fire wall 4, and no walkways past it.
A travelling gantry crane 5 is provided in the deck area 3, arranged to travel on rails 6 at the respective outer edges of the deck area 3. The gantry crane 5 comprises two support frames 7 running respective rails, and a crossbeam 8 connecting the support frames 7. The gantry crane 5 is arranged to travel across the entire deck area 3 and preferably also past the wall 4 to the manned part of the platform. This is useful when replacing equipment mounted to the crane and when transporting equipment to the pedestal crane 11, and also for carrying personnel past the wall 4 in a basket carried by the crane, as will be explained in greater detail below. The rails 6 may also be extended past the aft end 9 of the platform, allowing the gantry crane 5 to travel outside the main module deck 2, for instance to lift items from a ship.
Also shown is a flare stack 10 and a crane 11. A knuckle boom crane may be used instead of a conventional crane 11, making it possible to operate with a great degree of precision in the deck area 3.
Figure 2 shows the deck area 3 in Figure 1. Also shown is the gantry crane 5. Several racks 12 are provided in the deck area 3. These racks are constructed from simple steel girders joined to form rectangular frame structures. The racks 12 are arranged to support various types of process equipment 13 such as separators, compressors, valves etc. The racks 12 are arranged with a predetermined horizontal spacing so as to form corridors 14 between the racks 12. The racks may also be arranged in stacks of two or more, as shown to the left in the figure, or they may include several levels for arranging process equipment.
Figure 3 is a side view of the deck area 3. This also shows the travelling gantry crane 5 and the racks 12. The gantry crane is provided with a movable arm 16 carrying a personnel basket 17. This personnel basket is arranged to move along the corridors 15. The crew may enter the personnel basket 17 when the process plant has been shut down and depressurized. At this point, it will be situated in an appropriate location by the fire wall 4 which gives access for personnel. The personnel may then position the basket in the corridor 15 and at the location which provides access to the equipment for which maintenance is required.
The personnel basket 17 will not be used during operation of the process equipment. Any inspection, operation, maintenance and lifting/hauling operations can then be carried out by a remote controlled arm arranged in the gantry crane. Monitoring can be carried out by use of one or more cameras, lighting, fire and gas detectors. The arm may be equipped with different tools, among other things tools capable of retrieving and installing entire process units, e.g. valves or assemblies of pipes, valves, instrumentation and pressure vessels.
For replacement of large process units the most appropriate will be for the gantry crane 5 to grip the rack 12 in which the process unit is located, and then to transport it to the aft end 9 of the platform, lifting it over any racks on the outside.
Figure 4 is a schematic top view of the deck area 3, showing the racks 12 and the gantry crane 5. Also visible are rails 6. These extend outside the aft end 9 of the platform, thus forming a moon pool 18 aft of the platform area 3. Process units and racks may be lifted on board the platform via this, through use of the travelling gantry crane 5, directly to the designated location in deck area 3.
The location of tie-in points is predetermined in order to facilitate connection and disconnection of process units. As a result of this, new process units may quickly be connected to the existing process plant. Connection can be carried out by personnel during a shut down of the plant, or it may be performed during operation of the plant, by remote controlled arms equipped with the appropriate tools.
Figure 5 shows a rack according to the principles of the present invention. In this instance the rack 12 comprises two levels, each of which holds a separator and associated equipment. The rack may be a unit or consist of a unit for each level, where the upper unit is placed on top of the lower unit.
Each rack 12 includes a corridor 15 or free space on at least one long side of the rack /2. The width of the corridors 15 may vary, as the width is adapted according to the equipment to be retrieved or installed via the respective corridor.
In order to simplify the operation of retrieving or installing equipment in the rack, the equipment may be displaceably mounted on rails in the rack, which allows the equipment unit to be pulled out into the corridor 15 on these rails after being disconnected from adjacent process equipment. Then, after releasing any locking devices between the equipment and the rails, the unit may be lifted up and over the racks 12 to be transported to the moon pool 18. This order is reversed for installation of an equipment unit.
The racks 12 may include one or more defined slots for particular types of process units. This makes it possible to leave empty slots in which equipment may be retrofitted. The only requirements for the retrofit unit are that it must not exceed the dimensions of the slot, and that support brackets and tie-in points are positioned according to a predetermined specification.
Figures 6 -9 illustrate another aspect of the present invention, in which module 30 is attached to a platform 31. The module 30 comprises a module deck 32 and a rack 33. In this case the rack 33 has three levels.
The module 30 is attached to the platform at the edge of the platform deck 34, and as a continuation of the process equipment area on the platform. The module 30 is attached to the platform 31 by means of fasteners 35 between the module deck 32 and the platform deck 34. Further fasteners 36 between the rack 33 and the nearest rack 37 on the platform deck 34 provide module 30 stabilization. The rack 33 will be permanently fixed to the module deck 32.
The module 30 also comprises a lifting device 38, best seen in Figures 7 and 8. This comprises a cantilever beam 39 attached to the top of the rack 33. From the beam 39 there is suspended a telescopic arm 40, the lower end of which is provided with a basket 41. There are rollers 42 arranged in the bottom of the basket. Thus equipment units 43 to be retrieved from the rack 33 or installed in the rack 33 can be rolled in and out on this basket 41.
The module 30 may be installed through lifting it from a ship and attaching it to the platform deck 34. After the module has been attached to the platform 31, the process equipment in the module will be connected up to the process equipment on the platform. Figure 9 shows exemplary process equipment in the module 30 (inside the dotted quadrangle) and part of the process equipment on the platform 31 (outside the dotted quadrangle). In this case the platform required more separator capacity due to tie-in of additional wells. The additional wells are tied-in to the process equipment 44 in the module, and separated oil is transferred to the process equipment on the platform via line 45.
Preferably the connection of the process equipment in the module to the process equipment on the platform takes place by use of remote controlled devices. AU access to the process equipment in the module will take place via the lifting device 38, which operates outside the module 30. If the module is connected to a conventional process plant where personnel is allowed access also during operation, it will be appropriate for the module and its associated process equipment to be constructed so as also to allow personnel to access this during operation. If the module is connected to a process plant where personnel is not allowed access while the equipment is pressurized, it would be appropriate for personnel not to have access to the module either, as long as this equipment is in operation.

Claims

C l a i m s
1.
An arrangement of process equipment for treatment of hydrocarbons on an offshore surface installation or an onshore installation., which installation comprises a deck, characterized in that the deck comprises a permanently unmanned area in which the process equipment is located, and to which personnel has no access while the equipment is pressurized and operating, and a manned area to which personnel normally has access, which permanently unmanned area is separated from the manned area by a fire and explosion proof wall which prevents personnel traffic into the permanently unmanned area while the process equipment is pressurized and operating.
2.
An arrangement in accordance with Claim 1, characterized in that a crane or a robot mounted on a crane is arranged to move past the wall, either over it or by the side of it, in order to carry tools or equipment between the permanently unmanned area and the manned area.
3. An arrangement in accordance with Claim 2, characterized in that the crane is a travelling gantry crane that runs on rails which extend from the permanently unmanned area past the wall and into the manned area, allowing the gantry crane to move over and past the wall.
4.
An arrangement of process equipment for treatment of hydrocarbons on an offshore surface installation or an onshore installation., which installation comprises at least one deck, characterized in that it comprises a number of racks arranged on the deck, where the racks accommodate the process equipment and are located at one or more levels, each of which racks has a corridor on at least one side, access to the process equipment in the racks being provided via a tool introduced into the corridor.
5. An arrangement in accordance with Claim 4, characterized in that the tool is arranged to move in at least one horizontal plane by the racks for travel between two or more corridors.
6.
An arrangement in accordance with Claim 4 or 5, characterized in that the tool can move in a plane above the racks and is arranged to be inserted into the corridors from above.
7.
An arrangement in accordance with Claim 5 or 6, characterized in that the tool is disposed in a crane, e.g. a travelling gantry crane, a knuckle boom crane or a system of rails.
8.
An arrangement in accordance with one of the preceding Claims 4-7, characterized in that each rack comprises predefined slots arranged to accommodate an equipment unit or a combination of equipment units.
9.
An arrangement in accordance with one of the preceding claims, characterized i n that the tool is remote controlled or automatic, thus eliminating the need for personnel to be present at the site of the physical operations.
10.
A process module for tie-in to an installation for treatment of hydrocarbons, which installation comprises a platform deck, characterized in that the module is equipped with connecting means arranged to secure the module at the edge of the platform deck.
11.
A module in accordance with Claim 10, characterized in that the module comprises a module deck on which there is arranged a rack containing process equipment.
PCT/NO2006/000279 2005-07-15 2006-07-14 Unmanned platform maintenance WO2007011237A2 (en)

Applications Claiming Priority (2)

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NO20053481 2005-07-15
NO20053481A NO328786B1 (en) 2005-07-15 2005-07-15 Unmanned platform maintenance

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WO2007011237A3 WO2007011237A3 (en) 2007-05-10

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NO337356B1 (en) * 2014-04-22 2016-03-21 Aker Engineering & Tech As processing plants
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NO328786B1 (en) 2010-05-18
WO2007011237A3 (en) 2007-05-10
NO20053481L (en) 2007-01-16

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