WO2016201531A1

WO2016201531A1 - Intervention and installation system for at least one production flow and elevation device inside at least one production riser in a floating production unit

Info

Publication number: WO2016201531A1
Application number: PCT/BR2015/000088
Authority: WO
Inventors: Roberto Rodrigues
Original assignee: Petróleo Brasileiro S.A. - Petrobras
Priority date: 2015-06-18
Filing date: 2015-06-18
Publication date: 2016-12-22

Abstract

The present invention relates to an intervention and installation system for at least one production flow and elevation device inside at least one production riser (2) in a floating production unit (1), in which at least one production riser (2) is held by a balcony (6) of the floating production unit (1), in which there is a sliding system (50) on top of the balcony (6), in which at least one intervention and installation device is supported on the sliding system (50), in which optionally the sliding system is a sliding structure on rails (20), in which the at least one intervention and installation device is supported on the sliding structure (50), in which optionally the at least one flow and elevation device may include at least one of the following: a pump, a BCS (14), an electric heater (21), a gas-lift mandrel (22) and a jet pump, and in which optionally the at least one intervention and installation device may include at least one of the following: a probe (7), a hose unit (8), a wire unit (19), an overhead crane and a hoist.

Description

"INTERVENTION AND INSTALLATION SYSTEM AT LEAST ONE PRODUCTION LIFT AND OUTLET EQUIPMENT AT LEAST ONE PRODUCTION RISER IN A FLOATING PRODUCTION UNIT"

FIELD OF INVENTION

[0001] The present invention relates to an artificial lifting system and production flow guarantee for subsea oil wells. More specifically, the invention relates to the assembly of equipment within production risers of FPSO type floating production units.

BACKGROUND OF THE INVENTION

[000?] During the process of producing offshore oil, especially in deep water, various systems and equipment have been developed to provide energy to the oil in both pressure and heat form to facilitate its flow to the surface.

The use of pumps inside oil wells allows, where applicable, to increase well production. However, such equipment has a high failure rate, averaging about 1 failure every two 2 years for centrifugal pumps i.

BCS, the most commonly used type. Underwater wells failures

Wet completion requires costly maintenance intervention as they are required: production shutdown, removal of the production column and its pump, use of an offshore rig. In many cases these high costs represent an obstacle to the economic viability of production development projects. Several alternatives to mitigate this problem have been proposed. Currently for subsea wells, where pressure conditions and free gas quantity are favorable, pumps are preferably installed outside the producing well over the seabed; facilitating its installation and eventual replacement in case of failure. Examples of this practice are described in US7314084 and US7516795.

Nevertheless, even for the failure of pumps installed on the seabed, special probes and / or vessel resources still need to be generated, leading to considerable production losses. In addition to the high cost of these naval resources, it is necessary to wait for their availability and movement, and it may take dozens of days before such operations can be performed.

[0006] Some embodiments have been proposed with the aim of enabling pump installation and removal solutions from the production unit itself without the use of other naval resources not always readily available. An example is patent application PI 0109766-0 which describes a riser system used for both transporting fluids produced as a physical medium to house and guide the descent, installation and uninstallation of production equipment, including a pump.

In US6412562 / PI 0113728-0 after the

PI 0109766-0, it is also proposed to install a BCS above a wet Christmas tree, ANM, descended into a riser. In the proposed configuration it is necessary and mandatory that the riser is vertical, ie without curvature, and has a motion compensation system, making it difficult to apply in systems Floating Production Storage and Offloading.

Also in US8857519 a method of modernization of production systems, popularly known as retrofitting, is proposed, where subsea separation and pumping systems can be installed and lowered through production risers.

US8087464 proposes a balcony-like structure installed on the side of an FPSO for supporting and exchanging BCS-type pumps for subsea pumping module systems.

Thus, despite the merits of the various patent applications for installing pumps inside production risers, no solution is presented that reduces the difficulty of installing a rig or other means of intervention with access to the top of a set of production risers, mainly in FPSO-type production units with classic ship shaped hulf.

Thus, the current state of the art lacks a system that facilitates the installation / replacement / repair of equipment within a set of risers, in particular pumps, line heating or depressurization equipment, in floating production systems. FPSO type.

SUMMARY OF THE INVENTION

The main object of the present invention is to provide a system of intervention and installation of equipment within a set of risers in floating production units without requiring the use of high cost naval resources. Thus, in order to achieve this objective, the present invention provides an intervention and installation system of at least one production lifting and lifting equipment within at least one production riser in an FPSO floating production unit. where at least one intervention and installation equipment is supported on a sliding frame that moves easily over the top of the production riser assembly. Lifting and lifting equipment installed within the risers may comprise at least one of: a pump; a BCS; an electric heater; a gas arbor // ^' #; and a jet bomb. Intervention and installation equipment may comprise at least one of: a probe; a flexible tube unit; a wire unit; an overhead crane; and a crane.

In addition, a new h-riser geometry is still proposed in order to facilitate the accommodation of one or more hoisting and lifting equipment within the production risers.

BRIEF DESCRIPTION OF THE FIGURES

The detailed description given below makes reference to the accompanying figures and their respective reference numbers, representing the embodiments of the present invention.

Figure 1A illustrates a view of a floating production unit in accordance with an optional embodiment of the present invention.

Figure 1B illustrates a front cross-sectional view of the floating production unit shown in Figure 1A.

Figure 2A illustrates an optional embodiment of the present invention wherein a BCS pump with a Shroud's inverted flow controller is installed with a production column inside a riser.

Figure 2B illustrates an optional embodiment of the present invention, wherein a shroudless BCS pump is installed with a production column within a riser.

Figure 2C illustrates an optional embodiment of the present invention, wherein the production column and power cable elements are integrated into a single circular structure.

Figure 3A illustrates an optional embodiment of the present invention in which a BCS pump is installed within a riser with the aid of a reinforced electrical cable.

Figure 3B illustrates an optional embodiment of the present invention wherein a BCS pump is installed within a riser with the aid of a reinforced power cable, where the power cable is positioned externally to the riser.

Figure 4A illustrates an optional embodiment of the present invention wherein an electric heating system is installed within a riser.

Figure 4B illustrates an optional embodiment of the present invention wherein a flexible duct system having a lift gas chuck is installed within a riser.

Figure 5A illustrates an optional embodiment of the present invention wherein a BCS type pump is installed within a riser and is driven by a rod.

Fig. 5B illustrates a view of a variant configuration of Fig. 5A wherein the rod is driven by a higher power motor. Figure 5C illustrates an optional embodiment of the present invention, wherein a concentric double hose system is installed together with a jet pump within a riser.

[00028] † Figure 6A illustrates an optional configuration of a split vertebra element in its open position.

[00029] Figure 6B illustrates an optional configuration of a split vertebra element in its closed position.

Figure 6C illustrates an optional embodiment of the present invention, wherein a split vertebra type elements are installed in three risers.

Figure 7 illustrates an optional embodiment of the present invention wherein a pocket type h riser is adopted.

Figure 8 illustrates an optional embodiment of the present invention in which a pocketless h-type riser 6o is adopted. DETAILED DESCRIPTION OF THE INVENTION

Firstly, it is emphasized that the following description will start from a preferred embodiment of the invention applied to an oil production system comprising a floating hull, cylindrical hull or longitudinal hull in the form of ship shaped hull, which has a counter where production risers are hung. As will be apparent to any person skilled in the art, however, the invention is not limited to that particular embodiment.

The present invention relates to an intervention and installation system of at least one production lifting and flowing equipment within a set of production risers in a floating production unit with a counter where production risers are hung.

In addition, the counter comprises a sliding system, which is supported by at least one intervention and installation equipment, such as a probe, hose assembly and wire unit, which can move over the top of the production riser assembly. Thus, a single sliding system, preferably a rail structure, enables the installation of production equipment within a set of production risers, so that such production equipment may comprise at least one of BCS, electric heater, lift gas chuck, jet pump, hydraulically driven pump among others.

Thus, according to the proposed invention, the operation of installation of production equipment, such as a BCS pump, can be performed from a system comprised within the FPSO itself, without waiting for the availability and movement of vessels. dramatically reducing the time and costs of BCS replacement operations.

Also according to the present invention, in the upper portion of the risers, which is positioned above the counter, horizontal or conventional dry Christmas trees are installed, with or without the adoption of production heads. In this configuration, the production columns are supported by hangers, so that Christmas tree exits are used to send the produced oil to an oil separation plant.

In order to facilitate the intervention of equipment housed within the riser assembly, where necessary, The invention provides a slide-supported rail structure positioned above the counter. In this structure is installed at least one intervention equipment with technology similar to those used for well intervention, such as probe, hydraulic unit, flexible tube unit and wire unit. In addition, other equipment such as crane and crane can be added to work in conjunction with the sliding frame to facilitate equipment movement.

Optionally, production risers, where production equipment is based, may have either conventional (catenary) geometry or h-geometry with or without rathole.

Thus, the invention described herein comprises mounting equipment inside suspended risers on counters of floating production units, such as FPSO.

In the following, figures will be described illustrating optional embodiments of the invention which will facilitate understanding thereof.

Figure 1A illustrates a view of a floating production unit 1 according to an optional embodiment of the present invention, and Figure 1B illustrates a front cross-sectional view of the floating production unit 1 shown in Figure 1A. As shown, the floating production unit 1 of the present invention comprises a counter 6 provided with intervention systems supported by a sliding rail system 50 for the installation of lift and flow equipment within riser assembly 49, wherein intervention systems they may be a probe 7 and / or a hose assembly 8 and / or a wire assembly 19, among others. Still in the figure are shown the illustrative elements: anchor lines 3, torch 5, set of production risers 49.

Additionally, the invention also provides a short riser element 32 used for controlled atmosphere storage and testing which can be used for pre-testing the operation of used BCS assemblies.

Again with reference to Figure 1B there is an upper portion of a riser 2 connected to a dried Christmas tree 13. In optionally adopted configuration, the dried Christmas tree 13 is of the horizontal type, however in alternative configurations. , a conventional dry Christmas tree may be adopted. The dried Christmas tree 13 comprises a production outlet 9 through which the hydrocarbons produced by the oil well flow, which are directed to a separation and production unit 4. Also shown in the Figure is the illustrative element: sea surface 36.

In addition, it is noted that intervention systems, such as probe 7, flexible tube unit 8 and wire unit 19, are installed on a sliding system 50, preferably a rail 20, so that such intervention systems can be moved over the intervention heads of each riser 2. The intervention heads are devices known in the state of the art that have the function of facilitating interventions in risers 2, such as descent and installation of equipment, similar to those performed in wellheads. with dry completion. In particular, the intervention heads can be used to assist in the installation of a pump, optionally a BCS, inside the risers. The following figures, namely Figures 2A, 2B, 2C, 3A, 3B, 4A, 4B, 5A, 5B and 5C, illustrate various mounting configurations of a riser pump with column without column, with flexible column, with integrated umbilical flexible column, with cable, with rod, with gas separation, without separation, etc. Although not shown in the figures, the pump can be installed in any relative position, even in the horizontal section of a catenary riser.

Figure 2A illustrates an optional embodiment of the present invention wherein a BCS type 14 pump is installed inside a riser 2 so that the BCS 14 is powered by an electrical power cable 15 and connects to a a production column 16. The riser 2 is further connected to a dry christmas tree 13 which comprises a production outlet 9 through which pumped oil from the well which flows to the separation and production unit 4 flows. of floating production unit 1. Preferably a horizontal dry Christmas tree 13 is adopted.

In an annular space, defined between the production column 16 and the interior of riser 2, gas separation and accumulation usually occurs, so that the gas outlet 27 and its control valve 28, both in the spindle 13, are used for gas withdrawal control. In the optional configuration illustrated, the production takes place with liquid gas separation.

In addition, the dried Christmas tree may comprise one or more shunt valves 11, which allow the flow to the production line 9 to be blocked when desired.

In addition, a gas removal automation, control and optimization system (not shown in the figure) can perform an optimization of the amount of gas drawn from the gas outlet 27 and its control valve 28 and may even operate in non-separation mode if this is the best condition for a given production scenario.

Also optionally, a dynamic or static gas and liquid separator 30 is installed in suction 24 of BCS 14 to intensify the liquid gas separation. Preferably the gas and liquid separator 30 is of the inverted tube type.

Also shown in the Figure are the illustrative elements: column hanger 29 and marine soil 26.

Figure 2B illustrates a variant embodiment of that illustrated in Figure 2A, wherein a configuration is adopted wherein the riser 2 is connected to a conventional Christmas tree 10, so that a production head is required. 12 connecting riser 2 to the Christmas tree 10. In this particular configuration, the gas and liquid separator 30 shown in Figure 2A is deleted.

Figure 2C illustrates an optional embodiment of the present invention, wherein the production column elements 16 and electrical power cable 15 are integrated into a single umbilical circular flexible structure 31, facilitating their surface handling by a single winding reel.

Figure 3A illustrates an optional embodiment of the present invention wherein riser 2 is coupled to a horizontal dry christmas tree 13, wherein a BCS 15 is installed within riser 2 with the aid of the 15. In the illustrated configuration, a locking element 17 and seal (optionally a packer) is used to lock the BCS 14 set in its ideal position inside the riser. In the illustrated embodiment, there is no gas and liquid separation.

Figure 3B illustrates an optional embodiment of the present invention wherein riser 2 is coupled to a horizontal dry christmas tree 13, wherein a BCS 14 is installed within riser 2, wherein the power cord 15 is installed externally to riser 2. In this configuration, the installation and removal of the BCS 14 is done with the aid of a hose assembly 8 or wire assembly 19.

Figure 4A illustrates an optional embodiment of the present invention wherein riser 2 is coupled to a horizontal dry christmas tree 13 in which an electric heater 21 is installed within riser 2.

Figure 4B illustrates an optional embodiment of the present invention wherein riser 2 is coupled to a horizontal dry christmas tree 13, where a flexible tube 18 which is provided with a lift gas chuck 22 in its lower end is installed inside a riser (2).

Figure 5A illustrates an optional embodiment of the present invention wherein riser 2 is coupled to a horizontal dry christmas tree 13. In the optionally adopted configuration, a BCS type 14 pump is driven by a rod 40, which is actuated by an electric motor head 41. The elements: rotation amplifier 45 and pump discharge 46 are also shown.

Fig. 5B illustrates a variant configuration of Fig. 5A, wherein the rod 40 is driven by a higher power motor 42. In this way, a gear reducer is also used. rotation 43, as well as a rotation transmission 44, the latter coupled to the rod 40.

Figure 5C illustrates an optional embodiment of the present invention wherein riser 2 is coupled to a horizontal dry christmas tree 13 in which a concentric double-hose system 25 provided with a jet pump 23 in its lower end is lowered through the interior of riser 2. The described configuration can be adopted for depressurization operations for hydrate mitigation purposes or even for production purposes.

Additionally, in order to promote a stiffening of the catenary riser stretch where the pump is housed, making the stretch substantially linear, the present invention also provides for the use of a split vertebra element 33, as illustrated in FIGS. 6A, 6B and 6C. The split vertebra element 33 is made of rigid material and is configured to surround riser 2, significantly reducing flexion in the stretch where it is positioned. In addition, the split vertebra 33 may comprise transverse fins that increase its stability.

Figure 7 illustrates an optional embodiment of the invention wherein an h-type riser 2 is adopted, wherein riser 2 comprises a substantially vertical portion so that its lower end is spaced from the sea floor. In addition, riser 2 comprises a side branch 35 above its lower end, creating a rathole 48. A moor 37 may be used to restrict the movement of riser 2 due to undersea currents. [00064] In the particular embodiment described, the riser 2 vertical section can be probe-installed from the junction of pipes connected to each other by soldering and / or connector and / or thread.

The 2 in h riser geometry can also be used for general applications in large water slides as a way to mitigate fatigue problems, even for applications that do not require pumping inside riser 2.

Figure 8 illustrates a particular embodiment of the invention wherein riser 2 comprises a pocket 47 in its lower portion, such that the pocket has a substantially larger diameter than that of the riser, in particular compared to the central portions. and top of riser 2, so that pocket 47 accommodates a pump 14 and a tube-type separator 30 disposed therein.

In this configuration, at its lower end, after pocket 47, riser 2 comprises a curved portion and a funneled mandrel 34 to allow connection to a pre-launched undersea line 39, even before anchoring. of the production unit at the location. Optionally, depending on the diameter of riser 2 and pump 14, pocket 47 may be suppressed such that the vertical riser comprises substantially the same diameter throughout its length.

[00068] In alternative embodiments, when it is not intended to perform liquid and gas separation on riser 2 itself, the gas outlet line 27 shown in the various figures may be deleted.

Optionally, furthermore, in embodiments requiring sealing in riser 2, to prevent backflow between pump discharge and suction 14, usual well elements such as shutter 17, telescopic joint may be employed. by tubing seal receptacler (TSR), or bypass valve, not all illustrated in all figures.

Briefly, therefore, the present invention provides an intervention and installation system for at least one production lifting and lifting equipment within at least one production riser 2 in a floating production unit 1, wherein a production riser assembly 49 is supported by a counter 6, where at least one intervention and installation equipment is supported on a sliding rail structure 20 which easily moves over the top of the production riser assembly 49. The equipment The lift and flow system installed within the risers 2 may comprise at least one of: a pump; a BCS 14; an electric heater 21; a lift gas chuck 22; and a jet pump 23. Intervention and installation equipment may comprise at least one of: a probe 7; a hose assembly 8; a wire unit 19; an overhead crane; and a crane.

Claims

1. Intervention and installation system of at least one production lifting and flow equipment inside a production riser (2) supported by a counter (6) of the floating production unit (1), characterized by the counter (6 ) comprise a sliding system 50, in which at least one intervention and installation equipment is supported on the sliding system 50.

2. System, according to claim 1, characterized in that the sliding system 50 is a sliding structure on rails 20, in which at least one intervention and installation equipment is supported on a sliding system 50.

3. System, according to claim 1 or 2, characterized in that the at least one lifting and flow equipment comprises at least one of: a pump; a BCS (14); an electric heater (21 ); a gas lift chuck (22); and a jet pump.

4. System, according to one of claims 1 to 3, characterized in that the at least one intervention and installation equipment comprises at least one of: a probe (7); a flexible tube unit (8); a wire unit (19); an overhead crane; and a crane.

5. System according to one of claims 1 to 4, characterized in that the upper end of the at least one production riser (2) is connected to at least one of: a conventional dry Christmas tree (13); a horizontal dry Christmas tree (13); and a production head (12).

6. System, according to one of claims 1 to 5, characterized in that the riser (2) comprises an h-shaped geometry, in that the riser (2) comprises at least a vertical portion, wherein its lower end is set away from the seabed, and wherein the riser (2) comprises a lateral bifurcation above its lower end.

7. System, according to claim 6, characterized in that the riser (2) comprises a pocket (47) in its lower portion, wherein the pocket comprises a diameter greater than the diameter of the central and upper portions of the riser (2) , in which the pocket accommodates a pump (14) and a tube-type separator (30) invested inside it.

8. System, according to claim 7, characterized in that the riser (2) comprises a curved section and a mandrel with funnel (34) adapted to allow connection with a submarine line (39).

9. System, according to one of claims 1 to 8, characterized by additionally comprising a short riser element (32) for testing and storage in a controlled atmosphere.

10. System, according to one of claims 1 to 9, characterized in that the Christmas tree (13) comprises a liquid outlet (9), adapted to flow the hydrocarbons produced by the oil well, and directs them to a unit separation and production (4).

11. System according to one of claims 1 to 10, characterized in that the dry Christmas tree can comprise at least one maneuver valve (11) adapted to block the flow of production liquid.

12. System according to one of claims 1 to 11, characterized in that the dry Christmas tree comprises at least a gas control valve (28), adapted to direct a gas flow to a gas outlet (27).

13. System according to one of claims 1 to 12, characterized in that the at least one lifting and flow equipment comprises a BCS (14), in which a gas and liquid separator (30) is installed in the suction of the BCS (14 ), in which the gas and liquid separator (30) is of the inverted tube type.

14. System, according to one of claims 1 to 13, characterized in that the riser comprises a split vertebra element (33) made of rigid material, adapted to surround the riser, wherein the split vertebra element (33) comprises transverse fins.

5. System, according to one of claims 1 to 14, characterized in that the floating production unit (1) has a ship-shaped hull.

16. System, according to one of claims 1 to 14, characterized in that the floating production unit (1) has a cylindrical shaped hull.