WO2017176789A1

WO2017176789A1 - Modular wellhead

Info

Publication number: WO2017176789A1
Application number: PCT/US2017/025988
Authority: WO
Inventors: Brian K. Brown; Daryl Parker; Allan FORBES; Narendranath PALAKAL
Original assignee: J. Ray Mcdermott, S.A.
Priority date: 2016-04-05
Filing date: 2017-04-04
Publication date: 2017-10-12

Abstract

The present disclosure generally relates to a modular wellhead, as well as methods of installing and using the same. The modular wellhead includes modular components, such as a jacket, a well bay, a topside, and optionally other ancillary items. The modular components may be pre-engineered and prefabricated to allow quick erection of a rig upon request.

Description

Field

[0001] Embodiments of the present disclosure generally relate to modular components for offshore hydrocarbon production rigs, and methods of constructing the same.

Description of the Reiated Art

[0002] A wellhead is a component of a hydrocarbon-producing rig (e.g., a production platform) that provides a structural and pressure-containing interface for drilling and production equipment. For each new EPIC (engineering, procurement, installation, commissioning) contract, the wellhead and production platform are completely redesigned depending on the needs of a customer. The complete redesign results in a significant delay in oil production due to the designing and fabrication required prior to installation of the wellhead, as well as a significant investment due to the individualized engineering of each wellhead and associated platform.

[0003] What is needed is a rig which can be more quickly and less expensively erected.

SUMMARY

[0004] The present disclosure generally relates to a modular rig, as well as methods of installing and using the same. The modular rig includes modular components, such as a jacket, a well bay, a topside, and optionally other ancillary items. The modular components may be pre-engineered and prefabricated to allow quick erection of a rig upon request. [ooos] In one example, a jacket comprising legs having first openings and second openings therein at an upper end thereof for receiving modular components; a first modular component engaging the first openings of the legs, the first modular component comprising a well bay; and a second modular component engaging the second openings of the legs, the second modular component comprising a topside.

[0008] In another example, a method of constructing a modular rig comprises installing a jacket on a sea bed, the jacket comprising legs having openings therein at an upper end thereof for receiving modular components; installing a first modular component on the jacket, the first modular component comprising a well bay; and installing a second modular component on the jacket, the second modular component comprising a topside.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only exemplary embodiments and are therefore not to be considered limiting of its scope, may admit to other equally effective embodiments.

[0008] Figures 1A-1 E illustrate a modular rig during fabrication, according to one aspect of the disclosure.

[0009] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation. DETA!LED DESCRIPTION

[001 D] The present disclosure generally relates to a modular wellhead, as well as methods of installing and using the same. The modular wellhead includes modular components, such as a jacket, a well bay, a topside, and optionally other ancillary items. The modular components may be pre-engineered and prefabricated to allow quick erection of a rig upon request.

[0011] Figures 1A-1 E illustrate a modular rig during fabrication, according to one aspect of the disclosure. Figure 1A illustrates a jacket 101 of a rig. The jacket 101 is a frame of tubular members and includes one or more levels 102 (three are shown). It is to be noted that the number of levels 102 or the distance therebetween may be adjusted to accommodate a desired water depth. The tubular members defining the jacket 101 include a plurality of legs 103 (four are shown) that facilitate support of the jacket 101 on a sea floor, as well as plurality of cross members 104 (one is labeled) coupling the legs 103 to provide rigidity and support thereto. In one example, a plurality of the cross members 104 may be coplanar with and/or partially defining the levels 102. The legs 103 are disposed at an angle relative to vertical. In one example, legs 103 on opposite sides of the jacket 101 are positioned to be angled towards one another. In such an example, legs 103 on the same side of the jacket 101 are parallel and/or coplanar. The relative angles of the legs 103 provide a wider base to facilitate structural rigidity of the jacket 101 .

[0012] As referred to herein, cross members 104 may refer to any of the structural elements that provide support between legs 103. Cross members 104 may be arranged longitudinally and transversely in a plane of each level 102. Cross members 104 may also be arranged in an angled configuration adjoining longitudinal and transverse members in each plane of a level 102, and/or, cross members 104 may extend between adjacent levels 102.

[0013] Each of the legs 103 includes an opening 105 formed in an upper end thereof to receive elements of a modular component therein. Elements may include, for example, support legs of other structural members of modular components. To facilitate modularity of the rig, additional openings 105 may be provided in vertical supports 106a, 106b (four are shown). The vertical supports 106a, 106b are positioned parallel to and positioned adjacent to one or more legs 103, and may be coupled to a plurality of cross members 104. The vertical supports 106a are sized similarly to the legs 103, but may be shorter in length than the legs 103 and thus do not support the jacket 101 on the sea bed. Rather, the vertical supports 106a provide additional openings 105 for securing elements thereto, thereby providing modular flexibility for coupling modular components to the jacket 101 .

[0014] Vertical supports 106b have a diameter smaller than vertical supports 106a and legs 103, but similarly include openings 105 at an upper end thereof to accommodate modular components. The upper ends of the legs 103 and the vertical supports 106a, 106b may be positioned at the same height relative to the base of the jacket 101 . In one example, it is contemplated that the vertical supports 106a, 106b, may be the same size as one another. In another example, the vertical supports 106a, 106b are positioned midway between adjacent legs 103. In yet another example, each of the vertical supports 106a, 106b may be coplanar with at least two legs 103.

[0015] To facilitate routing of production tubuiars such as pipes, one or more levels 102 include a pipe rack 107 formed from cross members 104 that allows pipes to be routed vertically therethrough. The one or more pipe racks 107 (two are shown) are axially aligned to facilitate pipe routing.

[0016] The jacket 101 is fabricated onshore and deliverable to an offshore weilsite. Due to the modularity of the jacket 101 , a rig which incorporates the jacket 101 is suitable for a variety of configurations. Therefore, the jacket 101 can be fabricated prior to a request from a customer, and stored at an onshore location to later be configured with customer-specific modules. Upon receiving an EPIC request, the jacket 101 can be quickly delivered to an offshore weilsite without engineering and constructing the jacket 101 . The modularity of the jacket 101 allows the jacket 101 to accommodate a variety of modular elements or components, mitigating the need for individualized engineering and design of the jacket 101 . The reduction in engineering and design allows a quicker installation of the jacket 101 while also reducing the cost of erection due to mitigated design costs, !t is contemplated that the jacket 101 may be configured for water depths between about 25 meters and about 60 meters by adjusting the length of legs 103.

[0017] Figure 1 B illustrates installation of a well bay 1 10 on the jacket 101 . The well bay 1 10 is one of many modular components that may be installed on the jacket 101 . The well bay 1 10 includes one or more levels 1 1 1 a, 1 1 1 b, 1 1 1 c (two are shown). On the middle level 1 1 1 b, equipment 1 12 such as valves, oil and gas separators, free-water knockouts, gas scrubbers, pumps, compressors, and the like, is installed. An upper level 1 1 1 c is positioned vertically above the lower level 1 1 1 a and provides additional space for equipment, and/or provides shelter for equipment located on the middle level 1 1 1 b. The equipment 1 12 is coupled to one or more pipes 1 13 extending vertically through the pipe racks 107 of the jacket 101 to facilitate hydrocarbon production. The one or more pipes 1 13 may be fluidly coupled to a well or other production equipment at a lower end thereof. The well bay 1 10 may support 9, 12, 15, or more pipes 1 13, and may allow dual completion.

[0018] The well bay 1 10 includes four or more support legs 1 14 (one is labeled). The support legs 1 14 are received in openings 105 (shown in Figure 1A) of the legs 103 and vertical supports 106b of the jacket 101 . Because the dimensions of the jacket 101 are standardized between rigs, the well bay 1 10 can be fabricated prior to an EPIC contract, knowing that the dimensions of the well bay 1 10 will be compatible with the dimensions of the jacket 101 . Upon issuance of an EPIC contract, the well bay 1 10 can be configured with the desired equipment 1 12, and installation of the well bay 1 10 can begin much sooner than conventional approaches. Moreover, once the well bay 1 10 is installed, hydrocarbon production can commence. Aspects of the disclosure greatly reduce the time between EPIC contract issuance and hydrocarbon production in contrast to conventional approaches. Moreover, it should be noted that if a customer has needs which are not meant by the well bay 1 10, a supplier may have other versions of a well bay on hand and ready for installation, thus exemplifying the modularity of the present disclosure.

[0019] Figure 1 C illustrates installation of a top side 120 on the jacket 101 . The topside 120 is positioned on the jacket 101 adjacent to the well bay 1 10. The topside 120 includes a deck structure 121 having a lower level 122a and an upper level 122b positioned above the lower level 122a. The lower level 122a and the upper level 122b are coupled together by support posts 124 (four are shown) extending therebetween. Legs 125 (four are shown) are arranged coaxiaily with respect to the support posts 124 and extend from a lower surface of the lower level 122a. The legs 125 engage the openings 105 (shown in Figure 1A) at upper ends of the legs 103 of the jacket 101 . Due to the modular nature of the top side 120, the top side 120 can easily be installed on the jacket 101 at an offshore location, before or after installation of the well bay 1 10.

[002D] Facilities 123, such as piping or other equipment, are installed on one or both of the lower level 122a and the upper level 122b. The top side 120 is fabricated onshore, and facilities 123 are installed on shore, to reduce installation time on the jacket 101 at an offshore location. Because the top side 120 utilizes only two levels, e.g., lower level 122a and upper level 122b, the top side 120 weighs less than conventional top sides, allowing a wider selection of heavy lift vessels to transport the top side 120 to an off shore location. The greater selection of heavy lift vessels may result in cost savings. Moreover, the modular nature of the top side 120 allows other top side configurations to be utilized without redesigning the jacket 101 or the well bay 1 10. Rather, by maintaining the general dimensions of the legs 125, an alternative topside may be used to suit the needs of a specific site. In this respect, minimal reengineering is needed, thereby reducing construction costs,

[0021] Figure 1 D illustrates the deck structure 121 shown in Figure 1 C. Each of the lower level 122a and the upper level 122b include plurality of longitudinal beams 130 and transverse beams 131 , and may optionally be covered with flooring or plating (not shown). In examples where the upper level 122b is plated, the upper level 122b may be classified as safe area. In such examples, the local equipment room (LER), a switch room, or temporary refuge may be located on the upper level 122b, and thus, located in a non-hazardous area.

[0022] Each of the lower level 122a and the upper level 122b are coupled to the legs 125, which are sized and spaced to engage jacket 101 (shown in Figure 1 C). Each of the lower level 122a and the upper level 122b may optionally include respective extending portions 132, 133 which extend laterally outward beyond the outer-most legs 125, It is contemplated that the sizes of the extending portions 132, 133 may be selected to provide a desired amount of storage thereon,

[0023] Figure 1 E illustrates installation of ancillary equipment, according to one aspect of the disclosure. Ancillary equipment may include, but is not limited to, equipment such a crane 140, a landing pad 141 , and other items useful in the recovery of hydrocarbons at offshore rigs. In the illustrated example, the landing pad 141 is coupled to the upper level 122b. Thus, in the event of escape or evacuation, personnel located on the upper level 122b can reach the landing pad 141 without traveling through hazardous areas.

[0024] While aspects herein describe the connections of modular components via legs received in openings, such as openings 105 shown in Figure 1A, other forms of connection are also contemplated. For example, modular components may be coupled to a jacket via welding, fasteners such as bolts, through coupling sleeves, or any other suitable method. [002S] Benefits of the disclosure include reduced installation costs, reduced installation time, and improved operabiiity and maintainability due to modularity. In addition, the benefits of the disclosure include reduced-weight topsides due to a reduced number of levels of the topsides. In addition, the modular nature of the disclosed rigs provide simplified designs, thereby reducing engineering costs, and facilitates simplified hook up of components, including piping and facilitates, between modular components. Moreover, wells can be drilled, perforated, and cleaned up before topside installation, thereby reducing costs of drill rig mobilization and demobilization. Because, wells can be drilled, perforated, and cleaned up before topside installation, production operations can begin sooner than with respect to conventional rigs.

[0028] In addition, the modular components described herein allow for installation on a reduced or shortened schedule. The utilization of modular components allows prefabrication of the modular components, e.g., the components may be fabricated prior to initiation of an EPIC contract. The modular components may be fabricated and stored, and once an EPIC contract issues, the desired modular components may be selected. Such an installation scheme greatly reduces engineering and fabrication time between EPI contract initiation and rig installation. Even in events where modular components are not fabricated beforehand and stored, the utilization of modular components facilitates the use of standard materials for multiple designs. The standard materials may be stocked to reduce procurement cycle times. Moreover, the use of standardized materials may reduce costs by obviating the use of special grade materials.

[0027] In addition, aspects of the disclosure may result in reduced fabrication times, since a single design may be used multiple times due to the modular nature of disclosed components. In one example, it is contemplated that aspects of the present disclosure may reduce total contract value about 15% to about 20% compared to conventional approaches. In addition, the modular components disclosed herein have much simpler designs than conventional rigs, and thus, embodiment herein benefit from reduced fabrication schedules.

[0028] While the foregoing is directed to embodiments of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.

Claims

What Is claimed Is:

1 . A modular rig, comprising:

a jacket comprising legs having first openings and second openings therein at an upper end thereof for receiving modular components;

a first modular component engaging the first openings of the legs, the first modular component comprising a well bay; and

a second modular component engaging the second openings of the legs, the second modular component comprising a topside.

2. The modular rig of claim 1 , wherein the jacket includes a plurality of vertical supports positioned between adjacent legs of the jacket, each vertical support of the plurality of vertical supports including openings at an end thereof for receiving modular components.

3. The modular rig of claim 2, wherein each vertical support of the plurality of vertical support has a length less than a length of the legs of the jacket.

4. The modular rig of claim 3, wherein the plurality of vertical supports includes a first subset of vertical supports having a first diameter, and a second subset of vertical supports having a second diameter less than the first diameter.

5. The modular rig of claim 4, wherein the well bay is configured to engage the second subset of vertical supports.

6. The modular rig of claim 2, wherein the plurality of vertical supports are positioned at midway points along sides of the jacket.

7. The modular rig of claim 2, wherein the top side is configured to engage openings formed in the legs of the jacket and openings formed in one or more vertical supports of the plurality of vertical supports.

8. The modular rig of claim 7, wherein the top side comprises two levels.

9. The modular rig of claim 1 , wherein the jacket comprises a plurality of axially aligned pipe racks.

10. A method of constructing a modular rig, comprising:

installing a jacket on a sea bed, the jacket comprising legs having openings therein at an upper end thereof for receiving modular components;

installing a first modular component on the jacket, the first modular component comprising a well bay; and

installing a second modular component on the jacket, the second modular component comprising a topside.

1 1 . The method of claim 10, further comprising beginning hydrocarbon production after installation of the well bay and prior to installation of the topside.

12. The modular rig of claim 10, wherein the jacket includes a plurality of vertical supports positioned between adjacent legs of the jacket, each vertical support of the plurality of vertical supports including openings at an end thereof for receiving modular components.

13. The modular rig of claim 12, wherein each vertical support of the plurality of vertical support has a length less than a length of the legs of the jacket.

14. The modular rig of claim 13, wherein the plurality of vertical supports includes a first subset of vertical supports having a first diameter, and a second subset of vertical supports having a second diameter less than the first diameter.

15. The modular rig of claim 14, wherein the well bay is configured to engage the second subset of vertical supports.

18. The modular rig of claim 12, wherein the plurality of vertical supports are positioned at midway points along sides of the jacket.

17. The modular rig of claim 12, wherein the top side is configured to engage openings formed in the legs of the jacket and openings formed in one or more vertical supports of the plurality of vertical supports.

18. The modular rig of claim 17, wherein the top side comprises two levels.

19. The modular rig of claim 10, wherein the jacket comprises a plurality of axialiy aligned pipe racks.