Systems and methods for riser coupling

Systems and methods for riser coupling are disclosed. A riser coupling system comprises a riser joint connector comprising a first tubular assembly coupled to a second tubular assembly. The riser coupling system further comprises a spider assembly which receives the riser joint connector and has a connector actuation tool. The connector actuation tool comprises a dog assembly, a clamping tool and a splined member. The dog assembly selectively extends a dog to engage the riser joint connector. The clamping tool couples the first tubular assembly and the second tubular assembly. Finally, the splined member actuates a locking member of the riser joint connector.

BACKGROUND

The present disclosure relates generally to well risers and, more particularly, to systems and methods for riser coupling.

In drilling or production of an offshore well, a riser may extend between a vessel or platform and the wellhead. The riser may be as long as several thousand feet, and may be made up of successive riser sections. Riser sections with adjacent ends may be connected on board the vessel or platform, as the riser is lowered into position. Auxiliary lines, such as choke, kill, and/or boost lines, may extend along the side of the riser to connect with the wellhead, so that fluids may be circulated downwardly into the wellhead for various purposes. Connecting riser sections in end-to-end relation includes aligning axially and angularly two riser sections, including auxiliary lines, lowering a tubular member of an upper riser section onto a tubular member of a lower riser section, and locking the two tubular members to one another to hold them in end-to-end relation.

The riser section connecting process may require significant operator involvement that may expose the operator to risks of injury and fatigue. For example, the repetitive nature of the process over time may create a risk of repetitive motion injuries and increasing potential for human error. Moreover, the riser section connecting process may involve heavy components and may be time-intensive. Therefore, there is a need in the art to improve the riser section connecting process and address these issues.

DETAILED DESCRIPTION

The present disclosure relates generally to well risers and, more particularly, to systems and methods for riser coupling.

Illustrative embodiments of the present disclosure are described in detail herein. In the interest of clarity, not all features of an actual implementation may be described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation specific decisions must be made to achieve the specific implementation goals, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of the present disclosure. To facilitate a better understanding of the present disclosure, the following examples of certain embodiments are given. In no way should the following examples be read to limit, or define, the scope of the disclosure.

For the purposes of this disclosure, a sensor may include any suitable type of sensor, including but not limited to optical, radio frequency, acoustical, pressure, torque, or proximity sensors.

FIG. 1Ashows an angular view of one exemplary riser coupling system100, in accordance with certain embodiments of the present disclosure.FIG. 1Bshows a top view of the riser coupling system100. The riser coupling system100may include a spider assembly102adapted to one or more of receive, at least partially orient, engage, hold, and actuate a riser joint connector104. The spider assembly102may include one or more connector actuation tools106. In certain embodiments, a plurality of connector actuation tools106may be spaced radially about an axis103of the spider assembly102. By way of nonlimiting example, two connector actuation tools106may be disposed around a circumference of the spider assembly102in an opposing placement. The nonlimiting example ofFIG. 1show three pairs of opposing connector actuation tools106. It should be understood that various embodiments may include any suitable number of connector actuation tools106.

As depicted inFIG. 1B, certain embodiments may include one or more orienting members105disposed radially about the axis103to facilitate orientation of the riser joint connector104. By way of example without limitation, three orienting members105may include a cylindrical or generally cylindrical form extending upwards from a surface of the spider assembly102. The orienting members105may act as guides to interface the riser joint connector104as the riser joint connector104is lowered toward the spider assembly102, thereby facilitating orientation and/or alignment. In certain embodiments, the orienting members105may be fitted with one or more sensors (not shown) to detect position and/or orientation of the riser joint connector104, and corresponding signals may be transferred to an information handling system at any suitable location on a vessel or platform by any suitable means, including wired or wireless means.

The spider assembly102may include a base108. The base108, and the spider assembly102generally, may be mounted directly or indirectly on a surface of a vessel or platform. For example, the base108may be disposed on or proximate to a rig floor. In certain embodiments, the base108may include or be coupled to a gimbal mount to facilitate balancing in spite of sea sway.

FIG. 2shows an angular view of the spider assembly102prior to receiving the riser joint connector104(depicted inFIGS. 1A and 1B). The nonlimiting example of the spider assembly102with the base108includes a generally circular geometry about a central opening110configured for running riser sections therethrough. Various alternative embodiments may include any suitable geometry.

FIG. 3Ashows an angular view of one exemplary connector actuation tool106, in accordance with certain embodiments of the present disclosure.FIG. 3Bshows a cross-sectional view of the connector actuation tool106. The connector actuation tool106may include a connection means112to allow connection to the base108(omitted inFIGS. 3A,3B). As depicted, the connection means112may include a number of threaded bolts. However, it should be appreciated that any suitable means of coupling, directly or indirectly, the connector actuation tool106to the rest of the spider assembly102(omitted inFIGS. 3A,3B) may be employed.

The connector actuation tool106may include a dog assembly114. The dog assembly114may include a dog116and a piston assembly118configured to move the dog116. The piston assembly118may include a piston120, a piston cavity122, one or more hydraulic lines124to be fluidically coupled to a hydraulic power supply (not shown), and a bracket126. The bracket126may be coupled to a support frame128and the piston120so that the piston120remains stationary relative to the support frame128. The support frame128may include or be coupled to one or more support plates. By way of example without limitation, the support frame128may include or be coupled to support plates130,132, and134. The support plate130may provide support to the dog116.

With suitable hydraulic pressure applied to the piston assembly118from the hydraulic power supply (not shown), the piston cavity122may be pressurized to move the dog116with respect to one or more of the piston120, the bracket126, the support frame128, and the support plate130. In the non-limiting example depicted, each of the piston120, the bracket126, the support frame128, and the support plate130is adapted to remain stationary though the dog116moves.FIGS. 3A and 3Bdepict the dog116in an extended state relative to the rest of the connector actuation tool106.

The connector actuation tool106may include a clamping tool135. By way of example without limitation, the clamping tool135may include one or more of an upper actuation piston136, an actuation piston mandrel138, and a lower actuation piston140. Each of the upper actuation piston136and the lower actuation piston140may be fluidically coupled to a hydraulic power supply (not shown) and may be moveably coupled to the actuation piston mandrel138. With suitable hydraulic pressure applied to the upper and lower actuation pistons136,140, the upper and lower actuation pistons136,140may move longitudinally along the actuation piston mandrel138toward a middle portion of the actuation piston mandrel138.FIGS. 3A and 3Bdepict the upper and lower actuation pistons136,140in a non-actuated state.

The actuation piston mandrel138may be extendable and retractable with respect to the support frame128. A motor142may be drivingly coupled to the actuation piston mandrel138to selectively extend and retract the actuation piston mandrel138. By way of example without limitation, the motor142may be drivingly coupled to a slide gear144and a slide gear rack146, which may in turn be coupled to the support plate134, the support plate132, and the actuation piston mandrel138. The support plates132,134may be moveably coupled to the support frame128to extend or retract together with the actuation piston mandrel138, while the support frame128remains stationary.FIGS. 3A and 3Bdepict the slide gear rack146, the support plates132,134, and the actuation piston mandrel138in a retracted state relative to the rest of the connector actuation tool106.

The connector actuation tool106may include a motor148, which may be a torque motor, mounted with the support plate134and driving coupled to a splined member150. The splined member150may also be mounted to extend and retract with the support plate134. It should be understood that while one non-limiting example of the connector actuation tool106is depicted, alternative embodiments may include suitable variations, including but not limited to, a dog assembly at an upper portion of the connector actuation tool, any suitable number of actuation pistons at any suitable position of the connector actuation tool, any suitable motor arrangements, and the use of electric actuators instead of or in combination with hydraulic actuators.

In certain embodiments, the connector actuation tool106may be fitted with one or more sensors (not shown) to detect position, orientation, pressure, and/or other parameters of the connector actuation tool106. For nonlimiting example, one or more sensors may detect the positions of the dog116, the clamping tool135, and/or splined member150. Corresponding signals may be transferred to an information handling system at any suitable location on the vessel or platform by any suitable means, including wired or wireless means. In certain embodiments, control lines (not shown) for one or more of the motor148, clamping tool135, and dog assembly114may be feed back to the information handling system by any suitable means.

FIG. 4shows a cross-sectional view of a riser joint connector104, in accordance with certain embodiments of the present disclosure. The riser joint connector104may include an upper tubular assembly152and a lower tubular assembly154, each arranged in end-to-end relation. The upper tubular assembly152sometimes may be referenced as a box; the lower tubular assembly154may be referenced as a pin.

Certain embodiments may include a seal ring (not shown) between the tubular members152,154. The upper tubular assembly152may include grooves156about its lower end. The lower member154may include grooves158about its upper end. A lock ring160may be disposed about the grooves156,158and may include teeth160A,160B. The teeth160A,160B may correspond to the grooves156,158. The lock ring160may be radially expandable and contractible between an unlocked position in which the teeth160A,160B are spaced from the grooves156,158, and a locking position in which the lock ring160has been forced inwardly so that teeth160A,160B engage with the grooves156,158and thereby lock the connection. Thus, the lock ring160may be radially moveable between a normally expanded, unlocking position and a radially contracted locking position, which may have an interference fit. In certain embodiments, the lock ring160may be split about its circumference so as to normally expand outwardly to its unlocking position. In certain embodiments, the lock ring160may include segments joined to one another to cause it to normally assume a radially outward position, but be collapsible to contractible position.

A cam ring162may be disposed about the lock ring160and may include inner cam surfaces which are slidable over surfaces of the lock ring160. The cam surfaces of the cam ring162may provide a means of forcing the lock ring160inward to a locked position. The cam ring162may include an upper member162A and a lower member162B with corresponding lugs162A′ and162B′. The upper member162A and the lower member162B may be configured as opposing members. The cam ring162may be configured so that movement of the upper member162A and the lower member162B toward each other forces the lock ring160inward to a locked position via the inner cam surfaces of the cam ring162.

The riser joint connector104may include one or more locking members164. A given locking member164may be adapted to extend through a portion of the cam ring162to maintain the upper member162A and the lower member162B in a locking position where each has been moved toward the other to force the lock ring160inward to a locked position. The locking member164may include a splined portion164A and may extend through a flange152A of the upper tubular assembly152. The locking member164may include a retaining portion164B, which may include but not be limited to a lip, to abut the upper member162A. The locking member164may include a tapered portion164C to fit a portion of the upper member162A. The locking member164may include a threaded portion164D to threadedly engage the lower member162B.

The riser joint connector104may include one or more auxiliary lines166. For nonlimiting example, the auxiliary lines166may include one or more of hydraulic lines, choke lines, kill lines, and boost lines. The auxiliary lines166may extend through the flange152A and a flange154A of the lower tubular assembly154. The auxiliary lines166may be adapted to mate between the flanges152A,154A, for example, by way of a stab fit.

The riser joint connector104may include one or more connector orientation guides168. A given connector orientation guide168may be disposed about a lower portion of the riser joint connector104. By way of example without limitation, the connector orientation guide168may be coupled to the flange154A. The connector orientation guide168may include one or more tapered surfaces168A formed to, at least in part, orient at least a portion of the riser joint connector104when interfacing one of the dog assemblies114. When the dog assembly114contacts one or more of the tapered surfaces168A of the connector orientation guide168, the one or more tapered surfaces168A may facilitate axial alignment and/or rotational orientation of the riser joint connector104by biasing the riser joint connector104toward a predetermined position with respect to the dog assembly114. In certain embodiments, the connector orientation guide168may provide a first stage of an orientation process to orient the lower tubular assembly154.

The riser joint connector104may include one or more orientation guides170. In certain embodiments, the one or more orientation guides170may provide a second stage of an orientation process. A given orientation guide170may be disposed about a lower portion of the riser joint connector104. By way of example without limitation, the orientation guide170may be formed in the flange154A. The orientation guide170may include a recess, cavity or other surfaces adapted to mate with a corresponding guide pin172(depicted inFIG. 5).

FIG. 5shows a cross-sectional view of landing a riser section, which may include the lower tubular assembly154, in the spider assembly102, in accordance with certain embodiments of the present disclosure. In the example landed state shown, the dogs116have been extended to retain the tubular assembly154, and the two-stage orientation features have oriented the lower tubular assembly154. Specifically, the connector orientation guide168has already facilitated axial alignment and/or rotational orientation of the lower tubular assembly154, and one or more of the dog assemblies114may include a guide pin172extending to mate with the orientation guide170to ensure a final desired orientation.

A running tool174may be adapted to engage, lift, and lower the lower tubular assembly154into the spider assembly102. In certain embodiments, the running tool174may be adapted to also test the auxiliary lines166. For example, the running tool174may pressure test choke and kill lines coupled below the lower tubular assembly154.

In certain embodiments, one or more of the running tool174, the tubular assembly154, and auxiliary lines166may be fitted with one or more sensors (not shown) to detect position, orientation, pressure, and/or other parameters associated with said components. Corresponding signals may be transferred to an information handling system at any suitable location on the vessel or platform by any suitable means, including wired or wireless means.

FIG. 6shows a cross-sectional view of running the upper tubular assembly152to the landed lower tubular assembly154, in accordance with certain embodiments of the present disclosure. The running tool174may be used to engage, lift, and lower the upper tubular assembly152. The upper tubular assembly152may be lowered onto a stab nose178of the lower tubular assembly154.

In certain embodiments, the running tool174may include one or more sensors176to facilitate proper alignment and/or orientation of the upper tubular assembly152. The one or more sensors176may be located at any suitable positions on the running tool174. In certain embodiments, the tubular member152may be fitted with one or more sensors (not shown) to detect position, orientation, pressure, and/or other parameters of the tubular member152. Corresponding signals may be transferred to an information handling system at any suitable location on the vessel or platform by any suitable means, including wired or wireless means.

FIG. 7shows a cross-sectional view of orienting the upper tubular assembly152with respect to lower tubular assembly154, in accordance with certain embodiments of the present disclosure. It should be understood that orienting the upper tubular assembly152may be performed at any suitable stage of the lowering process, or throughout the lower process.

FIG. 8shows a cross-sectional view of the upper tubular assembly152landed, in accordance with certain embodiments of the present disclosure.

FIG. 9shows a cross-sectional view of the connector actuation tool106engaging the riser joint connector104prior to locking the riser joint connector104, in accordance with certain embodiments of the present disclosure. As depicted, the actuation piston mandrel138may be extended toward the riser joint connector104. The upper actuation piston136may engage the lug162A′ and/or an adjacent groove of the cam ring162. Likewise, the lower actuation piston140may engage the lug162B′ and/or an adjacent groove of the cam ring162. The splined member150may also be extended toward the riser joint connector104. As depicted, the splined member150may engage the locking member164. In various embodiments, the actuation piston mandrel138and the splined member150may be extended simultaneously or at different times.

FIG. 10shows a cross-sectional view of the connector actuation tool106locking the riser joint connector104, in accordance with certain embodiments of the present disclosure. As depicted, with suitable hydraulic pressure having been applied to the upper and lower actuation pistons136,140, the upper and lower actuation pistons136,140moved longitudinally along the actuation piston mandrel138toward a middle portion of the actuation piston mandrel138. The upper member162A and the lower member162B of the cam ring162are thereby forced toward one another, which may act as a clamp that in turn forces the lock ring160inward to a locked position via the inner cam surfaces of the cam ring162. As depicted, the locking member164may be in a locked position after the motor148has driven the splined member150, which in turn has driven the locking member164into the locked position to lock the cam ring162in a clamped position. In various embodiments, the locking member164may be actuated into the locked position as the cam ring162transitions to a locked position or at a different time.

FIG. 11shows a cross-sectional view of the connector actuation tool106retracted, in accordance with certain embodiments of the present disclosure. From that position, the running tool174(depicted in previous figures) may engage the riser joint connector104and lift the riser joint connector104away from the guide pin172. The dogs114may be retracted, the riser joint connector104may be lowered passed the spider assembly102, and the process of landing a next lower tubular may be repeated. It should be understood that a dismantling process may entail reverses the process described herein.

Accordingly, certain embodiments of the present disclosure allow for hands-free riser section coupling systems and methods. Certain embodiments allow for minimal and remote operator involvement. As a result, certain embodiments provide safety improvements in part by eliminating or significantly reducing direct operator involvement that would otherwise expose an operator to risks of injury, fatigue, and increased potential for human error. Moreover, certain embodiments allow for increased speed and efficiency in the riser section coupling process. Certain embodiments allow for lighter coupling components, for example, by eliminating or significantly reducing the need for heavy bolts and flanges. This may save material usage and augment the speed and efficiency of the riser section coupling process.

Therefore, the present disclosure is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Even though the figures depict embodiments of the present disclosure in a particular orientation, it should be understood by those skilled in the art that embodiments of the present disclosure are well suited for use in a variety of orientations. Accordingly, it should be understood by those skilled in the art that the use of directional terms such as above, below, upper, lower, upward, downward and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure.

Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. The indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that the particular article introduces; and subsequent use of the definite article “the” is not intended to negate that meaning.