ROTATING FLUID MANIFOLD

Abstract: Disclosed is a method and apparatus for maintaining fluid flow between a subsea wellhead riser conduit 10, 12, 14 and a weathervaning floating production, storage and off-loading (FPSO) vessel without swivel or sliding seals. The riser conduit 10, 12, 14 is divided into first and second flowpaths A, B which terminate in connectors 22, 24. First and second drums 34, 36, coaxially mounted for rotation about a vertical axis, have connectors 26, 28 which are connectable with the flowpath connectors 22, 24. The drum connectors 26, 28 are connected to one end of flexible pipes, 41, 41, 43, 50, 51, 52, at least partially wound around a respective drum, with the other end tensioned and connected fixably to the FPSO vessel. Enough flexible pipe is on each drum 34, 36 to permit the drum to rotate about a connection arc of greater than 180° when its respective connector 26, 28 connects one flowpath with the FPSO vessel. The connectors and drums are disposed such that each connection arc overlaps the other arc at both ends of each arc. Fluid flow is maintained through the first flowpath A until the weathervaning vessel approaches the end of the connection arc of the first drum, 34. After the overlap region is reached flow is established in the second flowpath B through the second drum 36 and flowpath connector 24. When the end of the connection arc of the first drum 34 is reached, the first flowpath connector 22 is disconnected thereby terminating fluid flow in the first flowpath A while fluid flow is maintained in the second flowpath B. Should further weathervaning continue such that the first drum connection arc is again reached, reconnection of the first drum 34 and flowpath A occurs.

Description: The present invention relates to a fluid manifold which permits the rotation of one end of the manifold with respect to the other without an interruption of fluid flow therethrough. Such a manifold is particularly intended for the transport of seabed well fluids to a floating production, storage and off-loading (FPSO) vessel. An FPSO vessel moored at an exposed location must be able to rotate or weathervane on its mooring as the wind direction changes. In the past, multiple path fluid swivels have been employed at the interface between the riser conduit from the seabed well and the vessel in order to permit weathervaning. Such a multi-path swivel is described in Gentry et al, U. S. Patent No. 4,436,048. However, although this multi-path fluid swivel provides a solution to the weathervaning problem, pressure limitations on the swivel seals prevent its application on FPSO vessels in oil fields where pressures above about 14000 kPa (2000 psi) are encountered. It is an object of the present invention to provide an improved method and apparatus for providing a continuous, rotatable connection between a fluid conduit and a vessel. In one aspect, the invention resides in a method of providing a continuous fluid connection from at least one riser conduit to a vessel which is free to rotate about an axis, comprising the steps of: dividing the fluid flow from said conduit into first and second flowpaths, each flowpath ending in a respective first connector; positioning first and second drums adjacent said first and second flowpaths, respectively, said first and second drums having respective second connectors which can be releasably connected to the first connectors of the first and second flowpaths, respectively, and each of said first and second drums being capable of flexible connection to said vessel and being rotatable with respect to said vessel about said axis through an arc greater than 180°, the rotational arc for one drum overlapping the rotational arc of the other drum at both ends of each arc; and passing fluid through the first flowpath by way of the connectors to the first drum and said vessel when said vessel is positioned within the rotational arc of the first drum, passing fluid through the second flowpath by way of the connectors to the second drum and said vessel when said vessel is positioned within the rotational arc of the second drum; and disconnecting the first and second connectors connecting a respective flowpath to its adjacent drum prior to angular movement of the vessel outside the rotational arc of said adjacent drum. In a further aspect, the invention resides in a manifold for continuously connecting at least one riser conduit to a vessel, said vessel being rotatable with respect to said conduit about a first axis and said manifold comprising: a first drum rotatable relative to said vessel about said first axis through a first arc greater than 180°; at least one conduit channel around the periphery of said first drum; at least one first flexible conduit having one end disposed in said conduit channel; first connector means, disposed on said first drum, for connecting and disconnecting said one end of said first flexible conduit to a first flowpath portion of said riser conduit; means for connecting the other end of said first flexible conduit to said vessel; a second drum rotatable relative to said vessel about said first axis through a second arc which is greater than 180° and which overlaps said first arc at each end thereof; at least one conduit channel around the periphery of said second drum; at least one second flexible conduit having one end disposed in said second conduit channel; second connector means, disposed on said second drum, for connecting and disconnecting said one end of said second flexible conduit to a second flowpath portion of said fixed riser conduit; at least one of said first and second connector means connecting its associated conduit to the riser when said vessel is within the rotational arc of the associated drum; and means for connecting the other end of said second flexible conduit to said vessel. In the accompanying drawings, Fig. 1 is a side cross-sectional schematic illustration of a multi-path manifold in accordance with one example of the present invention; Figs. 2a-2c are simplified side perspective views illustrating operation of a manifold according to a further example of the invention; Fig. 3 is a side view partially in section of the manifold of the further example; and Fig. 4 is a side view illustrating the manifold of the further example installed in a floating production, storage and off-loading (FPSO) vessel. Referring to the drawings, wherein like reference numerals represent similar elements throughout the several views, Fig. 1 shows fixed riser conduits 10, 12 and 14, which are connected to a wellhead or group of wellheads for transporting fluid from the wellhead(s) to a storage vessel. The conduits are fixed only to the extent that the vessel will be rotating therearound and are housed at their free ends in a turret 20. Tether chains 16 and 18 are connected to the turret 20 and anchored on the sea floor with the floating production, storage and off-loading (FPSO) vessel weathervaning around the turret. Although a three-conduit multiple-path manifold is illustrated, any number of multiple paths could be used and it is envisioned that a six-path manifold would be particularly advantageous in FPSO vessel situations. From the turret, each conduit flow path separates into "A" and "B" flowpaths 10a and 10b, 12a and 12b, 14a and 14b. The "A" flowpaths terminate in lower "A" connectors 22, while the "B" flowpaths terminate in lower "B" connectors 24. The lower connectors 22, 24 are engageable and disengageable with upper connectors 26 and 28, respectively. These connectors can be conventional wellhead connectors which are mechanically or hydraulically operated and which carry at least the working pressure of the manifold. Such connectors would include isolation valves to seal the respective flowpaths when connectors are disconnected, and vent and drain lines to prevent spillage of fluids during disconnection. The lower connectors of the "A" and "B" flowpaths can be raised into connecting relationship with the upper connectors by actuators 30 and 32, respectively. The actuators could be electrically or mechanically operated, but are preferably hydraulic actuators. It may be advantageous to utilize connectors with internal guide pins or flanges so as to ensure proper orientation between the connectors. Furthermore, it is desirable that the connectors be self-sealing so as to prevent loss of fluid when the connectors are disconnected. The conduits in a preferred embodiment would carry primarily well fluids, such as crude oil, gas and water, but could also be utilized to carry electricity, high pressure hydraulic fluid or high pressure air, as desired. The upper connectors 26 and 28 are connected to first and second drums 34 and 36, respectively, which are rotatable on a frame (not shown) mounted on the vessel about an axis which is parallel to the axis of rotation of the ship about the turret during the weathervaning process. In a preferred embodiment, the rotation is about a vertical axis Y, as shown. First drum 34 has three channels 38, 39 and 40 disposed around its periphery, in which are disposed respective portions 41, 42 and of a 43 flexible high pressure pipe. Similarly, the second drum has channels 46, 47 and 48, with portions 50, 51 and 52 of a second flexible high pressure pipe disposed therein. Internally disposed in said drums are conduits indicated schematically by dotted lines 55-60 connecting the upper connectors associated with conduits 10a, 12a, 14a, 10b, 12b, and 14b, with the flexible pipe portions 41, 42, 43, 50, 51 and 52, respectively. The flexible pipe portions 41, 42, 43, 50, 51, 52 may be any flexible pipe consistent with the materials and working pressures contained therein. With respect to wellhead fluids, it is desirable to employ Coflexip pipe which can be obtained from Coflexip and Service, Inc., 4242 SW Freeway, Houston, Texas, U.S.A. The first and second drums 34 and 36 have a radius greater than the minimum bending radius of the flexible pipe, such that the pipe can be wound and unwound onto and off the drums without undue wear. The flexible pipe portions 41, 42, 43 for flowpath "A" and flexible pipe portions 50, 51 and 52 for flowpath "B" are connected to the fixed internal piping on the FPSO vessel. A desired level of tension on the flexible pipe portions is maintained where the flexible pipe first contacts the drum around which it is wrapped due to the weight of free-hanging bights 62-67 after the portions pass over sheaves 70-75, respectively. The other end portions of the flexible pipes are connected to the FPSO vessel at fixed fittings 77-82. Although, in Fig. 1, fittings 77 and 80 are illustrated on opposite sides of the drawing, it is anticipated that they would be interconnected together at the vessel, since they are both ends of flowpath 10. Moreover, although the sheaves are illustrated with relatively small diameters, they would have a similar diameter to that of the first and second drum, as would the free-hanging bights, in order to prevent damage to the flexible pipe due to a small radius bend. When the upper and lower connectors are disconnected, as shown with respect to connectors 28 and 24, in Figure 1, drive means can rotate the drum associated with the disconnected connector, with the free-hanging bight taking up any slack. Although any drive system could be utilized, advantageously hydraulic drive motors 84 and 85 acting through respective drive gears drive the first drum 34 and the second drum 36 independently about axis of rotation Y in order to position their respective connectors for a sealing engagement. The operation of the Fig. 1 embodiment is as follows. Although it is the vessel which rotates or weathervanes around the turret 20 and the fixed conduit from the subsea wellhead, in reviewing the operation of the invention in Fig. 1, it may be easier to consider the turret to be rotating, with the sheaves and fittings connected to the FPSO vessel being fixed. Accordingly, it can be seen that the first drum 34 must rotate as the vessel weathervanes in order to maintain its connected position through upper and lower connectors 26 and 22, respectively, with the "A" path of fluid flow through turret 20. As drum 34 rotates, a greater or lesser quantity of flexible conduit is wound into the channels 38, 39 and 40 on the periphery of the drum, depending upon the direction of rotation of the drum. Accordingly, the free-hanging bights 62-64 will either lengthen or shorten, depending on the rotation of the drum. It can be seen that based upon the length of flexible conduit in the bight, that the drum can rotate only a certain number of degrees before the bight has been impermissibly shortened and begins stressing the fixed fittings 77, 78 and 79 (in the case of the conduit being wound onto the drum) or that the interconnection between the flexible conduit and the internal connecting conduits is reached (in the case of the flexible pipe unwinding from the drum). Drum 36 operates in a similar manner as drum 34. The angular movement over which each drum can move is considered to be the connecting arc of the drum and, in the case of a two-drum system, would have to be greater than 180°. In fact, in a preferred embodiment, each drum would have a connecting arc of 450° and the flexible conduit would be wound on top of itself in the grooved channel. It is also necessary that where the connecting arcs are not greater than 360°, that the arcs overlap at each end with the arc from the other drum. For example, if drums 34 and 36 had connecting arcs of 270° each and the arcs were positioned directly opposite each other, there would be two overlapping areas, one at each end of an arc and equal to 90°. With the arrangement shown in Figure 1, such that the connectors 24, 28 are disconnected, when drum 34 approaches the end of its connecting arc, the position of the vessel will be such that it is within the connecting arc for the second drum 36. Hydraulic drive motor 85 is then energized to rotate drum 36 until upper connector 28 is aligned with lower connector 24. Once aligned, the "B" flowpath actuator 32 raises connector 24 into a connecting relationship with the upper connector 28, permitting fluid flow through the "B" flowpath and into the FPSO vessel fittings 80, 81 and 82. At this point, there would be two flowpaths into the FPSO vessel. As additional weathervaning occurs and first drum 34 reaches the absolute limit in its connecting arc, the "A" flowpath actuator 30 disconnects the lower connector 22 from upper connector 26, terminating the dual flowpath flow of wellhead fluids. In a preferred embodiment, it is the connection of the upper and lower connectors which serve to rotate drums 34 and 36 during weathervaning with respect to the FPSO vessel (actually the vessel rotates around these drums). As the vessel continues weathervaning through the connecting arc for second drum 36, it will approach the other end of the connecting arc for the first drum 34 and the region of overlap between the two connecting arcs. When this region has been entered by a predetermined number of degrees (in the event the overlap region is 90°, an entry of 45° might be used), drive motor 84 would rotate the first drum 34 so that connectors 22 and 26 are in alignment, whereupon "A" actuator 30 will again connect the connectors 22, 26 establishing the "A" flowpath, so that there is again a dual flowpath into the FPSO vessel. By rotating the drums and connecting and disconnecting the connectors, it can be seen that any number of rotations of the FPSO vessel about the turret 20 can be accommodated while maintaining at least one flowpath. Although individual connectors will be connected and disconnected, one set of connectors will always be connected and there will always be at least one flowpath for each riser conduit from the wellhead through the turret to the FPSO vessel. Fig. 1 illustrates a sheave and bight assembly to maintain a desired level of tension on the flexible pipe, as well as a supply of flexible pipe which can be drawn from and wound onto the rotating drums. However, other methods of accomplishing this are envisioned. For example, a traveling sheave assembly could be used as disclosed in Fig. 2 of Anderson, U. S. Patent No. 4,273,066. However, the Anderson device and the present Fig. 1 embodiment require some support for the flexible pipe 41-43, 50-52 between the channels 38-40, 46-48 on the periphery of the drum and the sheaves 70-75, over which they pass. The support schematically shown as 86 in Fig. 1 could be in the form of shelves or channels coated with a low friction material, such as polytetrafluoroethylene, or could have roller bearings or other devices to support the pipe without unduly restricting its movement over the sheaves. However, in an alternative embodiment of the invention illustrated in Figures 2 and 3, the requirement for such supports is eliminated by transfering the line directly from the periphery of one drum to the periphery of another drum rotating at an angle thereto, preferably 90°. Referring now to Figs. 2a-2c, a vertical axis drum, represented by disc 90, includes upper and lower connector portions 92 and 94, respectively, which serve to interconnect the "A" flowpath with one end of a flexible pipe 96 disposed around its periphery. The other end of the flexible pipe 96 is disposed around the periphery of a horizontal axis drum, schematically illustrated by disc 98. An internal conduit 100 connects an end portion of flexible pipe 96 to a further flexible pipe segment 104 extending around a takeup drum 102 affixed to disc 98. The further flexible pipe segment 104 extends from the drum 102 to a fixed FPSO vessel fitting 106 by way of a free-hanging bight 108. In Fig. 2b, the disc 90 is shown as having been rotated clockwise an angular amount equal to alpha (or depending upon one's perspective, the FPSO vessel can be considered to have rotated counterclockwise an amount equal to alpha), with respect to the orientation illustrated in Fig. 2a. It can be seen that this rotation requires more flexible pipe 96 to be wound onto the vertical axis drum 90, and less flexible pipe will be wound on the horizontal axis drum 98. Because the horizontal axis drum has rotated counterclockwise, it will effectively "unwind" flexible pipe 104 off of the takeup drum 102, increasing the length of bight 108. In Fig. 2c, the rotation of the vertical axis drum 90 is counterclockwise (or the FPSO vessel has rotated in a clockwise direction) by an angular amount beta from the orientation shown in Fig. 2a. A portion of flexible pipe 96 is thereby wound from the periphery of the vertical axis drum 90 onto the periphery of the horizontal axis drum 98, while the rotation of the horizontal axis drum 98 causes takeup drum 102 to wind on a greater portion of flexible pipe segment 104, reducing the length of bight 108. It can be seen that the utilization of two drums having axes of rotation at an angle can serve to transfer the flexible pipe from a channel around the periphery of one drum to the channel around the periphery of another drum without the need for a separate structure to support the flexible pipe. If this is combined with internal conduit connecting the flexible pipe end on the horizontal axis drum to the flexible pipe end on a takeup drum from which the free-hanging bight falls, there will be no need for any additional support structure at all. While it can be seen that the rotation of vertical axis drum 90 in the clockwise direction (Fig. 2b) will cause the counterclockwise rotation of the horizontal axis drum 98 (by virtue of the flexible pipe being withdrawn from the periphery of disc 98), it may be necessary to provide a rotational bias to the horizontal axis drum in order to wind the flexible pipe 96 onto its periphery when it rotates in a clockwise direction (Fig. 2c). The bias could be the weight of the bight, in which case it would have to be wound around the takeup drum 102 in the opposite direction from that illustrated in Fig. 2c. Alternatively, and more preferably, the periphery of the two drums could be interconnected by either gear teeth or by an endless drive belt or cable circumferentially connecting both drums. Although, for the sake of simplicity, only a single flowpath "A" and the drums associated therewith are illustrated in Figs. 2a-2c, the complete manifold of this further example utilizes two flowpaths and is illustrated in Fig. 3. Referring to Figure 3, a three conduit manifold system is illustrated, although the number of paths could be greater or less than 3. Fixed riser conduits 110, 112 and 114 terminate in junctions with flexible pipes forming "A" and "B" flowpaths to pass fluids into a plurality of lower connectors 122 and 124 for the "A" and "B" flowpaths. In Figure 3, details of the lower connectors 122 and 124, upper connectors 126 and 128 and hydraulic actuators 130 and 132 for only the 110 "A" and "B" flowpaths can be seen since the connectors and actuators for the other flowpaths are hidden from view. The "B" flowpath is shown disconnected, with the "A" flowpath shown connected in Fig. 3. A first conical drum 134 is mounted for rotation about a vertical axis Y on support frame 135, which is secured to turret 120. A second conical drum 136 is also mounted for rotation about the vertical axis Y on the support frame 135. Channels 138-140 are provided in the first conical drum 134 and channels 146-148 provided in the second conical drum 136 for the 110, 112 and 114 flowpaths, respectively. Drive motors 184 and 185 drive the first conical drum 134 and the second conical drum 136, respectively. Adjacent the first and second conical drums 134, 136 are third and fourth conical drums 141 and 142, respectively, which rotate about a horizontal axis. Immediately adjacent first conical drum 134 channels 138-140 are channels 149-151 on the third conical drum 141. Similarly, immediately adjacent channels 146-148 on the second conical drum 136 are disposed channels 154-156 on the outer periphery of the fourth conical drum 142. As in the schematic shown in Fig. 2a, the respective horizontal axis and vertical axis drums are interconnected by means of flexible pipes which are disposed in their respective channels and which serve to connect internal conduits on each of the vertical axis drums, with corresponding internal conduits on each of the horizontal axis drums. Fig. 3 illustrates only a single flexible pipe and, in phantom lines, an internal conduit in the horizontal axis drums. The internal conduit on the vertical axis drums are shown schematically by the dotted lines. The third and fourth drums 141 and 142 each have takeup drums 158 and 159, which have channels 161-163 and 165-167, respectively, thereon. Interconnected to the internal connecting conduits are flexible pipe segments which are disposed in channels 161-163 and 165-167. These flexible pipe segments form free-hanging bights and are connected to fixed fittings on the FPSO vessel, in the manner described and disclosed with reference to Figs. 2a-2c. The first and second conical drums, the connectors 122, 124, 126, 128, their actuators 130 and 132 and drive motors 184 and 185 all operate in a sequence and in a manner discussed with reference to Fig. 1. However, where the Fig. 1 embodiment takes the flexible pipe from the drum in a horizontal direction (thus requiring some type of support structure), the Fig. 3 embodiment withdraws the pipe from the conical drum channels in a vertical direction and then internally connects the pipe to another portion of flexible pipe on the takeup drums. Consequently, the three bights (not shown) can hang from each of the takeup drums 158 and 159 without the need for additional support structures. As discussed earlier, any number of flowpaths could be used in the Fig. 3 embodiment and different hose diameters and wellhead connectors could be utilized, depending upon the pressures and flow rates required by the specific seabed well. As discussed with reference to Fig. 2a, the rotation of the horizontal axis conical drums and takeup drums could be by geared drive motors, so as to maintain the appropriate tension on the flexible pipe but, in a preferred embodiment, a mechanical belt or cable would serve to rotate the horizontal axis drums in synchronism with the vertical axis drums. Cables 170 and 172, shown in Fig. 3, would accomplish this result. It is important to note that the smallest diameter channels 138 and 149 would have a radius equal to or larger than the minimium bend radius of the flexible pipe. Further, although in a preferred embodiment the diameters of adjacent horizontal and vertical axis channels would be equal, the diameters could be different. The angular relationship between the axes of rotation could be greater than or less than 90° as long as the apices of the cones are coincident (which insures a matched peripheral velocity in the adjacent channels). It should further be noted that although the first and second conical drums are mounted on support frame 135, which is in turn mounted on the rotating turret, they could also be mounted on frames 180 and 182 which support the horizontal axis drums. In this manner, the only structures present on the turret would be the lower connectors and their respective actuators. Fig. 4 illustrates the placement and orientation of the Fig. 3 device, except that only the second drum 136 and fourth drum 142, along with takeup drum 159, are visible. However, bight 208 of flexible pipe segment 204 can be seen disposed in well 210, and interconnected with fittings 206 on FPSO vessel 220. It is clear that due to the influence of tether chains 116 and 118 the turret system 120 will maintain a relatively fixed position, permitting vessel 220 to weathervane therearound, with the apparatus disclosed in more detail in Fig. 3 providing continuous interconnection between the fitting at 206 and the wellhead riser 222.

Claims: 1. A method of providing a continuous fluid connection from at least one riser conduit to a vessel which is free to rotate about an axis, comprising the steps of: dividing the fluid flow from said conduit into first and second flowpaths, each flowpath ending in a respective first connector; positioning first and second drums adjacent said first and second flowpaths, respectively, the first and second drums having respective second connectors which can be releasably connected to the first connectors of the first and second flowpaths, respectively, and each of said first and second drums being capable of flexible connection to said vessel and being rotatable with respect to said vessel about said axis through an arc greater than 180°, the rotational arc for one drum overlapping the rotational arc of the other drum at both ends thereof; and passing fluid through the first flowpath by way of the connectors to the first drum and said vessel when said vessel is positioned within the rotational arc of the first drum, passing fluid through the second flowpath by way of the connectors to the second drum and said vessel when said vessel is positioned within the rotational arc of the second drum; and disconnecting the first and second connectors connecting a respective flowpatrh to its adjacent drum prior to angular movement of the vessel outside the rotational arc of said adjacent drum. 2. A manifold for continuously connecting at least one riser conduit to a vessel, said vessel being rotatable with respect to said conduit about a first axis and said manifold comprising: a first drum rotatable relative to said vessel about said first axis through a first arc greater than 180°; at least one conduit channel around the periphery of said first drum; at least one first flexible conduit having one end disposed in said conduit channel; first connector means for connecting and disconnecting said one end of said first flexible conduit to a first flowpath portion of said riser conduit; means for connecting the other end of said first flexible conduit to said vessel; a second drum rotatable relative to said vessel about said first axis through a second arc which is greater than 180° and which overlaps said first arc at each end thereof; at least one conduit channel around the periphery of said second drum; at least one second flexible conduit having one end disposed in said second conduit channel; second connector means for connecting and disconnecting said one end of said second flexible conduit to a second flowpath portion of said riser conduit; at least one of said first and second connector means connecting its associated conduit to the riser when said vessel is within the rotational arc of the associated drum; and means for connecting the other end of said second flexible conduit to said vessel. 3. A manifold as claimed in Claim 2, wherein each of said first and second connector means includes a connector mounted on the associated drum, a mating connector on the associated riser flowpath portion and actuator means for controllably engaging and disengaging the connectors. 4. A manifold as claimed in Claim 2 or Claim 3, wherein said means for connecting the other end of each flexible conduit to the vessel comprises: a further drum rotatable about a second axis generally perpendicular to said first axis; at least one conduit channel which extends around the periphery of said further drum and which receives said other end of said flexible conduit; a takeup drum rotatable with said further drum about said second axis and defining channels around at least a portion of its periphery; and a flexible pipe adapted at one end for connection to the vessel and connected to said flexible conduit at its other end, at least a portion of the pipe being received in the channels in the further drum and the length of the pipe being sufficient to allow limited relative rotational movement between the vessel and the drums.

Inventors: BULOW, ROLAND ERIC
Applicants: MOBIL OIL CORPORATION
Application year: 1985
Main classification: F16L3
IPC codes: B63B27, E21B33, E21B43, B65H75, F16L3