Abstract:
A method of providing buoyancy, the method comprising the steps of: (a) adding a buoyant fluid to a container, the buoyant fluid comprising a base fluid, an activator and from 25 to 60% vol/vol microspheres; and (b) increasing the viscosity of the buoyant fluid to at least 80,000 mPa·s at a shear rate of 0.8 s −1  at 293K. The structure may be a tubular-shaped container that is used subsea, such as a frame of a cable laying plough. Embodiments thus provide a convenient method of adding buoyancy to a structure.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority under 35 U.S.C. §119 to United Kingdom patent application serial number 1315122.0 filed Aug. 23, 2013, and titled, “METHOD OF PROVIDING BUOYANCY” and to United Kingdom patent application serial number 1315313.5 filed Aug. 28, 2013, and titled, “METHOD OF PROVIDING BUOYANCY,” the disclosure of each of which is incorporated herein by reference. 
       RELATED ART 
     Field of the Invention 
       [0002]    The present disclosure relates to a method of providing buoyancy for underwater items. 
       INTRODUCTION TO THE INVENTION 
       [0003]    The subsea industry employs a variety of different subsea technologies and infrastructure. The equipment not fixed to the seabed often requires, or is aided by, the provision of attached buoyancy modules. For example, risers which carry pump produced fluids from a subsea wellhead through the water column to a surface facility, such as an offshore platform, often have syntactic buoyancy modules attached thereto. At enhanced depths the riser is so heavy that it cannot support its own weight in the water and there is a significant risk of failure. 
         [0004]    Syntactic buoyancy is used to reduce this “top tension” on risers or other subsea elements by providing distributed support. These syntactic buoyancy modules can also assist in shaping the underwater configuration of the risers in order to facilitate flow of the produced fluids, and allow enough slack to cope with the heave or other movement of a floating surface facility caused by the surface conditions. 
         [0005]    Also, remotely operated vehicles (ROVs) often have a large syntactic buoyancy module provided therein. Buoyancy is added to ROVs to render them neutrally buoyant. This reduces the power required to maintain and maneuver the ROV in the water. 
         [0006]    Whilst generally satisfactory, the inventor of the present invention has noted some limitations. 
         [0007]    In accordance with a first aspect of the present invention there is provided a method of providing buoyancy, the method comprising the steps of: (a) adding a buoyant fluid to a container, the buoyant fluid comprising a base fluid, an activator and from 25 to 60% vol/vol microspheres; and, (b) increasing the viscosity of the buoyant fluid to at least 80,000 mPa·s at a shear rate of 0.5 s −1  at 293K. 
         [0008]    The method may include the step of lowering the container into water. The water is typically seawater. The water may be salt-water and/or brine. 
         [0009]    The method may further include the step of sealing the container. The container may be sealed before it is lowered into the water. 
         [0010]    The step of lowering the container into the water is typically after the step of adding the buoyant fluid to the container but the buoyant fluid may be added to the container when the container is already located in the water. 
         [0011]    The step of increasing the viscosity of the buoyant fluid may take from 1 minute to 24 hours, normally from 1 minute to 3 hours and optionally from 1 minute to 1 hour. 
         [0012]    The invention may provide a convenient method of adding buoyancy to a structure including the container because it is first added as a fluid with a relatively low viscosity and then after about 1 hour, the viscosity of the buoyant fluid will typically have increased such that the fluid then has the viscosity of a thick paste. The thick paste can typically hold the microspheres in suspension over a very long period of time, such as 10 or 20 years. 
         [0013]    The viscosity of a thick paste is such that the buoyant fluid will remain in a suitable container such as a 500 ml jar when the container is inverted. 
         [0014]    The container may be part of the structure that, in use, is located subsea. The container may be tubular-shaped. The tubular-shaped container may be part of a frame of the structure. The structure may be part of equipment used subsea and may for example be a pipe and/or cable laying plough and/or skid. 
         [0015]    The method may include the step of sinking the structure after the buoyant fluid has been added to the container. In an alternative embodiment the buoyant fluid may be added to the container and/or structure when it is already in place subsea. It can be very difficult to place conventional buoyancy subsea because the material is buoyant and needs to be weighed down or pulled into place particularly if the buoyancy needs to be placed at depth. 
         [0016]    The container may be referred to as a buoyancy module. The method of providing buoyancy may be a method of providing a buoyancy module. 
         [0017]    The buoyant fluid may have a viscosity of at least 80,000 mPa·s at a shear rate of 0.8 s −1  at 293K, typically at least 100,000 mPa·s at a shear rate of 0.8 s −1  at 293K and optionally at least 120,000 mPa·s at a shear rate of 0.8 s −1  at 293K. 
         [0018]    At a shear rate of 2.09 s −1  and temperature of 293K, the viscosity may be at least 15,000 mPa·s optionally at least 25,000 mPa·s. 
         [0019]    At a shear rate of 4.18 s −1  and temperature of 293K, the viscosity may be at least 10,000 mPa·s optionally at least 15,000 mPa·s. 
         [0020]    The viscosities thus render the buoyant fluid unpumpable once it has set. This is in sharp contrast and against the teaching of EP 1 867 564 where a different buoyant fluid is provided for a different purpose—a much less viscous fluid which is pumpable to manipulate and vary buoyancy. 
         [0021]    The buoyant fluid may remain in the container for at least 10 years, typically at least 20 years. It is typically the increased viscosity of the buoyant fluid that helps keep the fluid in the container for this extended period of time. 
         [0022]    In accordance with a second aspect of the present invention there is provided a method of providing buoyancy, the method comprising the steps of: (a) transporting a base fluid to an onsite location; (b) separately transporting an activator to the onsite location; (c) adding one of the base fluid and activator to a container; and (d) adding the other of the base fluid and activator to the container at the onsite location, such that the base fluid and activator combine to provide a buoyant fluid with a viscosity greater than that of the base fluid, where one or both of the base fluid and activator comprises from 25 to 60% vol/vol microspheres. 
         [0023]    The step of combining the base fluid and activator may include mixing the two components in a mixing vessel and/or in an input or mixing tube. 
         [0024]    The inventor of the present invention has noted that buoyancy can be provided much more conveniently by following the steps according to a method of the invention. The container and components can be conveniently transported to the onsite location and one or both adding steps can be performed locally. In this way, the viscosity of the buoyant fluid increases onsite which provides a variety of benefits, for example transportation costs can often be saved compared to moving large syntactic buoyancy modules of odd shapes and sizes. Moreover the involved process to make syntactic buoyancy, including for example heat treatment, can be reduced or sometimes entirely avoided. 
         [0025]    The steps of the method can be conducted in any order. The activator is however typically added to the container after the base fluid. The step of adding one of the base fluid and activator to the container is also typically done at the onsite location. 
         [0026]    The base fluid may be transported to the onsite location in the container. 
         [0027]    The microspheres can be added separately or may be in either the base fluid or activator. Normally the base fluid comprises the microspheres. 
         [0028]    The viscosity of the buoyant fluid may be greater than that of the base fluid after from 1 minute to 24 hours, normally from 1 minute to 3 hours and optionally from 1 minute to 1 hour. 
         [0029]    The onsite location may be a surface vessel, such as ship or an offshore platform. The onsite location may be onshore, but preferably close to the area of use. The closer to the area of use the more benefit that may result from reduced transportation costs. Thus preferably the onsite location is within 10 miles, optionally within 2 miles of the area of use. 
         [0030]    The onsite location may be underwater and/or subsea. When the onsite location is underwater and/or subsea the buoyancy, also referred to as permanent buoyancy, can be installed in situ. 
         [0031]    In one embodiment, the container may be pre-filled with a starter fluid such as water. The container may have at least one inlet and at least one outlet. The base fluid may be added to the container through the at least one inlet, thus displacing the starter fluid through the outlet. This may make it easier to locate and/or place the container in situ because the container is less buoyant. The buoyancy including the buoyancy fluid may then be added to the container. 
         [0032]    For certain embodiments the container is attached to a structure on which it is to be used, before the activator is added, or indeed, before the base fluid is activated. In this way it can be much easier to attach the container when it does not have the fluids therein. 
         [0033]    The base fluid, normally comprising the microspheres, is transported to the onsite location typically having a first three-dimensional (3D) shape. This shape is normally defined by a vessel used to transport the base fluid. The buoyant fluid normally has a different second three-dimensional (3D) shape. The first 3D shape may be one which is convenient to transport the base fluid and the second 3D shape may be one which is convenient to its intended use, which may be a 3D shape that is difficult to transport. 
         [0034]    The container may be a bag. Preferably the container is at least partially deformable. A variety of containers with different shapes can be used to form the shapes required for the different application of the buoyancy, for example to attach to a riser or to fit within a void in an ROV. One suitable shape is a tubular shape. 
         [0035]    The viscosities detailed herein were determined using a ThermoHaake™ ViscoTester™ 7 L with L3 and L4 spindles. 
         [0036]    The viscosity of the base fluid before combination with the activator may be approximately 14,000 mPa·s at a shear rate of 0.8 s −1  at 293K. 
         [0037]    The viscosity of the buoyant fluid is relatively high, and so difficult if not impossible to pump after it has set, for example after about 1 hour after mixing. This maintains the microspheres in the body of the container over an extended period of time, rather than the microspheres being able to gravitate to the surface. 
         [0038]    The container may be one or more of flexible, malleable and bendable. When the buoyant fluid is in the container the viscosity and/or pressure of the buoyant fluid in the container may add to the rigidity of the container but the container will typically remain one or more of flexible, malleable and bendable. 
         [0039]    It may be an advantage of the present invention that the flexibility, malleability and/or bendability of the container means that in the event of an object colliding with the container, the container can absorb some of the impact of the collision. Other known and/or regular buoyancy modules are not able to absorb the force of an impact in this way. The flexibility, malleability and/or bendability of the container may mean that in the event of an impact, the risk of damage to the container and/or object is reduced and/or the container remains in place rather than being dislodged from where it is secured. 
         [0040]    The buoyant fluid may be compressible. The buoyant fluid may be compressible by approximately 5% under normal working conditions of the invention. The container may further comprise a bladder to help absorb some of the impact of a collision between an object and the container. 
         [0041]    Optionally the buoyant fluid has a specific gravity of less than 0.70 g/cm 3 , more optionally less than 0.65 g/cm 3 , especially less than 0.60 g/cm 3 , and perhaps less than 0.55 g/cm 3 . 
         [0042]    The base fluid may have a specific gravity of more than 0.40 g/cm 3 , optionally more than 0.45 g/cm 3 , and may be more than 0.50 g/cm 3 . 
         [0043]    The base fluid may comprise water. 
         [0044]    The base fluid typically comprises an oil. The oil is preferably a low toxicity oil, such as a hydrocarbon, an alkane, an aliphatic oil, poly-alpha-olefin, alkyl ester or vegetable oil that is a triglyceride such as one having the structure: 
         [0000]    
       
                 
         
             
             
         
       
     
         [0000]    where R I , R II  and R III  are hydrocarbon chains typically with a chain length of from C12 to C22 to give a range of fatty acids. The hydrocarbon chains may have from zero to three double bonds. 
         [0045]    Preferably the oil is derived from nature. The oil may be vegetable oil and/or biodegradable. Thus for certain embodiments of the invention, the inherent environmental risk of the buoyant fluid and therefore also the base fluid and oil leaking from the container is mitigated and therefore not a significant concern because the vegetable and/or biodegradable oil used does not present an environmental risk or concern to wildlife. 
         [0046]    In an alternative embodiment the oil is synthetic. 
         [0047]    The base fluid may also comprise a viscosifying agent such as an organophilic clay, dispersed silica, long chain polymeric materials, surfactants or mixtures thereof. 
         [0048]    The activator is typically a fluid. The activator may be a blend of different chemicals. The blend may comprise a gelling agent such as a phosphate ester and may be an iron phosphate ester (FePO 3 ). Alcohol ethoxylate may also be included in the blend. A Fe(III) salt such as iron sulphate may also be included in the blend. The buoyant fluid may comprise from 0.5 to 6 wt %, preferably 1 to 4 wt % activator. 
         [0049]    The microspheres may each have a sealed chamber containing a gas or a vacuum. The microspheres may be from 5 microns to 5 mm in diameter, optionally from 10 to 500 microns in diameter and more optionally from 20 to 200 microns in diameter. 
         [0050]    The microspheres are typically rigid and so are typically incompressible at the pressures found in underwater environments. The microspheres may be obtained from 3M. The microspheres may be rated to over 31,000 kPa (4500 psi), preferably over (41,000 kPa) 6000 psi. Other microspheres with different strengths and densities may be used and generally stronger microspheres have higher densities. 
         [0051]    The microspheres may be glass microspheres. The microsphere may lower the density of the buoyant fluid to a density of approximately 475 kg/m 3  at room temperature. 
         [0052]    The buoyant fluid typically comprises from 30 to 50% vol/vol microspheres. 
         [0053]    The containers and methods of providing buoyancy described herein may be used as a buoyancy module for a subsea riser. In an alternative embodiment the container and methods of providing buoyancy described herein may be used as a buoyancy module for an ROV. 
         [0054]    The optional features of the first aspect of the present invention can be incorporated into the second, third and fourth aspects of the present invention and vice versa. 
         [0055]    According to a third aspect of the present invention there is provided a use of a buoyancy module comprising a buoyant fluid having a viscosity of at least 80,000 mPa·s at a shear rate of 0.8 s −1  at 293K and comprising from 25 to 60% vol/vol microspheres, as a buoyancy aid for a subsea riser. 
         [0056]    The optional features of the first and second aspects of the present invention can be incorporated into the third and fourth aspects of the present invention and vice versa. 
         [0057]    According to a fourth aspect of the present invention there is provided the use of a buoyancy module comprising a buoyant fluid having a viscosity of at least 80,000 mPa·s at a shear rate of 0.8 s −1  at 293K and comprising from 25 to 60% vol/vol microspheres, as a buoyancy aid for a remotely operated vehicle. 
         [0058]    The optional features of the first, second and third aspects of the present invention can be incorporated into the fourth aspect of the present invention and vice versa. 
         [0059]    The preferred and optional features of the container and buoyancy module as described herein are also applicable and are preferred and optional features of the buoyancy module according to the use aspects of the invention. 
         [0060]    According to a fifth aspect of the invention, there is provided a method of adding buoyancy to a subsea structure, the method comprising adding a buoyant fluid to a bore of a tube, the tube being part of a tubular frame associated or integral with the subsea structure. 
         [0061]    The subsea structure may be a plough, a pipe connector, or alternatively it may be another piece of subsea equipment. The frame normally comprises a series of tubes, and more than one of said tubes is normally filled with said buoyant fluid. 
         [0062]    The buoyant fluid according to the fifth aspect of the invention is normally the buoyant fluid described herein with reference to other aspects of the invention. 
         [0063]    Unless otherwise specified, all component mixtures are determined by weight. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0064]    An embodiment of the invention will now be described by way of example only and with reference to the accompanying drawings, in which: 
           [0065]    a.  FIG. 1  shows a buoyant fluid in a bag or other receptacle attached to a subsea riser to create a catenary bend in the subsea riser; 
           [0066]    b.  FIG. 2  shows the buoyant fluid in a plastic shell or bag fitted around a vertical riser to provide buoyancy; 
           [0067]    c.  FIG. 3  shows the buoyant fluid in an element to create a bend in a pipeline; 
           [0068]    d.  FIGS. 4A and 4B  show a bag filled with buoyant fluid face on and edge on; and, 
           [0069]    e.  FIG. 4C  shows a number of bags fitted to a subsea skid to make it neutrally buoyant. 
           [0070]    f.  FIG. 5  is a subsea pipe connector suitable for use with embodiments of the invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0071]    The exemplary embodiment of the present disclosure is described and illustrated below to encompass methods of providing buoyancy for underwater items. Of course, it will be apparent to those of ordinary skill in the art that the embodiment discussed below is exemplary in nature and may be reconfigured without departing from the scope and spirit of the present disclosure. However, for clarity and precision, the exemplary embodiment as discussed below may include optional steps, methods, and features that one of ordinary skill should recognize as not being a requisite to fall within the scope of the present invention. 
         [0072]    Embodiments of the invention provide a container or buoyancy module comprising a viscous unpumpable fluid which is used for a variety of long-term subsea applications. 
         [0073]    To assemble a buoyancy module  20 , a deformable bag is provided with a fluid comprising a base fluid including an oil and a plurality of microspheres. The fluid comprises 77% paraffin, 0.5% phosphate ester, 0.5% FeSO 4 , 0.2% ethylene oxide and 21.8% microspheres wt/wt. 
         [0074]    The bag is transported to the onsite location, typically a vessel. The viscosity of the base fluid allows it to be shaped as required during transport. 
         [0075]    At the onsite location, an activator which acts as a setting agent, is then added, which increases the viscosity of the base fluid and now buoyant fluid to more than 80,000 mPa·s at a shear rate of 0.8 s −1  at 293K. The activator may be referred to as an additive. The buoyant fluid can then be shaped according to is intended use. The buoyant fluid may be a gel. 
         [0076]    The activator is a mixture of a phosphate ester, FeSO 4 , ethylene oxide and a surfactant. The buoyant fluid thus has a composition of 75% linear paraffin, 1.5% phosphate ester, 1% ferric sulphate (20% solution), 0.5% alcohol ethoxylate, and 22% glass microspheres wt/wt. For different embodiments the amounts can be varied as required and in particular, the amount of glass microspheres can be varied depending on the buoyancy required and the depth of intended use. The present examples are rated to 3000 metres depth. 
         [0077]    In an alternative embodiment the buoyant fluid comprises: 73% linear paraffin, 2% attapulgite, 3% phosphate ester (the activator), 1% water and 21% glass microspheres wt/wt. The attapulgite is a gelling agent. 
         [0078]    The viscosities using various spindles and resulting viscosities, for the base fluid prior to activation are set out in table 1 below: 
         [0000]    
       
         
               
               
               
             
               
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
               
                   
                   
                 Base Fluid 
               
               
                 RPM 
                 spindle 
                 (pre-activation) 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 1 
                 L3 
                 38060 
               
               
                 1.5 
                 L3 
                 27290 
               
               
                 2 
                 L3 
                 22260 
               
               
                 2.5 
                 L3 
                 19380 
               
               
                 3 
                 L3 
                 17270 
               
               
                 4 
                 L3 
                 14590 
               
               
                 5 
                 L3 
                 12740 
               
               
                 6 
                 L3 
                 11330 
               
               
                 10 
                 L3 
                 8360 
               
               
                 20 
                 L4 
                 5700 
               
               
                 30 
                 L4 
                 4480 
               
               
                 50 
                 L4 
                 3490 
               
               
                 60 
                 L4 
                 3160 
               
               
                 100 
                 L4 
                 2460 
               
               
                   
               
             
          
         
       
     
         [0079]    The viscosities of the buoyant fluid once it has been activated are much thicker—to the extent that the L3 spindle couldn&#39;t be used. These are all based on using an L4 spindle and are shown in table 2. 
         [0000]    
       
         
               
               
               
             
               
               
               
             
           
               
                   
                 TABLE 2 
               
               
                   
                   
               
               
                   
                   
                 new 
               
               
                   
                 RPM 
                 (post-activation) 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 2 
                 154290 
               
               
                   
                 3 
                 105320 
               
               
                   
                 4 
                 79360 
               
               
                   
                 5 
                 64540 
               
               
                   
                 10 
                 34000 
               
               
                   
                 20 
                 16510 
               
               
                   
                 50 
                 6330 
               
               
                   
                 60 
                 5290 
               
               
                   
                 100 
                 3670 
               
               
                   
                   
               
             
          
         
       
     
         [0080]    To determine the shear rate based on the RPM the following conversion factors can be used: 
         [0000]      Shear rate (in s −1 )=RPM×0.210 when using the L3 spindle
 
         [0000]      Shear rate (in s −1 )=RPM×0.209 when using the L4 spindle
 
         [0000]    For example 10 RPM using an L4 spindle equates to a shear rate of 2.09 s − . 
         [0081]      FIG. 1  shows a vessel  10  receiving a riser  12  that transports fluids from a subsea well (not shown) to the vessel  10 . The riser or subsea riser  12  has a container or buoyancy module  20  attached thereto which reduces the weight of the riser  12  on the vessel  10  and also provides sufficient slack to allow for movement of the vessel  10  due to surface conditions. 
         [0082]    The container or buoyancy module  20  shown in  FIG. 1  is a bag. The bag  20  is attached to the riser which is deployed in the normal manner. For certain embodiments, the bag  20  may be added to the riser  12  first, and then the components of the buoyant fluid added subsequently. 
         [0083]      FIG. 2  shows the buoyant fluid in a plastic shell  20  fitted around a vertical riser to provide buoyancy. 
         [0084]      FIG. 3  shows the viscous or buoyant fluid (the combination of the base fluid, activator and microspheres) filling an element  20  to create a bend in a pipeline. 
         [0085]      FIGS. 4A and 4B  show a bag  20  filled with the viscous or buoyant fluid face on and edge on. Edges  22  with attachment points  24  are connected to the bag  20 . 
         [0086]      FIG. 4C  shows a number of bags  20   a ,  20   b ,  20   c  and  20   d  fitted to a subsea skid  30  to make it neutrally buoyant. 
         [0087]    In any case, the examples show a bag  20  containing buoyant fluid used to provide buoyancy subsea. 
         [0088]    In  FIG. 5  a subsea pipe connector  50  having a frame  60 . A variety of frames are used subsea, such as ploughs and the like. Oftentimes syntactic buoyancy units  40  are added to the pipe connector  50  in order to add buoyancy subsea. Embodiments of the present invention use the internal voids  62  in the frame as a container for the buoyant gel which is added thereto. This can reduce or remove the requirement to add syntactic buoyancy units, such as those  40  shown in  FIG. 5 . One or more advantages can ensue—the subsea equipment can be easier to move, and/or it can be smaller as there is no or less need for space for attached syntactic units. Moreover, for certain embodiments the frames can be rated to a lesser strength because the inner side of the tubular elements of the frame are filled and provide support to the frame, providing a closer pressure balance. 
         [0089]    An advantage of certain embodiments of the invention is that the bag or housing may be filled to the appropriate size. For example, in the event it is found that the buoyancy module is too large (or has too much buoyancy) for the intended use, embodiments of the invention can easily be manipulated onsite, to add or reduce the amount of fluid. In contrast, known solid buoyancy modules require portions to be cut off which is difficult, if at all possible, onsite and is approximate and cannot be reversed. 
         [0090]    An advantage of certain embodiments of the invention is that the bag and fluids may be conveniently transported to a location, compared to the existing practice of transporting large and odd shapes, which is much more cumbersome and expensive. 
         [0091]    An advantage of certain embodiments of the invention is that when filled with fluid, the bags are firm, for example like a bicycle tyre, and so can transfer pressure encountered subsea. The bag or container therefore need not in itself be strong enough to cope with subsea pressure without deforming. 
         [0092]    An advantage of certain embodiments of the invention is that the many fluids of the present invention can be tested and certified on a small scale compared to large syntactic buoyancy modules which need to be tested in a large hydro facility, which increases their cost. 
         [0093]    Following from the above description and invention summaries, it should be apparent to those of ordinary skill in the art that, while the methods and apparatuses herein described constitute exemplary embodiments of the present disclosure, the invention contained herein is not limited to these precise embodiments and that changes may be made to such embodiments without departing from the scope of the invention as defined by the claims. Additionally, it is to be understood that the invention is defined by the claims and it is not intended that any limitations or elements describing the exemplary embodiments set forth herein are to be incorporated into the interpretation of any claim element unless such limitation or element is explicitly stated. Likewise, it is to be understood that it is not necessary to meet any or all of the identified advantages or objects of the invention disclosed herein in order to fall within the scope of any claims, since the invention is defined by the claims and since inherent and/or unforeseen advantages of the present invention may exist even though they may not have been explicitly discussed herein.