Abstract:
An offshore loading system operable to load a substance between a first structure and a second structure separate from the first structure, the second structure including a manifold, includes a loading arm having a process pipe to carry the substance during a process of loading the substance by the loading arm, the process pipe including a free end, the loading arm coupled to the first structure. A control unit is coupled to the loading arm and operable to direct the free end of the loading arm, and a first acceleration sensor electronically coupled to the control unit. The first acceleration sensor is operable to detect relative movement of the first structure with respect to the second structure.

Description:
FIELD OF INVENTION 
       [0001]    The present invention is directed to an offshore loading system having at least one loading arm coupled to a control unit, especially to a hydraulic power unit. 
       BACKGROUND OF INVENTION 
       [0002]    U.S. Pat. No. 4,758,970, filed Aug. 8, 1984, and issued to Emco Wheaton, Inc. discloses a marine loading arm as an articulated device used to on-load or off-load fluids between a vessel and a loading region such as a dock, wharf or pier. Such devices are particularly useful in the petroleum transportation industry for which tremendous volumes of fluid must be transferred safely between the moored area and the dock. A marine loading arm typically includes a vertical mounting structure supporting a fulcrum about which a primary arm pivots. A secondary arm is pivotally linked to the primary arm and a counter weight is attached to the opposite end of the primary arm to balance the same about the fulcrum. The secondary arm has an end flange attached thereto which is coupled to a flange support on the vessel manifold to access the fluid. Three dimensional movement of the articulated arm, and, thus the end flange, is accomplished by pivotal movement of the primary arm about the fulcrum and the secondary arm pivoting with respect to the primary arm. Also the fulcrum is carried on an upper portion of the mounting structure which is rotably coupled to a lower portion of the mounting structure by a swing joint, thus allowing the articulated primary and secondary arms to move about the longitudinal axis of the mounting structure. Such a loading arm device can be controlled by hydraulic actuators of the piston cylinder type which pivot the articulated arm so as to position the end flange at a desired coupling location. 
         [0003]    The &#39;970 patent further discloses an apparatus for monitoring the spatial position of a reference point relative to a predetermined origin, the reference point being located on an articulated marine loading arm having a plurality of pivotally interconnected fluid conduits forming pivot angles at the interconnections of the conduits. The apparatus includes segments subtended by the pivot angles with means for sensing the length of the segments as the loading arm articulates. The dispensing means generates electrical signals proportional to segment lengths and a computer receives the electrical signals and calculates the position of the reference point based on the known geometry of the loading dock. 
         [0004]    U.S. Pat. No. 6,938,643, filed Jul. 31, 2003, and issued to Single Buoy Moorings, Inc., discloses a storage structure having a fluid transfer boom for transfer of cryogenic liquids such as liquid natural gas from a first storage structure to a vessel. The boom has two arms which are rotably connected at their ends via a swivel joint. A liquefied natural gas duct is supported within the first and second arms which form a gas tight housing around the liquefied natural gas duct. The transfer boom provides a redundant containment system wherein the liquid natural gas (LNG) duct is supported by the structurally strong and self-supporting transfer boom which contains the natural gas in case of a leak in the inner (LNG) duct. The transfer boom can have 7 swivel joints in total such that rotation in all directions is possible when the vessel is moored to the storage structure and has to cope with relative motions of yaw, pitch, roll, heave, sway and surge. The storage structure may for instance be an off shore storage buoy for liquefied natural gas which is anchored to the sea bed by means of anchor lines. The storage structure can be a weather waning vessel. 
         [0005]    International Patent Publication WO 2007/120039, filed Feb. 28, 2007 discloses a vessel with a motion compensation platform. The platform is provided with at least one carrier for bearing, moving or transferring a load. Actuators for moving the carrier relative to the vessel preferably in six degrees of freedom are coupled to the platform. A control system for driving the actuators is coupled to the actuators. Motion sensors which measure the motion of the vessel relative to at least one element in the surrounding area are pro- vided. The measurements are used as input the for the control system. 
       SUMMARY 
       [0006]    A loading system includes a loading arm. The loading arm has a process pipe which provides a conduit to carry fluid during a process of loading fluid by the loading arm. A hydraulic power unit is coupled as a control unit to the loading arm. The hydraulic power unit supplies hydraulic fluid to an actuator moving the loading arm to direct a free end of the loading arm during the process of loading fluid. A logic controller is coupled the hydraulic power unit. A first electronic sensor is electronically coupled to the logic controller. The first electronic sensor detects movement of a first structure to which the loading arm is mounted during the process of loading. The movement is relative to another second structure or the stationary world. 
         [0007]    During the process of loading, signals from the electronic sensor, carry information about the relative movement and the signals are transmitted to the logic controller. The logic controller based, at least in part, on the signals from the electronic sensor, transmits signals to the hydraulic power unit, and wherein based on, at least in part, the transmitted signals of the logic controller, the hydraulic power supplies hydraulic fluid to the actuator of the loading arm to move the loading arm to compensate for relative movement between said first structure and the second structure. 
         [0008]    The invention further concerns a method of loading fluid in an offshore loading system. The method includes determining relative movement, during a process of loading fluid by a loading arm, between a first structure and a second structure. As part of the method signals are transmitted based on the determination of the relative movement. Based on the transmitted signals, a control unit, especially a hydraulic power unit, supplies hydraulic fluid to an actuator to move the loading arm to compensate, at least in part, for the relative movement between the first and second structure. 
         [0009]    In one construction, an offshore loading system is operable to load a substance between a first structure and a second structure separate from the first structure. The second structure includes a manifold. The offshore loading system includes a loading arm having a process pipe to carry the substance during a process of loading the substance by the loading arm. The process pipe includes a free end and the loading arm is coupled to the first structure. A control unit is coupled to the loading arm and is operable to direct the free end of the loading arm. A first acceleration sensor is electronically coupled to the control unit. The first acceleration sensor is operable to detect relative movement of the first structure with respect to the second structure. 
         [0010]    In another construction, an offshore loading system is operable to transfer a substance between a first structure and a second structure separate from the first structure. The second structure includes a manifold. The offshore loading system includes a loading arm coupled to the first structure and having a conduit with a free end arranged to deliver or receive the substance and a plurality of actuators coupled to the loading arm and operable to move the free end. A first sensor is coupled to the first structure and is operable to measure at least one of an acceleration and position of the first structure, a second sensor is coupled to the second structure and is operable to measure at least one of an acceleration and position of the second structure, and a user input device is arranged to receive an input from a user indicative of a desired movement of the free end. A controller is operable in response to input from the first sensor, the second sensor, and the user input device to generate control signals, and a control unit is coupled to the loading arm and is operable in response to receipt of the control signals to direct the free end of the loading arm. 
         [0011]    In still another construction, an offshore loading system includes a first structure supporting a loading arm having a free end, and a second structure including a manifold selectively coupled to the free end to facilitate the transfer of a substance between the first structure and the second structure. A first sensor is arranged to detect at least one of a relative movement, a relative position, and a relative acceleration between the first structure and the second structure and a user input device is arranged to receive an input from a user indicative of a desired movement of the free end. A controller is operable in response to input from the first sensor and the user input device to generate control signals and a control unit is coupled to the loading arm and operable in response to receipt of the control signals to direct the free end of the loading arm. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a schematic representation of an offshore loading system embodying an example of my invention; the system has a loading arm, a hydraulic power unit, an electronic controller, which is a programmable logic controller, and a motion reference unit (MRU) onboard a floating production and storage and offtake vessel; a second motion reference unit is onboard a cargo carrier vessel; 
           [0013]      FIG. 2  is a stripped down representation of the type of loading arm used in  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION 
       [0014]    Now referring to  FIG. 1 , loading arm  20  is coupled to a hydraulic power unit  22 . The hydraulic power unit is coupled to or includes integrated therewith an electronic controller  24 . The electronic controller  24 , which is a programmable logic controller, can be a microprocessor or a computer or other type of programmable logic controller. At least one first electronic acceleration sensor  26  is coupled to the programmable logic controller. The acceleration sensor  26  is a motion reference unit (MRU). A second electronic acceleration sensor  28  which is a motion reference unit MRU  28  is also coupled to the electronic controller  24 . 
         [0015]    One embodiment of the system, when ready for operation, is assembled with a floating production, storage and offtake or offloading (FPSO) vessel  30  for liquid natural gas and a cargo carrier (cc) vessel  32 . The loading arm  20 , hydraulic power unit  22 , electronic controller  24  and first MRU  26  are onboard FPSO vessel  30 . The second MRU  28  is onboard the cargo carrier  32 . Both the first MRU  26  and second MRU  28  are electronically interfaced with the electronic controller  24 . The electronic interface can be by way of a hard wiring system or by way of a wireless transmission system. 
         [0016]    In operation the electronic controller  24  sends commands to the hydraulic power unit  22 , at least in part, based on signals received from the first  26  and second  28  motion reference unit. The commands are calculated to cause the hydraulic power unit  22  to supply hydraulic fluid to the loading arm&#39;s actuators to move the loading arm  20  to compensate for the movement of the vessels  30 ,  32  relative to each other. The compensation allows for the free end  34  of the loading arm  20  to be smoothly directed to the cargo manifold  36  of the cargo carrier  32 . Alternatively if the loading arm  20  is already connected to the cargo manifold, the compensation will result in the loading arm free end  34  tracking the movement of vessel  32  relative to vessel  30 . By tracking the movement, the stresses on the loading arm  20  caused by the movement of vessel  32  relative to vessel  30  are reduced. 
         [0017]    In more detail, FPSO  30  and cargo carrier  32 , when in a body of water, such as a sea, may each surge, sway, heave, roll, pitch and yaw due to the impact of the sea&#39;s waves on the respective vessels. The various movements will cause each vessel to move relative to the stationary world such as the floor of the sea and relative to each other. The first and second motion reference units  26  and  28  detect the movement of each vessel  30 ,  32  relative to the stationary world. Thus motion reference unit  26  detects movement of the production storage vessel  30  relative to the stationary world. Second MRU  28  detects the movement of the cargo vessel  32  relative to the stationary world. The first  26  and second  28  MRU transmit signals to the electronic controller  24  concerning the movement of their respective vessels. Based on the signals the electronic controller  24  determines the relative movement between the production storage vessel  30  and cargo carrier  32 . When the loading arm  20  is in the process of being connected to the manifold, the electronic controller  24  sends signals to actuate the hydraulic power unit  22  to supply hydraulic fluid to the loading arm&#39;s actuators  54 ,  58 ,  62  in a manner to move the sections of the loading arm  20  to compensate for the movement of the vessels  30 ,  32  relative to each other. The calculations are such that the sections of the loading arm  20  are driven (moved) by their actuators  54 ,  58 ,  62  so that unintended relative movement between the loading arm free end  34  and the manifold  36  of the cargo carrier  32  is as close as possible to zero. Accordingly, the only movement between the loading arm free end  34  and manifold  36  of the cargo carrier  32  is the movement caused by an operator to direct the free end  34  of the loading arm  20  to the manifold  36  of the cargo carrier  32 . When the loading arm  20  is already connected to the manifold, the electronic controller  24  sends signals to actuate the hydraulic power unit  22  to supply hydraulic fluid to the loading arm&#39;s actuators  54 ,  58 ,  62  to move the loading arm free end  34  in a manner to track, as near as possible, the movement of the cargo manifold  36  of vessel  32  relative to vessel  30 . By tracking the movement, the stresses on the loading arm  20  caused by movement of vessel  32  relative to vessel  30  are reduced. 
         [0018]    In still further detail, the loading arm  20  has three actuators  54 ,  58 ,  62  which are the hydraulic piston cylinder type. These actuators can be called hydraulic cylinders  54 ,  58 ,  62 . They are actuated by way of the hydraulic power unit  22  and can direct movement of the free end  34  of the loading arm  20  to the cargo manifold  36  of the cargo carrying vessel  32 . The hydraulic power unit  22  additionally supplies hydraulic fluid to the hydraulic cylinders  54 ,  58 ,  62 , based on commands from the electronic controller  24 , to compensate for relative movement between the vessels  30 ,  32 . As stated when the loading arm  20  is in the process of being connected to the manifold  36 , the cylinders drive (move), the sections of the loading arm  20  such that the unintended movement of the free end  34  of the loading arm  20  relative to the cargo manifold  36 , in all six degrees, is as near as possible, brought to zero. When the loading arm  20  is already connected to the manifold  36 , the electronic controller  24  sends signals to actuate the hydraulic power unit  22  to actuate the hydraulic cylinders  54 ,  58 ,  62  to move the free end  34  of the loading arm  20  in a manner to track, as near as possible, the movement of the cargo manifold of vessel  32  relative to vessel  30 . By tracking the movement, the stresses on the loading arm  20  caused by movement of vessel  32  relative to vessel  30  are reduced. 
         [0019]    The below discussion details the features of loading arm  20  and how these features operate in the system. As shown in  FIG. 2 , the loading arm includes a standpost or riser  38 . The riser  38  comprises an outer support conduit  39  and a portion  40   a  of process pipe  40 . Process pipe  40  carries the fluid, which in this case is liquid natural gas, from the storage vessel  30  to the cargo carrier  32 . The loading arm further includes and inner arm  42 . The inner arm  42  includes a portion  40   b  of process pipe  40 . It also includes support structure  41 . A swivel joint  44  couples process pipe portion  40   b  at the fulcrum  46  to process pipe portion  40   a.  The swivel connection  44  allows inner arm  42 , including process pipe portion  40   b,  to pivot relative to riser  38 , including process pipe portion,  40   a,  up and down relative to the riser  38  as indicated by arrow  60  ( FIG. 1 ). 
         [0020]    The loading arm  20  further includes an outer arm  50 . The outer arm  50  includes process pipe portion  40   c  and support structure  51 . A swivel joint  48  couples process pipe portion  40   c  to process pipe portion  40   b.  The swivel connection allows outer arm  50 , including pipe portion  40   c,  to pivot relative to inner arm  42 , including process pipe portion  40   b.  The arm  50  pivots outward and backward relative to the inner arm as indicated by arrow  66  ( FIG. 1 ). A portion of process pipe  40   a  towards the fulcrum includes a swivel joint  52  rotably connecting a first upper portion of process pipe  40   a  and to a second lower portion of process pipe  40   a.  The swivel connection allows the inner arm  42 , including pipe portion  40   b  to rotate about the vertical axis of riser  38  in the direction indicated by arrow  56  ( FIG. 1 ). In more detail the first upper pipe portion of process pipe  40   a  can rotate about the lower pipe portion of process pipe  40   a.    
         [0021]    A first hydraulic piston cylinder actuator, also called a slew cylinder,  54  is coupled to the first upper portion and second lower portion of process pipe  40   a.  The actuator  54  when actuated rotates inner arm  42 , including process pipe portion  40   b,  about the vertical axis of riser  38  in the direction indicated by arrow  56  ( FIG. 1 ). 
         [0022]    A second hydraulic piston cylinder actuator, also called a primary cylinder  58 , is coupled to the inner arm  42  and riser  38 . The actuator  58  when actuated causes the inner arm  42  to pivot relative to the riser  38  up and down as indicated by arrow  60  ( FIG. 1 ). A third hydraulic piston cylinder actuator, also called a secondary cylinder  62 , is coupled to the inner arm  42  and outer arm  50 . One end of the secondary cylinder  62  is coupled to the outer arm  50  via a linkage assembly  64 . The secondary cylinder  62  when actuated causes the outer arm  50  to pivot outward and backward relative to the inner arm  42 . 
         [0023]    The hydraulic power unit  22  is fluidly coupled to each of the above three described hydraulic piston cylinder type actuators  54 ,  58 ,  62 . The hydraulic power unit  22  when in operation supplies hydraulic fluid to the various actuators  54 ,  58 ,  62  to cause sections of the loading arm  20  to move about the swivel joints, as described above. An operator thus by commanding the hydraulic power unit can actuate the cylinders to move the loading arm free end  34  towards the cargo manifold  36 . Additionally the electronic controller  24 , based on signals received from the MRU&#39;s  26 ,  28  can send commands to the hydraulic power unit  22  to cause the unit  22  to supply hydraulic fluid to the actuators  54 ,  58 ,  62  to move the sections of the loading arm  20  to compensate for the movement of the vessels  30 ,  32  relative to each other. The compensation allows for the free end of the loading arm  20  to remain connected to the cargo manifold  36  in a manner which reduces stresses on the loading arm  20 . The compensation achieves minimal stresses because the actuators  54 ,  58 ,  62  are moving the free end  34  of the loading arm  20  to track, as near as possible, the movement of the cargo manifold  36  relative to vessel  30 . Accordingly the loading arm  20  is not being tugged and pulled on due to the movement of the vessels  30 ,  32  relative to one another. Also the compensation allows for the loading arm  20  to be smoothly directed to the cargo manifold  36  during the connection process because the unintended movement of the free end  34  of the loading arm  20  relative to the cargo manifold  36  is brought to, as near as possible zero. The following provides a first example of the workings of the system. In the first example the loading arm free end  34  is coupled to the manifold  36 . In this example, the first MRU  26  detects that the production storage vessel  30  is stationary relative to the stationary world. The second MRU  28  detects that vessel  32  is heaving, moving up. The First MRU  26  transmits its signals to electronic controller  24 . The second MRU  28  transmits its signals to the electronic controller  24 . The electronic controller  24 , based on the signals received from each of the MRU&#39;s  26 ,  28 , makes a determination as to vessel  30 &#39;s movement relative to vessel  32 . In this particular example the electronic controller  24  determines that vessel  32  is moving up in the positive Z direction relative to vessel  30 . To compensate for the relative upward movement of vessel  32 , electronic controller  24  commands hydraulic power unit  22  to actuate hydraulic primary cylinder  58  to pivot the inner arm up, in the positive Z direction as indicated by arrow  68  ( FIG. 2 ). It further commands the hydraulic power unit  22  to actuate secondary hydraulic cylinder  62  to pivot outer arm  50  outward relative to inner arm  42  in the direction indicated by arrow  70  ( FIG. 2 ). In this example it is the hydraulic piston cylinder actuators that cause the free end  34  of the loading arm  20  to move as opposed to vessel  32  causing the free end  34  to move. The free end  34  of the loading arm  20  thus tracks the movement of the cargo manifold  36  and thus minimizes stresses on the loading arm  20  caused by relative movement of the vessels  30 ,  32 . 
         [0024]    In a second example the free end  34  of the loading arm  20  is again coupled to the cargo manifold  36 . Vessel  30  is stationary relative to the stationary world. Vessel  32  is surging forward in a positive direction relative to the stationary world. The first and second MRU&#39;s  26 ,  28  send signals to the electronic controller  24 . The electronic controller  24  based on the signals determines the movement of vessel  32  relative to vessel  30  to be a surge forward. Electronic controller  24  to compensate for the movement, sends signals to the hydraulic power unit  22  to cause the hydraulic power unit  22  to supply hydraulic fluid to actuate the hydraulic cylinders of the loading arm  20  so that the loading arm&#39;s free end  34  tracks, as near as possible, the cargo manifold&#39;s movement relative to vessel to track the movement, the slew piston cylinder actuator  54  is actuated to rotate the inner arm in the direction of the surge forward. The secondary piston cylinder actuator  62  is actuated to pivot the outer arm outward relative to the inner arm. The primary piston cylinder actuator  58  is actuated to pivot the inner arm downward in the negative Z direction. 
         [0025]    Although the system has been described as using two MRU&#39;s, the system could use a single sensor such as an optical or photographic sensor to detect the movement of vessel  32  relative to vessel  30 . The sensor could be mounted on either vessel. The sensor would be electrically coupled to the electronic controller. The controller would interpret the signals from the one sensor to determine the movement of vessel  32  relative to vessel  30 . The controller would than activate the hydraulic power unit to drive the loading arms via the cylinders to compensate for the relative movement. The term hydraulic cylinder as used herein refers generally to an actuator of the hydraulic piston cylinder type. 
         [0026]    The system has been described with respect to the loading and off-loading of liquefied natural gas (LNG). The system can be used for all types of fluids. For instance the fluids can be liquefied petroleum gas, all types of crude oil, all types of fuels, chemicals or anything else that flows and is transported in bulk. 
         [0027]    The electronic acceleration sensor shown is an MRU. The invention is not limited to only an MRU type electronic acceleration sensor. Other electronic acceleration sensors will work. 
         [0028]    The diameter of the process pipe and free end can vary. The diameter can vary from 4″ to 20″. 
         [0029]    All of the features disclosed in this specification (including any accompany claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. 
         [0030]    Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. 
         [0031]    The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.