Abstract:
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.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present applications claims the benefit of provisional application Ser. No. 61/646,847 which was filed on May 14, 2012. 
    
    
     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. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Some specific exemplary embodiments of the disclosure may be understood by referring, in part, to the following description and the accompanying drawings. 
         FIG. 1A  shows an angular view of one exemplary riser coupling system, in accordance with certain embodiments of the present disclosure. 
         FIG. 1B  shows a top view of a riser coupling system, in accordance with certain embodiments of the present disclosure. 
         FIG. 2  shows an angular view of a spider assembly prior to receiving a connector assembly, in accordance with certain embodiments of the present disclosure. 
         FIG. 3A  shows an angular view of one exemplary connector actuation tool, in accordance with certain embodiments of the present disclosure. 
         FIG. 3B  shows a cross-sectional view of a connector actuation tool, in accordance with certain embodiments of the present disclosure. 
         FIG. 4  shows a cross-sectional view of a connector assembly, in accordance with certain embodiments of the present disclosure. 
         FIG. 5  shows a cross-sectional view of landing a riser section, which may include the lower tubular assembly, in the spider assembly, in accordance with certain embodiments of the present disclosure. 
         FIG. 6  shows a cross-sectional view of running the upper tubular assembly to the landed lower tubular assembly, in accordance with certain embodiments of the present disclosure. 
         FIG. 7  shows a cross-sectional view of orienting an upper tubular assembly with respect to a lower tubular assembly, in accordance with certain embodiments of the present disclosure. 
         FIG. 8  shows a cross-sectional view of an upper tubular assembly landed, in accordance with certain embodiments of the present disclosure. 
         FIG. 9  shows a cross-sectional view of the connector actuation tool engaging a riser joint prior to locking a riser joint, in accordance with certain embodiments of the present disclosure. 
         FIG. 10  shows a cross-sectional view of a connector actuation tool locking a riser joint, in accordance with certain embodiments of the present disclosure. 
         FIG. 11  shows a cross-sectional view of the connector actuation tool retracted, in accordance with certain embodiments of the present disclosure. 
     
    
    
     While embodiments of this disclosure have been depicted and described and are defined by reference to exemplary embodiments of the disclosure, such references do not imply a limitation on the disclosure, and no such limitation is to be inferred. The subject matter disclosed is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those skilled in the pertinent art and having the benefit of this disclosure. The depicted and described embodiments of this disclosure are examples only, and not exhaustive of the scope of the disclosure. 
     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 purposes of this disclosure, an information handling system may include any instrumentality or aggregate of instrumentalities operable to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, intelligence, or data for business, scientific, control, or other purposes. For example, an information handling system may be a personal computer, a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price. The information handling system may include random access memory (RAM), one or more processing resources such as a central processing unit (CPU) or hardware or software control logic, ROM, and/or other types of nonvolatile memory. Additional components of the information handling system may include one or more disk drives, one or more network ports for communication with external devices as well as various input and output (I/O) devices, such as a keyboard, a mouse, and a video display. The information handling system may also include one or more buses operable to transmit communications between the various hardware components. 
     For the purposes of this disclosure, computer-readable media may include any instrumentality or aggregation of instrumentalities that may retain data and/or instructions for a period of time. Computer-readable media may include, for example, without limitation, storage media such as a direct access storage device (e.g., a hard disk drive or floppy disk drive), a sequential access storage device (e.g., a tape disk drive), compact disk, CD-ROM, DVD, RAM, ROM, electrically erasable programmable read-only memory (EEPROM), and/or flash memory; as well as communications media such wires, optical fibers, microwaves, radio waves; and/or any combination of the foregoing. 
     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. 1A  shows an angular view of one exemplary riser coupling system  100 , in accordance with certain embodiments of the present disclosure.  FIG. 1B  shows a top view of the riser coupling system  100 . The riser coupling system  100  may include a spider assembly  102  adapted to one or more of receive, at least partially orient, engage, hold, and actuate a riser joint connector  104 . The spider assembly  102  may include one or more connector actuation tools  106 . In certain embodiments, a plurality of connector actuation tools  106  may be spaced radially about an axis  103  of the spider assembly  102 . By way of nonlimiting example, two connector actuation tools  106  may be disposed around a circumference of the spider assembly  102  in an opposing placement. The nonlimiting example of  FIG. 1  show three pairs of opposing connector actuation tools  106 . It should be understood that various embodiments may include any suitable number of connector actuation tools  106 . 
     As depicted in  FIG. 1B , certain embodiments may include one or more orienting members  105  disposed radially about the axis  103  to facilitate orientation of the riser joint connector  104 . By way of example without limitation, three orienting members  105  may include a cylindrical or generally cylindrical form extending upwards from a surface of the spider assembly  102 . The orienting members  105  may act as guides to interface the riser joint connector  104  as the riser joint connector  104  is lowered toward the spider assembly  102 , thereby facilitating orientation and/or alignment. In certain embodiments, the orienting members  105  may be fitted with one or more sensors (not shown) to detect position and/or orientation of the riser joint connector  104 , 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 assembly  102  may include a base  108 . The base  108 , and the spider assembly  102  generally, may be mounted directly or indirectly on a surface of a vessel or platform. For example, the base  108  may be disposed on or proximate to a rig floor. In certain embodiments, the base  108  may include or be coupled to a gimbal mount to facilitate balancing in spite of sea sway. 
       FIG. 2  shows an angular view of the spider assembly  102  prior to receiving the riser joint connector  104  (depicted in  FIGS. 1A and 1B ). The nonlimiting example of the spider assembly  102  with the base  108  includes a generally circular geometry about a central opening  110  configured for running riser sections therethrough. Various alternative embodiments may include any suitable geometry. 
       FIG. 3A  shows an angular view of one exemplary connector actuation tool  106 , in accordance with certain embodiments of the present disclosure.  FIG. 3B  shows a cross-sectional view of the connector actuation tool  106 . The connector actuation tool  106  may include a connection means  112  to allow connection to the base  108  (omitted in  FIGS. 3A ,  3 B). As depicted, the connection means  112  may include a number of threaded bolts. However, it should be appreciated that any suitable means of coupling, directly or indirectly, the connector actuation tool  106  to the rest of the spider assembly  102  (omitted in  FIGS. 3A ,  3 B) may be employed. 
     The connector actuation tool  106  may include a dog assembly  114 . The dog assembly  114  may include a dog  116  and a piston assembly  118  configured to move the dog  116 . The piston assembly  118  may include a piston  120 , a piston cavity  122 , one or more hydraulic lines  124  to be fluidically coupled to a hydraulic power supply (not shown), and a bracket  126 . The bracket  126  may be coupled to a support frame  128  and the piston  120  so that the piston  120  remains stationary relative to the support frame  128 . The support frame  128  may include or be coupled to one or more support plates. By way of example without limitation, the support frame  128  may include or be coupled to support plates  130 ,  132 , and  134 . The support plate  130  may provide support to the dog  116 . 
     With suitable hydraulic pressure applied to the piston assembly  118  from the hydraulic power supply (not shown), the piston cavity  122  may be pressurized to move the dog  116  with respect to one or more of the piston  120 , the bracket  126 , the support frame  128 , and the support plate  130 . In the non-limiting example depicted, each of the piston  120 , the bracket  126 , the support frame  128 , and the support plate  130  is adapted to remain stationary though the dog  116  moves.  FIGS. 3A and 3B  depict the dog  116  in an extended state relative to the rest of the connector actuation tool  106 . 
     The connector actuation tool  106  may include a clamping tool  135 . By way of example without limitation, the clamping tool  135  may include one or more of an upper actuation piston  136 , an actuation piston mandrel  138 , and a lower actuation piston  140 . Each of the upper actuation piston  136  and the lower actuation piston  140  may be fluidically coupled to a hydraulic power supply (not shown) and may be moveably coupled to the actuation piston mandrel  138 . With suitable hydraulic pressure applied to the upper and lower actuation pistons  136 ,  140 , the upper and lower actuation pistons  136 ,  140  may move longitudinally along the actuation piston mandrel  138  toward a middle portion of the actuation piston mandrel  138 .  FIGS. 3A and 3B  depict the upper and lower actuation pistons  136 ,  140  in a non-actuated state. 
     The actuation piston mandrel  138  may be extendable and retractable with respect to the support frame  128 . A motor  142  may be drivingly coupled to the actuation piston mandrel  138  to selectively extend and retract the actuation piston mandrel  138 . By way of example without limitation, the motor  142  may be drivingly coupled to a slide gear  144  and a slide gear rack  146 , which may in turn be coupled to the support plate  134 , the support plate  132 , and the actuation piston mandrel  138 . The support plates  132 ,  134  may be moveably coupled to the support frame  128  to extend or retract together with the actuation piston mandrel  138 , while the support frame  128  remains stationary.  FIGS. 3A and 3B  depict the slide gear rack  146 , the support plates  132 ,  134 , and the actuation piston mandrel  138  in a retracted state relative to the rest of the connector actuation tool  106 . 
     The connector actuation tool  106  may include a motor  148 , which may be a torque motor, mounted with the support plate  134  and driving coupled to a splined member  150 . The splined member  150  may also be mounted to extend and retract with the support plate  134 . It should be understood that while one non-limiting example of the connector actuation tool  106  is 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 tool  106  may be fitted with one or more sensors (not shown) to detect position, orientation, pressure, and/or other parameters of the connector actuation tool  106 . For nonlimiting example, one or more sensors may detect the positions of the dog  116 , the clamping tool  135 , and/or splined member  150 . 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 motor  148 , clamping tool  135 , and dog assembly  114  may be feed back to the information handling system by any suitable means. 
       FIG. 4  shows a cross-sectional view of a riser joint connector  104 , in accordance with certain embodiments of the present disclosure. The riser joint connector  104  may include an upper tubular assembly  152  and a lower tubular assembly  154 , each arranged in end-to-end relation. The upper tubular assembly  152  sometimes may be referenced as a box; the lower tubular assembly  154  may be referenced as a pin. 
     Certain embodiments may include a seal ring (not shown) between the tubular members  152 ,  154 . The upper tubular assembly  152  may include grooves  156  about its lower end. The lower member  154  may include grooves  158  about its upper end. A lock ring  160  may be disposed about the grooves  156 ,  158  and may include teeth  160 A,  160 B. The teeth  160 A,  160 B may correspond to the grooves  156 ,  158 . The lock ring  160  may be radially expandable and contractible between an unlocked position in which the teeth  160 A,  160 B are spaced from the grooves  156 ,  158 , and a locking position in which the lock ring  160  has been forced inwardly so that teeth  160 A,  160 B engage with the grooves  156 ,  158  and thereby lock the connection. Thus, the lock ring  160  may 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 ring  160  may be split about its circumference so as to normally expand outwardly to its unlocking position. In certain embodiments, the lock ring  160  may include segments joined to one another to cause it to normally assume a radially outward position, but be collapsible to contractible position. 
     A cam ring  162  may be disposed about the lock ring  160  and may include inner cam surfaces which are slidable over surfaces of the lock ring  160 . The cam surfaces of the cam ring  162  may provide a means of forcing the lock ring  160  inward to a locked position. The cam ring  162  may include an upper member  162 A and a lower member  162 B with corresponding lugs  162 A′ and  162 B′. The upper member  162 A and the lower member  162 B may be configured as opposing members. The cam ring  162  may be configured so that movement of the upper member  162 A and the lower member  162 B toward each other forces the lock ring  160  inward to a locked position via the inner cam surfaces of the cam ring  162 . 
     The riser joint connector  104  may include one or more locking members  164 . A given locking member  164  may be adapted to extend through a portion of the cam ring  162  to maintain the upper member  162 A and the lower member  162 B in a locking position where each has been moved toward the other to force the lock ring  160  inward to a locked position. The locking member  164  may include a splined portion  164 A and may extend through a flange  152 A of the upper tubular assembly  152 . The locking member  164  may include a retaining portion  164 B, which may include but not be limited to a lip, to abut the upper member  162 A. The locking member  164  may include a tapered portion  164 C to fit a portion of the upper member  162 A. The locking member  164  may include a threaded portion  164 D to threadedly engage the lower member  162 B. 
     The riser joint connector  104  may include one or more auxiliary lines  166 . For nonlimiting example, the auxiliary lines  166  may include one or more of hydraulic lines, choke lines, kill lines, and boost lines. The auxiliary lines  166  may extend through the flange  152 A and a flange  154 A of the lower tubular assembly  154 . The auxiliary lines  166  may be adapted to mate between the flanges  152 A,  154 A, for example, by way of a stab fit. 
     The riser joint connector  104  may include one or more connector orientation guides  168 . A given connector orientation guide  168  may be disposed about a lower portion of the riser joint connector  104 . By way of example without limitation, the connector orientation guide  168  may be coupled to the flange  154 A. The connector orientation guide  168  may include one or more tapered surfaces  168 A formed to, at least in part, orient at least a portion of the riser joint connector  104  when interfacing one of the dog assemblies  114 . When the dog assembly  114  contacts one or more of the tapered surfaces  168 A of the connector orientation guide  168 , the one or more tapered surfaces  168 A may facilitate axial alignment and/or rotational orientation of the riser joint connector  104  by biasing the riser joint connector  104  toward a predetermined position with respect to the dog assembly  114 . In certain embodiments, the connector orientation guide  168  may provide a first stage of an orientation process to orient the lower tubular assembly  154 . 
     The riser joint connector  104  may include one or more orientation guides  170 . In certain embodiments, the one or more orientation guides  170  may provide a second stage of an orientation process. A given orientation guide  170  may be disposed about a lower portion of the riser joint connector  104 . By way of example without limitation, the orientation guide  170  may be formed in the flange  154 A. The orientation guide  170  may include a recess, cavity or other surfaces adapted to mate with a corresponding guide pin  172  (depicted in  FIG. 5 ). 
       FIG. 5  shows a cross-sectional view of landing a riser section, which may include the lower tubular assembly  154 , in the spider assembly  102 , in accordance with certain embodiments of the present disclosure. In the example landed state shown, the dogs  116  have been extended to retain the tubular assembly  154 , and the two-stage orientation features have oriented the lower tubular assembly  154 . Specifically, the connector orientation guide  168  has already facilitated axial alignment and/or rotational orientation of the lower tubular assembly  154 , and one or more of the dog assemblies  114  may include a guide pin  172  extending to mate with the orientation guide  170  to ensure a final desired orientation. 
     A running tool  174  may be adapted to engage, lift, and lower the lower tubular assembly  154  into the spider assembly  102 . In certain embodiments, the running tool  174  may be adapted to also test the auxiliary lines  166 . For example, the running tool  174  may pressure test choke and kill lines coupled below the lower tubular assembly  154 . 
     In certain embodiments, one or more of the running tool  174 , the tubular assembly  154 , and auxiliary lines  166  may 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. 6  shows a cross-sectional view of running the upper tubular assembly  152  to the landed lower tubular assembly  154 , in accordance with certain embodiments of the present disclosure. The running tool  174  may be used to engage, lift, and lower the upper tubular assembly  152 . The upper tubular assembly  152  may be lowered onto a stab nose  178  of the lower tubular assembly  154 . 
     In certain embodiments, the running tool  174  may include one or more sensors  176  to facilitate proper alignment and/or orientation of the upper tubular assembly  152 . The one or more sensors  176  may be located at any suitable positions on the running tool  174 . In certain embodiments, the tubular member  152  may be fitted with one or more sensors (not shown) to detect position, orientation, pressure, and/or other parameters of the tubular member  152 . 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. 7  shows a cross-sectional view of orienting the upper tubular assembly  152  with respect to lower tubular assembly  154 , in accordance with certain embodiments of the present disclosure. It should be understood that orienting the upper tubular assembly  152  may be performed at any suitable stage of the lowering process, or throughout the lower process. 
       FIG. 8  shows a cross-sectional view of the upper tubular assembly  152  landed, in accordance with certain embodiments of the present disclosure. 
       FIG. 9  shows a cross-sectional view of the connector actuation tool  106  engaging the riser joint connector  104  prior to locking the riser joint connector  104 , in accordance with certain embodiments of the present disclosure. As depicted, the actuation piston mandrel  138  may be extended toward the riser joint connector  104 . The upper actuation piston  136  may engage the lug  162 A′ and/or an adjacent groove of the cam ring  162 . Likewise, the lower actuation piston  140  may engage the lug  162 B′ and/or an adjacent groove of the cam ring  162 . The splined member  150  may also be extended toward the riser joint connector  104 . As depicted, the splined member  150  may engage the locking member  164 . In various embodiments, the actuation piston mandrel  138  and the splined member  150  may be extended simultaneously or at different times. 
       FIG. 10  shows a cross-sectional view of the connector actuation tool  106  locking the riser joint connector  104 , in accordance with certain embodiments of the present disclosure. As depicted, with suitable hydraulic pressure having been applied to the upper and lower actuation pistons  136 ,  140 , the upper and lower actuation pistons  136 ,  140  moved longitudinally along the actuation piston mandrel  138  toward a middle portion of the actuation piston mandrel  138 . The upper member  162 A and the lower member  162 B of the cam ring  162  are thereby forced toward one another, which may act as a clamp that in turn forces the lock ring  160  inward to a locked position via the inner cam surfaces of the cam ring  162 . As depicted, the locking member  164  may be in a locked position after the motor  148  has driven the splined member  150 , which in turn has driven the locking member  164  into the locked position to lock the cam ring  162  in a clamped position. In various embodiments, the locking member  164  may be actuated into the locked position as the cam ring  162  transitions to a locked position or at a different time. 
       FIG. 11  shows a cross-sectional view of the connector actuation tool  106  retracted, in accordance with certain embodiments of the present disclosure. From that position, the running tool  174  (depicted in previous figures) may engage the riser joint connector  104  and lift the riser joint connector  104  away from the guide pin  172 . The dogs  114  may be retracted, the riser joint connector  104  may be lowered passed the spider assembly  102 , 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.