Unmanned ship for offshore hydrocarbon production, storage and offloading

Abstract

An offshore hydrocarbon production, storage and offloading vessel to be located on a body of water, comprising a ship-shaped hull, hydrocarbon processing equipment and a mooring system. The vessel comprises a superstructure holding the hydrocarbon processing equipment arranged longitudinally in at least three sections, wherein non-hydrocarbon processing modules are installed in a first section, low pressure / low explosion risk hydrocarbon processing modules in a second section, and high pressure hydrocarbon gas and toxic compound processing modules in a third section. The vessel is provided with one or more central processing and / or maintenance structures. A track is provided at a level above or at the top level of a section and configured for holding the one or more structures and allowing the structures to travel on the track.

Description

TECHNICAL FIELD

[0001] The present invention relates to a vessel for offshore hydrocarbon production, storage and offloading. Further, the present invention relates to a method for manufacturing such a vessel. BACKGROUND

[0002] Although unmanned wellhead facilities are well established in the offshore industry and have a 40-year track record, the minimum manned facilities for performing process elements (separation, dehydration or compression) offshore are far from it. In particular, the operation of a floating facility such as a floating hydrocarbon production, storage and offloading platform or vessel still requires a large number of personnel, e.g. consisting of production personnel, maintenance personnel and support personnel. Typically, the vessel or platform (hereinafter referred to as FPSO) is located far from the shore and the personnel stay on the FPSO for a relatively long time. Therefore, a relatively large part of the FPSO is used for facilities to support the personnel.

[0003] Further, in the prior art, the process equipment is arranged and laid out in a way that the operations can be performed by people, which can not be the optimal layout for hydrocarbon processing.

[0004] It is an object of the present invention to overcome or alleviate the drawbacks of the prior art. SUMMARY

[0005] This object is achieved by a vessel for offshore hydrocarbon production, storage and offloading to be located on a body of water, the vessel comprising a ship-shaped hull, a hydrocarbon process equipment and a mooring system.

[0006] The vessel comprises a topside structure holding the hydrocarbon process equipment, the hydrocarbon process equipment extending longitudinally from the stern to the bow and being arranged in at least three sections, wherein non-hydrocarbon process modules are installed in a first section, low pressure / low explosion risk hydrocarbon process modules in a second section and high pressure hydrocarbon gas and toxic compound process modules in a third section, the second section being located between the first section and the third section, wherein,

[0007] The vessel is provided with one or more central process and / or maintenance structures;

[0008] The track is provided at a level above or at the level of the top of the sections;

[0009] The track is configured for holding the one or more central process and / or maintenance structures and allowing the structures to travel on the track.

[0010] According to an embodiment, the vessel described above is provided, wherein the track comprises a guide rail and / or a plate structure, the one or more structures being able to travel on the guide rail and / or the plate structure.

[0011] According to an embodiment, the above described vessel is provided, wherein the track extends substantially along the length of the vessel.

[0012] According to an embodiment, the above described vessel is provided, wherein the track is arranged along a side wall of the hull or a centerline of the vessel.

[0013] According to an embodiment, the above described vessel is provided, wherein the central processing and / or maintenance structure is a maintenance structure equipped with a large capacity lifting device and the ability to deploy one or more robotic devices on the superstructure.

[0014] According to an embodiment, the above described vessel is provided, wherein the central processing and / or maintenance structure is a maintenance structure equipped with one or more robotic arms on which the robotic devices are mounted.

[0015] According to an embodiment, the above described vessel is provided, wherein the superstructure comprises one processing deck or a plurality of processing decks positioned at different levels above each other, and optionally, between the processing modules and along each processing deck of the processing modules, a service corridor is provided, wherein each service corridor is configured to be accessible by the robotic devices.

[0016] According to an embodiment, the above described vessel is provided, wherein each processing deck comprises a garage for holding the robotic devices, and optionally, the garage is provided with an elevator for allowing the robotic devices to move between different levels of the processing deck.

[0017] The garage provides docking and protection of the robotic devices that are not in use from the offshore environment. In addition, the garage has space for storing tools and equipment spares used by the robotic devices. In addition, the garage can be provided with a power supply to which the robotic devices can be connected for restoring their energy level.

[0018] The elevator provides that the robotic devices can be transferred from one processing deck level to another. In this way, the devices can be shared between the various deck levels, if needed. In addition, the elevator can be controlled by the robotic devices in such a way that the robotic devices can move autonomously between the various deck levels.

[0019] According to an embodiment, the above described vessel is provided, wherein on at least one processing deck, high energy rotating equipment comprising at least a generator and a compressor are arranged on the outside of the processing modules adjacent to the hull side walls, the high energy equipment is configured to have couplings for detachable coupling with other components of the processing modules, and comprises connectors for cranes on the equipment.

[0020] This arrangement allows relatively easy access to equipment types that normally require relatively frequent maintenance and / or replacement that can exceed the service capabilities of robotic equipment. By providing a connector for a crane on the equipment, the equipment can be removed or replaced by a crane on the vessel, but alternatively also by a crane on the support vessel.

[0021] According to an embodiment, the above described vessel is provided, wherein on at least one process deck, static equipment is arranged on the inner side of the process modules facing away from the hull side walls. This equipment normally requires less maintenance or replacement and can therefore be located further away from the support vessel. In addition, this type of equipment can be completely serviced by robotic equipment.

[0022] According to an embodiment, the above described vessel is provided, wherein the at least one process deck comprises a longitudinally extending central corridor, and the tracks are arranged above the central corridor.

[0023] According to an embodiment, the above described vessel is provided, wherein the central corridor comprises at least one service aisle for deploying one or more robotic devices from one or more central process and / or service structures.

[0024] According to an embodiment, the above described vessel is provided, wherein the hull is provided with a central vertical passage for arranging and accommodating risers connected between subsea hydrocarbon wells at the production location and hydrocarbon processing equipment, wherein optionally a third section is positioned adjacent to the bow and above the central passage.

[0025] The FPSO according to this embodiment is configured for spread mooring, so that it will have a fixed orientation at the location above the offshore hydrocarbon field. In addition, a central passage is provided inside the hull to allow risers, pipelines, etc. to enter the vessel. This arrangement of risers allows the riser deck to be removed to free up space for a ship-to-ship approach along the side of the hull. This creates flexibility so that the support vessel can freely approach the FPSO from either side for maintenance or other necessary intervention activities. Furthermore, arranging the processing equipment in three different zones with different operational tasks allows the hydrocarbon production process to become safer, as the process streams essentially follow the zone arrangement.

[0026] According to embodiments, the vessel further comprises a flare tower, wherein the flare tower is located at the stern, adjacent to the first section of the processing module; and / or comprises an auxiliary equipment module comprising at least a metering unit, at least one auxiliary generator and a pump unit, wherein the auxiliary equipment module is located between the stern and the first section of the processing module; and / or further comprises an offloading device, preferably located at the stern, having a floating hose for coupling to a shuttle tanker, and wherein the offloading device comprises a docking station for docking a free end of the floating hose when the floating hose is not coupled to a shuttle tanker.

[0027] By positioning the flare tower between the stern and the first section, the flare is isolated from the second and third sections of the processing equipment which have a relatively high explosion risk when exposed to fire. According to the prior art, the auxiliary equipment would be placed inside the hull. In this embodiment, by placing the equipment on deck, relatively more hull volume is available for fluid storage of liquid chemicals used in the hydrocarbon production process.

[0028] According to requirements, the equipment can be stacked, allowing for comparable risk equipment to be arranged within the same section.

[0029] In some embodiments, between the various processing modules and along each processing deck of the various processing modules, a service aisle is provided, wherein each service aisle is configured to be accessible by a robotic device. The service aisles present between the processing modules and along the processing modules allow for maintenance procedures to be carried out by robotic devices designed to interact with the processing modules. The robotic devices are provided with tools specifically for carrying out the maintenance, according to the required maintenance.

[0030] According to embodiments, the above described vessel is provided, wherein the at least one processing deck comprises a central corridor extending longitudinally and containing an area for one or more interconnecting pipe racks between the various equipment within the processing module on that processing deck.

[0031] According to embodiments, the above described vessel is provided, wherein the central corridor comprises at least one service aisle for a robotic device.

[0032] In some embodiments, the above described vessel is provided, further comprising an offloading device, preferably located at the stern, having a floating hose for coupling to a shuttle tanker, and wherein the offloading device comprises a docking station for docking a free end of the floating hose when the floating hose is not coupled to a shuttle tanker.

[0033] In some embodiments, the above described vessel is provided, wherein the hull is configured for allowing access to the vessel by foot boarding at each hull side wall by means of a gangway, preferably providing an overboard extending landing gallery. BRIEF DESCRIPTION OF DRAWINGS

[0034] The application will be explained in more detail below with reference to the drawing, which shows illustrative embodiments of the application. The drawing is intended to be only for illustrative purposes. The scope of the application is only limited by the definition given in the attached claims.

[0035] Figure 1 a perspective view of a hull portion of a ship is shown;

[0036] Figure 2 a perspective view of a hull portion of a ship is shown; Figure 1

[0037] Figure 3A a perspective view and a top view of a processing module area on a ship are shown, respectively, and Figure 3B

[0038] Figure 4 a cross-sectional view of a processing module area on a ship is shown. DETAILED DESCRIPTION

[0039] Figure 1 a perspective view of a ship 100 according to an embodiment is shown.

[0040] According to an embodiment of the application, an offshore hydrocarbon production, storage and offloading ship 100 is provided for mooring at a location above an oil and / or gas field at a location offshore. The ship is moored at the location using spread mooring with mooring lines 110 attached to a seabed anchor (or pile), not shown here. Alternatively, the ship 100 can be configured with a turret mooring system.

[0041] On the ship 100, hydrocarbon processing equipment is located on topside structures comprising one or more processing deck levels of a processing deck. The processing deck comprises at least three sections 20, 21, 22, 23.

[0042] In the first section 20, non-hydrocarbon processing modules associated with processes not involving the processing of hydrocarbons are installed.

[0043] In the second section 21, low pressure / low explosion risk hydrocarbon processing modules associated with the processing of hydrocarbons from feed in processes running at relatively low pressure and / or low explosion risk are installed.

[0044] Processes involving high pressure hydrocarbon gas and toxic compounds are run in the third section 22 of hydrocarbon processing modules.

[0045] The first, second and third sections are arranged longitudinally on the ship. The second section 21 with moderate explosion risk is located between the first section 20 and the third section 22. ​​

[0046] In embodiments, the third high risk section 22 is positioned adjacent to and / or above the center passage. The low risk first section 21 is positioned adjacent to the stern of the vessel.

[0047] Depending on the risks involved by the processes running in the additional sections, the additional sections 23 can be installed in the superstructure on the side of the third section or the first section.

[0048] For example, the additional sections 23 can comprise equipment for high pressure hydrocarbon ingress. As Figure 1 shown, the additional sections 23 are positioned adjacent to the third section 22.

[0049] According to embodiments, partitions in the superstructure are provided between the sections to protect the sections from each other.

[0050] The superstructure can comprise one or more cranes (26, see Figure 2 ).

[0051] According to embodiments, a track 70 is provided at a level above the top level of the sections 20, 21, 22, 23 or at the top level of the sections 20, 21, 22, 23, the track being configured for the travel of one or more central processing and / or maintenance structures (not shown). The track can comprise a rail and / or a plate-like structure on which the one or more central processing and / or maintenance structures can move.

[0052] In preferred embodiments, the track 70 extends substantially along the length of the vessel. Depending on the layout of the superstructure of the sections, the track can be arranged, for example, along the side walls of the hull or along the centerline of the vessel.

[0053] In this way, the movable central processing and / or maintenance structures can be located at any position above the sections. The function of the one or more central processing and / or maintenance structures will be explained in more detail with reference to Figure 2 to Figure 4 .

[0054] Figure 2 A longitudinal section of the vessel is shown. Figure 1 .

[0055] On the track 70, one or more central processing and / or maintenance structures are positioned. In the exemplary embodiment, two central processing and / or maintenance structures 71, 72 are provided. In this example, the first structure 71 is a maintenance structure equipped with a large capacity lifting device and the ability to deploy at least one robotic device. This central processing and / or maintenance structure 71 is configured to deploy a robot 73 at a certain position on the hull, for example in one of the sections, where the robot can perform some operations such as maintenance.

[0056] Further, the second structures 72 are arranged at different positions on the track. The second central processing and / or maintenance structures 72 are equipped with one or more robot arms 74. Thus, the second central processing and / or maintenance structures 72 are configured to perform local operations in one or more segments by means of the robot arms 74. Similar to the first structures 71, the second structures 72 are movable to selected positions on the track where operations of the robot arms are required.

[0057] The robots and / or robot arms are configured to operate autonomously or by remote control via a wired (electrical or optical) connection or by a wireless connection. In an embodiment, the wireless connection is provided by a satellite link.

[0058] According to an embodiment, the flare tower 28 comprising a flare tank is located at the stern 25 of the ship, away from the second and third segments 21, 22, 23 having a relatively moderate and higher explosion risk.

[0059] Inside the hull, the ship comprises storage tanks 30, 31, 32 for hydrocarbons and by-products.

[0060] According to an embodiment, the offloading system 33, 34 is arranged at the stern of the ship. The offloading system comprises a pumping system 33 and at least a floating hose 34 connected at one end to an offloading point on the ship. The other free end, configured to float on the water surface, is arranged to be connected to a shuttle tanker during the offloading process. When not in use, the free end of the floating hose can be connected to the ship near the waterline. The use of a permanently floating floating hose facilitates a relatively easy connection process with the oil tanker and reduces the duration of the offloading process.

[0061] Generally, the floating hose can have a length of at least 250 meters to allow a safe distance between the ship and the oil tanker.

[0062] Optionally, the hull 10 of the vessel is provided with a central vertical passage 27 through which risers from the oil and / or gas field enter and connect to hydrocarbon processing equipment on the vessel to provide processed oil and gas from the field. In addition, other connections to subsea equipment, such as power lines or communication lines, can be arranged to enter the vessel through the central passage. With this alternative arrangement of risers and other lines in the central passage, the arrangement of riser decks for connecting subsea risers to the side walls of the hull 10 is not required. By keeping the side walls free, the support vessel can be directly moored to the vessel on each of the side walls. With this optional arrangement, the vessel-to-vessel approach will be improved. Inside the hull 10, a central passage 27 is arranged which acts as a passage for risers connecting the subsea wells 120, 125 with hydrocarbon processing equipment on the deck of the vessel. In addition, the central passage 27 can be used as a passage for other lines and conduits, such as power lines and communication lines and water injection lines. The central passage 27 can be a moon pool or can consist of a central section in the hull 10 through which one or more pipes pass.

[0063] Figure 3A 、 Figure 3B A perspective view and a top view of the processing module area 40 on the vessel are shown, respectively.

[0064] In Figure 3A , a superstructure 20, 21, 22, 23 according to an embodiment is depicted. The superstructure comprises a number of processing decks 42, 43, 44 located on top of each other at various levels from the top deck of the hull. On the processing decks, (hydrocarbon) processing equipment 45, 46 is installed as explained above with reference to Figure 1 . Depending on the area required for the processing equipment, the number of levels of processing decks can vary from one to three or more.

[0065] In an embodiment, rails 70 are arranged at the side of the topmost deck 42 such that the rails extend along the length of the vessel and a central processing and / or maintenance structure 71, 72 can be moved along this side.

[0066] On each of the levels 42, 43, 44 of the processing decks, an infrastructure 50 is laid out to guide the robotic equipment 51, 52 deployed by the first structure 71 to a location on the deck, for example to service the processing equipment 45, 46. As Figure 3B shown, on the processing decks, there is an infrastructure comprising a walkway 50 which is detectable by the robotic equipment 51, 52. In addition, this infrastructure can comprise a number of (electronic) beacons 53 which are detectable by the robotic equipment for navigation.

[0067] According to embodiments, the lifting equipment of the first central handling and / or maintenance structure 71 is configured for transporting the robot to any of the levels 42, 43, 44 in the handling section 20, 21, 22, 23 if this section is provided with a vertically upwardly open aperture 75 on each level.

[0068] The infrastructure has a layout enabling the robot to position itself to a predetermined position in the vicinity of a handling module to perform a specific maintenance or repair of this module.

[0069] The robot 51, 52 can be configured with a dedicated tool for a specific maintenance task. Alternatively, the robot can be arranged to exchange tools depending on the actual maintenance task to be performed.

[0070] In case the robot is attached to a robot arm of the second structure 72, the second central handling and / or maintenance structure 72 can be moved along the track 70 to the position of a target equipment on which the robot tool 73 mounted on the robot arm can act. The robot arm is typically configured as a manipulator to position and align the robot tool with the target equipment.

[0071] The superstructure further comprises one or more garages 54 to store robot equipment on the respective levels of the handling deck (see Figure 3A ). The garages are included in the layout on the handling deck such that the robot equipment can reach the location of the garage.

[0072] According to embodiments, the garages on the respective levels of the handling deck are positioned above each other and are configured with an elevator to allow the robot equipment to travel from one level of the handling deck to another.

[0073] In alternative embodiments, the garage and the elevator are separate units.

[0074] According to embodiments, on the handling deck, one or more garages 54 can be arranged for storing and housing unused robot equipment. In addition, the garages can be used as storage space and for various tools used by the exchanging robot equipment. Preferably, the one or more garages comprise one or more docking stations for providing energy to the robot equipment.

[0075] Figure 4 A cross-sectional view of the handling module area 40 on the vessel 100 is shown.

[0076] In Figure 4 , the superstructure is shown in the transverse direction across the vessel.

[0077] In this exemplary embodiment, the superstructure comprises three tiers of process decks 42, 43, 44. A walkway 55 is arranged along the centerline of the vessel 100, which walkway 55 comprises an area for interconnecting pipe racks 56 and longitudinal passages 57 for robots and transport equipment. On each side of the walkway, process equipment 45, 46 is arranged on the process deck tiers. Rails 70 are arranged above the walkway 55, allowing one or more movable central process and / or maintenance structures 71, 72 to pass on either side of the rails for robot maintenance. As described above, the structure 71 can be configured to deploy a robot device at any of the tiers 42, 43, 44 in the process section.

[0078] In some embodiments, the rails 70 have a width allowing the central process and / or maintenance structures 71, 72 to pass each other.

[0079] According to embodiments, the process equipment is distributed between the side walls and the walkway area corresponding to the (estimated) maintenance requirements of the equipment. Process equipment with higher requirements is arranged in an outer portion 60 of the process deck adjacent to the side walls, another equipment is arranged in an inner portion 61 closer to the walkway area. Furthermore, the process equipment in the outer portion is configured to be removed by a support vessel using a crane. In this way, the equipment can be removed for maintenance or repair and replaced by another equipment delivered by a support vessel (not shown). Alternatively or additionally, a crane 26 can be located on the vessel 100.

[0080] Process equipment with higher maintenance requirements comprises dynamic equipment, such as rotating equipment: generators, pumps, etc. Equipment with lower maintenance requirements comprises static equipment, such as separators, scrubbers, storage tanks, valve equipment, etc.

[0081] It will be understood that the offshore hydrocarbon production, storage and offloading vessel as described above can also be embodied as a circular FPSO type vessel configured for extended mooring at a production location and having a hull provided with a central passage for arranging and accommodating risers connecting between subsea hydrocarbon wells at the production location and hydrocarbon process equipment.

[0082] The circular FPSO is configured with a superstructure holding the hydrocarbon process equipment segmented into at least three sections, wherein non-hydrocarbon process modules are installed in a first section, low pressure / low explosion risk hydrocarbon process modules in a second section, and high pressure hydrocarbon gas and toxic compound process modules in a third section. A partition wall can be placed between the sections for protection.

[0083] In a similar manner as described above, the superstructure comprises one process deck or multiple process decks positioned at different tiers above each other.

[0084] Between and along each processing deck of the various processing modules, maintenance aisles can be provided, with each maintenance aisle configured to be accessible by a robotic device. Each processing deck can include a garage for holding the robotic device, which can be connected to other processing decks by elevators.

[0085] The application has been described with reference to the preferred embodiments. Modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the application be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims.

Claims

1. An offshore hydrocarbon production, storage and offloading vessel to be located on a body of water, comprising a ship-shaped hull, hydrocarbon processing equipment and a mooring system, The vessel comprises a superstructure holding the hydrocarbon handling equipment, which extends longitudinally from the stern to the bow and is arranged in at least three sections, wherein non-hydrocarbon handling modules are installed in a first section, low pressure / low explosion risk hydrocarbon handling modules in a second section, and high pressure hydrocarbon gas and toxic compound handling modules in a third section, the second section being located between the first section and the third section, wherein, the vessel is provided with one or more movable central processing and / or maintenance structures; a track is provided at a level above the top level of the sections or at the level of the top of the sections, the track is configured for holding the one or more central processing and / or maintenance structures and allowing the one or more central processing and / or maintenance structures to travel on the track.

2. The boat of claim 1, wherein, the track comprises a rail and / or a plate-like structure on which the one or more central processing and / or maintenance structures can travel.

3. The vessel according to claim 1 or 2, wherein the track extends substantially along the length of the vessel.

4. The boat of claim 1, wherein, the track is arranged along a side wall of the hull or along a centerline of the vessel.

5. The boat of claim 1, wherein, the central processing and / or maintenance structure is a maintenance structure equipped with a large capacity lifting equipment and the ability to deploy one or more robotic devices on the topside structure.

6. The boat of claim 1, wherein, the central processing and / or maintenance structure is a maintenance structure equipped with one or more robotic arms on which a robotic device is mounted.

7. The vessel according to claim 5 or 6, wherein the topside structure comprises one processing deck or a plurality of processing decks positioned at different levels above each other.

8. The boat of claim 7, wherein, Each processing deck comprises a garage for holding the robotic device.

9. The boat of claim 7, wherein, On at least one processing deck, high energy rotating equipment comprising at least a generator and a compressor is arranged on the outer side of the processing modules adjacent to the hull side wall, the high energy rotating equipment is configured to have couplings for detachable coupling with other components of the processing modules, and comprises connectors for cranes on the high energy rotating equipment.

10. The boat of claim 9, wherein, On the at least one processing deck, static equipment is arranged on the inner side of the processing modules facing away from the hull side wall.

11. The boat of claim 9, wherein, The at least one processing deck comprises a longitudinally extending central corridor and the track is arranged above the central corridor.

12. The boat of claim 11, wherein, The central corridor comprises at least one service aisle for one or more robotic devices deployed from the one or more central processing and / or maintenance structures.

13. The boat of claim 1, wherein, The hull is provided with a central vertical passage for arranging and accommodating a riser connected between a subsea hydrocarbon well in a production location and the hydrocarbon processing equipment.

14. The vessel of claim 1, further comprising a flare tower, wherein, the flare tower is located at the vessel stern adjacent to the first section of the processing module; and / or comprises an auxiliary equipment module comprising at least a metering unit, at least one auxiliary generator and a pump unit, wherein the auxiliary equipment module is located between the vessel stern and the first section of the processing module; and / or further comprises an offloading equipment having a floating hose for coupling to a shuttle tanker, and wherein the offloading equipment comprises a docking station for docking a free end of the floating hose when the floating hose is not coupled to the shuttle tanker.

15. The boat of claim 13, wherein, Power cables, control cables and communication cables enter the vessel through the central vertical passage.

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