Flexible Joint Servicing via Riser Suspension and Segmentation
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Solution Overview
Problem
The existing methods for inspecting, repairing, and replacing flexible joints in offshore riser systems are time-consuming and disruptive, leading to prolonged production shutdowns, safety risks for workers, and significant economic losses due to the need for extensive curtailment of operations and exposure to hazardous conditions.
Innovation Solution
A method and apparatus that support the riser system, allowing for the removal and servicing of flexible joints while maintaining flow through the system, using a winch and support apparatus with slips and gimbal tables to suspend the riser, enabling disassembly and inspection or replacement of individual components without full shutdown, and facilitating reconnection with standardized flexible elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional inspection and repair methods are used, then thorough inspection and repair can be performed, but production shutdown time increases significantly
Solution Approach 1:
The flexible joint is divided into separable components (flexible element, end fittings, reinforcement elements) that can be independently inspected and replaced. This allows partial repair without complete disassembly, reducing shutdown time while maintaining inspection quality
Solution Approach 2:
备用 flexible elements are pre-positioned on the vessel before deployment. When inspection is needed, these pre-positioned elements can be quickly swapped in without lengthy preparation, reducing production shutdown time while ensuring thorough inspection of the original element
2Reliability
If complete flexible joint replacement is performed, then system reliability is improved, but operational disruption and cost increase
Solution Approach 1:
The flexible joint is segmented into replaceable components, allowing only the damaged flexible element to be replaced rather than the entire assembly. This maintains reliability by replacing the failed component while minimizing production disruption
Solution Approach 2:
The damaged flexible element is discarded and replaced with a new or refurbished element, while the reusable components (end fittings, reinforcement elements, housing) are recovered and reused. This improves reliability by replacing the failed element while maintaining productivity through component reuse
3Reliability
If traditional retrieval and off-site repair methods are used, then comprehensive repair can be performed, but worker safety risks and operational costs increase
Solution Approach 1:
The flexible element is extracted from the flexible joint assembly while the assembly remains positioned on the vessel. This allows repair to be performed in a controlled environment on the vessel rather than requiring complete retrieval to shore, reducing worker safety risks while maintaining repair quality
Solution Approach 2:
A positioning apparatus with support structures acts as an intermediary to hold the flexible joint assembly in a stable, accessible position during inspection and repair. This eliminates the need for dangerous manual handling and complete retrieval, reducing worker safety risks while enabling comprehensive repair
Data Source
AI summary
A method for servicing a component of a riser system, such as a flexible joint is disclosed. The riser system may be supported in a support apparatus such that the flexible joint and an adjoining section of riser are detached to allow for inspection, servicing, repair, and/or replacement of the flexible joint or various subcomponents thereof. An apparatus is also disclosed for supporting the flexible joint during servicing.