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WO2010030901A2 - Système et procédé pour une installation de production haut volume d’éléments modulaires en eau profonde - Google Patents

Système et procédé pour une installation de production haut volume d’éléments modulaires en eau profonde Download PDF

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Publication number
WO2010030901A2
WO2010030901A2 PCT/US2009/056687 US2009056687W WO2010030901A2 WO 2010030901 A2 WO2010030901 A2 WO 2010030901A2 US 2009056687 W US2009056687 W US 2009056687W WO 2010030901 A2 WO2010030901 A2 WO 2010030901A2
Authority
WO
WIPO (PCT)
Prior art keywords
production
modular components
barge
production system
facility
Prior art date
Application number
PCT/US2009/056687
Other languages
English (en)
Other versions
WO2010030901A3 (fr
Inventor
James V. Maher
Edward E. Horton, Iii
Lyle David Finn
Greg Navarre
Original Assignee
Horton Deepwater Development Systems, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Horton Deepwater Development Systems, Inc. filed Critical Horton Deepwater Development Systems, Inc.
Publication of WO2010030901A2 publication Critical patent/WO2010030901A2/fr
Publication of WO2010030901A3 publication Critical patent/WO2010030901A3/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
    • B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING 
    • B63B73/00—Building or assembling vessels or marine structures, e.g. hulls or offshore platforms
    • B63B73/60—Building or assembling vessels or marine structures, e.g. hulls or offshore platforms characterised by the use of specific tools or equipment; characterised by automation, e.g. use of robots
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
    • B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING 
    • B63B73/00—Building or assembling vessels or marine structures, e.g. hulls or offshore platforms
    • B63B73/40—Building or assembling vessels or marine structures, e.g. hulls or offshore platforms characterised by joining methods
    • B63B73/43—Welding, e.g. laser welding

Definitions

  • Embodiments of the invention relate generally to production systems and methods for manufacturing of components for offshore structures, including fixed or floating platforms and vessels. More particularly, embodiments of the invention relate to systems and associated methods for high- volume fabrication of modular components for the offshore structures.
  • Conventional methods for fabrication and assembly of offshore structures are driven by the design of the offshore structures themselves and typically require special procedures that can be performed only by skilled technicians. Consequently, production of an offshore structure is a lengthy and expensive process. Limited capacity of existing yards wherein offshore structures may be fabricated and assembled further increases production costs and completion time for these structures. Moreover, in some locations, expansion beyond existing yard capacity to reduce production time and cost is either impossible due to a lack of space or undesirable due to local conditions. In other locations, expansion is possible but not desirable for economic reasons. For example, there may be only a short term need for expansion of an existing yard or construction of a new yard that does not justify the associated expense.
  • the production system includes a production barge and a production facility disposed on the production barge.
  • the production facility is operable to produce a plurality of modular components for use in construction of an offshore structure, wherein the modular components comprise at least one of a stiffened plate and a stiffened tubular.
  • the production system a production facility adapted to produce modular components for use in construction of an offshore structure, wherein the modular components comprise at least one of a stiffened tubular and a stiffened plate modified using automation within the production facility, a yard assembly area proximate the production facility, wherein the modular components are assembled to form a portion of the offshore structure, and a load out barge operable to deliver the portion of the offshore structure to an offshore installation site.
  • Some methods for producing an offshore structure include identifying modular components that are manufacturable substantially using automation, developing a design for the offshore structure, the design incorporating a plurality of the modular components, fabricating the modular components within a production facility positioned proximate a load out barge, and transporting the modular components on the load out barge to an offshore installation site.
  • the embodiments of the invention comprise a combination of features and advantages that enable substantial enhancement of production systems and associated methods for offshore structures.
  • Figure 1 is a schematic representation of a production system in accordance with the principles disclosed herein;
  • Figure 2 depicts a stiffened tubular column and a deck fabricated by the production system of Figure 1;
  • FIG. 3 is a schematic representation of another embodiment of a production system in accordance with the principles disclosed herein;
  • Figure 4 depicts rolling of joined plate members in line 132 of Figure 3;
  • Figure 5 depicts a T-beam fabricated by either line 134 or line 136 of Figure 3;
  • Figure 6 depicts a portion of the deck fabricated by line 138 of Figure 3;
  • Figures 7 and 8 illustrate assembly of a stiffened tubular column;
  • Figure 9 illustrates assembly of the deck;
  • Figures 1OA and 1OB depict a stiffened plate member which may be fabricated by the production system of Figure 3;
  • FIG. 11 is a schematic representation of another embodiment of a production system in accordance with the principles disclosed herein;
  • Figures 12A and 12B depict an embodiment of the production system of Figure 11, wherein modular pontoons are fabricated and assembled to form a hull of an offshore platform;
  • Figure 13 depicts an embodiment of the production system of Figure 11, wherein the mechanized production facility is land-based, rather than on a barge;
  • Figures 14A and 14B depict an embodiment of the production system of Figure 11, wherein modular spacer barges are fabricated and assembled with pontoons to form a transport barge;
  • Figure 15 depicts an embodiment of the production system of Figure 11, wherein modular tubular members are fabricated and assembled to form buoyancy cans of an offshore platform;
  • Figure 16 depicts the load out barge of Figure 11 transporting an offshore platform
  • Figure 17 depicts the load out barge of Figure 11 transporting a topside for an offshore platform
  • Figure 18 depicts floatover installation of the topside of Figure 17 using the load out barge of Figure 11.
  • Production system 100 includes a production facility 105 that may be land-based or installed on a vessel, such as a barge.
  • Production facility 105 receives raw material(s) and/or components formed of raw material(s) 110 and modifies the raw materials/components 110 received to produce modular components, or modules, 115 which are subseqiiently assembled to form, or assembled with other equipment to form, a portion of an offshore structure, such as but not limited to a fixed or floating platform or vessel.
  • Raw materials/components 105 includes tubulars and plates.
  • modules 115 such as but not limited to tubular structures for a cell or column in a spar, a buoyancy can or suction pile for a platform, or a stiffened plate structure for a pontoon, truss member for a topside, or topside deck.
  • Production facility 105 has a manufacturing layout 120 within a receiving end 125 and a delivery end 130.
  • Receiving end 125 and delivery end 130 can be situated anywhere with respect to one another in production facility 105.
  • receiving end 125 and delivery end 130 can be adjacent one another or opposite one another as illustrated.
  • Raw materials/components 105 are input to production facility 105 at receiving end 125.
  • Modules 115 produced by facility 105 are output from facility 105 at delivery end 130.
  • the spatial requirements for manufacturing layout 120 are determined by the installed location of facility 105.
  • production facility 105 may be installed on a production vessel or barge, enabling production facility 105 to be relocatable.
  • Manufacturing layout 120 includes one or more fabrication or assembly lines 140, each line 140 having one or more stations 150 disposed therein.
  • layout 120 further includes one or more storage containers 152 for storing tools, replacement parts, and/or other devices useful for maintaining operation of lines 140.
  • Each station 150 receives an input 155, modifies that input 155 in some manner, and delivers an output 160. If a particular station 150 is positioned proximate receiving end 125 of facility 105, input 155 is raw material(s)/component(s) 110.
  • input 150 is output 160 from an adjacent or nearby station 150.
  • station 150 modifies input 155, such as by but not limited to cutting, bending, heating, repositioning, coating, painting, joining with another input 155 by welding for example, and/or assembly with another input 155.
  • output 160 is then delivered from station 150 to another station 150 or from facility 105 through delivery end 130.
  • Input 155 may be received and output 160 delivered by station 150 via automated means, such as by conveyor belt or gantry, or by manual means, such as by one or more human technicians. Modification of input 155 by station 150 may be via automated means, such as by one or more gantries configured to lift, weld, cut, set, or perform another task, via skilled technicians, or a combination thereof. Preferably, all tasks performed by station 150 are automated or mechanized to minimize the use of human labor. This enables high-volume, repeatable, and continuous production of modules 115 by facility 105, which, in turn, enables faster production of offshore structures at reduced expense, as compared to conventional production systems and methods.
  • Manufacturing layout 120 is flexible.
  • Each line 140 and stations 150 disposed therein are arranged such that facility 105 modifies raw material(s)/component(s) 110 in a systematic and efficient manner to produce modules 115.
  • One or more of lines 140 may extend such that the direction of work flow within the line, defined by arrows extending betweens stations 150 in the line, is parallel to or in series with another line 140.
  • lines 132, 134, 136, and 138 are in parallel, while line 133 is in series with parallel lines 132, 134, 136, 138.
  • tasks performed by stations 150 of lines 132, 134, 136, and 138 preferably occur at least to some degree simultaneously.
  • production facility 105 is operable to mass produce stiffened tubular members 117 using a plurality of plate members 116, stiffeners 112, and girders 114.
  • raw material/components 110 provided to facility 105 are plate members 116, stiffeners 112, and girders 114, and modular components 115 produced by facility 105 are stiffened tubular members 117.
  • stiffened tubular members 117 may form a portion of a cell for a cellular spar, a column for an offshore platform, and/or a buoyancy can for an offshore platform.
  • Each stiffened tubular member 117 includes one or more stiffened tubular columns 200 joined end to end and a deck 205 coupled thereto.
  • stiffened tubular columns 200 and decks 205 are modular subcomponents of stiffened tubular member 117. Turning briefly to Figure 2, two tubular columns 200 joined end to end and one deck portion 205 are shown.
  • lines 132, 134, 136, 138 are pre-fabrication lines operable to produce or fabricate various parts or subassemblies 123 which are subsequently joined at station 215.
  • Station 215 is an automated fabrication and assembly station that receives components/subassemblies 123 and joins them to form modular subcomponents 121, which in this embodiment, are tubular columns 200 and decks 205.
  • Station 215 is reconfigurable depending on the type of modular component 115 to be produced by facility 105.
  • Stations 240 downstream of station 215 are assembly stations wherein modular subcomponents 121 are joined to form modular components 115, which as previously stated are stiffened tubular members 117 in this embodiment.
  • Lines 132, 134, 136 are operable to fabricate portions of tubular columns 200, and line 138 is operable to fabricate portions of deck 205.
  • plate members 116 are received by station 150 proximate receiving end 125 of production facility 150.
  • plate members 116 are rolled to form a quarter panel 210, as illustrated by Figure 4.
  • quarter panels 210 are then output to an automated assembly and welding station 215 proximate the end of line 132.
  • each T-beam 220 includes a plurality of plate members 116 joined end to end by welding to form a web 225. Another plurality of plate members 116 are rolled and then welded to web 225 to form a flanged portion 230. Together, web 225 and flanged portion 230 form the T-beam 220.
  • Lines 134, 136 deliver T-beams 220 to station 215.
  • line 138 receives plate members 116, stiffeners 112, and girders 114.
  • Line 138 cuts stiffeners 112 to appropriate lengths, as needed, and welds each stiffener 112 to a circular plate member 116.
  • Line 138 then positions girders 114 over and extending substantially normally to stiffeners 112 and welded to circulate plate 116.
  • This assembly 235 shown in Figure 6, is then delivered to station 215.
  • tubular columns 200 and decks 205 are formed. Specifically, two T- beams 220 and four quarter panels 210 are assembled and joined through welding to form each tubular column 200, as illustrated by Figures 7 and 8. Also, one T-beam and four quarter panels 210 are assembled about and joined to assembly 235 to form each deck 205, as illustrated by Figure 9. Although only one quarter panels 210 is shown in Figure 9, three additional quarter panels 210 are also joined to assembly 235 and T-beam 220 to complete deck 205. A completed deck 205 is shown in Figure 2. Upon their completion, tubular columns 200 and decks 205 are delivered from station 215 to one or more assembly stations 240.
  • stiffened tubular member 117 is delivered from production facility 105 through delivery end 130.
  • line 132 is depicted as including three stations 150, line 132 may have fewer or more stations 150 than shown, wherein tasks necessary to form quarter portions 210 are combined or distributed, as needed.
  • lines 140 of production facility 105 including lines 133, 134, 136, 138.
  • the tasks performed within each line 140 may be executed in varied order.
  • plate members 116 may be rolled and welded end to end to form flanged portion 230, and additional plate members 116 then welded to flanged portion 230 to form web 225, rather than web 225 formed initially and plate members 116 subsequently welded thereto to form flanged portion 230 as described above.
  • production facility 105 is operable to combine plate members 116, stiffeners 112, and girders 114 to from stiffened tubular members 117.
  • production facility 105 may be reconfigured to produce other types of modular components 115 using many of the same, preferably automated, processes.
  • production facility 105 may be configured to mass produce stiffened plate members 119, illustrated in Figures 1OA and 1OB. As will be shown and described, stiffened plate members 119 may form a portion of a pontoon for an offshore platform.
  • stiffened plate member 119 may be formed using substantially the same raw materials/components 110, meaning a plurality of plate members 116, stiffeners 112, and girders 114, albeit assembled and joined in a different arrangement than that of stiffened tubular members 117 previously described.
  • stiffened plate members 119 may be formed using many of the same processes described above with respect to lines 132, 133, 134, 136, 138.
  • production system 100 further includes a yard assembly area 300 and a load out barge 305.
  • Facility 105 whether land-based or on a barge, is preferably positioned adjacent yard assembly area 300.
  • load out barge 305 is preferably docked adjacent yard assembly area 300.
  • yard assembly area 300 includes a module assembly area 310 and a stacking area 315.
  • Modules 115 produced by facility 105 are delivered from facility 105 preferably by skids to yard assembly 300 where modules 115 are, if necessary, assembled in area 310 to form, or assembled in area 310 with other components and/or equipment to form, a portion of an offshore structure.
  • FIGS 12A and 12B illustrate an embodiment of production system 100, wherein modular pontoons 400 are fabricated and assembled by production facility 105. Modular pontoons 400 are formed essentially of stiffened plate members 119. Upon delivery from facility 105, pontoons 400 are assembled on skids 405 within yard assembly area 300 using a crane 410, as needed, to form a hull 415 for an offshore platform. Hull 415 is delivered by skids 405 to load out barge 305 for transport to the installation site of the offshore platform.
  • production facility 105 is located on a production barge 420 (Fig. 12A).
  • Figure 13 an embodiment of production system 100 is shown, wherein production facility 105 is land-based. In such embodiments, it is preferable to position facility 105 proximate water so that modules 115 produced by facility 105 may be assembled and then transported via load out barge 305 to their offshore installation site.
  • Figures 14A and 14B illustrate an embodiment of production system 100, wherein modular spacer barges 500 are fabricated and assembled by production facility 105. In this embodiment, production facility 105 is disposed on a production barge 525. Like pontoons 300 previously described, modular spacer barges 500 are formed essentially of stiffened plate members 119.
  • spacer barges 500 are delivered by skids 505 to one or more pontoons 515 within yard assembly area 300 and assembled with pontoons 515 using crane 510, again as needed, to form a transport barge 520.
  • Transport barge 520 is delivered by skids 505 to the edge of a dock, where barge 520 is launched.
  • transport barge 520 is a load out barge 305.
  • Figure 15 illustrates an embodiment of production system 100, wherein stiffened tubular members 117 are fabricated and assembled to form a plurality of buoyancy cans 600 for an offshore platform.
  • stiffened tubular members 117 are assembled within yard assembly area 300 to form buoyancy cans 600 and then buoyancy cans 600 are delivered by skids 610 to an assembled hull 615 and installed thereon using crane 620, as needed.
  • Hull 615 with buoyancy cans 600 coupled thereto is delivered via skids 610 to load out barge 305 for transport to its offshore installation site.
  • load out barge 305 is reconfigurable and submersible.
  • barge 305 includes two pontoons 700 with a plurality of pontoon members 705 connected therebetween.
  • Pontoon members 705 have a width 710 and a length 715 exceeding their width 710.
  • Pontoon members 705 may be connected between pontoons 700 such that the length 715 of each extends substantially normally between pontoons 700, as shown in Figure 16, or such that the width 710 of each extends substantially normally between pontoons 700, as shown in Figure 17.
  • topside 730 Floatover installation of topside 730 is possible because barge 305 has been configured such that its width 720 is less than the distance between columns 740 of platform 735. Once positioned over platform 735, barge 305 may be submerged to land topside 730 on platform 735 to complete the installation process.
  • production facility 105 is preferably automated to minimize the use of human labor in the production of modules 115.
  • This enables high- volume, repeated, and continuous production of modules 115, which in turn, reduces the time and associated cost for building offshore structures formed from such modules 115.
  • modules 115 formed from one or more basic or elementary shapes, such as a tubular and/or plate lend themselves to automated fabrication.
  • the offshore structure In further reduce the time and associated cost for building the offshore structure, it is preferable to design the offshore structure in such as way as to maximize the use of modules 115 produced by facility 105 and to minimize the use of components that cannot be fabricated using automated means. In this way, manufacturing of the offshore structure is not design driven. Rather, the opposite is true - that the design of the offshore structure is driven by manufacturing.
  • the types of modules 115 which may be produced by facility 105 given the constraints of its manufacturing layout 120 are initially identified. The design of the offshore structure is then developed based on a maximized use of the identified types of modules 115.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • Ocean & Marine Engineering (AREA)
  • Robotics (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Revetment (AREA)

Abstract

L’invention concerne des systèmes de production et des procédés associés. Selon certains modes de réalisation, le système de production comprend une barge de production et une installation de production montée sur ladite barge. L’installation de production peut fonctionner pour produire une pluralité de composants modulaires utiles pour la construction d’une structure en mer, les composants modulaires comprenant au moins une plaque rigide et/ou un élément tubulaire rigide.
PCT/US2009/056687 2008-09-11 2009-09-11 Système et procédé pour une installation de production haut volume d’éléments modulaires en eau profonde WO2010030901A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US9617408P 2008-09-11 2008-09-11
US61/096,174 2008-09-11

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WO2010030901A2 true WO2010030901A2 (fr) 2010-03-18
WO2010030901A3 WO2010030901A3 (fr) 2010-06-17

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US (1) US20100074691A1 (fr)
WO (1) WO2010030901A2 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL2028601A (en) * 2020-12-31 2022-07-21 Cosco Shipping Shipyard Nangtong Co Ltd A construction method for a main propulsor bsea of a deep-water dynamic positioning crude oil cargo transfer vessel

Families Citing this family (2)

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Publication number Priority date Publication date Assignee Title
US8070389B2 (en) * 2009-06-11 2011-12-06 Technip France Modular topsides system and method having dual installation capabilities for offshore structures
US10302068B2 (en) * 2016-10-31 2019-05-28 Zentech, Inc. Conversion of movable offshore drilling structure to wind turbine application

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US3962981A (en) * 1975-01-20 1976-06-15 Shoreline Precast Company Barge factory
KR100543690B1 (ko) * 2004-11-02 2006-01-23 (주) 선암기술연구소 스틸박스를 이용한 조립식 선박

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL2028601A (en) * 2020-12-31 2022-07-21 Cosco Shipping Shipyard Nangtong Co Ltd A construction method for a main propulsor bsea of a deep-water dynamic positioning crude oil cargo transfer vessel

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Publication number Publication date
WO2010030901A3 (fr) 2010-06-17
US20100074691A1 (en) 2010-03-25

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