U.S. patent application number 12/163176 was filed with the patent office on 2009-01-15 for system and method for coupling a topside to a floating substructure.
This patent application is currently assigned to Horton Technologies, LLC. Invention is credited to Richard L. Davies, Lyle David Finn, James V. Maher, Edmund Muehlner.
Application Number | 20090016822 12/163176 |
Document ID | / |
Family ID | 40160722 |
Filed Date | 2009-01-15 |
United States Patent
Application |
20090016822 |
Kind Code |
A1 |
Maher; James V. ; et
al. |
January 15, 2009 |
System and Method for Coupling a Topside to a Floating
Substructure
Abstract
Systems and methods for coupling a topside to a fixed or
floating substructure during float-over installation of the topside
are disclosed. Some system embodiments include a first plate
coupled to a leg of the substructure and a retaining wall coupled
to the first plate and extending substantially normally therefrom,
wherein the retaining wall and the first plate form a recess. The
system embodiments further include a second plate disposed at an
end of a leg of the topside, the second plate received within the
recess and engaging the first plate, and a plurality of shims
disposed between the second plate and the retaining wall, wherein
the plurality of shims are configured to inhibit translational
movement of the second plate relative to the first plate.
Inventors: |
Maher; James V.; (Houston,
TX) ; Finn; Lyle David; (Sugarland, TX) ;
Muehlner; Edmund; (Houston, TX) ; Davies; Richard
L.; (Houston, TX) |
Correspondence
Address: |
CONLEY ROSE, P.C.;David A. Rose
P. O. BOX 3267
HOUSTON
TX
77253-3267
US
|
Assignee: |
Horton Technologies, LLC
Houston
TX
|
Family ID: |
40160722 |
Appl. No.: |
12/163176 |
Filed: |
June 27, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60946647 |
Jun 27, 2007 |
|
|
|
Current U.S.
Class: |
405/205 |
Current CPC
Class: |
E02B 17/04 20130101 |
Class at
Publication: |
405/205 |
International
Class: |
E02D 23/02 20060101
E02D023/02 |
Claims
1. A system for coupling a topside to a substructure during
float-over installation of the topside, the system comprising: a
first plate coupled to a leg of the substructure; a retaining wall
coupled to the first plate and extending substantially normally
therefrom, wherein the retaining wall and the first plate form a
recess; and a second plate disposed at an end of a leg of the
topside, the second plate received within the recess and engaging
the first plate.
2. The system of claim 1, wherein the second plate is annular.
3. The system of claim 1, wherein the second plate has a lower
surface in contact with the first plate and wherein the topside leg
has a cross-section substantially parallel to the second plate,
wherein the lower surface in contact with the first plate has an
area greater than the area of the cross-section.
4. The system of claim 1, further comprising a plurality of shims
disposed between the second plate and the retaining wall, wherein
the plurality of shims are configured to inhibit translational
movement of the second plate relative to the first plate.
5. The system of claim 4, wherein the plurality of shims comprises:
a first plurality of inner shims, each inner shim positioned
adjacent the second plate; and an equal number of outer shims, each
outer shim positioned between one of the first plurality of inner
shims and the retaining wall.
6. The system of claim 5, wherein each inner shim comprises an
outer surface in contact with an inner surface of the adjacent
outer shim, wherein the outer surface of each inner shim and the
inner surface of each outer shim are configured to resist
translational movement relative to one another.
7. The system of claim 6, wherein the inner surface of each outer
shim and the outer surface of each adjacent inner shim are
tapered.
8. The system of claim 4, further comprising a coating layer
covering the plurality of shims.
9. The system of claim 8, wherein the coating layer comprises one
of the group consisting of epoxy resin and tar.
10. The system of claim 1, further comprising a hardenable material
layer disposed between the retaining wall and the second plate.
11. The system of claim 10, wherein the hardenable material layer
comprises one of the group consisting of epoxy resin and gout.
12. The system of claim 1, wherein the retaining wall is
circular.
13. The system of claim 1, further comprising a plurality of gusset
plates disposed circumferentially around the retaining wall and
extending substantially normally therefrom, wherein each gusset
plate is coupled to the retaining wall and the first plate.
14. The system of claim 1, further comprising a plurality of gusset
plates disposed circumferentially around the leg of the
substructure and extending substantially normally therefrom,
wherein each gusset plate is coupled to the leg of the substructure
and the first plate.
15. A system for coupling a topside to a substructure during
float-over installation of the topside, the system comprising: a
coupling system comprising: a solid plate coupled to a leg of the
substructure; a retaining wall coupled to the solid plate and
extending substantially normally therefrom, wherein the retaining
wall and the solid plate form a recess; and an annular plate
disposed at an end of a leg of the topside, the annular plate
received within the recess and engaging the solid plate; and a
tensioning system comprising: a connector coupled to the solid
plate; a support plate coupled to the topside; a rod extending
between the connector and the support plate; and a securing device
coupled to an end of the rod, the securing device configured to
apply a tension load to the rod.
16. The system of claim 15, wherein the connector is coupled to the
solid plate and disposed within the annular plate.
17. The system of claim 15, wherein the annular plate has a lower
surface in contact with the solid plate and wherein the topside leg
has a cross-section substantially parallel to the annular plate,
wherein the lower surface in contact with the solid plate has an
area greater than the area of the cross-section.
18. The system of claim 15, further comprising a plurality of shims
disposed between the second plate and the retaining wall, wherein
the plurality of shims are configured to inhibit translational
movement of the annular plate relative to the solid plate.
19. The system of claim 18, wherein the plurality of shims
comprises: a first plurality of inner shims, each inner shim
positioned adjacent the second plate; and an equal number of outer
shims, each outer shim positioned between one of the first
plurality of inner shims and the retaining wall; wherein each inner
shim comprises an outer surface in contact with an inner surface of
the adjacent outer shim, wherein the outer surface of each inner
shim and the inner surface of each outer shim are configured to
resist translational movement relative to one another.
20. The system of claim 15, further comprising a hardenable
material layer disposed between the retaining wall and the annular
plate.
21. The system of claim 15, further comprising a plurality of
gusset plates disposed circumferentially around the retaining wall
and extending substantially normally therefrom, wherein each gusset
plate is coupled to the retaining wall and the first plate.
22. The system of claim 15, further comprising a plurality of
gusset plates disposed circumferentially around the leg of the
substructure and extending substantially normally therefrom,
wherein each gusset plate is coupled to the leg of the substructure
and the first plate.
23. The system of claim 15, further comprising a coating layer
covering the plurality of shims.
24. A method for coupling a topside to a substructure during
float-over installation of the topside, the method comprising:
coupling a receptacle to a leg of the substructure, the receptacle
comprising: a first plate coupled to the leg of the substructure;
and a retaining wall coupled to the first plate, the retaining wall
extending substantially normally therefrom; wherein the retaining
wall and the first plate form a recess; disposing a second plate at
an end of a leg of the topside; and receiving the second plate
within the recess, wherein the second plate engages the first
plate.
25. The method of claim 24, further comprising installing a
plurality of shims between the second plate and the retaining wall,
wherein the plurality of shims are configured to inhibit
translational movement of the second plate relative to the first
plate.
26. The method of claim 25, further comprising covering the
plurality of shims with a coating layer.
27. The method of claim 24, wherein the receiving comprises
deballasting the substructure to position the second plate within
the recess and in engagement with the first plate.
28. The method of claim 24, further comprising coupling a first
plurality of gusset plate between an outer surface of the retaining
wall and the first plate and coupling a second plurality of gusset
plates between an outer surface of the leg of the substructure and
the first plate.
29. The method of claim 24, further comprising applying a
hardenable material layer between the retaining wall and the second
plate.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. provisional
application Ser. No. 60/946,647 filed Jun. 27, 2007, and entitled
"Big Foot and Docking Probe," which is hereby incorporated herein
by reference in its entirety for all purposes.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] Embodiments of the invention relate to systems and methods
for installing a topside or deck on a substructure to form a fixed
or floating offshore platform. More particularly, embodiments of
the invention relate to a novel system and method for coupling the
topside with the substructure during float-over installation of the
topside.
[0004] Float-over installations offer opportunities to install
heavy topsides beyond the lifting capacity of available crane
vessels on offshore substructures located in remote areas. A
float-over installation includes four primary procedures. The first
procedure involves transporting the topside or deck to the offshore
substructure. Typically, the topside is placed on a barge or heavy
transport vessel and towed to the substructure.
[0005] The second procedure involves docking the transport barge to
the installed substructure. The barge is maneuvered into the slot
of the substructure, such that the topside is floated over and
substantially aligned with the substructure. Once in the slot,
mooring lines, sometimes in combination with a fendering system,
are utilized to suppress surge and sway motions of the barge. After
the mooring lines are set, deballasting of the substructure
commences.
[0006] The third procedure involves transferring the load of the
topside from the barge to the substructure, and is a critical phase
of the float-over installation. Deballasting of the substructure
continues as the substructure rises toward the topside. Once the
topside and the substructure reach close proximity, the two bodies
may impact each other repeatedly due to wave action. Such impacts
may damage the structures when the relative motion between the two
bodies is not controlled. As deballasting of the substructure
continues, the weight of the topside is gradually transferred from
the barge to the substructure. After a critical fraction of the
weight is transferred, the relative motion between the two bodies
ceases. At that point, the two structures move as a single unit,
and the possibility of damage due to hard impact is eliminated.
Therefore, it is desirable to complete the load transfer up to the
critical fraction as quickly as possible.
[0007] After the topside is fully supported by the substructure,
the legs of the two structures are coupled by welding legs
extending downward from the topside to legs extending upward from
the substructure. To achieve the high quality welds required to
withstand the harsh load regimes of offshore environments, proper
alignment of the topside with the substructure during the
float-over operation is critical.
[0008] The final procedure involves separating the barge from the
topside, and is also a critical phase of the float-over
installation. The substructure is deballasted further until the
topside separates from the barge. At and immediately after
separation, the relative motions between barge and topside pose a
danger of damage due to impact between these bodies. That danger
can be minimized by rapid separation of the barge and the topside.
To promote such rapid separation, the topside may be supported on
the barge by a number of loadout shoes. At the appropriate time,
the loadout shoes are actuated to quickly collapse or retract,
thereby providing rapid separation between the barge and the
topside. These systems, however, have a propensity to malfunction
and permit hard contact between the loadout shoes and the topside.
In any event, hard contact between the barge and the topside may
continue until the substructure is deballasted to provide
sufficient separation between the barge and the topside. After
which point, the barge is towed from the installation site.
[0009] Thus, embodiments of the invention are directed to apparatus
and methods that seek to overcome these and other limitations of
the prior art.
SUMMARY OF THE PREFERRED EMBODIMENTS
[0010] A system and method for coupling a topside to a fixed or
floating substructure during float-over installation of the topside
are disclosed. Some systems embodiments include a first plate
coupled to a leg of the substructure, a retaining wall coupled to
the first plate, and a second plate disposed at an end of a leg of
the topside. The retaining wall extends substantially normally from
the first plate, such that the retaining wall and the first plate
form a recess. The second plate is received within the recess and
engages the first plate. The system embodiments may further include
a plurality of shims disposed between the second plate and the
retaining wall, wherein the shims are configured to inhibit
translational movement of the second plate relative to the first
plate.
[0011] The system embodiments may further include a tensioning
system. The tensioning system includes a connector coupled to the
first plate and disposed within the second plate, wherein the
second plate is annular. The tensioning member further includes a
support plate coupled to the topside, a rod extending between the
connector and the support plate, and a securing device coupled to
an end of the rod. The securing device is configured to apply a
tension load to the rod.
[0012] Some method embodiments for coupling a topside to a fixed or
floating substructure during float-over installation of the topside
include coupling a receptacle to a leg of the substructure. The
receptacle includes a first plate coupled to the leg of the
substructure and a retaining wall coupled to the first plate. The
retaining wall extends substantially normally from the first plate,
wherein the retaining wall and the first plate form a recess. The
method embodiments further include disposing a second plate at an
end of a leg of the topside, receiving the second plate within the
recess, wherein the second plate engages the first plate, and
installing a plurality of shims between the second plate and the
retaining wall. The plurality of shims are configured to inhibit
translational movement of the second plate relative to the first
plate.
[0013] Thus, the embodiments of the invention comprise a
combination of features and advantages that enable substantial
enhancement of float-over installation systems and methods. These
and various other characteristics and advantages of the invention
will be readily apparent to those skilled in the art upon reading
the following detailed description of the preferred embodiments of
the invention and by referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] For a detailed description of the preferred embodiments of
the invention, reference will now be made to the accompanying
drawings in which:
[0015] FIGS. 1A and 1B are cross-sectional and top views of
weldless topside coupling system in accordance with embodiments of
the invention;
[0016] FIG. 2 is a cross-sectional view of an installed
substructure including some components of the coupling system of
FIG. 1;
[0017] FIG. 3 is a cross-sectional view of a topside including the
remaining components of the coupling system of FIG. 1 floated over
the substructure of FIG. 2;
[0018] FIG. 4 is a cross-sectional view of a tensioning member
coupled between a topside and a substructure; and
[0019] FIG. 5 is a cross-sectional view of a weldless coupling
system and tensioning member coupled between the topside and the
substructure of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Various embodiments of the invention will now be described
with reference to the accompanying drawings, wherein like reference
numerals are used for like parts throughout the several views. The
drawing figures are not necessarily to scale. Certain features of
the invention may be shown exaggerated in scale or in somewhat
schematic form, and some details of conventional elements may not
be shown in the interest of clarity and conciseness.
[0021] Preferred embodiments of the invention relate to a weldless
system and method for coupling a topside with an installed
substructure to form a fixed or floating platform. The invention is
susceptible to embodiments of different forms. There are shown in
the drawings, and herein will be described in detail, specific
embodiments of the invention with the understanding that the
disclosure is to be considered an exemplification of the principles
of the invention and is not intended to limit the invention to that
illustrated and described herein. It is to be fully recognized that
the different teachings of the embodiments discussed below may be
employed separately or in any suitable combination to produce
desired results.
[0022] As described above during a conventional float-over
installation of a topside on an installed substructure, the topside
is floated over and substantially aligned with the substructure
using a barge. The substructure is then deballasted to engage and
lift the topside from the barge, thereby assembling the fixed or
floating platform. The topside is then coupled to the substructure
by welding. Embodiments of the invention are directed to a system
and method for coupling the topside to the substructure without the
need for precise alignment of the topside relative to the
substructure and subsequent welding.
[0023] FIGS. 1A and 1B depict representative cross-sectional and
top views, respectively, of a topside or deck installed via
float-over on a representative cross-section of a substructure 105
for a semi-submersible offshore platform, such as a multicolumn
floating (MCF) platform. More specifically, a leg 110 of the
topside is shown coupled to a leg 115 of the substructure by a
weldless topside coupling system 120. Coupling system 120 includes
an annular plate 125 disposed at the lower end 130 of leg 110. In
this exemplary embodiment, plate 125 is formed separately from leg
110 and then coupled to leg 110 as shown. In other embodiments,
however, plate 125 may be formed integrally with leg 110. After the
topside is landed on the substructure, as shown, leg 115 of the
substructure supports leg 110 of the topside. By disposing annular
plate 125 at end 130 of leg 110, the area or footprint of leg 110
in contact with leg 115 is significantly increased, in comparison
to the footprint of leg 110 that would otherwise contact leg 115 in
the absence of plate 125. Because annular plate 125 increases the
footprint of leg 110, annular plate 125 is also referred to the big
foot.
[0024] Weldless coupling system 120 further includes a receptacle
or bucket 135 disposed at the upper end 140 of leg 115. Bucket 135
includes a base plate 145 having an upper surface 155 and a
retaining wall 150 coupled thereto. Retaining wall 150 extends
substantially normally upward from upper surface 155. As shown in
FIG. 1B, retaining wall 150 is generally circular in shape.
Further, the inner envelope of retaining wall 150 is selected such
that annular plate 125 may be received therein.
[0025] For additional support, one or more small gusset plates 160
are coupled to bucket 135 between upper surface 155 of base plate
145 and the outer surface 165 of retaining wall 150. Plates 160
provide support to retaining wall 150 when lateral force is applied
to the inner surface 170 of wall 150, where the lateral direction
is substantially parallel to base plate 145. Also for additional
support, one or more large gusset plates 175 are coupled to bucket
135 between the lower surface 180 of base plate 145 and the outer
surface 185 of leg 115. Plates 175 provide support to base plate
145 when an asymmetric vertical load, defined relative to a
longitudinal centerline 190 through leg 115, is applied to upper
surface 155 of base plate 145.
[0026] In some embodiments, weldless coupling system 120 further
includes two or more pairs of tapered or wedge-shaped shims 200
disposed on upper surface 155 of base plate 145 between the outer
surface 205 of plate 125 and inner surface 170 of retaining wall
150. When installed, shims 200 prevent translational movement of
plate 125 relative to base plate 145, and thus lateral movement of
leg 110 relative to leg 115. In at least some embodiments, shims
200 are formed of steel. Each pair of shims 200 comprises an inner
shim 210 proximate plate 125 and an adjacent outer shim 215
proximate retaining wall 150. The adjacent surfaces of inner shim
210 and outer shim 215 form a non-slip taper 220 configured to
prevent sliding of shims 210, 215 relative to each other.
[0027] Weldless coupling system 120 may further include a coating
225 disposed between retaining wall 150 and plate 125 and covering
shims 200. Coating 225 is configured to prevent corrosion of shims
200 and potential slippage of inner shims 210 relative to outer
shims 215. Coating 225 may include an epoxy resin material, such as
chalk-fast, tar, or other equivalent material known in the art.
[0028] Alternatively, weldless coupling system 120 may include a
hardenable material 455 (FIG. 5) in place of shims 200 and coating
layer 225, if present. Hardenable material 455 is disposed within
bucket 135 surrounding and covering plate 125. Further, hardenable
material 455 is applied in liquid form but subsequently hardens
into solid form. Like shims 200, material 455, once hardened,
prevents slippage of plate 125 relative to base plate 145, and thus
lateral movement of leg 110 relative to leg 115. Hardenable
material 455 may include a grout, epoxy resin, or other equivalent
material.
[0029] With the exception of shims 200, coating layer 225 and
hardenable material 455, components of docking system 110 are
coupled to leg 110 of the topside or leg 115 of the substructure,
as appropriate, prior to transport of the topside and the
substructure to the desired offshore installation site. Bucket 135
and plates 160, 175 are coupled to leg 115 of the substructure, for
example, by welding. Similarly, annular plate 125, if formed
separately from leg 110, is coupled to leg 110, for example, by
welding.
[0030] The substructure, with leg 115 and components of weldless
coupling system 120 coupled thereto, is then towed to the
installation site, as shown in FIG. 2. Upon reaching the
installation site, the substructure 105 is ballasted to the desired
depth. The topside 100, with leg 110 and components of weldless
coupling system 120 coupled thereto, is next towed to and floated
over substructure 105 by a barge 107, as previously described and
shown in FIG. 3.
[0031] After topside 100 is aligned over substructure 105,
substructure 105 is deballasted to engage topside 100. More
particularly, substructure 105 is deballasted to allow bucket 135,
coupled to upper end 140 of leg 115, to receive annular plate 125,
coupled to lower end 130 of leg 110, such that plate 125 lands on
upper surface 155 of base plate 145 within retaining wall 150, as
shown in FIG. 1A. Continued deballasting of substructure 105
enables load transfer of topside 100 from barge 107 to substructure
105. In other words, substructure 105 begins to lift topside 100
from barge 107.
[0032] When the load of topside 100 is completely supported by
substructure 105, shims 200 may then hammered into position between
annular plate 120 and retaining wall 150. Once installed, shims 200
prevent subsequent sliding of plate 125, and leg 110 coupled
thereto, relative to bucket 135, and leg 115 coupled thereto.
Lateral loads exerted by leg 110 in response to the surrounding
water are instead transferred through shims 200 to retaining wall
150, which resists these loads with support from gusset plates 160.
If desired, coating 225 is then applied between plate 125 and
retaining wall 150 to cover shims 200. Alternatively, hardenable
material 455 may be applied to fill bucket 135 and cover plate 125
and allowed to harden. Finally, barge 107 is released from topside
100.
[0033] Weldless coupling system 120 does not require welding to
couple the topside to the substructure. Analysis has shown that
welding is unnecessary because the dynamic motions of the
substructure, even during expected hurricane conditions, will not
cause plate 125 to separate or lift off of bucket 135 due to the
weight of installed topside 100. Further, when weldless coupling
system 120 is utilized to couple a topside to a substructure,
precise alignment of the topside prior to deballasting the
substructure to engage and lift the topside is also unnecessary for
a number of reasons. For one, the topside will not be welded to the
substructure once engaged. Also, bucket 135 provides a
significantly increased area upon which leg 110 may land, relative
to that available during conventional float-over procedures in the
absence of coupling system 120. Thus, the topside may be misaligned
to a degree and leg 110 will still land within the inner envelope
of bucket 135 as the substructure is deballasted. Further, the
structural integrity of base plate 145 in combination with support
from gusset plates 175 is capable of supporting leg 110 with
annular plate 125 coupled thereto of withstanding asymmetric
vertical loading, such as those resulting when leg 110 lands within
bucket 135 off-center of centerline 190 of leg 115. Similarly,
annular plate 125 is also capable of withstanding asymmetric
vertical loading resulting from off-center engagement of plate 125
with bucket 135.
[0034] If desired, weldless coupling system 120 may be supplemented
with a positive tie-down means coupled between topside 100 and
substructure 105 in case of an unforeseen extreme event, such as an
atypical hurricane or an earthquake. For example, and referring now
to FIG. 4, one or more tensioning members 400 may be coupled
between topside 100 and substructure 105, as shown. Tensioning
member 400 includes a support plate 405, a connector 410 and a tie
rod 415 extending therebetween. Support plate 405 is coupled to an
upper surface 420 of topside 100. Support plate 405 includes a
throughbore 435 configured to receive the upper end 440 of tie rod
415. Connector 410 is coupled to an upper surface 430 of
substructure 105. Tie rod 415 is coupled to connector 410 and
extends upward through throughbore 435 of support plate 405. In
some embodiments, tie rod 415 extends within a deck column member
425, as shown. Upper end 440 of tie rod 415 is coupled to support
plate 405 by a tensioning and securing device 445 seated on plate
405. Device 445 is configured to apply a tension load to tie rod
415.
[0035] Like those of coupling system 120, components of tensioning
member 400 are coupled to topside 100 or substructure 105, as
appropriate, prior to transport of topside 100 and substructure 105
to the desired offshore installation site. After topside 100 is
landed on substructure 105 as described above, meaning leg 110 of
topside 100 with plate 125 thereto is landed within bucket 135
coupled to leg 115 of substructure 105, tie rod 415 is inserted
through throughbore 435 of support plate 405 and lowered to engage
connector 410. Securing and tensioning device 445 is then disposed
over upper end 440 of tie rod 415 and seated on support plate 405.
Device 445 is next operated to apply a tension load to tie rod 415.
Once tie rod 415 is tensioned to the desired load, installation of
tensioning member 400 is complete.
[0036] In some embodiments, tensioning member 400 may be installed
between legs 110, 115 of topside 100 and substructure 105,
respectively, coupled using weldless topside coupling system 120,
shown and described above with reference to FIGS. 1-3. In such
embodiments, connector 410 of tensioning member 400 is coupled to
upper surface 155 of base plate 145 of weldless coupling system
120, as shown in FIG. 5. Also, support plate 405 of tensioning
member 400 is coupled to an upper surface 115 of topside 100 from
which leg 110 extends. Otherwise, the remaining components of
tensioning member 400 are positioned and installed as described
above in reference to FIG. 4.
[0037] While preferred embodiments have been shown and described,
modifications thereof can be made by one skilled in the art without
departing from the scope or teachings herein. The embodiments
described herein are exemplary only and are not limiting. Many
variations and modifications of the systems are possible and are
within the scope of the invention. For example, the relative
dimensions of various parts, the materials from which the various
parts are made, and other parameters can be varied. Accordingly,
the scope of protection is not limited to the embodiments described
herein, but is only limited by the claims that follow, the scope of
which shall include all equivalents of the subject matter of the
claims.
* * * * *