U.S. patent number 3,878,687 [Application Number 05/380,730] was granted by the patent office on 1975-04-22 for grouting of offshore structures.
This patent grant is currently assigned to The Western Company of North America. Invention is credited to Arthur Frank Tragesser, Jr..
United States Patent |
3,878,687 |
Tragesser, Jr. |
April 22, 1975 |
Grouting of offshore structures
Abstract
A method for grouting the annulus between the jacket and piling
in the legs of an offshore structure in which air is introduced to
expel water from the lower end of the annulus, and grouting
material is pumped into the annulus at the bottom, displacing air
upwardly. When sufficient grouting material is introduced to
balance the hydrostatic head of the sea water, the grouting is
allowed to set up. Additional grouting material may then be
introduced from the top.
Inventors: |
Tragesser, Jr.; Arthur Frank
(Houston, TX) |
Assignee: |
The Western Company of North
America (Houston, TX)
|
Family
ID: |
23502244 |
Appl.
No.: |
05/380,730 |
Filed: |
July 19, 1973 |
Current U.S.
Class: |
405/225;
405/227 |
Current CPC
Class: |
E02B
17/0008 (20130101) |
Current International
Class: |
E02B
17/00 (20060101); E02b 017/00 (); E02d
005/64 () |
Field of
Search: |
;61/46,53,52,53.5,53.74 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Shapiro; Jacob
Attorney, Agent or Firm: Robinson; Murray Conley; Ned L.
Rose; David Alan
Claims
I claim:
1. A method of grouting an offshore structure having at least one
supporting leg including a tubular jacket extending downwardly from
above the waterline into the sea bed and a piling driven through
said jacket deeper into the sea bed with an annular space existing
between the inside of the jacket and said piling; said method
comprising the steps of
sealing the upper end of said jacket to said piling so as to close
said annular space at the upper end of the jacket;
introducing compressed air into said annular space under sufficient
pressure to expel substantially all of the water from said space
through the lower end of the jacket;
introducing fluid grouting material into said annular space at a
point adjacent the lower end of the jacket after the water has been
expelled from said space as aforesaid;
simultaneously with the introduction of said grouting material
gradually releasing the air pressure in said annular space at a
rate which will maintain a pressure sufficient to prevent ingress
of water through the lower end of said jacket but insufficient to
force a substantial proportion of the grouting material out of the
lower end of the jacket, whereby the level of the grouting will
rise in the annular space, displacing air upwardly;
stopping the introduction of grouting material when the air
pressure is reduced to substantially atmospheric pressure,
permitting the grouting material to set,
introducing additional grouting material into said annular space at
a point adjacent the upper end of the jacket, and
permitting the additional grouting material to set.
2. Method of grouting an offshore structure having at least one
supporting leg including a tubular jacket extending downwardly from
above the water line into the sea bed and a piling driven through
said jacket deeper into the sea bed with an annular space existing
between the inside of the jacket and said piling, said annular
space being closed at its upper end and open to the sea bed at its
lower end, said method comprising the steps of
introducing compressed air into the upper end of said annular space
under sufficient pressure to force substantially all of the water
in the annular space out the lower end thereof, thereby reaching an
air pressure in said annular space sufficient to overcome the
pressure head of the overlying sea water,
introducing fluid grouting material into said annular space at a
point adjacent the lower end of the jacket after substantially all
of the water has been expelled from said annular space as
aforesaid, said fluid grouting material comprising a first
quick-setting portion and a second portion which sets more slowly,
the amount of said first quick-setting portion being sufficient to
form an annular plug in said annular space below the point of
introduction of said fluid grouting material but being insufficient
to form a plug in said annular space at or above said point of
introduction,
allowing the quick-setting portion to set up,
releasing the air pressure in said annular space,
injecting additional slower setting fluid grouting material at said
lower point sufficient to substantially fill said annular space,
and
allowing said additional grouting material to set.
Description
CROSS-REFERENCE TO RELATED APPLICATION
Part of the disclosure herein relates to subject matter disclosed
in the application of Max Bassett, Ser. No. 358,009, filed May 7,
1973, now abandoned. Such subject matter is the invention of
Bassett, is claimed in his application, and is not claimed
herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the grouting of offshore structures.
2. Description of the Prior Art
Offshore structures have come into increasing use in recent years
to support platforms for drilling of oil and gas wells and for
producing oil and gas from such oil wells. Such structures may be
erected in water from comparatively shallow depths up to several
hundred feet deep. A variety of forms of structure and methods of
construction of such platforms have been utilized. One such method
which has been found to be particularly desirable in deep water is
that which is illustrated, for example, in U.S. Pat. No. 3,209,544
to Borrmann, in which the legs of the structure are fabricated and
assembled on shore. The legs are hollow, and may be sealed to make
the structure buoyant, so that it can be towed out to the desired
offshore location. Valves in the legs are opened to allow flooding
with sea water, so that the leg structure will sink in a vertical
position and settle onto the bottom. As the legs sink they fill
with water up to the water level of the sea. It will be appreciated
that the legs will sink into the ocean bottom a distance dependent
upon the weight of the structure and the softness of the ocean
bed.
A platform which is built only on such legs would have a high
degree of instability, particularly in heavy storms. It has,
therefore, been the practice to more rigidly connect the structure
to the ground by driving hollow steel pilings down through the
legs, which then become jackets for the pilings. When a piling is
dropped down through a jacket, it knocks off the seals closing the
bottom ends of the jackets, so that the jackets tend to sink deeper
into the bottom, and mud and silt from the bottom may enter the
annulus between the piling and the jacket.
When the piling has been fully driven (usually to refusal), it has
been the practice to fill the annulus between the piling and the
jacket with a grouting material which solidifies in place. This not
only increases the rigidity and, therefore, the strength of the
structure, but also helps to keep out water so as to prevent
corrosion of the piling. If the grouting fills the annulus all the
way down to the bottom of the jacket, the piling is protected
through the soft mud of the sea bed.
Various methods have been utilized for grouting such structures.
One method, as shown in the aforesaid Borrmann patent, for example,
requires the use of a seal member at the bottom of the annulus. In
this method the grouting material is pumped into the bottom of the
annulus and rises upwardly therein to the top. This method usually
requires the use of divers, and in addition, it often fails to
produce fully satisfactory results because water cannot be
effectively excluded from the annular space so that the grouting
material becomes diluted and difficult to set.
Evans et al., in U.S. Pat. No. 3,492,824, describe a method
comprising injecting air through a nipple into the top of the
annulus to expel water through a nipple at the bottom of the
annulus, and then injecting grouting material through the bottom
nipple. The grouting material is supposed to rise up through the
annulus to above the water line, displacing air out the top. As a
practical matter such a system would be very unsatisfactory. The
ocean bed is normally soft and porous at the bottom of the jacket
so that as soon as enough grouting material is pumped in to
overcome the hydraulic head of the overlying sea water, the
grouting material would begin to run out the bottom of the jacket
and would be lost. Thus, it would be necessary to utilize some kind
of seal or closure at the bottom of the annulus to hold the
grouting in.
Evans et al. also disclose a method whereby air is injected into
the nipple at the bottom of the annulus to drive the water upwardly
through the annulus out the top. It is apparent that such a system
would be extremely inefficient in expelling water, since the air,
being lighter, will rise up through the water. The same problem of
losing grout out the bottom would also exist in this method.
Blount et al, in their U.S. Pat. No. 3,564,856, disclose another
grouting system in which the grouting material is injected through
nipples at the bottom of the annulus. They use water to wash out
mud from the location of their injection nipples upwardly, but they
make no attempt to remove water or mud from below the injection
point. Furthermore, their annulus is filled with water at the
start, which must be expelled upwardly by the rising grouting
material. Thus a large excess of grouting material would be
necessary in order to insure that all of the water is expelled out
of the top of the annulus.
Olsen and Bassett disclose, in their U.S. Pat. No. 3,601,999, a
system which avoids many of the problems encountered in other
grouting systems. As described in the patent, in this system air is
injected into the top of the annulus under sufficient pressure to
drive the water out the bottom of the annulus, and then grouting
material is injected into the top of the annulus.
SUMMARY OF THE INVENTION
According to the present invention, water is expelled from the
annular space out its lower end by the application of air pressure,
and fluid grouting material is introduced into the lower end of the
annular space while sufficient air pressure is maintained on the
annular space to prevent water from returning, and the grouting
material is allowed to set up in the annular space. By this method
any possibility of air being entrapped in the grouting material and
forming a void in it is avoided, since the grouting material rises
upwardly in the annulus and displaces the air.
Other features of the invention may be best explained in connection
with the accompanying drawing and the following detailed
description.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an elevational view showing a typical installation of an
offshore structure on the sea bed;
FIG. 2 is a semi-schematic view of apparatus suitable for
practicing one embodiment of the method of this invention;
FIG. 3 is an enlarged fragmentary vertical sectional view of one of
the legs of the structure of FIG. 1, showing the method step of
expelling water from the annulus between the jacket and the piling
of the legs;
FIG. 4 is a fragmentary sectional view, similar to the lower
portion of FIG. 3, and showing a portion of the grouting material
in place according to one embodiment of the invention; and
FIG. 5 is a fragmentary vertical sectional view of one of the legs
of the structure showing the grouting material in place.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 of the drawing, a typical offshore
structure 10 is shown, such as is used in the oil and gas industry
for offshore drilling and production. The structure 10 as shown is
only the base portion which is being installed on the sea bed 12,
prior to providing the base portion with the usual platform and
superstructure (not shown). The structure 10 includes a plurality
of supporting legs, each in the form of a tubular jacket 13 which
extends downwardly from above the water line 14 into the sea bed
12, the several leg jackets being secured together by cross members
15 and diagonals 16 in a conventional manner. As is known, the sea
bed is usually comparatively soft and porous, and in many instances
the structure 10 (not including pilings) will sink of its own
weight until the jackets 13 sink as much as 30 feet into the sea
bed.
When the structure 10 is properly placed the pilings 17 are driven
through the jackets into the sea bed, usually to the point of
refusal, to provide a final support for the platform. As shown, the
pilings are normally of tubular steel, and are usually of at least
one pipe size smaller than the size of the jackets, so that an
annular space 18 exists between each piling and its surrounding
jacket. The annular space is not, of course, uniform, since no
means are used to center the piling in the jacket. On the average,
however, the annulus will have a radial thickness of from 1 inch to
21/2 inches, in leg jackets measuring from 16 inches to 54 inches
in diameter. It is this annulus which must be filled with grouting
material, particularly in the region of the lower end of the jacket
13, not only in order to attain leg rigidity sufficient to
withstand tides, storms, ocean currents and the like, but also to
protect the piling and the inside of the jacket against corrosion
by sea water and air.
After the piling 17 has been driven through the jacket 13 into the
sea bed 12, the piling is cut off at the upper end of the jacket
and the two components are secured together as by welding in a
heavy steel ring 19, prior to installation of the deck and other
superstructure. The welding in of this ring 19 provides a pressure
tight seal at the top of the annulus 18.
One form of apparatus which has been found suitable for performing
the method of this invention is shown in somewhat schematic form in
FIG. 2. In this structure two pressure tanks 30, 32 are provided
for storage tanks for dry cement. These pressure tanks may, for
example, be of the type provided with an air slide bottom, as shown
in U.S. Pat. No. 2,609,125 to Schemm or as shown in U.S. Pat. No.
2,934,223 to Scruby et al. In such structure dry cement is put into
the tanks and lies on a porous sloped bottom, and air flowing
through the bottom fluidizes the material in the tank to cause it
to flow down the slope. In the structure shown air for such
fluidizing is provided by a low pressure air compressor 34, from
which air passes through conduits 36, 38 to tanks 30, 32
respectively. Valves 40, 42 are provided to control flow to one or
the other of the tanks.
Fluidized cement is carried from the pressure tanks through
conduits 44, 46 through which flow is controlled by valves 48, 50.
The fluidized cement flows from one of the tanks at a time to a
surge tank 52 provided with a suitable dry material valve 54 at its
lower end. The valve may, for example, be of the type shown in U.S.
Pat. No. 2,858,966 to Pfening. When the valve 54 is opened the dry
cement falls into a hopper 56 which is connected at its lower end
to a mixing chamber 58. A nozzle 60 extends into the mixing
chamber, perpendicular to the outlet of the hopper 56 and coaxially
with a mixed cement line 62. Water is provided to the nozzle 60 by
means of a suitable pump 64 which takes suction from a water
storage tank 66 through a water line 68. The water tank may be
provided with any convenient gauge so that the amount of water used
can be accurately determined.
It will be appreciated that cement falling from the hopper 56 into
the mixing chamber 58 is thoroughly admixed into water sprayed from
the nozzle 60. The mixture passes through the line 62 into a slurry
tub 70. A suitable pump 72 mounted in a discharge line 74 is
connected to pump the fluid grouting material into one of lines 73,
75. Line 73 is connected to the annulus between the jacket 13 and
the piling 17 near the upper end of the annulus, and is provided
with a valve 76 and a check valve 77 to allow flow only toward the
annulus.
As seen in FIGS. 3, 4 and 5, line 75 is connected to the annulus
near the sea bed, and is provided with a valve 78 and a check valve
79, as well as a valve 80 adjacent the connection to the jacket.
Valve 80 is preferably remotely operable. In addition, line 75 is
preferably provided with a connection to valve 80 which is readily
separated from a remote location, so that the line 75 can be
removed without the use of a diver. A dump line 88 is also
connected to line 74, and is provided with a valve 90. This may be
used to dispose of grouting material which cannot be used.
For the pump 72, centrifugal pumps are satisfactory in many
instances, but where high pressure is required, as in deep water
installations, a reciprocating pump may be more desirable.
To provide high pressure air for expelling water from the annulus
and for the grouting operation, a high pressure air compressor 81
is provided. This air compressor provides air through a conduit 82,
fitted with a suitable valve 83, a pressure gauge 84, and a bleed
line 86 having a valve 85 therein. The pressure gauge is preferably
one which reads in feet of sea water, for a purpose which will
hereinafter be explained. To avoid getting grout in the air line,
the line 73 may be connected below, and on the same side of the
jacket as, conduit 80, as shown in FIGS. 3, 4 and 5.
In the practice of a preferred embodiment of the method of this
invention, air under pressure is introduced into the annulus 18 by
operating the compressor 81 and adjusting the valve 83 to allow
flow through the line 82 to the annulus, bleed valve 85 being
closed. As air pressure is increased in the annulus, it will force
the water therein downwardly and out the bottom. In some instances,
however, the jacket 13 may be resting within a highly compacted
bottom formation so that the air pressure available is insufficient
to force water through it. In such an event water under high
pressure may be pumped into the annulus by means of the pump 72
until the formation is broken down enough to allow water to be
forced through it by air pressure. The pump is then shut off and
air pressure utilized to expel the water from the annulus.
As has previously been noted, mud, comprising sea water and such
solid materials as may form the sea bed, will in many cases fill
the annulus from the bottom of the jacket to approximately the
level of the bottom of the sea bed 12. It is particularly important
that substantially all of such mud be removed from the annulus, so
that there will be no voids in the grouting material which is to be
placed therein. Such voids, filled with mud and sea water, not only
greatly reduce the strength and rigidity of the structure, but also
provide means by which corrosion of the piling and of the interior
of the jacket is greatly accelerated. The expulsion of water in the
annulus out the bottom of the annulus helps to wash out the
mud.
When all of the water has been expelled from the annulus this will
be apparent from the surface because air escaping from the bottom
of the annulus may be detected as air bubbles rising to the
surface. At this time the compressor may be stopped and valve 83
closed. Valve 85 may then be opened to bleed air pressure from the
annulus until the bubbles stop rising to the surface. The pressure
gauge 84 should then read a pressure equal to the pressure head of
the sea water. This pressure is held on the annulus to insure that
water and mud do not come back up into the annulus at the
bottom.
In some instances it may be desirable to further wash out mud at
the lower end of the annulus. This may be accomplished by
circulating additional water through the annulus, using the pump 72
to pump water. Since this water falls a substantial distance in the
annulus, it will have a tendency to erode any mud remaining in the
annulus. If desired, air pressure in the annulus can be increased
at this time to insure that the circulating water is blown out the
bottom of the annulus.
When the operator is satisfied that the annulus has been properly
cleaned of mud, circulation of the water is stopped and air
pressure is again brought back to a level just enough to keep water
and mud out of the lower end of the annulus, i.e. equal to the sea
water head. The structure is now ready for grouting.
The preferred grouting material to use is an expanding type
grouting material, i.e. one which expands during at least a portion
of the setting period. Such a material has a greater bond to steel
in shear than ordinary grouting materials. This has been found to
be an important consideration in achieving a maximum strength
structure. Expanding type cements have been known for use in the
construction industry, where they are known as "self-compensated"
cements. One expanding type cement useful to form expanding type
grouting materials is that sold under the trademark CHEMCOMP
manufactured by Texas Industries, Inc. Also, various additives,
such as sodium chloride or sodium sulfate, may be added to cement
to make it expand.
To make the grouting material, water is mixed with the cement in
the ratio recommended by the cement manufacturer or in accordance
with the standards of the American Petroleum Institute. Such water
ratios make a fluid grouting material which may have a viscosity
from 5 to 20 poises. A grouting material within this range is
viscous enough that it will have little tendency to flow through
the mud in which the jacket 13 is positioned. Such grouting
materials usually have a density of from about 14 to 16 pounds per
gallon (i.e. about twice the density of water) although grouting
materials having densities outside this range may also be used in
the practice of the method of this invention.
According to the present invention, grouting material from the tub
70 is first pumped by the pump 72 down line 75, valve 76 being
closed and valve 78 being open. In a typical grouting operation, an
initial batch of grouting material is pumped into the annulus at
the lowest possible point at a rate of, for example, 2 to 3 barrels
per minute. As this grouting material is pumped in, preferably air
pressure is released enough to compensate for the pressure head
exerted by the grouting material, so that the pressure at the
bottom of the annulus is maintained high enough to prevent water
and mud from rising in the annulus, but not so high that excessive
amounts of grouting material flow out the bottom of the annulus.
This operation may be continued until a hydrostatic balance between
the grouting material and the head of sea water is reached. At this
point no air pressure is required to prevent water from moving
upwardly into the annulus. In a typical situation the annulus
should then be approximately one-half full of grout, since the
density of the grout is approximately twice that of sea water.
When the air pressure in the annulus has been reduced to
atmospheric, the compressor 81 and its associated conduit valve and
pressure gauge may be moved to another leg of the platform to begin
expelling water from that leg.
In many instances it is then desirable to pump in enough additional
grouting material to get at least about 8 to 10 feet of additional
height of grouting material in the annulus. The pressure created by
this additional grouting material will force the grouting material
out the bottom of the annulus and carry out any water that may have
seeped upwardly and any mud that may remain at the bottom of the
annulus. This grouting material which is forced out will flow into
any voids in the mud created by the water which was previously
expelled from the annulus, and in many cases the pressure of the
grouting material will force the surrounding mud away from the
lower end of the jacket. If desired, additional grouting material
can be introduced in the annulus at this time to increase the
amount which is expelled from the bottom of the annulus. This
expelled material when it sets up will form a foundation bell which
will greatly increase the stability of the structure.
Such expulsion of grouting material from the bottom of the annulus
may be achieved at an earlier stage of the grouting operation by
maintaining a pressure at the bottom in excess of the pressure
needed to balance the head of the sea.
Valve 80 is now ready to be closed, and preferably line 75 is
disconnected from the valve and retrieved. The grouting material in
the annulus is allowed to set up sufficiently that it will support
an additional column of grouting material on top of it. Then valve
78 in line 75 is closed, and valve 76 in line 73 is opened. The
pump 72 is utilized to pump additional grouting material into the
upper end of the annulus, filling the annulus to the top, or as
high as desired.
Although it is preferred to inject as much grouting material as
possible through the lower opening connected to line 75, it may be
desirable in some instances to inject a lesser amount at the
bottom, allowing it to set up and injecting the remainder at the
top.
Alternatively, injection of grouting material into the bottom of
the annulus may, if desired, be discontinued at an earlier time,
with the valve 80 then being closed and line 75 disconnected, and
the cement in the annulus is allowed to set up.
As a further alternative, sufficient grouting material may be
pumped in to form a plug in the bottom of the annulus below the
connection of line 75, this grouting material preferably being made
of a quick-setting cement, followed by a small amount of slower
setting grouting material. The amount of quick-setting cement
should be such that it will all be below the connection of line 75,
so that additional slower setting material may be injected through
this line. When the quick-setting plug sets up, it will prevent
water from rising in the annulus, so air pressure may be released.
The following slower setting material will not set up, so that
additional grouting material may then be pumped in through line 75
to fill the annulus as high as desired, even all the way to the top
of the annulus. The present plug provides a support for the
additional grouting material, preventing it from flowing out the
bottom. In this embodiment of the invention it is usually necessary
to have only enough of the quick-setting grouting material to fill
the annulus a distance of from 1 to 3 feet, because this has been
found to be sufficient, when set up, to support the weight of the
fluid grouting material which is to be put on top of it, filling
the annulus up to above the water line.
Quick-setting cements are well known in the art, usually being
formed by adding a material such as calcium chloride. For example,
any of the various quick-setting cements described in the aforesaid
patent to Blount et al may be used satisfactorily. It will be
appreciated that this short portion of quick-setting grouting
material will set up quite rapidly as compared to the regular
grouting material.
Although the grouting operation of this invention has been
described in terms of grouting the legs of a new offshore
structure, it is apparent that the procedure is also suitable for
grouting old completed structures which were not grouted upon
initial construction. The method of this invention can also be used
in grouting structures in which a seal is provided at the bottom of
the annulus, if the seal is one which will allow water to flow
outwardly from the annulus. In some prior art grouting procedures
an inflatable packer is used to close the bottom end of the
annulus. Such packers can be deflated as necessary to allow
expulsion of water or grouting material from the lower end of the
annulus.
Although several embodiments of the invention have been shown and
described herein, the invention is not limited to such embodiments
but instead extends to the full scope of the accompanying
claims.
* * * * *