"US 200802! cu») United States 2) Patent Application Publication — co) Pub. No.: US 2008/0292407 AL Jonker et al. (54) SYSTEM AND METHOD FOR INS FOUNDATION ELEMENTS, ALLING (76) Inventors: Geert Jonker, Bussum (NL): Artis Van Duljvenboden, Ktwijk Aan Zee (NL) GREENBERG TRAURIG, LLP 200 PARK AVE., PO. BOX 677 FLORHAM PARK, NJ 07932 (US) (21) Appl. No. 11913,133, (2) PCT Tiled May 3, 2006 (43) Pub, Date Nov. 27, 2008 (86) PCT No PCTIBP2006(062006 $371 OU. @,@)Dae: May 8, 2008 G0) Foreign Application Pri 005 ity Data May3, ey 051037133 Publication Classification (1) Incl EOD 710 (2006.01) (52) US.CL 405/228 6 ABSTRACT Te invention pertains to a system (1) for installing founda tion elements, such as ples or conductors (2), in a sub-sea ‘round formation (3), comprising a hydraulic driver (and a power comerter (9) for generating hydraulic pressure in a Enydraulc uid forthe diver (8). The driver (8) and the con- verter (9) are aclapted to fit inside dhe Foundation elements (2). 4Patent Application Publication Nov. 27, 2008 Sheet 1 of 2 US 2008/0292407 AI jsPatent Application Publication Nov. 27, 2008 Sheet 2 of 2 26 B— Fig.2 US 2008/0292407 AIUS 2008/0292407 AI SYSTEM AND METHOD FOR INSTALLING FOUNDATION ELEMENTS, 10001} The invention pertains to a system for installing ‘oundation elements, suchas piles or conductors, in subsea ‘round formation, comprising a hydraulic driver anda power ‘converter for penerating hydraulic pressure in a hydraulic {uid forthe driver. The iavention also relates to a method of installing foundation element [0002] "U.S, Pat, No, 4,964,473 relates to a method for driving a hyde suhmerged too, whereby the hydraulic pressure energy is generated ina submerged power converter AAs explained in US. Pat, No. 4,964,473, uch a method was the ar, ie, from the Netherlands patent 3240, which corresponds to US. Pat. No {0003} pile diver to which an clectcaly driven hymulic power ‘The latter document discloses hydraulically driven Unit is attached in which electric power is converted into hydraulic power. Feoding this power converter occurs by supplying electric energy by electric cables to the power ‘converter ffom a generator located above water ashore, or on 4 ship or on a work platform. In the same way other sub ‘merged tools are driven, suchas drilling tools, sampling appa ratuses and tools for working at or inspecting submarine 10008) The electrical cables are uncoled from a reel on ‘deck o follow the power converter lowered below the water For work ships with ther restricted deck space and hoisting ‘capacity suchlike reels with eables and diesel-electric power units are wery aggravating, 10005] Further, with an increase of the depth on which has tobe worked, extension ofthe electric cables is lost impos: sible or very complicated, because in most cases these are ‘combines cables lor eleetical power, electrical signals and supply. These cables moreover ae rather heavy, costly and vlaerable 10006] |The invention underlying U.S. Pat. No. 4.964.473 sims to provide a method as well asa device for driving 2 hydraulic submerge tool with whieh these problems can be solved nan easy way. According o U.S. Pat. No. 4,964,473, this object is obtained by driving the converter with pres surised surounding water, which, after the enengy transfer, is ‘exhausted into the surrounding Water. Herewith a simple drive is obtained whereby no retum conduct is necessary. Especially with drilfing ships in which high-pressure sea ‘water pumps arealready present andin which thedeling pipe ‘composed of sections also ean be used for transporting the pressurised sca water. this method will ive a considerable ‘cost redtion, wheres the working depth may be very large, [0007] _Ttisanobjectof the present invention to improverthe system according to the opening paragraph, 10008] To this end, the system according to the present ‘vention i characterised i tat the driver and the converter are adapted to fit inside the foundation elements [0009] This system enables so-called “pile toe driving” ‘without the need for an umbilical between the converter and the driver, 10010] Typically, hydraulic pile drivers are connected to @ tank fora hydraulic fs and comprise a hydrauliceylinder,& piston accommodated in the hydraulic cylinder, an impact ‘weight connected tothe piston, high and low-pressure ace rmulators, a valve system for alterately connecting, the Nov. 27, 2008 hydraulic eylinder (othe high and low-pressure aecumul- tors, and conduits for operatively connecting these compo- ‘ents in a manner known in ise [011] Ie is preferred thot the tank is mounted on or inte- arated with thoconvercerIisalso preferred that theeylinder, piston, accumulators, and the valvesystem are mounted on oF Sntograted with the converter to form a converter drive unit [0012] By integratingoneor more components of thedever ‘with the converter, preferably most orall components except forthe impact weight, handling of the system is simplified, a housing forthe weight may be omitted andlor tolerances and shape of the weight become less erie 0013} To farther separate the weight from the converter ‘rive unit, iis prefered thatthe weight is comnected to the piston by means ofa flexible element, such as a cable, chain ‘ortelescopie member, and preferably a shock absorber. [0014] The invention further relates toa method of istall- ‘ng hollow foundation eloments, such as piles or conductors, ‘na sub-sea ground formation, by means ofa hydraulic driver anda power converte for generating hydraulic pressure in a hnydraulic fluid for the driver, which method comprises the steps of (inna paticular order) [0018] mounting the driver inside a foundation clement ‘and, typically subsequently, mounting the eonverter inside the foundation element, and [0016] lowering the foundation clement, the driver and the power converter froma vessel, seh a an drilling platform oF Ship, preferably by means ofa drill string. [0017] It is profered that an energy’ transfering uid, in particular water taken from the surroundings ofthe drilling platform or ship, is fed to the convertor through the dill string [018] Its noted that WO 2004/051004 discloses a “pile- riving apparatus comprising pile, ashoetip coupled toatoe ‘ofthe pile anda dil string disposed within he pile. The dell String comprises gripping device eoupling the drill string to the pile aad a hammer deployed into the ile such that the ‘hammers capable of transmitting force tothe shoe tp.” The ‘hammer receves fd (© generate the force, used to drive the she tp, and controlling signals via an umbilical. 019} Further, U.S. Pat. No. 6.626.248 discloses a “method fordeving adrive pipe into asub-Sea formation, said ‘method comprising: accelerating at east one mass relative to the deive pipe, wherein the atleast one mass is aecelerated ‘within the drive pipe; transferring energy from the ecceler ated atleast one mass tothe dive pipe: Suspending the drive pipe froma dil string; and isolating [by means ofa “running ool" the drill sting from the transfered energy from the accelerated a least one mas [0020]. ‘The invention will nose be explained in more detil ‘ith eference tothe figures, which show a preferred embod ‘ment ofthe system accorting to the present invention. [0021] FIG. 1 schematically shows a system according 10 the present invention suspended from drilling platform by ‘means ofa drill ting. [0022] FIG. 2 isan enlarge view of the system shown in FIG.1. [0023] It is noted thatthe drawings are not necessarily to scale and tat details, which ate not required for understand. ing the present invention, may have been omitted [0024] The Figures show a system 1 for installing founda- tion elements, such a tubular piles or conductors 2, in a seabed 3, sespended from a drilling platform 4 hy means of = cable, a reinforced umbilical or, preferably, a drill ting,US 2008/0292407 AI 10025] In this example, the foundation element is so- called conductor pipe 2, -e.a hollow metal tube, which typ ‘ally as length ina range from 50 to 125 m or even up 10 250m Gin deep Water) anda diameter ina range from 7010 100 ‘em, for instance 30 0 36 inch, Nea its bottom, the conductor Pipe? is provided with adrve shoe 6anda toe driveussembly, steel plate ora solid stee! anvil. 10026] The system 1 comprises a hydraulic driver 8 and a power converter 9 for generating hydraulic pressure in a hydraulic uid and supplying the same to the dever 8, whieh boll fit inside the conductor pipe 2 [0027] -Thedriver8 comprises a tank 10 for hydraulic Nu, such as hydraulic oil or (seawater optionally including appropriate additives, a hydraulic cylinder 11, a piston 12 reciprocatingly accommodated in the hydraulic eylindet 1, high and low-pressureaccumulators 13,14, avalve system 18 for alterotely connecting the hydraulic cylinder 11 10 the high and low-pressure secumultors 13, 14, a volume com pensator (not shown), typically a piston compensator, for ‘compensating fhicttations of the volume of hydra iin the tank 10 (esulting from the movements ofthe piston 12), and an impact weight 17. Further, an acceleration chamber 16 is positioned above the piston 12 and connected tothe valve system 1S. 10028] Inaccondance witha preferred aspect ofthe present Svention, the impact weight 17 has been separated from the ‘ther components 10-18 ofthe dever 8 ad has been adapted to reciprocate inside the conductor pipe 2. The impact weight 17 comprises a plurality of guides 18, preferably mounted slong the circumference ofthe impact weight 17 and at least ‘aC oF near its upper and lower ends. The guides 18 abu the ‘inner wall of the foundation element 2 and are preferably made ofa synthetic material, such as HDPE, ora metal, sueh ts brass. The guides IN eliminate nearly all wear on the impact weight 17 and allow the weight 17 t work at inclina- 10029] The impact weight 17 is connected tothe ower end ‘ofthe piston 12 by means ofa flexible element 19,e.2. steel ‘able, and a shock absorber 20 10030] The converter 9 is preferably a uid pressure con- verter comprising a so-called mud motor 24 a Mid inlet 22 ‘connected fo the cil string , such that a fluid, in particular seawater taken from the surroundings of the dling platform 44-canbe fod through the dil string 5 tothe converter 9, and ‘pump 28 connected the high-pressoreaccuimulator Land the valve system 15, Further, conduits 24,28 are provided to ‘connect the low-pressure accumulator 14 tothe tank 10 and the pump 23 tothe tank 10 and the high-pressure aceumulator 13, respectively. 10031] |The mud motor 21, ex. 2 Moyno 962N3460 or a 21288625 ex Roper pumps is known in tel and comprises ‘8 power section, connected, via the fluid inlet 22, to the dill, string 8, a tansmission, and an output shalt connected to the pump 23, 10032] In an alternative embodiment (oot shown), mostly suitable for foundation elements having a lange diameter, the ‘converter comprises one or more work eyinders, which each by means ofa Mating piston are divided ina space filed with pressurised water and a space filled with a hydnalie work medium, switching means being provided which are set ‘ated each time that a floating piston reaches the end of its work stroke, by reason of which at each work eylinder the space which can be filled with pressurised water altematly is ‘connected either to a feed conduit of pressurised water, Nov. 27, 2008 particular the dil string 8, o oa fee exhaust (aot shown), ‘ach work eylinder atthe side ofthe hydraulic work medusa being connected © the pressure conduit 28 running to the high-pressure accumulator 13. With this relatively simple vice, a practically loss free energy conversion is realize Funluer deus on this type of converter canbe found in US. Pat, No. 4,964,473, which is incorporated herein by refer [0033] In the preferred embodiment shown in the Figures, the tank, cylinder, piston, accumlators, and valve system hha been integrated with the converter fo form a converter river unit 26. An expandable ring, for instance so-called packer 27, ora gripper has been attached about the czcum- ference ofthe wit 26, eg, halfway or at both the upper and Jower ends ofthe unit 26, to temporarily secure the unit 2610 the inner wall of the foundation element 2. Optionally, the sing 27 andthe anvil 7 provide ar ght seals, in which case water below the unit 26 can be replaced by e.g. air ths reducing the resistance on the impact weight 17 during recip- ‘cating movement inside the foundation element 2 [0034] The conductor pipe 2 is installa in the seabed 3, by Jowering the conductor pipe 2 from the platform 4 into the sa, mounting the impact weight 17 and the converter driver ‘uit 26 inside the pipe 2 attaching the converter diver u ‘the dilsring, securing the latter agains the inner wall of the pipe 2, eg. by expanding the ring 27 andlor connecting the pipe 2 to the dell sting $ by means of (W)ROV diseonnect- able slings, lowering the assembly thus obtained from the tilling platform 4 by means ofthe dil string 8, and pos ‘ioning the condvetor pipe 2 on the seabed 3. [0035] The operating eyele begins with an upward move- ‘ment involving the iting ofthe piston 12 and the impact ‘Weight 17, A first valve (within the valve system 15) ia the high-pressure line (2) is opened snd a second valve in the relum line (24) is closed, Once a preset siroke has boca ‘eachied, the fist valve is closed and the socand valve pened, allowing the impact weight 17 wo sta its dawavard move. ‘ment. In this example, the flexible element 19 is sufficiently short to enable the piston 1210 abut and hence accelerate the impact weight 17 during downward movement by connecting the chamber 16 above the piston 12 to the high-pressure line, aiving the impact weight 17 total seceleration of up to 2 2 ‘This reduces the actual stoke required andinereasesthe bow rate. At impact the weight strikes the anvil7 and the pipe 2 is riven into the seabed 3 [0036] From the above examples it willbe clear tht sys- fem according to the invention enables so-called “pile toe driving” without the need for an umbilical Between the eon- verter and the driver Purler, by integrating one or more components of the diver with th converter, preferably most forall components exeept for the impact Weight, handling of the system is simplified, a housing for the weight may’ be ‘omitted and/or tolerances and shape of the weight become less erties [0037] The invention is not restricted to the abovede- sod embodiments, which ean be varied in a number of ‘ways within the scope of the claims. or instance, the impact ‘weight (17) may be rigidly connected to the piston (12). The smeans (27) fr securing the converter driver unit the inner ‘wall of the foundation element ean be employed to absor® torque generate in the converter, thus reducing or even pre- venting torque inthe drill string [038] Also, the converter may comprise two or more ‘Pumps, ez Wo main pumps driven in opposite direetoUS 2008/0292407 AI (oan, ducing torque) and a pump for diving a jet for removing obstacles in the way ofthe impact weight. 10039] "Further, the converter andl driver can be configured ‘separate units, preferably connected by «exible element ‘and suitable conduits forthe hydra ful andor each pro> Vided with a means for securing the same to the inner wall of the foundation clement 1. System (1) for installing foundation elements, such as piles or conductors (2), in a sub-sea ground formation (3), ‘comprising & hydmulc diver (8) and a power converter (9) Jor generating hydraulic pressure ina hydraulic Mui forthe driver (8) characterisedin thatthe driver(®) and theconverter (0) are adapted to fit inside the foundation elements (2). 2. System (1) according o elas 1, comprising a tank (10) {ora hydraulie Mud, whieh tank (10) is mounted on or inte- rated withthe converter (9), 3, System (1) acconiing to claim 1 or 2, comprising a hydraulic eylinder (11), a piston (12) accommodated in the hydraulic eylinder (11), high and low-pressure secumultors (13.14), and a valve system (18) fr alternately connecting theirydrauiceylinder(11) tothe high and low-pressure acew- mulators (13, 14), wherein the eylinder (11), piston (12), accumulators (13, 14), and valve system (18) aremounted on ‘or integrated with the converter (9; 26), 4 System (1)according to any anc the preceding claims ‘comprising an impact weight (17) adapted to reciprocate inside a foundation element (2) and preferably to abut the ‘nger yall ofthe foundation element 2), which impact weight (17) is connected to the piston (11) by means of a fexible element (19). 8, System (1) according toany one ofthe preceding claims, ‘comprising an acceleration compartment located above the Piston (11) andior communicating with chamber (16) above the piston (11). 6. System (1) according to any one ofthe preceding claims wherein the driver (8) and/or the converter (9; 26) comprises ‘ameans for securing the driver (8) and/or the converter 9:16) ‘and any components integrated therewith to de inner wall of the foundation clement 2). Nov. 27, 2008 7. Systea (1) aocording to any one ofthe preceding els wherein the converter (9; 26), preferably a fluid pressure converter comprises a Mud inlet adapted to be connected toa rill string (8), sueh that a fluid can be fed through the dil string (S) tothe converter (9; 26) 8, Method of installing hollow foundation elements, such aspiles or conductors 2), na sub-sea ground formation (3) by icons ofa hydaalc driver (8) and a power comverter (9) {or generating hydraulic pressure ina hydraulic uid forthe river (8), which method comprises the steps of ‘mounting the driver (8) andthe converter (9:26) inside the foundation elemeat (2). lowering the foundation element (2), the diver (8), andthe power converter (9) from a vessel (4). 9. Method according to claim 8, wherein the converter (9 26) and any components integrated therewith is lowered by ‘means of drill string 8). 10, Method according to claim 9, wherein sn enengy trans- ‘ering, id s Fed tothe converter (9; 26) through the dil string (8). 11, Method aecording o any one of claims 8-10, wherein te driver (8) and the power converter (9) re positioned and preferably scoured inside the foundation clement (2) before Jowering the foundation element (2), the driver (8), and the power converter (9) tothe formation (3) 12, Method aecording to any one of claims 8-11, wherein the converter (9; 26) and elemens integrated therewith are secured to the inner wall of the foundation clement (2) 13, Method aecording to any one of claims 8-12, wherein water below the converter (9; 26) is replaced by a gs, thus reducing the resistance on the impact weight (17) during ‘eiprocating movement inside the foundation element (2). 14. Method! according o any one of claims 8-13, whorcin the impact weight (17). during reciprocating movement, is agided hy the inner wall ofthe foundation clement (2,