System and Method for Modular, High Volume Deepwater Facility Production

Abstract

Production systems and associated methods are disclosed. In some embodiments, 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.

1 . A production system comprising:
 a production barge; and   a production facility disposed on the production barge, the production facility 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.   
   
   
       2 . The production system of  claim 1 , wherein the production facility comprises at least one production line with one or more stations, each station adapted to receive an input, modify the input to yield an output, and deliver the output. 
   
   
       3 . The production system of  claim 2 , wherein each station is adapted to modify the input by at least one of cutting, bending, twisting, heating, joining, repositioning, lifting, and setting the input. 
   
   
       4 . The production system of  claim 3 , wherein joining comprises welding. 
   
   
       5 . The production system of  claim 2 , wherein a majority of the stations modify their respective inputs via automation. 
   
   
       6 . The production system of  claim 2 , wherein the modular components are delivered from the production facility on skids. 
   
   
       7 . The production system of  claim 6 , further comprising a yard assembly area, wherein the modular components are received on the skids and assembled one to another. 
   
   
       8 . The production system of  claim 7 , further comprising a load out barge receiving the assembled modular components for transport to an offshore installation site. 
   
   
       9 . The production system of  claim 2 , wherein a first production line is parallel to a second production line and wherein a third production line is in series with the first production line. 
   
   
       10 . A production system comprising:
 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.   
   
   
       11 . The production system of  claim 10 , wherein the production facility is disposed on a production barge. 
   
   
       12 . The production system of  claim 10 , wherein the production facility is disposed on land proximate the barge. 
   
   
       13 . The production system of  claim 10 , wherein the production facility comprises at least one production line with one or more stations, each station adapted to receive an input, modify the input to yield an output, and deliver the output. 
   
   
       14 . The production system of  claim 13 , wherein each station is adapted to modify the input by at least one of cutting, bending, twisting, heating, joining, repositioning, lifting, and setting the input. 
   
   
       15 . The production system of  claim 14 , wherein joining comprises welding. 
   
   
       16 . The production system of  claim 13 , wherein a majority of the stations modify their respective inputs via automation. 
   
   
       17 . The production system of  claim 10 , wherein the load out barge is at least one of reconfigurable and submersible. 
   
   
       18 . A method for producing an offshore structure, the method comprising:
 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.   
   
   
       19 . The method of  claim 18 , further comprising maximizing incorporation of the modular components into the design. 
   
   
       20 . The method of  claim 18 , wherein the identifying precedes the developing. 
   
   
       21 . The method of  claim 18 , further comprising delivering the modular components from the production facility to a yard assembly area, wherein the modular components are assembled, via skids. 
   
   
       22 . The method of  claim 21 , further comprising delivering the assembled modular components from the yard assembly area to the barge via skids. 
   
   
       23 . The method of  claim 18 , further comprising positioning the production facility on a production barge.