U.S. patent application number 15/070027 was filed with the patent office on 2016-07-07 for pump with integral caisson discharge.
The applicant listed for this patent is FLOWSERVE MANAGEMENT COMPANY. Invention is credited to Thomas Albers, Mirja Koekenbier, Axel Helmut Tank-Langenau.
Application Number | 20160195102 15/070027 |
Document ID | / |
Family ID | 43496243 |
Filed Date | 2016-07-07 |
United States Patent
Application |
20160195102 |
Kind Code |
A1 |
Koekenbier; Mirja ; et
al. |
July 7, 2016 |
PUMP WITH INTEGRAL CAISSON DISCHARGE
Abstract
A caisson for submersible pumps and method of operating a pump
that is fluidly cooperative with the caisson. The pump discharge
and the caisson are fluidly coupled to one another such that upon
discharge of a fluid being pumped, the caisson acts as the fluid
conduit, thereby removing the need for redundant riser pipes. In
one form, the pump is a seawater lift pump for use with floating
production storage and offloading (FPSO), offshore platforms or
related structures.
Inventors: |
Koekenbier; Mirja; (Hamburg,
DE) ; Tank-Langenau; Axel Helmut; (Remmels, DE)
; Albers; Thomas; (Ahrensburg, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FLOWSERVE MANAGEMENT COMPANY |
IRVING |
TX |
US |
|
|
Family ID: |
43496243 |
Appl. No.: |
15/070027 |
Filed: |
March 15, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12843528 |
Jul 26, 2010 |
|
|
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15070027 |
|
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61228717 |
Jul 27, 2009 |
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Current U.S.
Class: |
415/7 |
Current CPC
Class: |
E21B 43/01 20130101;
F04D 3/00 20130101; F04D 13/08 20130101; F04D 29/528 20130101; F04D
29/605 20130101; F04D 29/181 20130101; F04D 13/10 20130101; Y10T
137/85978 20150401; F04D 29/426 20130101; F04D 1/06 20130101; F04D
29/086 20130101; Y10T 137/0379 20150401; E21B 43/121 20130101; F04D
29/22 20130101; F04D 1/063 20130101; F04D 29/628 20130101; F04D
29/648 20130101 |
International
Class: |
F04D 29/08 20060101
F04D029/08; E21B 43/01 20060101 E21B043/01; F04D 1/06 20060101
F04D001/06; F04D 3/00 20060101 F04D003/00; F04D 29/64 20060101
F04D029/64; F04D 29/18 20060101 F04D029/18; F04D 29/22 20060101
F04D029/22; F04D 29/42 20060101 F04D029/42; F04D 29/52 20060101
F04D029/52; F04D 29/62 20060101 F04D029/62; E21B 43/12 20060101
E21B043/12; F04D 13/08 20060101 F04D013/08 |
Claims
1. A seawater pumping assembly comprising: an offshore platform;
and a lift pump assembly cooperative with said offshore platform
such that placement of said offshore platform within an ambient
body of seawater results in said lift pump assembly being exposed
directly thereto, said lift pump assembly comprising: a pump
comprising a motor section and an impeller section; a caisson
coupled to said pump and comprising an interior portion and an
exterior portion such that when said caisson is disposed within
said ambient body of seawater that is in contact with said exterior
portion, said caisson acts as a non-redundant fluid barrier between
said ambient body of seawater and a pressurized seawater flowpath
that is both (a) formed downstream of said impeller section during
operation of said pump and (b) defined by said interior portion; a
plurality of flanges formed on said caisson, said plurality of
flanges comprising: a first flange disposed within said interior
portion to provide at least one of radial support and vertical
support to said pump; and a second flange situated at the top of
said caisson to define both (a) a fixed vertical support of said
pump and (b) sealed isolation of said pressurized seawater from
said ambient seawater along said seawater flowpath; and a gasket
disposed within at least one of said ambient seawater and said
pressurized seawater and placed between (a) said pump and (b) at
least one of said first and second flanges to define a galvanic
decoupling structure therebetween.
2. The seawater pumping assembly of claim 1, wherein said lift pump
assembly comprises a middle-intake design where said motor section
is disposed axially below said impeller section.
3. The seawater pumping assembly of claim 1, wherein said lift pump
assembly comprises a bottom-intake design where said motor section
is disposed axially above said impeller section.
4. The seawater pumping assembly of claim 1, further comprising a
cover situated at the top of said caisson such that said sealed
isolation of said pressurized seawater from said ambient seawater
along said seawater flowpath is formed by a pressure-tight
connection in a region of said interior portion that is adjacent at
said second flange.
5. The seawater pumping assembly of claim 1, wherein said offshore
platform is selected from the group consisting of a fixed offshore
platform and a floating production storage and offloading
facility.
6. The seawater pumping assembly of claim 5, wherein said at least
one of said pump and said caisson is situated outside a hull of
said floating production and storage offloading facility.
7. The seawater pumping assembly of claim 5, wherein said at least
one of said pump and said caisson is situated outside a leg support
structure on said fixed offshore platform.
8. The seawater pumping assembly of claim 1, wherein at least said
first flange comprises a metal that is dissimilar to that of the
portion of said pump.
9. The seawater pumping assembly of claim 1, wherein said first
flange provides both said radial support and said vertical support
to said pump that is coupled to said gasket.
10. The seawater pumping assembly of claim 1, wherein said gasket
comprises a plurality of gaskets such that each is placed between
(a) said pump and (b) a respective one of said first and second
flanges to define a galvanic decoupling structure therebetween.
11. An oil and gas extraction device comprising: an offshore
platform selected from the group consisting of (a) a floating
production storage and offloading facility and (b) an offshore rig;
and a lift pump assembly cooperative with said offshore platform
such that placement of said offshore platform within an ambient
body of seawater results in said lift pump assembly being exposed
directly thereto, said lift pump assembly comprising: a pump
comprising a motor section and an impeller section; a caisson
coupled to said pump, said caisson comprising an interior portion
and an exterior portion such that when said caisson is disposed
within an ambient body of seawater that is in contact with said
exterior portion, said caisson acts as a non-redundant fluid
barrier between said ambient body of seawater and a seawater
flowpath that is both (a) formed downstream of said impeller
section and (b) defined by said interior portion; a plurality of
flanges formed on said caisson, said plurality of flanges
comprising: a first flange disposed within said interior portion to
provide at least one of radial support and vertical support to said
pump; and a second flange situated at the top of said caisson to
define both (a) a fixed vertical support of said pump and (b)
sealed isolation of said pressurized seawater from said ambient
seawater along said seawater flowpath; and a gasket disposed within
at least one of said ambient seawater and said pressurized seawater
and placed between (a) said pump and (b) at least one of said first
and second flanges to define a galvanic decoupling structure
therebetween.
12. The assembly of claim 11, wherein said motor section is
disposed axially below said impeller section.
13. The assembly of claim 11, wherein said lift pump assembly
comprises a bottom-intake design where said motor section is
disposed axially above said impeller section.
14. The assembly of claim 11, further comprising a cover situated
at the top of said caisson such that said sealed isolation of said
pressurized seawater from said ambient seawater along said seawater
flowpath is formed by a pressure-tight connection in a region of
said interior portion that is adjacent at said second flange.
15. The assembly of claim 11, wherein said first flange comprises a
metal that is dissimilar to that of the portion of said pump that
is coupled to said gasket.
16. The assembly of claim 11, wherein said first flange provides
both said radial support and said vertical support to said
pump.
17. The assembly of claim 11, wherein said gasket comprises a
plurality of gaskets such that each is placed between (a) said pump
and (b) a respective one of said first and second flanges to define
a galvanic decoupling structure therebetween.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional application of U.S. application Ser.
No. 12/843,528, filed Jul. 26, 2010 which claims the benefit of the
filing date of U.S. Provisional Application No. 61/228,717, filed
Jul. 27, 2009.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to a pump assembly for
submerged operations, such as those used in platforms and related
offshore structures, and more particularly to a pump assembly with
reduced component redundancy.
[0003] Much of the world's extraction of oil and gas comes from
offshore structures. In one form of such a facility or site, a
floating production storage and offloading (FPSO) facility,
typically in the form of a ship, employs one or more seawater lift
pumps (SWLPs) to convey the seawater to a deck level of the
facility for use in engine cooling, air conditioning, compressor
use, water injection, production requirements or general service
water. Such pumps, which are submersible, can be situated either on
the outside of the hull or the inside. In another form of an
offshore structure, an offshore platform may be outfitted with
SWLPs. SWLPs for use on either the FPSO or offshore platform are
often powered by an electric motor; in such case, they are part of
a class of pumps known as electric submersible pumps (ESPs) which
may include either a middle-intake or bottom-intake configuration.
In the former (more common) configuration, the motor is situated
below the pump, while in the latter, the motor is above the pump
and is often utilized for situations where limited submergence
results in low net positive suction head (NPSH) and is needed to
avoid the bottom of the unit substantially projecting from the
bottom of the FPSO or offshore platform. Risers (or similar piping)
that are typically located at the SWLP discharge may be used to
convey the pumped seawater to a desired end use within the FPSO or
offshore platform, such as those mentioned above. In a conventional
SWLP design, the pump is supported by such piping connected to the
pump discharge.
[0004] In either of the above offshore production configurations,
it is conventional to use a caisson as a secondary fluid vessel
around SWLPs to protect the pump during operation against wave
motion, as well as changes in water current or the presence of
flotsam in the water. Such caissons may be used for both the
aforementioned middle-intake and bottom-intake SWLP construction.
In a conventional configuration, the SWLP is installed at the
bottom of an open caisson that is submerged in the seawater. As
with the riser discussed above, the caisson is typically of
elongate cylindrical construction, and includes an inner space
possessive of sufficient volume to house the pump and its
associated electrical power leads, control lines, the riser and
other service lines. Caissons are typically made from conventional
structural materials, including steel or the like. In the present
context, a caisson can be a pipe, frame or related structure in
which pumps can be installed. Their use is convenient on FPSOs and
other offshore platforms, but is also suitable in other
applications, such as caverns or the like.
[0005] The risers used for offshore structures typically pass
through a top (or cover) plate of the caisson. Features such as
this, as well as the nature of the overlapping use of concentric
risers and caissons introduces additional weight and complexity to
both the FPSO and offshore platform configurations. In addition,
the possibility of friction losses, galvanic corrosion (such as due
to the presence of disparate metal structures in contact with one
another in a saltwater environment), relatively unstable high
center-of-gravity and other technical difficulties may be present
with a conventional SWLP-caisson combination. Without a continuous
flow of seawater, the corrosion problem can be exacerbated by a
region within the riser that can accumulate stagnant water. For at
least these reasons, it is desirable to reduce these weight,
complexity and susceptibility to corrosion problems.
SUMMARY OF THE INVENTION
[0006] This desire is met by the present invention, where in one
aspect thereof, a SWLP assembly is disclosed. The pump (such as an
ESP) is encased in the bore of a caisson so that seawater is
discharged from the pump to flow directly through the bore without
the need for a now-redundant riser. Such design (referred to herein
as a riserless design or a riserless pump and caisson combination)
avoids having to use riser pipes over the length of the caisson in
order to convey the seawater to the deck level of an FPSO, platform
or related facility. Advantages associated with using the caisson
as discharge include lower price per installation (due to the
removal of costly discharge (riser) pipes) relative to a
traditional configuration that employs a riser and reduced
installation time, lower center of gravity as well as possible
reduction in weight. Likewise, the galvanic corrosion problem
discussed above is reduced or eliminated, as the riser structure is
no longer present. In addition, the design of the upper pressurized
caisson section is such that it facilitates the continuous flow of
seawater, thereby minimizing or eliminating the presence of
stagnant seawater and the concomitant corrosion problem and
reducing or even eliminating the need of using anodes. Such
elimination or reduction is additionally helpful in reducing
weight, cost and installation time. The riserless seawater lift
pump assembly includes a seawater lift pump with both a motor
section and a pumping section. The pumping section includes a
seawater inlet, a seawater outlet and a pump impeller, rotor or
related pressure-imparting means to pressurize the fluid between
the seawater inlet and the seawater outlet. The caisson is fluidly
cooperative with the pumping section such that pressurized seawater
being discharged through the outlet forms a flowpath that is
defined by the caisson. By having the flowpath be defined in this
way (i.e., by the caisson), the inner wall of the caisson is in
contact with the pumped seawater such that it serves as a channel
or related guide for the pressurized water. In such a
configuration, there is no riser or other intermediate piping used
to form the flowpath for the pressurized fluid leaving the pump
section. Such reduction in redundant structure may result in weight
savings for the assembly.
[0007] In one optional configuration, the motor is mounted below
the pump suction in the aforementioned middle-intake design. In
this way, standard submersible motors and motor housings may be
used, as the pressure environment about the motor is merely the
ambient pressure of the fluid to be pumped, rather than the
elevated pressure associated with the pump discharge. This is one
form of cost and weight savings, as such a configuration permits
use of a standard submersible motor design. In another
configuration, the motor is situated above the pump (i.e., the
bottom-intake design) to reduce the required pump operating water
depth and to keep the protrusion associated with the pump intake to
a relatively short vertical length.
[0008] In other options, the assembly can be secured to an offshore
structure, such as an FPSO facility or an offshore platform. When
connected to an FPSO, one or both of the seawater lift pump and the
caisson can be situated either inside the FPSO facility's hull or
outside of it. Likewise, it will be appreciated by those skilled in
the art that the use of the riserless configuration is not limited
to offshore platforms or FPSO structures, but can be used in
situations where the use of a caisson is conventional or expected,
an example of which includes caverns used for the storage of oil,
gas and related valuable natural resources. As such, the use of the
riserless configuration of the present invention is not limited to
pumping seawater.
[0009] According to another aspect of the invention, a method of
pumping seawater is disclosed. The method includes discharging
pressurized seawater from a SWLP assembly such that a substantial
entirety of a flowpath formed by the discharged seawater is defined
by a caisson that, along with the pump, makes up the assembly. The
lift pump is configured to include a pump inlet, a pump outlet and
an impeller, rotor or related pressurizing member fluidly coupled
to the inlet and outlet.
[0010] In one optional form, the caisson is affixed (such as by a
flanged, bolted arrangement) or otherwise coupled to the seawater
lift pump to be in fluid communication with a pressurized water
outlet formed as part of the pump. By having the substantial
entirety of the discharged seawater flowpath defined by the
caisson, the method of the present invention avoids having to use a
riser or other intermediate structure that (if present) would add
significant weight and complexity to the seawater lift pump
assembly. In such configuration, the upper wall of the caisson is
in direct contact with at least a portion of the pressurized
seawater, while a lower wall of the caisson is in direct contact
with ambient seawater that surrounds the pump. In another option,
the seawater lift pump can be of either a middle-intake design or a
bottom-intake design as discussed above in conjunction with the
previous aspect. The method may additionally include placing the
caisson in fluid communication with an offshore structure, such as
a FPSO or offshore platform, in order to deliver the pressurized
seawater to such structure. In the case of an FPSO, the caisson can
be placed either inside or outside of the FPSO's hull. In addition,
the caisson may be secured or affixed to the hull.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The following detailed description of the present invention
can be best understood when read in conjunction with the following
drawings, where like structure is indicated with like reference
numerals and in which:
[0012] FIG. 1 is an elevation view of a conventional SWLP pump
according to the prior art, where the riser or discharge pipes
extending from the pump discharge are coaxially disposed within a
caisson;
[0013] FIGS. 2A and 2B show respectively a middle intake ESP and a
bottom-intake ESP that are each usable in the riserless design of
the present invention;
[0014] FIG. 3 is an elevation view of a middle intake caisson pump
according to an aspect of the present invention;
[0015] FIGS. 4A and 4B show an FPSO with SWLPs mounted on the
inside and the outside of the hull respectively;
[0016] FIGS. 5A and 5B show an offshore platform with a
middle-intake SWLP and a bottom-intake SWLP, respectively; and
[0017] FIGS. 6A and 6B show alternate riserless offshore platform
SWLP mounting configurations according to an aspect of the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] Referring initially to FIG. 1, a seawater lift pump assembly
1 according to an aspect of the prior art is shown. The assembly 1
includes a seawater lift pump 10 that includes a motor section 12
and a pump section 14 with intake 16, and is disposed within, and
generally secured to, a caisson 20. The corrosive nature of
seawater is such that the seawater lift pump 10 and all associated
parts such as risers are made from materials (such as bronze,
stainless steel, duplex and various nickel-based compounds) that
can withstand such an environment Likewise, the construction of
such seawater lift pump 10 is such that it can withstand the
environments associated with deep subsurface placement. Additional
components may make up the balance of the assembly, including a
cooling shroud 13 that surrounds the motor section 12, and adapter
15 and non-return flap 17 situated at the outlet of pump 14, as
well as flexible tubes 19 (only one of which is shown) that extends
from the header tank 80 at the top and run the axial length of the
assembly 1; such tubes 19 are used for motor cooling fluid or the
like. For example, such tubes 19 may include a tube for filling and
a tube for venting between the motor section 12 and the header or
top of the assembly 1.
[0019] A fluid conduit, otherwise known as a riser 30, is secured
to the outlet of the pump 10 in order to convey the seawater being
pumped therefrom to a desired location. The riser 30 is shown
having numerous axially-connected sections that extend upwardly
from the discharge of pump section 14. As such, there is a
concentric arrangement of the riser 30 within the caisson 20 such
that both can be supported by a cover plate 40, such as attaching
the caisson 20 through a flange 50. Caisson cover plate 40 and
flange 50 may be secured to one another such that a gasket (not
shown) is disposed between them. Additional equipment, such as
power cable 60 to deliver electrical current to motor section 12, a
signal cable 70 and pipes to a header tank 80, as well as a
junction box 90 for the power cable 60 and signal cable 70 are
shown, where at least the cables 70 and 80 can be placed between
the riser 30 and the caisson 20. In a typical medium-sized
configuration, the length and diameter of the seawater lift pump 10
is approximately 20 feet and 4.5 feet respectively, and the length
and diameter of the riser 30 is approximately 100 feet and 4 feet
respectively. Such a seawater lift pump assembly 1 with such
dimensions (and including other miscellaneous items, such as a
non-return flap, adapter, well head, cooling shroud, cables and
various accessories) may weigh upwards of 45,000 to 50,000
pounds.
[0020] Referring next to FIGS. 2A and 2B, examples are shown of
both a middle intake pump 10A and a bottom intake pump 10B that can
be used in assembly 1. As shown with particularity in FIG. 2A, pump
section 14A of the middle intake configuration may be made up of
numerous axially-aligned impellers. In such case, an intake 16A is
formed between the motor section 12A and the pump section 14A to
permit the seawater to be introduced to the lowermost of the
impellers. Likewise, as shown with particularity in FIG. 2B, pump
section 14B of the lower intake configuration has one or more
impellers, this time situated adjacent intake 16B that forms the
lowermost portion of the pump 10B; such a configuration is
particularly compatible with limited water depths. The partial
cutaway view depicted in FIG. 2B shows a shroud 13B about the motor
section 12B, and a coupling 15B to rotatably connect the shafts of
the pump and motor sections 14B and 12B, as well as how such
sections can be bolted together at flanges situated at adjacent
axial ends of each section. Cable sealing 11B can be used to
provide environmental protection for the electric power cable,
while a filling hose and connection 8B are shown to allow cooling
for motor section 12B. A discharge housing 9B can be bolted or
otherwise connected to shroud 13B.
[0021] Referring to FIG. 3, a seawater lift pump assembly 100
according to an aspect of the present invention is shown. The
assembly 100 includes a seawater lift pump 110 encased within a
caisson 120. Pump 110 includes a motor section 112 and a pump
section 114 with intake (also referred to as a suction housing) 116
and non-return flap 117 and adapter 115, yet unlike the assembly 1
depicted in FIG. 1, has no riser extending from its discharge or
outlet, instead forming a direct fluid connection with caisson 120.
In the present context, such a configuration is considered to be
riserless. In other aspects, seawater lift pump assembly 100
includes a header tank 180 and junction box 190 in a manner
generally similar to that of assembly 1. In the assembly 100 of the
present invention, the caisson 120 forms a substantially
fluid-tight conduit through which seawater or other fluid that
exits the pump section 114 discharge can flow. In this
configuration, there is then no need for a riser (such as riser 30
of the assembly 1 of FIG. 1). Additional equipment, such as power
cable 160 and signal cable 170, are also shown. Flange 150 formed
at the top of the caisson 120 and underneath the cover plate (also
called a caisson mating flange) 140 is used to secure the seawater
lift pump 110 to the caisson 120. Likewise, a pump supporting
flange 152 is situated within caisson 120 for pump 110. The
riserless configuration of the present invention preferably
includes a pressure-tight connection between the cover plate 140
and flange 150. The pump 110 is fitted and sealed to the caisson by
means of a splined ring with pin (neither of which are shown), or a
related fastening mechanism. This prevents turning of the pump 110
during start and stop operations. Furthermore, a gasket (not shown)
will be used to seal the pump 110, relying upon the weight of the
unit itself to form the seal. The pump 110 can be raised and
lowered by a conventional lifting device 118 known to those skilled
in the FPSO and offshore platform art. In contrast to the typical
seawater lift pump configuration shown in FIG. 1, the seawater lift
pump assembly 100 with comparable length and diameter dimensions
(and including similar miscellaneous items discussed above) may
weigh about 35,000 pounds, saving between about 10,000 and 15,000
pounds. Other features are generally similar to the assembly 1 of
FIG. 1, such as a motor cooling fluid flexible tube 119.
[0022] FIGS. 4A, 4B, 5A, 6A and 6B show other SWLP configurations
in simplified form for clarity. These SWLPs can be employed in
numerous locations, including on an FPSO 200 (shown as internal
SWLPs 300A in FIG. 4A and external SWLPs 300B in FIG. 4B).
Likewise, FIGS. 5A and 5B show offshore platforms 400, 600 with
middle-intake SWLPs 500 and bottom-intake SWLPs 700, respectively.
FIG. 6A shows an alternate riserless offshore platform 400 (which
is generally similar to that of the platform 400 SWLP in FIG. 5A)
with mounting configurations for SWLPs 800 (in FIG. 6A) and 900 (in
FIG. 6B). The bottom-intake configuration of SWLP 900 shown in FIG.
6B includes a motor section 912, a pump section 914 with intake
916. A supporting ring 915 is formed between the pump section 914
and the motor section 912, and is sized to allow axial passage of
the pump 900 (including its widest part just above the suction
strainer of intake 916. Further, and in a manner generally similar
to that of FIG. 3, a pressure-tight connection between the cover
plate 940 and flange 950 forms the top of the assembly of SWLP
900.
[0023] While certain representative embodiments and details have
been shown for purposes of illustrating the invention, it will be
apparent to those skilled in the art that various changes may be
made without departing from the scope of the invention, which is
defined in the appended claims.
* * * * *