DEPLOYMENT MECHANISM AND METHOD FOR OVERBOARD PUMP

Abstract

A deployment system is utilized to deploy an overboard pump over the side of an offshore rig or vessel. A reel of hose with an overboard pump is securable to an end of the reel of hose. A bend restrictor supports the hose as the hose bends downwardly for deployment in water. The bend restrictor is mounted for movement with respect to the reel whereby the bend restrictor is movable away from the reel, preferably along a fixed and predetermined path, to a deployment position to permit the overboard pump and the hose to be deployed into the water over the side of the offshore rig. The bend restrictor is also movable to a non-deployed position such that the hose guide is above the rig floor where the pump may be serviced.

Description

The present invention claims benefit of U.S. Provisional Patent Application No. 61/263,611 filed Nov. 23, 2009.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to overboard pumps that are deployed over the side of an offshore rig or vessel and, more particularly, to a deployment mechanism for use with a hose reel system comprising a movable bend restrictor for deploying and retrieving the overboard pump.

2. Description of the Prior Art

Hose reel systems designed to raise and lower electric motor driven submersible seawater pumps are well known and may be used for purposes such as supplying the offshore rig ballast water, raw sea water for rig use, such as engine cooling or fire water.

Prior art hose reel systems of this type can require significant modification to the side and upper deck of the rig to provide a service deck and a scaffold with an opening for lowering the pump and for maintenance on the pump when the pump is raised to the side of the offshore vessel as well as mounting the reel system above the service deck. The scaffolding may typically include a floor with the opening through which the pump and hose may be lowered to the sea. The added floor around the opening is required for maintenance on the pump or hose when required. The additional deck and/or scaffolding must be added to the offshore rig at the shipyard and may require considerable engineering costs. Significant time and cost is involved in installing the scaffolding. In addition, the use of the vessel crane or some other form of lifting device must be utilized to remove the pump from service deck area over the side of vessel to main area deck for service or removal for installation of new unit.

The following are examples of prior art hose reels that are utilized over the side of an offshore rig:

The technical manual for Superior Hose Reel System Model HR8, with a revision date of February 2004, shows a hose reel system connected to the overboard pump with a six inch water hose, one inch electrical cable, and one-half inch steel lifting cable where the pump is lifted and lowered using the main hose reel.

United States Patent Publication 20060245958, to Carter, of Nov. 2, 2006, shows a bulk delivery system for moving bulk material from an elevation below the surface of a host to the host surface. The delivery system includes a storage system mounted on the host surface, a device submersible in the bulk material for lifting the bulk material to the host surface, and a flexible conduit connecting the storage system with the lifting device. The device for lifting the bulk material may be a pump or an eductor. When an eductor is used, a motive conduit is attached to the eductor for introducing a motive product, such as air or previously recovered bulk material into the eductor for drawing the bulk material therein and into the flexible conduit leading to the host surface. The storage system is rotatably mounted on the host for rotation between an operating position in which the flexible conduit and lifting device are located over the bulk material and a storage position in which the flexible conduit and lifting device are stored on the host.

The above cited art does not show a compact deployment mechanism for an overboard pump for use over the side of an offshore rig, wherein the pump is raised and lowered utilizing a hose reel, which avoids the problem of installing scaffolding on the side of the offshore vessel or the need of mounting system above the service deck. Those of skill in the art will appreciate the present invention which addresses the aforementioned problems.

SUMMARY OF THE INVENTION

It is a general purpose of the present invention to provide an improved hose reel system and method.

One possible object of the present invention is to provide an improved deployment system and method for deploying the overboard pump over the side of the rig or vessel.

Accordingly, the present invention provides a deployment system for deploying an overboard pump over the side of an offshore rig or vessel. The system may comprise elements such as, for example, a reel of hose with an overboard pump securable to an end of the reel of hose. A hose guide or bend restrictor supports the hose as the hose bends downwardly for deployment in sea water.

The hose guide is mounted for movement with respect to the reel whereby the hose guide is movable away from the reel to a deployment position to permit the overboard pump and the hose to be deployed over the side of the rig or vessel. The hose guide or bend restrictor is movable with respect to the reel to a non-deployed position such that the hose guide is above the rig floor.

At least one of a hydraulic mechanism, electrical mechanism, pneumatic mechanism, or manual mechanism may be utilized to move the hose guide between the deployment position and the non-deployed position.

In one possible embodiment, the hose guide may be mounted for movement in a straight line between the deployment position and the non-deployed position.

A frame may be utilized to support the hose guide. The hose guide may be mounted for movement on the frame between the deployment position and the non-deployed position.

The frame may be affixed to or fixably mounted with respect to the reel of hose.

In one possible embodiment, roller surfaces may be formed on the frame and a plurality of rollers may be secured to the hose guide to support the hose guide as the hose guide is moved between the deployment position and the non-deployed position.

A piston rod may be secured to the rollers, a piston may be secured to the piston rod, and the piston may be mounted within a piston cylinder.

The invention also comprises a deployment method for deploying an overboard pump over the side of an offshore rig or vessel. The method may comprise steps such as providing a reel of hose to which an overboard pump may be secured and providing a hose guide to support the hose as the hose bends downwardly for deployment in water.

Other steps may comprise providing that the hose guide is mounted for movement with respect to the reel, whereby the hose guide is movable away from the reel to a deployment position over the side of the rig to permit the overboard pump and the hose to be deployed over the side of the rig or vessel into the water. As well, the hose guide is movable with respect to the reel to a non-deployed position such that the hose guide is above the rig or vessel floor.

In accord with the system described above, the method may also comprise providing at least one of a hydraulic mechanism, electrical mechanism, pneumatic mechanism, or manual mechanism to move the hose guide between the deployment position and the non-deployed position.

The deployment method may further comprise providing that the hose guide is mounted for movement in a straight line between the deployment position and the non-deployed position.

The deployment method further comprise providing a frame to support the hose guide and mounting the hose guide for movement on the frame between the deployment position and the non-deployed position.

The deployment method may further comprise affixing the frame with respect to the reel of hose.

The deployment method may further comprise providing roller surfaces formed on the frame, and securing a plurality of rollers to the hose guide to support the hose guide as the hose guide is moved between the deployment position and the non-deployed position.

The deployment method may further comprise connecting a piston rod secured to the rollers, securing a piston to the piston rod, and mounting the piston within a piston cylinder.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the invention and many of the attendant advantages thereto will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts and wherein:

FIG. 1A is a side elevational view, partially in hidden lines, of a reel system with the hose guide and pump in a non-deployed or service position in accord with one possible embodiment of the present invention.

FIG. 1B is a front elevational view, partially in hidden lines, of a hose guide and support frame of the system of FIG. 1A in accord with one possible embodiment of the present invention;

FIG. 2A is a side elevational view, partially in hidden lines, of a reel system with the hose guide and pump in a deployment position in accord with one possible embodiment of the present invention.

FIG. 2B is a side elevational view, partially in hidden lines, of another embodiment of a reel system having a longer boom for use with a pump in a cage and with the hose guide and pump in a deployment position in accord with one possible embodiment of the present invention.

FIG. 3 is an enlarged side elevational view, partially in hidden lines, showing a support frame, piston-cylinder, and roller mounted hose guide in the non-deployed or service position in accord with one possible embodiment of the present invention.

FIG. 4 is an enlarged side elevational view, partially in hidden lines, showing a support frame, piston-cylinder, and roller mounted hose guide in the deployment position in accord with one possible embodiment of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings and, more particularly, to FIGS. 1A and 1B, there is shown pump deployment system 10 in accord with one possible embodiment of the present invention.

The preferred embodiment of deployment system 10 of the present invention may be utilized on an offshore rig, which as used herein, may comprise any offshore vessel, rig, or the like, of which there are many kinds, commonly used in drilling, production, maintenance, and repair for offshore oil and gas wells.

Deployment system 10 is utilized in conjunction with a hose reel such as hose reel 12, which may be utilized to reel in and reel out hose 14 for inserting and removing a submersible pump into the water.

Hose 14 may preferably comprise heavy duty collapsible or non-collapsible hose. In one possible embodiment, hose 14 may comprise a rather large diameter in the range of about ten to eleven inches although hose 14 may be any desired diameter suitable for the desired flow rates, e.g., six to twenty inches, although the hose may be larger or smaller. Generally, it will be appreciated that deployment system 10 is required to be useable to handle a large hose with attached corresponding large submersible pump system 30 as necessary for use in offshore rigs.

Hose 14 may typically comprise elastomeric material, plastics, filaments, fibers, and/or other non-metallic material. However, hose 14 may also comprise metallic cable, strands, or the like.

In a presently preferred embodiment, hose 14 is selected to be strong enough to reliably support pump 30 by itself without the need for additional cables or the like. For example, hose 14 may be rated to lift 20,000 lbs and pump 30 may be in the range of less than about five thousand pounds. By utilizing a stronger hose, it is possible to avoid the need for cables to support pump 30 and the associated problems of running additional cables to support pump 30 as has been done in the prior art, as discussed hereinbefore.

In one present preferred embodiment, electrical cable 15 is run inside of hose to supply electrical power to overboard pump 30. In this embodiment, it is not therefore necessary to run additional power lines or the like to the pump, which simplifies deployment of the pump. Suitable connectors are provided for this purpose.

Hose 14 will have a minimum bending radius to which the hose can be bent without a likelihood of damage to the hose. Generally, the larger the diameter of the hose, the greater is the minimum bending radius of the hose. Preventing sharper bends, which may be less than the minimum bending radius, will lengthen the lifetime operation of the hose. Therefore, hose reel 12 and hose guide/bend restrictor 38 are, in one preferred embodiment, selected with the minimum bending radius in mind, as discussed in more detail hereinafter.

It will be noted that several wraps or layers of hose may typically be found on hose reel 12, even though hidden lines show that hose 14 connects directly to swivel joint connector 16 in FIG. 1A. It will be understood, that hose reel 12 contains a sufficient length of hose 14 to lower pump 30 to the desired level in the water below deck floor 18. If desired, additional hose may be provided on hose reel 12 so that if some hose is cut off, then the same hose reel may be used without the need to change out the hose reel. For example, FIG. 2B shows another possible entry position of hose 14 onto hose reel 12 near to and roughly aligned with reel circumference 20.

Hose reel 12 is supported for rotation on hose reel frame 22, which may comprise base 24 and/or other components. Additional struts, beams, or the like may be utilized to make hose reel frame 22. Accordingly, it will be appreciated that hose reel frame 24 may be built in many different ways to support the hose reel and operation thereof. The drive system to rotate hose reel 12 is not shown but may comprise suitable means to rotate hose reel 12 such as hydraulic, electrical, or mechanical drive mechanisms.

A frame or deployment frame, which may be a rigid frame, is utilized to support bend restrictor 38. As one example, deployment frame 28 comprises and preferably rigidly supports deployment boom 26 such that deployment boom 26 extends outwardly over the side of the rig. However, if desired, deployment boom 26 and/or deployment frame 28 could be moveable, such as pivotable.

In one presently preferred embodiment, deployment boom 26 may comprise an I-beam or other type of beam. As one possible non-limiting example, the components of the I-beam are shown from the front in FIG. 1B and include an upper horizontal flange 58, a lower horizontal flange 56, and a vertical member 60.

In a presently preferred embodiment, deployment frame 28 is rigidly mounted to hose reel frame 22, and may be welded or bolted thereto. In this way, the entire structure may be supplied as a single unit, which is then placed on at a desired position on the floor of the rig adjacent the side of the rig. Deployment frame 28 may comprise additional support elements such as struts, columns, beams, and the like, as desired. This construction rigidly secures reel frame 22 with respect to deployment boom 26 so that deployment boom 26 and reel 12 do not move with respect to each other.

Other or separate constructions for deployment boom support frame 28 can be provided but should be mounted so that reel 12 and deployment boom 26 are secured to the rig floor deck in a manner that at least limits relative movement therebetween or, as in the preferred embodiment, completely prevents relative movement there between.

In this embodiment, deployment boom 26 is a straight elongate boom mounted to be perpendicular to an axis of reel 12 and is aligned with the flanges 42 of hose reel 12 as indicated in FIG. 1B. In this way, boom 26 is also aligned with the lay of hose 14, where each wrap of hose may be stacked vertically on top of each other, as indicated in FIG. 1B. While deployment boom 26 is preferably mounted perpendicular to an axis of reel 12, it could also be mounted substantially perpendicular, e.g. within plus or minus ten degrees from the perpendicular.

The width of reel flanges 42 is, in this embodiment, sized slightly larger than the diameter of hose 14 so that each wrap of hose is constrained to lay on top of each other. In other words, each wrap includes only a single loop rather than having wraps which multiple loops to form layers where the hose is laid side to side.

However, multiple hoses may be provided on hose reel 12 for simultaneous deployment. For example two or possibly more hoses with attached pumps may simultaneously be deployed from the same hose reel 12. In this case, deployment boom 14 may deployment both hoses using the same or multiple bend restrictors.

The organization of using wraps with single loops for each hose in accord with a preferred embodiment aids substantially in or completely prevents lateral bends in hose 14. If each wrap comprised multiple loops then additional lateral stress occurs as the hose is reeled on and off due to lateral movement.

Although the present invention could incorporate additional multiple loop wraps, the resulting deployment mechanism may then require a longer spacing between hose reel 14 and bend restrictor 38 to reduce the bending stress created thereby. However in the present embodiment, due to using wraps with single loops, hose guide or bend restrictor 38 may be positioned quite closely to hose reel 12. For example, in the embodiment of FIG. 1A, hose guide or bend restrictor 38 is less than a few feet, or about seventy inches from the exit position 40 of hose 14 from hose reel 12.

In the embodiment shown in FIG. 1A, deployment boom 26 is rigidly fixed in a horizontal or substantially horizontal position but could be angled upwardly or downwardly, if desired.

In a presently preferred embodiment, hose reel 12 is preferably suitably sized so that hub 43, which supports the smallest diameter wrap of hose 14, prevents damage to hose 14 due to the limited bending radius of hose 14. As the hose is wrapped on top of the bottom wrap, the sharpness of the bend on each successive layer decreases.

Deployment boom 26 may be utilized to deploy and retrieve pump 30, which comprises a submersible pump system. In FIG. 1A, pump 30 is in a non-deployed position above deck floor 18. In the non-deployed position, operators can access pump 30 and/or connection 32 to hose 14 for maintenance purposes. In a preferred embodiment, bend restrictor 38 is moved closer to hose reel 12 in the non-deployed position, perhaps inches to several feet, and away from reel 12. In the deployed position, bend restrictor 38 may be moved typically by about five to fifteen feet away from hose reel 12, so that there is a clearance of a few inches to a few feet with the side of the rig floor.

In FIG. 2A, pump 30 is in a deployment position for deployment over the side of the rig. In this example, bend restrictor 38 and pump 30 has been moved outwardly by about seventy-four inches from the non-deployed position so that pump 30 now has a clearance of about thirty inches from edge 34 from rig floor 18. In this position, pump 30 can now be lowered into the water around the offshore rig. In FIG. 2B, bend restrictor 38 and pump/cage assembly 36 is moved outwardly from the non-deployed position by about double the distance of the embodiment of FIG. 1B, or about one-hundred forty inches, whereupon pump and cage 36 has a clearance of about two feet distance with respect to edge 34 of rig floor 18.

In this embodiment, bend restrictor 38 is moved in a straight line deployment path along deployment boom 26 utilizing a hydraulic mechanism. It will be appreciated that the deployment path is predetermined and fixed. However, if desired, the deployment path could be a curved path but is nonetheless predetermined and fixed. As well, it will be understood that bend restrictor 38 could be moved by an electrical mechanism, pneumatic mechanism, or manual mechanism, if desired.

As perhaps best shown in FIG. 3 and FIG. 4, hydraulic piston 44 is moved between the non-deployed position and deployed position utilizing hydraulic piston 44 operating in cylinder 46. It will be understood that hydraulic connections (not shown) may be utilized at each end of cylinder 46 to control movement in both directions. Movement of piston 44 then moves shaft 48, which is connected to roller guide 50 of bend restrictor 38.

In this embodiment, roller guide 50 comprises a plurality of upper rollers 52 and lower rollers 54 supported on metal bars, such as upper bar 62 and lower bar 64. The rollers can be utilized to reduce friction during movement with respect to lower flange 56 of deployment boom 26 along a predetermined and, in this embodiment, straight deployment path. Rollers are not necessarily required. Other means might be utilized to move bend restrictor 36 such as, for example only, various types of gears, chains, ratchets, linkages, belts, or the like.

In this embodiment, curved hose support member 66 is carried by roller guide 50. For this purpose, brackets 68 and 70 (see FIG. 3 and FIG. 4) may be secured to opposite ends of curved hose support member 60, wherein bracket 68 is longer than bracket 70 due to the orientation of curved hose support member 66.

Curved hose support member 66 provides a frame for wheels or rollers 72, which guides hose 14 along a predetermined curved path designed so that the hose can bend from hose reel 12 to a vertical position for entering the seawater, preferably with a bend that has greater bend radius than the minimum bend radius for hose 14.

Although not necessarily required, a plurality of rollers, such as rollers 72, are mounted to curved hose support member 66 on the frame formed by curved support member 66 and/or other such members. If desired, the rollers may have a concave profile so as to be shaped to mate to the hose. Thus, in a presently preferred embodiment, hose guide or bend restrictor 38 provides a curved support equivalent to a large rotatable wheel but without the need for a large wheel to provide suitable support for preventing too sharp of a bend in hose 14. At a minimum, hose guide or bend restrictor 38 limits the bending of hose 14.

In operation, pump deployment system 10 is positioned adjacent edge 34 of the deck floor of an offshore rig as shown in FIG. 1A, FIG. 2A and FIG. 2B. It is not necessary to build special scaffolding to utilize pump deployment system 10 of the present invention. Thus, the present invention avoids the time and cost of sending the offshore rig to the shipyard for modification.

After being mounted on the rig floor, bend restrictor 38 may initially be placed in the non-deployed position in order to service or connect pump 30 to hose 14. When the pump is connected to hose 14 and ready to be deployed, an actuator (in this case hydraulic piston 44) is utilized to move bend restrictor 38 to a deployment position. Movement is preferably along a straight line deployment path which is perpendicular to an axis of rotation of hose reel 12 directly away from hose reel 12 until pump 30 is positioned over the side of the offshore rig on the outside of edge 34 of rig floor 18. At a minimum, the deployment path is fixed and predetermined but could be curved. At this point, hose reel 12 can be rotated to lower submersible pump 30 into the seawater. Once in the water, submersible pump 30 may be operated to pump seawater. Electrical cables and the like to power pump 30 are not shown.

Many additional changes in the details, components, steps, and organization of the system, herein described and illustrated to explain the nature of the invention, may be made by those skilled in the art within the principle and scope of the invention. It is therefore understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.

Claims

1. A deployment system for deploying an overboard pump over the side of an offshore rig into water, comprising:

a reel frame;

a reel of hose mounted to said reel frame, said overboard pump securable to an end of said reel of hose;

a rigid elongate deployment boom secured with respect to said reel frame, said deployment boom being mounted perpendicular or substantially perpendicular to an axis of rotation of said reel;

a moveable bend restrictor which guides said hose from said reel and supports said hose as said hose bends downwardly for deployment into said water, said bend restrictor being mounted to said deployment boom for movement along a deployment path, said deployment boom defining said deployment path to be predetermined and fixed along a length of said deployment boom, said bend restrictor being movable away from said reel to a deployment position to permit said overboard pump and said hose to be deployed over said side of said rig into said water, said bend restrictor being movable toward said reel to a non-deployed position such that said bend restrictor is positioned above said rig floor.

2. The deployment system of claim 1, further comprising a curved frame for said bend restrictor, a plurality of rollers being mounted to said curved frame to support said hose, said curved frame and said plurality of rollers being defining a curved path for said hose which prevents said hose from bending less than a minimum bending radius for said hose.

3. The deployment system of claim 1, further comprising at least one electrical cable to supply power to said overboard pump, said at least one electrical cable being positioned inside said hose.

4. The deployment system of claim 1, wherein said overboard pump weighs over fifteen hundred pounds and is supported only by said hose when in said deployed position.

5. A method for making a deployment system for deploying an overboard pump over the side of an offshore rig into water, comprising:

providing a reel frame;

mounting a hose reel to said reel frame;

securing a rigid deployment frame with respect to said reel frame;

providing a moveable bend restrictor which receives hose from said reel and supports said hose as said hose bends downwardly for deployment into said water;

mounting said moveable bend restrictor to said deployment frame such that movement is constrained along a straight line whereby said moveable bend restrictor is movable away from said reel to a deployment position to permit said overboard pump and said hose to be deployed over said side of said rig, said moveable bend restrictor being movable along said deployment frame with respect towards said reel to a non-deployed position such that said bend restrictor is positioned above said rig floor.

6. The method of claim 5, further comprising providing a curved frame for said moveable bend restrictor, and mounting a plurality of rollers to said curved frame to support said hose, providing that said curved frame and said plurality of rollers define a curved path for said hose which prevents said hose from bending less than a minimum bending radius for said hose.

7. The method of claim 5, further comprising providing a plurality of roller surfaces on said deployment frame, and providing a plurality of rollers secured to said bend restrictor operable to support said bend restrictor on said roller surfaces as said bend restrictor is moved between said deployment position and said non-deployed position.

8. The method of claim 5, further comprising providing an elongate deployment boom as part of said deployment frame.

9. The method of claim 5, further comprising positioning at least one electrical cable inside said hose to supply power to said overboard pump.

10. A method for making a deployment system for deploying an overboard pump over the side of an offshore rig or vessel, comprising:

providing a reel of hose to which an overboard pump may be secured;

providing a moveable bend restrictor to support said hose as said hose bends downwardly for deployment in water;

providing that said moveable bend restrictor is mounted so as to be constrained to a pre-determined and fixed path of movement with respect to said reel whereby said moveable bend restrictor is movable away from said reel to a deployment position to permit said overboard pump and said hose to be deployed over said side of said rig, said bend restrictor being movable to a non-deployed position above said rig floor.

11. The method of claim 10, further comprising providing a curved frame for said moveable bend restrictor, and mounting a plurality of rollers to said curved frame to support said hose, providing that said curved frame and said plurality of rollers define a curved path for said hose which prevents said hose from bending less than a minimum bending radius for said hose.

12. The method of claim 9, further comprising providing roller surfaces formed on said frame, and securing a plurality of rollers to said bend restrictor to support said bend restrictor as said bend restrictor is moved between said deployment position and said non-deployed position.

13. The method of claim 9, further comprising positioning at least one electrical cable inside said hose to supply power to said overboard pump.