BATTERY POWERED SUBSEA PUMPING SYSTEM

Abstract

A battery powered pumping skid system comprises a frame, comprising a battery compartment and an equipment compartment; a battery disposed within the battery compartment; a motor operatively connected to the battery and disposed within the equipment compartment; a pump operatively connected to the motor and disposed within the equipment compartment; and a motor controller operatively connected to the battery and the motor and disposed within the equipment compartment. Optionally, one or more floatation compartments with one or more floats may be provided. Powered operation may be provided to a subsea device by deploying the battery powered pumping skid system subsea, either on an as needed or longer term basis, maneuvering the battery powered pumping skid system close to a subsea device, and, once in place, using the battery powered pumping skid system to perform one or more predetermined functions with respect to the subsea device, such as supplying a fluid from the pump to the subsea device using electrical power from the battery.

Description

RELATION TO OTHER APPLICATIONS

This application claims priority through U.S. Provisional Application 61/933,094 filed Jan. 29, 2014 and U.S. Provisional Application 62/012,030 filed Jun. 13, 2014.

BACKGROUND

Some subsea devices can require power, potentially large amounts of power, to effect certain functionality. By way of example and not limitation, blowout preventers (BOPS) currently have large accumulator bottles on them that store hydraulic fluid under high pressures. This accumulated power is used in the event of an emergency blowout or loss of control of the well to close the BOP rams. When closed, the BOP rams are capable of shearing a drill pipe in the well bore and containing the well bore pressures. The BOP accumulator systems have a number of negative implications, e.g. they take up a lot of space on the BOP stack; they weigh a lot; and they have reduced efficiency as water depth increases.

Accordingly, skid supplied power may be used but skid architecture typically uses power from a remotely operated vehicle (ROV) or an umbilical to accomplish tasks like these. Normal skid architecture known in the industry uses power from the ROV or an umbilical to provide the power required to drive a motor/pump in a subsea environment. However an ROV may not be able to supply enough power to close the BOP rams within the specified time outlined by API 53. No current ROV-based BOP skid in the industry can meet the requirements set by API 53.

FIGURES

Various figures are included herein which illustrate aspects of embodiments of the disclosed inventions.

FIG. 1 is a block diagram of an exemplary system;

FIG. 2 is a top view schematic diagram of an exemplary skid;

FIG. 3 is a view in partial perspective of an exemplary battery;

FIG. 4 is a block diagram of an exemplary battery module;

FIG. 5 is a view in partial perspective of an exemplary pump and motor;

FIG. 6 is a side view in partial perspective of a further exemplary skid; and

FIG. 7 is a block view in partial perspective of an exemplary skid deployment.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

The various powered pumping skid systems disclosed herein contain one or more batteries, electric motors, motor controllers and/or variable frequency drives, electrical contacts, and pumps. In combination, these elements may be configured to be capable of pumping seawater or other fluid media at power rates from around zero to over 500 horsepower. The disclosed systems will typically be capable of pumping over 100 GPM at 5,000 PSI for two minutes before requiring recharge, but the actual flow rate will be controllable by varying the motor speed, if required. Run time may be longer than two minutes when running at less than full pressure or full speed.

A block diagram of battery powered subsea pumping skid 1 (FIG. 2) or 2 (FIG. 6) is shown in FIG. 1 where the disclosed battery powered subsea pumping skids (1 (FIG. 2), 2 (FIG. 6)) use batteries to provide the amounts of power required to drive a motor/pump in a subsea environment. Using battery powered subsea pumping skid 1 or 2, amounts of power required for certain subsea functionality may be supplied in a short period of time that could not otherwise be supplied by a work class remotely operated vehicle (ROV) such as ROV 300 (FIG. 7).

Referring now to FIGS. 1 and 2, in an embodiment battery powered pumping skid 1 comprises frame 10; equipment compartments 102, 105, 109; one or more battery modules 40 disposed within battery compartments 104, 106; motor 20 operatively connected to one or more battery modules 40 and disposed within one or more of equipment compartments 102, 105, 109, and more preferably within equipment compartment 105; pump 30 operatively connected to motor 20 and disposed within one or more of equipment compartments 102, 105, 109; motor controller 22 operatively connected to one or more battery modules 40 and to motor 20, where motor controller 22 is disposed within one or more of equipment compartments 102, 105, 109. In some embodiments, battery powered pumping skid skid 1 further comprises one or more floatation compartments 101, 103, 107, 108 and one or more floats 50 disposed within at least one of floatation compartments 101, 103, 107, 108.

In embodiments, battery powered pumping skid 1 may weigh approximately 3,500 pounds (lbs) in air, be neutrally buoyant in seawater, and/or be around 9 feet by 5 feet by 20 inches in dimension.

Typically, frame 10 is configured to be neutrally buoyant in seawater and made with extruded aluminum. Frame 10 may be configured to be mountable to a work class ROV, e.g. ROV 300 (FIG. 7), or a work class ROV cage and may further be configured to be affixed to a subsea piece of equipment such as a tree, a manifold, a blowout preventer (BOP) stack, or the like, or a combination thereof. In certain embodiments, frame 10 may be configured to allow battery powered pumping skid 1 to be disposed on or proximate sea floor 350 (FIG. 7).

Frame 10 typically comprises one or more battery compartments, e.g. 104 and 106, and is typically substantially rectangular, although it need not be so shaped, although. substantially rectangular shape is typically desired if battery powered pumping skid skid 1 is to be attached or otherwise mounted to an ROV.

In embodiments, frame 10 comprises a plurality of floatation compartments 101, 103, 107, 108 and float 50 comprises a corresponding plurality of floats 50, each float 50 of the plurality of floats 50 disposed within a corresponding one of plurality of floatation compartments 101, 103, 107, 108. If present, one or more floatation compartments 50 are typically disposed at predetermined portions of frame 50 which, in a preferred embodiment, comprises each of the four corners of frame 50. Other locations are also possible, by way of illustration and not limitation including top, bottom, and/or at the sides of frame 50.

Motor 20 may comprise an oil-filled, pressure compensated motor 20, such as one comprising a 16 pole permanent magnet 3 phase AC motor capable of 400 shaft horsepower at 1,200 RPM. Motor 20 may also comprise a variable frequency drive 24.

Motor controller 22 may comprise a pressure tolerant, oil filled controller capable of driving the 400 HP motor from a DC source of 435-630 Volts.

One or more equipment compartments, e.g. 102, 105, 109, may be present and variously configured. In an embodiment, motor compartment 105 is disposed substantially within a middle interior portion of frame 10, such as by having motor 20 disposed within motor compartment 105; pump compartment 109 is disposed proximate a middle exterior section of frame 10, with pump 30 disposed within pump compartment 109; and controller compartment 102 is disposed proximate a middle exterior section of frame 10 opposite pump compartment 109, where motor controller 22 is disposed within controller compartment 102. However, as the need arises, any of these (motor 20, motor controller 22, pump 30) may be disposed at least partially within a single equipment compartment or span several equipment compartments, e.g. 102, 105, 109.

One or more battery modules 40 may be disposed within one or more battery compartments. In typical embodiments, first battery compartment 104 and second battery compartment 106 are present, each disposed towards an outer perimeter of frame 10 proximate a middle section of frame 10, but disposed opposite each other. In such embodiments, first battery module 40a is typically disposed within first battery compartment 104 and second battery module 40b disposed within second battery compartment 106.

Referring additionally to FIGS. 3 and 4, one or more battery modules 40 may comprise pressure tolerant battery 42 (FIG. 3) which may be a pressure tolerant lithium polymer battery 42 (FIG. 3). Each battery module 40 may comprise a number of separate battery modules 40, e.g. six separate modules 4, where each battery module 40 contains a predetermined number of batteries 42.

In embodiments, battery 42 may comprise battery housing 41, one or more pressure tolerant battery cells 42 disposed within battery housing 41, and one or more contacts 44 configured to prevent live pins, i.e. pins that are conducting electricity, until everything is plugged in and a signal is received to become conductive.

In embodiments, battery housing 41 may comprise an oil-filled, pressure compensated housing 41. In a further embodiment, battery housing 41 may comprise a pressurized housing, by way of illustration and not limitation including a one atmosphere subsea canister which may then contain one or more batteries 42 adapted for use in such a canister. In a further embodiment, battery housing 41 may comprise a potted unit which contains no oil inside and in which an epoxy fills all voids in between cells and the like.

Each pressure tolerant battery cell 42 may further comprise a lithium polymer pressure tolerant battery cell which may be configured to provide around 500 VDC at up to 900 amperes. In other configurations, pressure tolerant cells 42 may be configured to allow one or more battery modules 40 to provide a predetermined voltage, e.g. 555 Volts DC nominal, having a predetermined discharge capacity, e.g. 5 Ampere hours, and be configured to discharge continuously at a predetermined rate, e.g. 30C 150 Amps and 50C peak 250 Amps.

In typical embodiments, battery modules comprise a 150 slp configuration of lithium polymer pressure tolerant cells 42, although, as will be familiar to those of ordinary skill in the battery arts, other battery types may be used, by way of illustration and not limitation including lithium iron phosphate, nickel metal hydrate, or the like, or a combination thereof. Alternatively, other battery modules may be used, by way of illustration and not limitation including 10 s2p modules and the like.

In an alternative embodiment, to allow for long term standalone subsea deployment without the need for recharging, one or more thermal batteries 43 may be used. These may be configured to supply sufficient amounts of power for functions such as blowout preventer (BOP) intervention work and the like and may include long shelf life.

In embodiments, batteries 42 will be rechargeable subsea such as via an ROV umbilical or other power source or at a different location such as topside.

Typically, battery powered subsea pumping skid 1 will be able to operate at full pressure on less than all of battery modules 40 being available without damage to batteries 42. This allows battery powered subsea pumping skid 1 to continue to perform in the event of an emergency or where one or more of battery modules 40 is down or otherwise unavailable.

Referring back to FIG. 1 and to FIG. 5, pump 30 is operatively connected to motor 20 and typically comprises a high flow, high volume pump. Pump 30 is further typically configured to be capable of pumping seawater or other fluid media at power rates from around zero to over 500 horsepower with a flow rate of around 110 GPM at 1,200 RPM, at up to around 5,000 PSI. Pump 30 may comprise an axial piston pump. Pump may further contain no oil for lubrication.

Battery recharge port 11 may be present and operatively connected to one or more battery modules 40, especially where battery module 40 comprises a rechargeable battery 42. Typically, battery recharge port 11 comprises a remotely operated vehicle (ROV) umbilical compatible battery recharge port.

In a further embodiment, referring now to FIG. 6, battery powered pumping skid system 2 comprises substantially rectangular frame 210 configured to be neutrally buoyant in seawater, frame 210 comprising first row 211, third row 213 disposed opposite first row 211 within frame 210, and second row 212 disposed intermediate first row 211 and third row 213. Each row 211, 212, 213 comprises three columns: 214, 215, 216. The three rows 211, 212, 213 and three columns 214, 215, 216 define nine separate compartments. Battery powered pumping skid system 2 further comprises one or more floats 250 disposed in outer compartments first row 112 and/or third row 114. Various covers, e.g. 217 and 221, may cover one or more individual compartments or portions thereof.

One or more first battery modules 240 (shown in FIG. 6 but obscured by cover 217) may be disposed within middle compartments first row 211 and third row 213.

Motor 220 (shown in FIG. 6 but obscured by cover 221) is operatively connected to at least one of the first battery modules 240 and typically disposed within an interior compartment of second row 212. Motor controller 222 (shown in FIG. 6 but obscured by cover 223) is typically operatively connected to at least one of the first battery modules 240 and motor 220, and is typically disposed in a middle compartment of outer column 216.

Pump 230 is operatively connected to motor 220 and is typically disposed within an outer compartment of column 214.

One or more umbilical interfaces 218 may be present and adapted to provide an interface between an umbilical such as an ROV umbilical and one or more components in battery powered pumping skid system 2 such as motor 220, motor controller 222, pump 230, and/or battery modules 240. In certain embodiments, one or more battery modules 240 may comprise one or more rechargeable batteries 42 and umbilical interface 218 may further comprise a battery recharge interface operatively connected to rechargeable battery 42.

Additionally, one or more instruments 219 may be disposed on, within, or proximate frame 210 and be operatively in communication with umbilical interface 218, such as, by way of example and not limitation, a pressure transducer, a flow meter, a temperature sensor, and the like, or a combination thereof, where instruments 219 may be configured to relay performance information in real time using umbilical 303 (FIG. 7) operatively connected to umbilical interface 218 to another instrument device such as a processor on a remotely operated vehicle, e.g. vessel 320 (FIG. 7).

In the operation of exemplary embodiments, referring additionally to FIG. 7, a battery powered subsea pumping skid such as battery powered subsea pumping skid 1 (FIG. 2) or battery powered subsea pumping skid 2 (FIG. 6 and FIG. 7) is maneuvered close to a subsea device such as BOP 310. Battery powered subsea pumping skid 2 may have a full set of charged batteries 42 (FIG. 2) and/or may have its battery modules 40 (FIG. 2) charged once disposed subsea, such as via battery recharge port 11 operatively connected to ROV umbilical compatible battery recharge port 302.

Once in place, skid 1 (FIG. 2) (or skid 2 (FIG. 6)) is used to perform one or more functions with respect to the subsea device, by way of example and not limitation including closing BOP rams by using pump 30 driven by motor 20 to deliver pressure and flow to the BOP rams.

When deployed, one or more instruments 219 (FIG. 6) may be placed into communication with a monitoring system such as ROV 300 or topside vessel 320, such as via umbilical 303 operatively connected to umbilical interface 218. Instruments 219 can then be used to monitor one or more desired environmental characteristics such as pressure, flow, temperature, and the like, or a combination thereof, and relay the information in real time via back to the monitoring system.

In certain embodiments, a battery powered subsea pumping skid (1 (FIG. 2) or 2 (FIG. 7)) are deployed on as-needed basis. In other embodiments, the battery powered subsea pumping skid may be deployed long term subsea without the need for continuous maintenance and charging of the power supply. This enables a standalone solution, e.g. a BOP intervention solution, to be deployed substantially continuously for a length of time, e.g. 2 months or less, for standalone or ROV controlled operation.

The foregoing disclosure and description of the inventions are illustrative and explanatory. Various changes in the size, shape, and materials, as well as in the details of the illustrative construction and/or an illustrative method may be made without departing from the spirit of the invention.

Claims

1. A battery powered pumping skid system, comprising:

a. a frame, comprising: i. a battery compartment; and ii. an equipment compartment;

b. a battery disposed within the battery compartment;

c. a motor operatively connected to the battery and disposed within the equipment compartment;

d. a pump operatively connected to the motor and disposed within the equipment compartment; and

e. a motor controller operatively connected to the battery and the motor and disposed within the equipment compartment.

2. The battery powered pumping skid system of claim 1, further comprising:

a. a floatation compartment; and

b. a float disposed within the floatation compartment

3. The battery powered pumping skid system of claim 2, wherein:

a. the floatation compartment comprises a plurality of floatation compartments; and

b. the float comprises a corresponding plurality of floats, each float of the plurality of floats disposed within a corresponding one of plurality of floatation compartments.

4. The battery powered pumping skid system of claim 1, wherein the frame is configured to be neutrally buoyant in seawater.

5. The battery powered pumping skid system of claim 1, wherein:

a. the frame is substantially rectangular;

b. the battery compartment comprises a first battery compartment and a second battery compartment, each disposed towards an outer perimeter of the frame proximate a middle section of the frame; and

c. the battery comprises a first battery disposed within the first battery compartment and a second battery disposed within the second batter compartment.

6. The battery powered pumping skid system of claim 1, wherein:

a. the frame is substantially rectangular;

b. the equipment compartment comprises: i. a motor compartment disposed substantially within a middle interior portion of the frame; ii. a pump compartment disposed proximate a middle exterior section of the frame; and iii. a controller compartment disposed proximate a middle exterior section of the frame opposite the pump compartment;

c. the motor is disposed within the motor compartment;

d. the pump is disposed within the pump compartment; and

e. the motor controller is disposed within the controller compartment.

7. The battery powered pumping skid system of claim 1, further comprising a battery recharge port operatively connected to the battery, the battery comprising a rechargeable battery.

8. The battery powered pumping skid system of claim 7, wherein the battery recharge port comprises a remotely operated vehicle umbilical compatible battery recharge port.

9. The battery powered pumping skid system of claim 1, wherein the battery comprises a pressure tolerant battery.

10. The battery powered pumping skid system of claim 1, wherein the battery comprises a pressure tolerant lithium polymer battery.

11. The battery powered pumping skid system of claim 1, wherein the battery compartment comprises a one atmosphere subsea battery housing.

12. The battery powered pumping skid system of claim 1, wherein the battery comprises a battery module comprising:

a. a battery housing;

b. a pressure tolerant battery cell disposed within the battery housing; and

c. a contact configured to prevent live pins until everything is plugged in and a signal is received.

13. A method of providing power to a subsea device, comprising:

a. deploying a battery powered pumping skid system subsea, the battery powered pumping skid system comprising: i. a frame, comprising: 1. a battery compartment; and 2. an equipment compartment;

ii. a battery disposed within the battery compartment; iii. a motor operatively connected to the battery and disposed within the equipment compartment; iv. a pump operatively connected to the motor and disposed within the equipment compartment; and v. a motor controller operatively connected to the battery and the motor and disposed within the equipment compartment;

b. maneuvering the battery powered pumping skid system close to a subsea device; and

c. once in place, using the battery powered pumping skid system to perform a predetermined function with respect to the subsea device, the predetermined function comprising supplying a fluid from the pump to the subsea device using electrical power from the battery.

14. The method of providing power to a subsea device of claim 13, wherein the predetermined function comprises closing a blowout preventer (BOP) ram by using the pump driven by the motor to deliver fluid pressure and flow to the BOP ram.

15. The method of providing power to a subsea device of claim 13, further comprising:

a. providing an instrument; and

b. placing the instrument into communication a monitoring system.

16. The method of providing power to a subsea device of claim 15, further comprising placing the instrument into communication a monitoring system via an umbilical interface.

17. The method of providing power to a subsea device of claim 15, further comprising:

a. using the instrument to monitor a predetermined sensed characteristic; and

b. relaying the sensed characteristic in real time via back to the monitoring system.

18. The method of providing power to a subsea device of claim 17, wherein the sensed characteristic comprises pressure, flow, and/or temperature.

19. The method of providing power to a subsea device of claim 13, further comprising deploying the battery powered pumping skid system on as-needed basis.

20. The method of providing power to a subsea device of claim 13, further comprising deploying the battery powered pumping skid system on a long term basis subsea without a need for continuous maintenance and charging of the battery.