submersible fluid system for operating submerged in a body of water and method for coupling an elect

专利摘要:
COUPLING OF AN ELECTRIC MACHINE AND FLUID END. A submersible fluid system for submerged operation in a body of water includes a fluid end having a fluid rotor disposed in a fluid end housing. An electrical machine housing is coupled to the fluid end housing and includes a hermetically sealed cavity. An electrical machine, such as a motor and/or generator, is disposed entirely within the cavity of the electrical machine housing. The electrical engine includes an electrical engine stator and an electrical engine rotor. A magnetic coupling couples the electric machine rotor and the fluid rotor.
公开号:BR112015005563B1
申请号:R112015005563-0
申请日:2012-09-12
公开日:2021-04-20
发明作者:Christopher E. Cunningham；Co Si Huynh
申请人:Fmc Technologies, Inc；
IPC主号:

专利说明:

FUNDAMENTALS
[001] Operation of fluid systems such as pumps, compressors, mixers, separators and other such systems submerged in water is difficult because the operating environment is harsh, especially if this environment is deep sea water. The water around the system and often the process fluid that flows through the system is corrosive. The environment can be cold, making many materials brittle and causing large thermal expansion/contraction of equipment as equipment cycles between hot operating state and cold non-operating state. The hydrostatic pressure of water and/or process fluid can be substantial. In addition, installation and access to fluid systems for maintenance and repair is difficult and expensive, as the systems are often deployed in geographically distant locations and at depths inaccessible by divers, thus requiring purpose-built ships, qualified personnel and equipment. robotics. SUMMARY
[002] The concepts here encompass a submersible fluid system to operate submerged in a body of water. The submersible fluid system includes a fluid end that has a fluid rotor disposed in a fluid end housing. An electrical machine housing is coupled to the fluid end housing and includes a hermetically sealed cavity. An electrical machine, such as a motor and/or generator, is disposed entirely within the cavity of the electrical machine housing. The electrical engine includes an electrical engine stator and an electrical engine rotor. A magnetic coupling couples the electric machine rotor and the fluid rotor.
[003] The concepts here encompass a method of coupling an electrical machine to a fluid end of a submersible fluid system. According to the method, an electric machine rotor is held in an area of a first pressure which is hermetically sealed from a fluid end fluid rotor. The fluid end fluid rotor resides in an area of a second different pressure. The electric motor rotor is coupled to the fluid rotor with a (no touch) magnetic coupling through a stationary wall between the electric machine rotor and the fluid rotor. The (no touch) magnetic coupling makes the fluid rotor move with the electric machine rotor, or vice versa.
[004] The concepts here encompass a submersible fluid end. A has a shaft contained in a submersible fluid end housing. The shaft has a permanent magnet. The has a rotor extending into the electric machine. The motor has a permanent rotor magnet and the rotor resides in a hermetically sealed cavity defined by an electrical machine housing. The permanent magnet resides close to the rotor permanent magnet communicating magnetic flux between the permanent magnet and pump permanent magnet to couple the shaft with the rotor shaft.
[005] The above concepts may cover some, none, or all of the following features.
[006] In certain cases, one end of the fluid rotor may extend into an inner hole of the electric machine rotor and a magnet is coupled to an outer end of the fluid rotor. Another magnet is attached to the electric machine rotor, and resides inside the hole of the electric machine rotor. A wall is provided between the magnets. In certain cases, the wall includes a substantially non-magnetically conductive cylinder. In certain cases, a support may be provided which extends from one end of the electrical machine housing to the fluid end housing which secures the cylinder between the support and the fluid end housing. The bracket can be spring biased towards the fluid end housing. In certain cases, a fluid passage may be provided through the support and into an interior of the cylinder. The fluid passage can be coupled to receive fluid from outside the fluid system and communicate fluid to an interior of the cylinder. In certain cases, this fluid can be substantially gas. In certain cases, the cylinder may be an inner sleeve made of gas-impermeable ceramic or glass within a fiber matrix composite outer sleeve. In certain cases, the outer sleeve can compressively stretch the inner sleeve. In certain cases, the sleeve may include a sealing surface on one end and a sealing surface on an opposite end.
[007] In certain cases, the sealed cavity of the electrical machine housing may contain gas at a pressure of about one atmosphere, and an interior of the cylinder may contain a fluid at a pressure of about the pressure of the fluid entering the rotor of fluid at the fluid end. In certain cases, the seals sealing the cavity from the fluid end housing are entirely static seals. In certain cases, the electric machine includes a magnetic bearing supporting the electric machine rotor to rotate inside the electric machine stator. The magnetic bearing can be entirely contained within the sealed cavity. In certain cases, the fluid end may contain a fluid film-like bearing supporting the fluid rotor. In certain cases, the electric machine rotor includes a permanent magnet that interacts with the electric motor stator to rotate the electric machine rotor relative to the stator and/or to generate electricity when rotated relative to the stator. In certain cases, the electric machine is a motor and the fluid rotor is a pump rotor. DESCRIPTION OF DRAWINGS
[008] Figure 1 is a side view of an example fluid system.
[009] Figure 2A is a cross-sectional side view of an example of an integrated electrical machine and fluid end that can be used in the example fluid system of Figure 1.
[0010] Figure 2B is a cross-sectional side view of a fluid inlet portion and magnetic coupling between an electrical machine rotor and a fluid end rotor in the example fluid system of Figure 2A.
[0011] Figure 2C is a side cross-sectional view of an example fluid end crankcase and fluid outlet portion of Figure 2A.
[0012] Figure 3 is a flow diagram of the example fluid system of Figure 1. DETAILED DESCRIPTION
[0013] Fluid systems of the type described herein act on fluids ("process fluids") which may comprise substantially single phases, for example, water, oil or gas, or a mixture of more than one phase ("multiphase") which may include two or more phases and frequently entrenched solids, eg sand, metal particles and/or rust flakes, wax and/or scale agglomerations, etc. Figure 1 is a side view of an example fluid system. Figure 1 illustrates an example fluid system 100 constructed in accordance with the concepts described herein. Fluid system 100 includes a fluid end 102 coupled to an electrical machine 104. In certain cases, fluid system 100 may also include a fluid separator system 108.
[0014] Fluid system 100 can be operated submerged in open water, for example, outside an injection well or hydrocarbon production in a lake, river, sea or other body of water. To this end, the fluid end 102 and electric motor 104 are packaged within a sealed pressure vessel to prevent the passage of fluid between the interior of the pressure vessel and the surrounding environment (e.g., surrounding water). Fluid system 100 components are constructed to withstand ambient pressure on fluid system 100 and thermal loads exerted by the surrounding environment, as well as pressures and thermal loads incurred when operating electrical machine 104 and fluid end 102.
[0015] In certain cases, for example subsea applications, fluid end 102, electric machine 104 and fluid separator system 108 may be transported on a shim 110 or other fluid system structure 100 that aligns with and engages other subsea structures , for example, by means of guide tubes 112 that capture guide posts of a corresponding underwater structure, or through the interaction of a cone-to-cone plus pin and large cam arrangement (not shown, but familiar to those skilled in the art of systems submarines without a guideline). When the fluid system is referred to as a "subsea" fluid system, this is not to say that the fluid system is designed to operate only on the seabed. Instead, the subsea fluid system is of a type that is designed to operate under the rigors found at or near the bottom of an open body of water, such as an ocean, lake, river, or other body of fresh water. or salty. An auxiliary liquid source 114 can be connected to a shim 110 to supply liquids to the system, for example, corrosion inhibiting chemicals, scale and hydrate.
[0016] One or more dampers 120 may be affixed external to the fluid system 100 to cushion the impact of the fluid system 100 with surfaces, such as on an underwater structure or a transport ship deck. Buffers 120 can be configured to maintain an orientation level of the fluid system 100 in situations where the surface is not flat. Dampers 120 can be fluid dampers or other types of shock or impact absorbing devices.
[0017] As described in more detail below, electrical machine 104 is an alternating current (AC), synchronous, permanent magnet (PM) electrical machine with a rotor that includes permanent magnets and a stator that includes a plurality of formed windings. or cable and a core (typically) of stacked laminations. In other cases, the electrical machine 104 may be another type of electrical machine, such as an AC machine, asynchronous, an induction machine in which both the rotor and stator include windings and laminations, or even another type of electrical machine. Electric machine 104 can operate as a motor for producing mechanical motion from electricity, a generator for producing electrical energy from mechanical motion, or switching between electric and motor power generation. In motor racing, the mechanical movement output of electrical machine 104 can drive fluid end 102. In generation, fluid end 102 provides mechanical movement to electrical machine 104, and electrical machine 104 converts mechanical movement into electrical energy.
[0018] In cases where the fluid end 102 is driven by electric motor 104, the fluid end 102 may include any of a variety of different devices. For example, fluid end 102 may include one or more of rotation and/or shuttle pumps, rotation and/or shuttle compressors, mixing devices, or other devices. Some examples of pumps include centrifuge, axial, rotary vane, gear, screw, lobe, progressive cavity, shuttle, plunger, diaphragm and/or other types of pumps. Some examples of compressors include centrifugal, axial, rotary vane, screw, shuttle and/or other types of compressors, including that class of compressors sometimes referred to as "wet gas compressors" that can accommodate a higher liquid content in the flow. gas than is typical for conventional compressors. In other cases, the fluid end 102 may include one or more of a fluid engine operable to convert fluid flow to mechanical energy, a gas turbine system operable to combust an air/fuel mixture and convert the combustion energy in mechanical energy, an internal combustion engine and/or another type of primary engine. In either case, the fluid end 102 can be a single or multi-stage device.
[0019] While Figure 1 illustrates a vertically oriented electrical machine 104 coupled to a vertically oriented fluid end 102, other implementations may provide for a horizontally oriented electrical machine coupled to a horizontally oriented fluid end, a vertically oriented electrical machine 104 coupled to a horizontally oriented fluid end 102, a horizontally oriented electrical machine 104 coupled to a vertically oriented fluid end 102, as well as yet other orientations of the electrical machine 104 and fluid end 102, including non-linear and non-perpendicular arrangements.
[0020] Although shown with a single fluid end 102, electrical machine 104 may also be coupled to two or more fluid ends 102 (to drive and/or be driven by fluid ends 102). In certain cases, one or more fluid ends 102 may be provided at each end of the electrical machine 104, and in any orientation with respect to the electrical machine 104. For example, in a configuration with two fluid ends 102, one may be provided. at one end of the electric machine 104 and another provided at an opposite end of the electric machine 104, and the fluid ends 102 may be oriented at different angles relative to the electric machine 104. In another example, a configuration with two fluid ends 102 may have one provided at one end of the electrical machine 104 and another coupled to the first fluid end 102. In addition, if multiple fluid ends 102 are provided, they need not all be the same type of device and need not run on the same fluid , that is, they can operate in different fluids.
[0021] Figure 2A is a side cross-sectional view of an electrical machine of example 202 and fluid end 204 that may be used in the fluid end system of example 100 of Figure 1. Fluid end 204 includes a fluid rotor 206 disposed in a fluid end housing 208. Fluid end housing 208 contains process fluids that flow from an inlet 250 proximal to the electrical machine 202 to an outlet 272 distal to the electrical machine. Electric machine 202 is carried by, and contained in, an electric machine housing 210 attached to fluid end housing 208 of fluid end 204 by means of bell end 214a. Electric machine housing 210 is attached at its upper end to bell end 214b, which is attached to cover 233. The aforementioned fastenings are sealed to create a pressure vessel encapsulating electric machine 202 that prevents the passage of fluid between its interior. and the surrounding environment (eg water). Another set of parts and interfaces (described later in this specification) prevent the passage of fluid between electrical machine 202 and fluid end 204. As a result of the aforementioned barriers, electrical machine 202 operates in its own fluid environment, which can be gas or liquid depending on specific exchanges (with gas preferred from a general system efficiency point of view). Figure 2A shows a one-piece subsea fluid system 200 in which electrical machine structural elements 202 attach directly to fluid end structural elements 204.
[0022] Electric machine 202 disposed within electric machine housing 210 includes an electric machine stator 218 and an electric machine rotor 220. Electric machine housing 210 is coupled to fluid end housing 208 and includes a hermetically sealed cavity . The cavity has a gas at a pressure less than the hydrostatic pressure at the specified underwater depth. The electric machine 202 is disposed within the cavity of the electric machine housing. Electric engine stator 218 is interacted with an external power supply by penetrators / connectors 238 which pass through lower bell end 214a. It is known to those skilled in the art of underwater electrical power interconnection systems that minimizing pressure differential acting across these interfaces is recommended for long-term success. Electric machine rotor 220 is magnetically coupled to rotate with process fluid rotor 206 with a magnetic coupling 258. In other cases, a mechanical coupling could be used. Electric machine rotor 220, which may be tubular, includes a rotor shaft (or core, in the case of an AC machine) 221 and permanent magnets 226 affixed to the outside of the rotor shaft 221, particularly in an area close to the core of stator 222. Magnetic coupling 258 couples electric machine rotor 220 and fluid rotor 206 to rotate at the same speed and without contact (i.e., magnetic coupling out of contact). The rotor fluid 206 is arranged to rotate in the fluid end housing 208 and to receive and interact with a process fluid flowing from the inlet 250 to the outlet 272 of the fluid end housing 208. The fluid rotor 206 is configured to push up to the top edge when rotating.
[0023] The permanent magnets 226 are secured to the rotor shaft 221 by a sleeve 228 including any material and/or construction material that does not negatively affect the magnetic field and that satisfies all other design and functional requirements. In certain cases, sleeve 228 may be made from a suitable non-ferrous metal, for example, American Iron and Steel Institute (AISI) 316 stainless steel or a nickel chromium alloy, for example, Inconel (a product of Inco Alloys, Inc.), or may include a composite construction of high strength fibers such as carbon fiber, ceramic fiber, basalt fiber, aramid fiber, fiberglass, and/or other fiber in, for example, a thermoplastic or thermoset matrix. Permanent magnets 226 provide a magnetic field that interacts with a magnetic field of stator 218 for at least one rotation of electrical machine rotor 220 relative to stator 218 in response to electrical energy supplied to stator 218, or to generate electricity in the stator 218 when rotor 220 is moved relative to stator 218.
[0024] Electric machine rotor 220 is supported to rotate on stator 218 by magnetic bearings 230a and 230b separated a significant distance from the length of the electric machine rotor 220, and usually, but not essentially, close to the ends of the machine rotor electrical 220. In at least one alternative to the configuration shown in Fig. 2a, magnetic bearing 230a may be positioned closer to stator core 222 such that a substantial portion or even all of the magnetic coupling 258 extends beyond the magnetic bearing. 230a in what is known to those skilled in the art of rotating machines as an overhung configuration. Magnetic bearing 230a is a combination magnetic bearing ("combo") that supports electric machine rotor 220 both axially and radially, and magnetic bearing 230b is a radial magnetic bearing. In the case of a vertically oriented electrical machine 202, a passive magnetic lifting device 254 may be provided to carry a significant portion of the weight of the electrical machine rotor 220 to reduce the capacity required for the axial portion of the magnetic combo bearing 230a, allowing smaller size and improved dynamic performance for 230a combo bearing. Machines incorporating magnetic bearings typically also include backup bearings 231a and 231b to restrain a 220 motor rotor while rotating to a stop in the event the magnetic bearings are no longer effective, for example, due to power loss or other failure. Spare bearings 231a, 231b will support motor rotor 220 whenever magnetic bearings 230a, 230b are not energized, for example, during transport of fluid system 100. The number, type and/or positioning of bearings on electrical machine 202 and end of fluid 204 may be different for different fluid 100 system configurations.
[0025] Other elements of the electric machine 202 are closely associated with integrated fluid end 204, and an overview of some higher level attributes for subsea fluid system 200 at this time may facilitate a reader's understanding of the functions and integrated operational nature of these other electrical machine elements 202.
[0026] Some modalities of the subsea fluid system 200 may include: an electrical machine 202 the contents of which operate in a gas environment at a pressure of nominally 1 atmosphere delivering lower losses than existing technologies (eg while housing machine 210 is externally exposed to potentially deep water and associated high pressure); an electric machine 202 using magnetic bearings 230a, 230b for additional loss reductions compared to machines operating in a submerged liquid environment using, for example, roller elements or fluid film bearings; a magnetic coupling 258 for which an inner portion 262 is contained in potentially very high pressure process fluid and is isolated from its associated outer portion 293 located within the nominally 1 atmosphere pressure environment of the electrical machine 202 by a static (non-rotating) sleeve 235 which together with its associated static (non-rotating) end seals 246, 248 is capable of withstanding the large pressure differential acting therethrough; an electric machine 202 which because of its 1 atmosphere operating environment, utilizes magnetic bearings 230a, 230b, and uses a magnetic coupling(s) 258 to engage its integrated fluid end(s) 204, produces much less heat during the operation compared to other known technologies (used in subsea fluid system 200 applications) and which, therefore, can transfer its heat to the environment using passive, durable and low-cost materials and techniques (including without circulated refrigerant and impeller associated pump, etc.); a way to cool the magnetic coupling 258 which, under certain circumstances, can allow the submerged process fluid portion of this coupling to rotate within a gas core (with less concordant loss and other advantages); one or more fluid ends 204 employing fluid film bearings 264a, 264b, 274 or any other types of bearings lubricated and cooled by process fluid (e.g., water or oil or a combination thereof), or alternative fluid; one or more fluid ends 204 employing bearings 264a, 264b, 274, provided as fluid film bearings, magnetic bearings or any other types of bearings at these same or different locations, or a combination of all bearing types; an upper inlet/lower outlet vertical fluid end arrangement 204 that provides a crankcase 271 at its lower end to protect fluid film bearings 264b, 274 in a useful environment.
[0027] While the contents of electrical equipment 202 have previously been described as operating in a pressure environment of nominally 1 atmosphere, fluid system 200 may be alternately configured to maintain the contents of electrical machine 202 in a compensated environment to be substantially equal to water pressure around fluid system 200.
[0028] While the magnetic coupling 258 has previously been described with the inner portion 262 in the process fluid and the outer portion 293 in the pressure environment of nominally 1 atmosphere of electrical machine 202, as an alternative, the magnetic coupling 258 can be provided with the opposite topology, having an inner portion in the pressure environment of nominally 1 atmosphere and an outer portion in the process fluid.
[0029] Electric machine housing 210 (and parts thereof) plus magnetic coupling 258 combined with sleeve 235 (and parts thereof) establish three substantially distinct environments that can be exploited at an unprecedented value for submerged fluid systems 200, namely: An inner sleeve of potentially process gas environment 235 at the upper end of the fluid end 204 (otherwise process fluid or multiphase liquid); an outer gas environment sleeve of nominally 1 atmosphere 235 and inner electrical machine housing 210; an underwater environment outside the electrical machine housing 210 (and also outer fluid end housing 208). In an alternative embodiment, the environment within the electrical machine housing 210 may be pressurized (e.g., with gas or liquid) a little or a lot (i.e., any of several levels up to and including that of the process fluid), with exchanges concordant in overall system efficiency (increased losses), possibly different cross section for eg electrical machine housing 210, upper sleeve 296 and lower sleeve 298, reduced sleeve cross section 235 and therefore increased magnetic coupling efficiency 258, different pressure field between, for example, electric power penetrators, different heat management considerations, etc. With the foregoing context, further description will now be provided for electrical machine components 202 and other subsea fluid system components 200.
[0030] In accordance with the present invention, it is to be understood that process fluid can be used to lubricate and cool Fluid film or other types of bearings 264a, 264b, 274 at the fluid end 204, and to cool magnetic coupling 258. It is further understood that the process fluid in liquid form will best meet the needs of lubricated and cooled process bearings (not applicable if the fluid end 204 uses magnetic bearings), and that the process fluid containing at least some of gas may benefit from the coupling-cooling application, i.e., by reducing the loss of drag associated with process fluid rotor movement 206 and heat conduction into sleeve 235. The process fluid for the applications noted may be from any of, or more than one of, several relative locations for subsea fluid system 200 in accordance with the properties of the process fluid at such location. l(s) of source (eg, water, oil, gas, multiphase), the pressure of such source(s) in relation to the point of use, and the properties required for fluid at the point of use. For example, process fluid may be from upstream from subsea fluid system 200, such as from temporary storage tank 278, liquid reservoir 284, or other sources including some not associated with the process stream passing through the subsea fluid system 200 and/or some associated with the process stream passing through the subsea fluid system 200 which are subject to, for example, preconditioning prior to entering the process stream passing through the subsea fluid system 200 (for example, a well stream that is throttled down to a lower pressure before being mixed with one or more lower pressure stream streams including the stream stream ultimately entering subsea fluid system 200). Process fluid may be obtained from the subsea fluid system itself 200 (e.g., from any pressure build-up stages of subsea fluid system 200, near outlet 272, from crankcase 271 and/or immediately adjacent to the respective desired point of use). Process fluid may be sourced downstream of the subsea fluid system 200, for example, from the downstream process flow stream directly or from the liquid extraction unit 287, among others. Non-process stream fluids can also be used for lubrication and cooling, such as chemicals available at the seabed location (which are typically injected into the process stream to inhibit corrosion and/or formation of, for example, hydrates and /or deposition of asphaltenes, scales, etc).
[0031] In cases where the upstream process fluid is used for lubrication and/or cooling, and the source does not exist at a pressure greater than the intended point of use, such process fluid may need to be "pushed" . That is, the pressure of such a process fluid can be increased using, for example, a dedicated/separate auxiliary pump, an impeller integrated with a rotating element within the subsea fluid system 200, or by other means. In certain implementations the pressure drop across the fluid end inlet homogenizer (i.e., mixer) 249 can create a pressure bias sufficient to deliver desired fluids from upstream thereof, e.g., upper radial bearing 264a and chamber of coupling 244, the latter being the space surrounding magnetic coupling interior portion 262 and residing within sleeve 235 (this implementation is discussed further below).
[0032] Regardless of the source of process fluid, it may be refined and/or cleaned before being delivered to the point(s) of use. For example, the multiphase fluid can be separated into a gas, one or more streams of liquids and solids (e.g. sand, metal particles, etc.), with solids typically diverted to flow into the fluid end 204 through its 250 main entrance and/or collected for disposal. Such fluid separation can be achieved using, for example, gravitational means, cyclonic and/or magnetic centrifuges (among other mechanisms) to achieve desired fluid properties for each point of use. After the fluid has been cleaned, it can also be cooled by passing the refined fluid through, for example, thin-walled tubes and/or thin plates separating small channels, etc. (ie heat exchangers) exposed to surrounding water fluid system 200.
[0033] Electric machine 202 includes a cover 233 attached to the upper bell end 214b. For the configuration shown in Figure 2A, point 234 is pressed down on sleeve 235 by spring mechanism 239 reacting between cam bearing ring 240 and cam bearing ring 289. Bell end 214b, electric machine housing 210, end bell 214a, fluid end housing 208, sleeve support ring 270, and various fasteners associated with the above items close the axial load path to tip 234 and sleeve 235. Tip 234 contains an inner axial duct 242 which connects the process environment within sleeve 235 with a cavity provided between the upper end of tip 234 and the lower end of cap 233. Cap 233 includes a duct 245 connecting the lower cavity with the outer service duct 290 which it offers, by example process-derived coolant for coupling (described above). Pressurized fluid transported through the noted ducts fills the cavity below cap 233 and acts on tip 234 through bellows 288, piston 286 and liquid supplied between bellows 288 and piston 286. The piston seal diameter 286 is dictated by the seal diameter of the sleeve 235 is the force created by spring mechanism 239, and is specified to ensure a substantially constant axial compressive load on sleeve 235 regardless of, for example, pressure and temperature acting inside and outside for subsea fluid system 200. In variants of the subsea fluid system 200 the aforementioned elements are modified to ensure that a substantially constant axial pulling load is maintained on sleeve 235. Sleeves 235 may be a cylinder. Sleeve 235 may be substantially non-magnetic defining a substantially non-magnetic wall, for example, made of a non-magnetic material. In certain cases, sleeve 235 may be made of an electrically conductive material which, while experiencing an associated magnetic field, the effects of such a magnetic field can be practically mitigated. Sleeve 235 may include a substantially non-conductive wall.
[0034] In certain cases sleeve 235 may be a ceramic and/or gas-impermeable glass cylinder held "in compression" for all loading conditions expected by an integrated support system, eg outer compression sleeve 292 for support radial and tip 234 plus sleeve support ring 270 for axial support. Sleeve 235 including outer compression sleeve 292 is ideally made of materials and/or constructed in such a way as not to significantly obstruct the magnetic field of magnetic coupling 258, and to generate little heat, if any, for example from eddy currents. associated with the coupling rotating magnetic field. In certain cases, the outer compression sleeve 292 may be a composite construction of high strength fibers, such as carbon fiber, ceramic fiber, basalt fiber, aramid fiber, fiberglass and/or other fibers, e.g. thermoplastic or thermoset matrix. In certain cases, sleeve 235 may have metallized end surfaces and/or other treatments to facilitate, for example, a metal-to-metal seal with the mating surfaces of tip 234 and sleeve support ring 270.
[0035] In certain embodiments of the subsea fluid system 200, the electrical machine 202 is filled with gas, for example, air or an inert gas such as nitrogen or argon, at or near a pressure of 1 atmosphere. Unlike a vacuum, which is difficult to establish and maintain, and which provides poor heat transfer properties, a very low gas pressure environment provides the best conditions for running an electrical machine efficiently (eg, low loss drag, etc.), assuming that heat produced by the machine can be efficiently removed.
[0036] When submerged in deep water the pressure outside gas-filled electric machine 202 will collapse, for example, electric machine housing 210 if not adequately strong or supported internally. In certain embodiments of the subsea fluid system 200, the electrical machine housing 210 is thin and possibly "tuned" to improve heat transfer between the electrical machine 202 and the surrounding environment. Machine housing 210 can be snugly fitted around stator core 222 and sleeves 296, 298, and their ends likewise can be snugly fitted onto bearing surfaces provided on bell ends 214a, 214b. Machine housing support structures 210 are sized to have sufficient strength for the purpose, and if possible (eg for sleeves 296, 298) these structures can be made from materials with a useful strength-to-mass balance. and heat transfer properties (eg carbon steel, low alloy steel and choice stainless steels including 316 stainless steel and high copper materials including beryllium copper, respectively, among others).
[0037] Figure 2B is a cross-sectional side view of a fluid inlet portion and magnetic coupling 258 between an electrical machine rotor 220 and a fluid end rotor 206 in an example fluid system 200 of Figure 2A. Permanent magnets 236a, 236b are affixed to an electrical machine rotor shaft inner diameter 221 and an upper end outer diameter 207 of process fluid rotor 206, respectively. Magnets 236a, 236b are joined to their respective rotors by sleeves 237A, 237B, and these sleeves also serve to isolate the magnets from their respective surrounding environments. Sleeves 237A, 237B are made of materials and/or are constructed in such a way as not to significantly obstruct the magnetic field of magnetic coupling 258, and to generate little heat, if any, for example from eddy currents associated with the magnetic field. coupling rotary. In certain instances sleeves 237A, 237B may be cylinders and made from a suitable non-ferrous metal, eg 316 AISI stainless steel or nickel chromium alloy eg Inconel (a product of Inco Alloys, Inc.), or may include a composite construction of high strength fibers such as carbon fiber, ceramic fiber, basalt fiber, aramid fiber, glass fiber, and/or other fiber e.g. a thermoplastic or thermoset matrix. Magnetic fields produced by permanent magnets 236A, 236B interact through sleeve 235 to magnetically block (for rotational purposes) electric machine rotor 220 and process fluid rotor 206, thus forming magnetic coupling 258.
[0038] Friction between rotating process fluid rotor 206 and fluid within coupling chamber 244 tends to "drag" the latter along (in the same direction) with the former (and resists movement of the former, consuming energy), but also because there is friction between static sleeve 235 and said fluid (which tends to resist fluid movement), the fluid will normally not rotate at the same speed as process fluid rotor 206. Centrifugal forces will be established on the process fluid rotating elements that will cause heavier elements (eg, solids and dense liquid components) to move outward (toward sleeve 235), while lighter elements (eg, less dense liquid components and gas that may have been mixed with heavier elements before being "rotated") will be relegated to a central core, in the vicinity of the rotating process fluid rotor 206. The relative motion described between the mechanical parts and the fluid, and between differences Other components of the fluid, among other phenomena, produce heat which is subsequently removed from the coupling chamber 244 by various mechanisms. Less heat will be generated and less energy will be consumed by the rotating process fluid rotor 206, if the fluid in the vicinity of the rotating process fluid rotor 206 has a low density and is easily sheared, which are characteristic of the gas. Fluid system 100 can deliver gas into coupling chamber 244 when gas is available from the process flow, for example, via tip 234 inside axial duct 242 (and associated ducts). Regardless of the fluid properties within coupling chamber 244, this fluid (made hot by shear, etc.) can be displaced with the cooler fluid to prevent overheating of nearby and surrounding components (eg motor).
[0039] The fluid inlet portion of Figure 2B is located near the electric machine 202 and magnetic coupling 258. The process fluid enters the fluid end 204 through three ducts before being combined immediately upstream of the first rotor 241 in the area mixing streams from all inputs 243. Because none of these three streams (described in greater detail below) normally originate downstream of subsea fluid system 200, they have not been actuated by subsea fluid system 200 and do not constitute a " loss" for purposes of calculating the overall efficiency of the system.
[0040] Most process fluid enters fluid end 204 through main inlet 250. Coupling coolant enters electrical machine 202 through port 245 in cover 233, and is directed to coupling chamber 244 by duct 242. Radial bearing coolant 264a enters through port 260 to joint gallery 262, from where it is directed through ports 251 to bearing chamber 247. For purposes of the present discussion, process fluid entering fluid end 204 must be considered to come from a common source close to subsea fluid system 200 (not shown in Figure 2a), and therefore the pressure in main inlet gallery 252, coupling chamber 244 and bearing chamber 247 can be assumed to be approximately the same. same. The mechanism that causes fluid to enter fluid end 204 through ports 260 and 245 with slight and "adjustable" preference for main inlet 250 is the pressure drop created by inlet homogenizer 249. inlet flow 251, and therefore refrigerant flows in mixing chamber 253 (by virtue of its shared influence via the mixing area of flows of all inlets 243) is less than the source of flows of all inlets, the which creates a pressure field sufficient to create the desired cooling flows.
[0041] For fluid in coupling chamber 244 to reach refrigerant fluid mixing chamber 253 it passes through bearing 264a. It does this through bypass ports 269 provided in cage ring 268. For fluid in bearing chamber 247 to reach refrigerant flows mixing chamber 253, it first exits chamber 247 by one of two ways. Most of the fluid exits chamber 247 through the clearance opening between the upper orifice, interior of the cage ring 268 and the outer diameter of the rotor sleeve 267. Once in the coupling chamber 244 it mixes with the coupling coolant fluid and reaches the mixing chamber of refrigerant streams through bypass holes 269.
[0042] Fluid may also exit bearing chamber 247 via seal 256 to emerge in refrigerant flow mixing chamber 253. An example of a seal that can be used as seal 256 is described more fully below in relation to seal 282 associated with crankcase top plate 280. Seal 256 has a much smaller clearance relative to rotor sleeve 267 which makes cage ring 268 (located on top of bearing 264a), and has a much higher leakage rate. low as a result. This configuration encourages fluid entering bearing chamber 247 to exit there at the upper end of bearing 264a. This pressure in combination with gravity and centrifugal forces that push heavier fluid components (e.g., liquids) downward and radially outward, respectively, also cause any gas that may be entrained in the fluid flow to enter the chamber. bearing 247 move radially inward so that it is exhausted immediately after cage ring 268.
[0043] Keeping gas out of bearing chamber 247 and quickly removing it if it is present in bearing chamber 247 will promote good performance and long life for 264a fluid film bearing. To increase the probability that active surfaces of bearing 264A are constantly submerged in liquid (i.e., inner surfaces of tilt blocks 266 and outer surface of rotor sleeve 267 adjacent to tilt blocks 266), tilt blocks 266 are positioned to interact with rotor sleeve 267 over a larger diameter than openings (above and below slope blocks 266) that allow fluid to move out of bearing chamber 247. The natural tendency for gas to separate from liquid and move toward the center of rotation in a rotating fluid system will ensure that gas moves out of chamber 247 before liquids whenever gas is present in bearing chamber 247. Adding an additional seal 256 that is positioned above bearing chamber 247 may improve ability to manage the gas inherently present in the process flow.
[0044] In some embodiments of the subsea fluid system 200, combined process fluid immediately upstream of the first rotor 241 in the flow mixing area of all inlets 243 is downstream thereof increased in pressure by hydraulic stages including impellers attached to process fluid rotor 206 interacting with intercalated static diffusers (known as stators). Static and dynamic seals are provided at appropriate locations within the hydraulic phases to minimize backflow from higher to lower pressure regions, thus improving fluid end hydraulic performance 204.
[0045] Figure 2C is a side cross-sectional view of a fluid outlet portion and crankcase of an example fluid end 204 of Figure 2A. There are five main regions of interest in this area separated by two significant functional elements. These elements are process fluid rotor thrust balancers 259 and crankcase top plate 280. Above, around and below thrust balancer 259 are end stage impeller 255, fluid end outlet gallery 257 204, and balancing circuit output device 261 (shown in Figure 2C as integrated with crankcase top plate 280, which is not a strict requirement), respectively. Above and below the crankcase top plate 280 are balancing circuit output devices 261 and crankcase 271, respectively.
[0046] The maximum pressure value in certain embodiments of the subsea fluid system 200 can occur immediately downstream of the final stage impeller 255. By passing through the openings 278 provided in the balancing device stator 263, the process fluid enters the outlet gallery 257 at slightly lower pressure, and exits at process fluid outlet 272 which is connected to a downstream pipe system. Total pressure change from the final stage impeller 255 to the inlet point to the downstream pipe may be a reduction (small if for example care is taken in the design of balancing device stator 263 fluid paths 278, geometry volute is supplied in exit culvert 257, and the transition from exit culvert 257 is carefully contoured, etc.) or an augmentation (for some modalities with some fluids for a well executed volute).
[0047] When submersible fluid system 200 is not in operation, that is, when process fluid rotor 206 is not rotating, fluid entering fluid end housing 208 at inlet 250 and flowing after the hydraulic stages (impellers / diffusers ) to exit through outlet 272 will give relatively little axial force on process fluid rotor 206. When process fluid rotor 206 is rotating, the interaction of impellers, diffusers and associated components creates pressure fields that vary in amplitude as a function of properties of local fluids exist at many physical locations within fluid end 204. These pressure fields of varying magnitudes act on various geometric areas of process fluid rotor 206 to produce substantial thrust. Such thrust generally tends to drive the process fluid rotor 206 in the inlet 250 direction, however various operating scenarios can produce "reverse thrust". Depending on the magnitude and direction of thrust, thrust bearings 291 may have sufficient capacity to restrain process fluid rotor 206. In the case of thrust acting on process fluid rotor 206, it exceeds the capacity of a practical thrust bearing 291 having in In view of the many complex exchanges known to those skilled in the art of fluid end design, a thrust balancing device 259 may be used. Thrust bearing 291 is located near the lower end of fluid end housing 204. Thrust bearing 291 includes an upwardly facing bearing surfaces over thrust ring 294 (coupled to fluid rotor 206), and upwardly facing bearing surfaces. low in fluid end housing 208, the bearing surfaces cooperate to support upward thrust of fluid rotor 206. Similar components and associated surfaces are provided on the opposite side of thrust collar 294 to resist "reverse thrust" and other scenarios. causing fluid rotor 206 to tend to move downward.
[0048] Several types of thrust balancing devices are known, with the two most common being referred to as "disc" and "piston" (or "drum") types. Each device type has positive and negative attributes, and sometimes a combination of the two and/or an entirely different device is appropriate for a given application. Embodiments described herein include a piston-type thrust balancing device; however, other types may apply.
[0049] A piston-type thrust balancing device is essentially a carefully defined diameter radial clearance rotary seal created between process fluid rotor 206 and a corresponding interface to generate a desired pressure drop by existing exploration pressure fields at the fluid end 204 to substantially balance the thrust loads acting on process fluid rotor 206. The thrust balancing device includes two main components (not including process fluid rotor 206), however, a fluid duct (balance circuit duct 27 6) connecting the low pressure side of impulse balance device 259 to inlet pressure 250 is also provided. Balancing device rotor 265 is secured to the process fluid rotor 206 in a manner that provides a pressure-tight seal therebetween. Alternatively, the balancer rotor profile 265 may be provided as an integral part of the fluid rotor 206. The balancer stator 263 is secured to the fluid end housing 208 through sealed interfaces with other components. A small clearance opening is provided between the balancing device rotor 265 and stator 263 to establish a "rotation seal." High pressure from end stage impeller 255 acts on one side of balancing device rotor 265 while low pressure corresponding to this at inlet 250 acts on the other side. Inlet pressure 250 is maintained on the low pressure side of balancing device 259 despite high pressure to low pressure fluid leaking through the clearance opening (between balancing device rotor 265 and stator 263) because this leakage is is small compared to the volume of fluid that can be accommodated by balance circuit duct 276. Balance circuit output device 261 collects and redirects fluid exiting balance device 259 to deliver it to balance circuit duct 276. The nominal diameter of the clearance opening (which defines the geometric areas where relevant pressures act) is selected to achieve the desired degree of residual pressure that must be supported by thrust bearing 291 (note that some residual is valuable from perspectives of bearing load and rotor dynamic stability).
[0050] Returning briefly to thrust bearing 291, the side that is normally loaded in operation is referred to as the "active" side (upper side in Figure 2C), while the other side is referred to as the "inactive" side. In certain embodiments, the active side of thrust bearing 291 is protected during long-term high-risk storage, shipping, transport, and deployment activities by keeping it "unloaded" during these activities. Specifically, process fluid rotor 206 "rests" on the idle side of thrust bearing 291 whenever subsea fluid system 200 is not functioning, for example, during storage, handling, transport and deployment. This arrangement is advantageous because design attributes that increase tolerance for, for example, high impact loads during deployment, which, however, can reduce normal operating capacity, can be implemented for the idle side of thrust bearing 291 without affecting the fluid end operating thrust capability 204. Such design attributes (among others) may include the selection of bearing block materials that are tolerant of prolonged static loads and/or impact loads, and which, however, do not have highest operational capacity available. In addition, one or more energy absorbing devices 295, eg dampers, springs, conformal blocks (made of elastomeric and/or thermoplastic materials, etc.) and/or "crushable" devices (ref. to " deformation areas" in automobiles) may be added integral to and/or below thrust bearing 291, as well as exterior to fluid end housing 208 (including over shim 110 and/or in transport stands, execution tools, etc. - see damper 120 described in Figure 1). It may also be advantageous to "lock" rotors 206, 220 so that they are prevented from "bouncing around" during, for example, transport, implantation, etc., or to support them in "breaker" devices that prevent, for example , bearing surfaces critical to make contact during these events. This locking and "separator" functionality can be accomplished using devices that can be engaged and/or released manually (eg locking screws, etc.) or, preferably, devices that are automatically engaged/disengaged depending on whether rotors 206, 220 they are stationary, turning, transitioning to stop or transitioning to turning. Devices providing the aforementioned attributes include permanent magnet attracting devices and/or electromagnets, among others ("locking" devices), and bearing type blocks or bushings / pedestal type supports, such as, among others, which have adequate geometry for the function of "separator" while rotors 206, 220 are not rotating and have, for example, a "less intrusive" geometry that allows bearings (intended to support rotors 206, 220 during operation) to perform their function when rotors 206, 220 are rotating ( "separator" devices). Displacement mechanisms that can activate the desired "dual geometry" feature for "separator" devices include mechanical, hydraulic, thermal, electrical, electromagnetic, and piezoelectric, among others. Passive automatic means for enacting the blocking and/or "splitter" functions can be used, however a control system can also be provided to ensure correct operation.
[0051] Crankcase top plate 280 in combination with seals 282 and 273 substantially isolate fluid in crankcase 271 from interacting with fluid end process fluid 204. Crankcase 271 contains fluid film type radial bearing 264b and thrust bearing 291 To allow for good performance and long service life, fluid film bearings are lubricated and cooled with clean liquid, and process fluid (especially crude hydrocarbon process fluid) may contain large volumes of gas and/or solids that could harm these bearings.
[0052] Seal 282 may be substantially the same as seal 256 associated with upper radial bearing 264a described above. Seal 282 is secured to crankcase top plate 280 and effects a hydrodynamic fluid film seal (typically micrometer gap gap) relative to rotor sleeve 275 (shown in Figure 2C as integrated with sleeve bearing 288, which is not a strict requirement) when the process fluid rotor 206 is rotating, and also a static seal (usually zero clearance) when the process fluid rotor 206 is not rotating. In certain cases, seal 282 may include a plurality of blocks spring-pressed inwardly against the rotor shaft to provide static seal, but allow formation of the hydrodynamic fluid film seal when the rotor is rotating. Seal 282 can be designed to maintain, increase or decrease its hydrodynamic clearance, even for zero clearance in operation, when subjected to differential pressure transients from either side (above or below), and therefore to substantially maintain , increase or decrease, respectively, its leakage rate during especially sudden pressure transients. Seal 282 includes features that allow its hydrodynamic performance which allows a small amount of leakage in dynamic mode (regardless of clearance magnitude with respect to rotor sleeve 27 5) and static mode whenever it is exposed to differential pressure, and therefore can for some applications be characterized as a flow restrictor rather than an absolute seal. A small amount of leakage is desired for application of crankcase 271. Seals 273 and 282 seal between fluid end housing 208 and fluid rotor 206, and define an upper limit of a crankcase 271 of fluid end housing 208 A fluid bearing 291 resides in crankcase 271 and seal 282 is responsive to provide a greater seal when subjected to a change in pressure differential between the crankcase and another portion of the fluid end housing.
[0053] Prior to implantation, and using port(s) 277 provided for this purpose (as well as for refilling crankcase and/or washing crankcase gas and/or debris, etc.), crankcase 271 can be filled with a fluid ideally having attractive properties for target field application, eg chemically compatible with process fluid and chemicals that can be introduced into process flow and/or crankcase 271, density higher than process fluid, useful viscosity over wide temperature range, good heat transfer performance, low gas absorption tendency, etc. After installation and over commissioning (period during which subsea fluid system 200 is operated), fluid end 204 will be pressurized according to its design and crankcase temperature 271 will increase significantly, the latter causing crankcase fluid to expand. Sealing ability 282 to transfer fluid axially in both directions ensures that pressure in reservoir 271 will not rise significantly as a result, and further ensures that pressure in reservoir 271 will substantially correspond to inlet pressure 250 of fluid end 204 during states of operation and non-operation except during 206 process fluid rotor axial position transients (explained below).
[0054] The low leakage rate, static sealing and hydrodynamic sealing capabilities of the 282 seal, combined with an otherwise "sealed" crankcase 271, provide unique and valuable attributes for fluid end 204. Seal 282 provides a rate low leakage even when subjected to a sudden high differential pressure, and therefore equalize the pressure more or less gradually depending mainly on the initial pressure differential and fluid properties in question (eg liquid, gas, multiphase and high / low viscosity, etc.). In one scenario, prior to initiating rotation of the process fluid rotor 206, an operator may inject liquid into port 277 at a speed sufficient to create a pressure differential across seal 282 suitable to lift the process fluid rotor 206, thus avoiding a potential rotor dynamic instability that can accompany transition from the "inactive" side of thrust bearing 291 (normally unused) to the "active" side (used during normal operations) after start-up. In another scenario, almost the entire reverse process can be employed. That is, before stopping the rotation of the process fluid rotor 206, liquid can be injected into port 277 at a rate sufficient to maintain port elevation. After shutdown, process fluid rotor 206 will continue to be raised until it no longer rotates, at which point liquid injection through port 277 can be stopped to allow process fluid rotor 206 to land smoothly, without rotation, on inactive surfaces of thrust bearing 291. This will reduce the potential for damage and thus promote long bearing life. In another scenario, any tendency to drive process fluid rotor 206 in crankcase 271 ("reverse thrust") will encounter "damped resistance" due to the fact that fluid must typically bypass seal 282 (which happens very slowly) so that the process fluid rotor 206 moves axially. Similar resistance will be encountered if process fluid rotor 206 is motivated to rise rapidly from its fully down position, however fluid must pass seal 282 to enter crankcase 271 in that case. The preceding attribute of "damped axial translation" will protect thrust bearing 291 and thus promote long life for subsea fluid system 200. In another scenario, in the event that process gas permeates crankcase fluid, and inlet 250 (which determines nominal crankcase pressure) is subsequently subjected to a sudden pressure drop, seal 282 will only gradually balance crankcase pressure to the lowest inlet pressure 250 and thus prevent a sudden expansion of crankcase gas that could evacuate the crankcase. This is a scenario for which designing a 282 seal to "reduce its clearance relative to the 275 impeller sleeve when subjected to differential pressure transients" (described above) may be applicable. As noted earlier, keeping liquid in crankcase 271 will facilitate the health of bearings 264b, 291. In any scenario that potentially subjects rotating process fluid rotor 206 to "reverse thrust", pressure higher than the time present at inlet 250 (and therefore crankcase 271) can be applied to crankcase door 277 to resist such "reverse thrust" and thus protect, for example, the idler side elements of thrust bearing 291. associated fast acting control system, possibly including automation algorithms, actuated valves and high pressure fluid source, can be utilized to effect the "process fluid rotor active shaft impulse management" functionality described herein. It is understood that a similar ability to apply pressure to the top of the process fluid rotor 206 (e.g., via the 308 supplemental fluid duct and the 321 gas duct discussed later in this disclosure) can be developed to provide sophisticated "active impulse management " for fluid end 204.
[0055] Significant heat will be generated in crankcase 271 caused by fluid shear and other phenomena associated with rotating process fluid rotor 206 and attached thrust collar 294. Cooling crankcase fluid 294 to optimize its properties for maintenance of bearing performance is achieved by circulating fluid through a heat exchanger 301 positioned in the water surrounding fluid end 204. Careful positioning of flow paths in and around bearings 264b, 291, and 301 for inlet and outlet ports. heat exchanger (302 and 300, respectively), combined with naturally occurring convection currents and aided by, for example, volute-type geometry and/or flow-directing (eg circumferential to axial) in the lower crankcase cavity 285 , will create a "pumping effect" for crankcase 271. Such a pumping effect can be enhanced by adding features, for example, "curved cutout", "propellers", "pal hetas", etc., to the outside of rotating elements including process fluid rotor 206 (e.g., at locations 279, 281; the latter on the end face of and/or possibly on an extension of the process fluid rotor 206) and/or thrust collar 294 (eg at location 283). Alternatively or in addition, an impeller or similar device may be attached to the lower end of the process fluid rotor 206.
[0056] It is unlikely that solids carried in the process fluid of significant size or volume will make their way to crankcase 271 of fluid system 200. As noted earlier, crankcase 271 is normally pressure balanced with respect to inlet 250 via the duct. balancing circuit 276, so normally there is no fluid flow between crankcase 271 and fluid end process fluid containing areas 204. In addition, seal 282 only allows transfer of small volume and low rate fluids through it (even during high differential pressure transients). In addition, a convoluted path with multiple intercalated axial and radial surfaces exists between the underside of the balancing device rotor retainer 298 and the top of the crankcase top plate 280, so that solids must intermittently move upward against gravity and inward against the centrifugal force before they can approach the top of the seal 282. Regardless, two or more ports 277 may be provided to circulate the liquid through the crankcase 271 and/or heat exchanger 301 to effectively wash it by minus one port for supplying fluid and one for evacuating fluid (for example, to any duct or container located upstream of inlet 250 or downstream of outlet 272). Ports 277 can be provided to intersect lower crankcase cavity 285 (as shown in Figure 2C), which represents a large diameter and lowest point in crankcase 271, and also an area where solids tend to collect. Alternate locations for ports 277 can also be provided, and can provide additional benefits including the ability to deliver high-speed flow of liquids directly to heat exchanger 301 to wash solids and/or gas (should one of these get stuck in it). Note that heat exchanger 301 can take several forms in addition to what is shown in Figure 2C, including some optimized for solids removal and/or gas removal.
[0057] Figure 3 illustrates an example subsea fluid system 300 that can be packaged within the fluid system 100 of Figure 1 for the purpose of extracting discrete service fluid flows from a multiphase process flow to serve the needs of the specific elements within the subsea fluid system 300 (also 200). Subsea fluid system 300 contains an integrated electrical machine 301, fluid end 302 and magnetic coupling 303 as previously described for the subsea fluid system 200 of Figures 2A-C. It also contains upstream and downstream processing packages 304 and 305 respectively. Upstream processing package 304 includes a temporary storage tank 306, a liquid reservoir 307, a supplemental fluid line 308, and a selection of flow control devices and interconnecting work tubes, various elements of which will be described later. in this description. Downstream processing package 305 contains a liquid extraction unit 339 and a flow regulation device (known as a process control valve or throttling) 309. An optional downstream service duct 336 including isolation valve 337 can be provided to connect liquid extraction unit 339 with eg liquid duct 330 (for reasons explained below).
[0058] Multiphase fluid enters subsea fluid system 300 at inlet 310 for transport through inlet tube 311 to temporary storage tank 306. Crude hydrocarbon production fluids delivered to subsea fluid system 300 from wells directly or by means of, for example, collectors, they may at various times include as much as 100% gas or 100% liquid, as well as all fractional combinations of gas and liquid (often with some volume of solids in addition). Transitions between liquid-dominated and gas-dominated multiphase flows may occur frequently (eg time intervals of seconds or less) or rarely, and such transitions may be gradual or abrupt. Abrupt changes from very high Gas Volume Fraction (GVF) flows to very low GVF flows, and vice versa (commonly referred to as "puff"), can be detrimental to the subsea fluid system 300 for reasons known to those skilled in the art. art of fluid augmentation devices and associated tube systems. Temporary storage tank 306 can accommodate even rapidly changing fluid conditions at inlet 319 and reduce the harshness of such fluid condition changes at its main outlet 320, and by doing so moderate the detrimental effects on downstream fluid system 300. Temporary storage tank 306 equates to a "fat spot" in inlet tube 31 that allows fluid to reside there long enough for gravity to drive heavier flows/elements (liquids, solids) to the bottom of the tank while simultaneously forcing gas to rise to the top of the tank. A perforated support tube 312 or similar device controls the speed at which the separate streams/elements are reconnected before leaving the tank at the main outlet 320. Namely, when a high GVF multiphase flow stream enters temporary storage tank 306 the volume of gas in the tank can increase relative to the volume of liquids/solids already in the tank, and similarly when a low GVF stream enters the tank the opposite can occur. Meanwhile, the GVF of the fluid leaving the tank will typically be different from the inlet because the outflow GVF is automatically (and gradually) adjusted according to the volume of gas and liquid/solids allowed to enter the perforated support tube 312 The gas/liquid interface level in temporary storage tank 306 determines the flow area (number of holes) accessible to each flow.
[0059] In certain embodiments of the subsea fluid system 300, separate gas 314 and separate liquid 313 may be withdrawn from temporary storage tank 306 through gas cock 315 and liquid cock316, respectively. It is beneficial that no solids enter the ducts downstream of gas tap 315 and liquid tap 316. Solids in the fluid stream entering provisional storage tank 306 will typically be loaded through it with the liquid phase(s), therefore, while some scenarios can be imagined so that solids can enter gas tap 315 (typically accompanied by liquids) or be formed in gas pipeline 321, subsea fluid system 300 is operated to minimize the chance for these scenarios to occur. The large size of liquid tap 316 relative to the small size of, and flow rate in, ducts downstream thereof allows for a substantially quiescent environment to establish within liquid tap 316 which allows solids to deposit there. The liquid faucet tilt angle 316 suggested in Figure 3 promotes gravity driven return of sedimented solids to the main chamber of temporary storage tank 306, from which they can later exit via main outlet 320. Deflector(s ) 317 and/or device(s)/or similar features may be added to liquid tap 316 to enhance the solids separation effect and/or otherwise inhibit transfer of solids to areas downstream of liquid tap 316.
[0060] Downstream of liquid tap 316 is normally open valve 318 through which ideally only liquid will pass to enter liquid reservoir 307. Level 327 monitor provides sensory feedback necessary for an associated control system to command valve 318 to close if the liquid level of temporary storage tank 306 is close to the level of liquid tap 316 and threatens to allow an unacceptable volume of gas to enter liquid reservoir 307 by that route. Liquid reservoir 307 and the duct including valve 318 can be oriented vertically, and are connected to the liquid tap 316 in such a way that solids possibly remaining in the fluid supplied to these spaces can sediment and fall into the liquid tap 316 (and subsequently temporary storage tank 306) so as not to be transported downstream of the liquid reservoir 307. The fluid in the liquid reservoir 307 will typically be quite immobile and, under certain circumstances, will reside in it for several minutes before the liquid phase makes its way over. downstream, substantially free of solids and free of gas.
[0061] There are two other flow paths into/out of the liquid reservoir 307, specifically gas line connection 322 with normally open isolation valve 323 and liquid line connection 324 with normally open isolation valve 325. It is beneficial that only gas flows through the gas duct connection 322, and that only liquid flows through the liquid duct connection 324. Level monitor 329 provides sensory feedback necessary for a control system associated with valve command 325 to close. Liquid level liquid reservoir 307 lies close to liquid duct connection level 324 and threatens to allow free gas to enter it. The main scenario for which valve 323 can be closed is related to the discharge of solids from liquid reservoir 307, which is described elsewhere in this disclosure.
[0062] Liquid level of liquid reservoir 307 can be forced upwards in an absolute direction than provisional storage tank 306 by manipulating isolation valves 323, 325 and gas flow control device (known as control valve process or throttling) 326. Maintenance of a liquid reservoir 307 substantially full of liquid is necessary for best performance. Using throttling 326 to reduce the pressure in gas duct 321 relative to the pressure in temporary storage tank 306 (therefore also in liquid tap 316 and liquid reservoir 307) will cause the fluid in liquid reservoir 307 to flow toward from (in) gas duct 321. Gas in liquid reservoir 307, if introduced through liquid tap 316 (as free gas or gas in solution) or gas duct connection 322, will, of course, be collected near the top of the liquid reservoir 307 and therefore depleted in gas pipeline 321 before liquids enter from below during the process of "filling the reservoir of liquid". 329 level monitor provides the sensory feedback necessary to effect a 307 liquid reservoir level control system.
[0063] Liquid reservoir 307 is provided to maintain a volume of liquid sufficient to lubricate bearing 264a (referred to with respect to the description in Figure 3, but shown in Figure 2B) for a specified period of time in the event that liquid is no longer available from temporary storage tank 306 for such a period of time. The time period depends on several factors such as size of liquid reservoir 307, pressure drop across fluid end inlet homogenizer 249, rate of leakage from bearing chamber 247, rate of fluid leaving coupling chamber 244 through bypass ports 269 and liquid viscosity are a few. Knowing the flow behavior and physical properties of process fluids entering inlet 310 allows you to correctly size liquid reservoir 307. Recognize that it is difficult to predict such attributes for new production fields, and predict how such attributes may vary over many years that most fields are expected to produce, field replacement of liquid reservoir 307 with, for example, a larger unit, independent of other elements within submersible fluid system 300, 100 and/or in combination with other elements within the submersible fluid system 300, 100, can be enabled. While specific features of enabling field reset for liquid reservoir 307 are not described in detail in this specification (Figure 1 shows process connectors 115 suggesting how such capability can also be provided for fluid system 100 containing liquid reservoir 307 ), it should be obvious to one skilled in the art of designing replaceable modular submersible systems how such a capability can be realized.
[0064] Nozzle 328 is the input to the liquid duct connection 324, and can also be used as an output device for a function described later in this description. It can be configured in any number of shapes and/or associated with, for example, diversion devices and/or baffles to passively resist ingestion of solids that may remain in the liquid entering or stored in liquid reservoir 307. Typically one or more substantially ports side-directed or downward-facing can be used in place of an upwardly angled port or ports to avoid the undesirable tendency of the latter alternatives to collect solids that may sediment out of the d307 liquid reservoir fluids, then transfer such solids for elements downstream of it. One or more of any number of filtering devices and/or devices may also be provided to resist ingestion of solids, regardless of the orientation of the ports noted.
[0065] Unless forced to behave otherwise by, for example, a flow restriction and/or added flow enhancement device, fluid (eg, liquid) will exit liquid reservoir 307 to flow through pipeline of liquid 330 to bearing 264a at a rate dictated by at least pressure drop across fluid end inlet homogenizer 249, rate of leakage from bearing chamber 247, rate of fluid exiting coupling chamber 244 via bypass ports 269, and liquid viscosity. Isolation valves 331, 332, 333 associated with supplemental fluid line 308 are normally closed, and therefore normally do not affect the flow rate through liquid line 330 (or gas line 321). Normally open isolation valve 334, when closed or substantially closed, allows fluid supplied from a source capable of supplying fluid at greater pressure than provisional storage tank 306, such as supplemental fluid duct 308 or downstream service duct 336 (when accessed by opening a normally closed isolation valve 337), to be directed into liquid reservoir 307 via nozzle 328 to, for example, fill liquid reservoir 307 with liquid and/or wash solids from liquid reservoir 307 (after valve 318 in liquid cock 316 and inside temporary storage tank 306). If it is desired to increase the pressure in the liquid duct 324 upstream of the closed or substantially closed isolation valve 334 to, for example, create or intensify a "blasting action" produced, for example, by nozzle 328, a pump 335 may be added (not normally required for downstream service duct 336, however possibly useful for supplemental fluid duct 308). An alternative to the 334 isolation valve is a throttling or process control valve which is generally better able to accommodate partial opening and potentially large associated pressure drop without experiencing significant wear. Such throttling or alternative process control valve, when associated with appropriate instrumentation, for example, upstream, downstream and/or differential pressure sensors, and control algorithms (controller) facilitates increased controllability of the liquid flow supplied to the bearing 264a, and therefore the rate of consumption of the liquid in the liquid reservoir 307.
[0066] A sufficiently sophisticated control system possibly including automation algorithms will be able to operate the various valves and especially process control/throttling valves (326 and which is an alternative to isolation valve 334) to optimize refrigerant flow to bearing 264a and magnetic coupling 258, and possibly effecting "active impulse management" for fluid end rotor 206. The controller may be configured to receive gas and liquid pressure information and, for example, component position information, etc., from one or more sensors located at relevant points in the submersible fluid system 200 and further configured to control one or more pressure regulating devices to adjust gas or liquid pressures in the submersible fluid system. In some applications the cost of achieving the flexibility and performance improvement delivered by an instrumented throttling, process control valve, or other variable position valve (an option for the 334) isolation valve is not justified, and a fixed flow restriction (eg, orifice or venturi) or no flow restriction may be sufficient to ensure that an acceptable supply of liquid is delivered to bearing 264a. Regardless, at least one open/close type isolation valve 334 can be used to activate fluid steering in the manner and for the same purposes described below for isolation valve 338.
[0067] Normally open isolation valve 338 is provided in gas duct 321 so that it can be closed on certain specific occasions, such as after shutdown of the submersible fluid system 200 when the duration of this shutdown is expected to be long enough for fluids processes can undergo property changes that can be detrimental to the subsequent operation of fluid system 300 (and 200). With isolation valve 338 closed, chemicals supplied by supplemental fluid duct 308 can be selectively routed to alternate locations throughout submersible fluid system 300 to displace potentially unwanted process fluids and/or otherwise protect against undesirable consequences, such as for example formation of hydrates, wax, etc. It is important to note that the ability to deliver heat to critical locations within submersible fluid systems described herein may be desirable, and may be accomplished using known techniques, eg, electrical heat tracing and/or heated liquids circulated through dedicated ducts, etc.
[0068] Several functions have already been described for supplemental fluid duct 308. Another function is to supply liquid to bearing 264a for as long as necessary in the event liquid becomes unavailable on a continuous basis from provisional storage tank 306 and by an additional period of time from liquid reservoir 307 (e.g., limited by its size). Facility providing supplemental fluid duct 308, eg, top-side hydraulic power unit (HPU) and associated electrical power supply, plus a single or multi-duct umbilical to transport chemicals from the HPU to the vicinity of underwater use points, are provided for subsea production systems as a matter of course to provide mitigation of potential "flow assurance" issues such as those mentioned throughout this disclosure (eg hydrates, wax, scale, etc. .). Submersible fluid systems capable of multiphase process fluid described herein do not require an additional top-side HPU, electrical power supply, umbilical ducts, and other expensive equipment (known as a "barrier fluid system") to be provided to cool and lubricate your bearings and other sensitive components.
[0069] Fluid systems disclosed herein are sophisticated devices designed to perform complex and challenging functions reliably over long periods of time. They contain many active devices, including electrical machines, fluid end, auxiliary pumps, valves and sensing instruments, among others. Condition and Performance Monitoring (CPM) of such devices and subsystems is recommended, and this requires that equally sophisticated data collection, mitigation, historian, control and potentially automation systems be implemented.
[0070] A number of modalities have been described. However, it will be understood that various modifications can be made. Thus, other embodiments are within the scope of the following claims.

权利要求:
Claims (17)
[0001]
1. Submersible fluid system for operating submerged in a body of water, characterized in that it comprises: a fluid end comprising a fluid rotor disposed in a fluid end housing; an electrical machine housing coupled to the fluid end housing and comprising a hermetically sealed cavity; an electric machine disposed entirely within the cavity of the electric machine housing, the electric machine comprising an electric machine stator and an electric machine rotor; a magnetic coupling coupling the electric machine rotor and the fluid rotor, wherein the magnetic coupling comprises: a magnet within the hermetically sealed cavity of the electric machine housing coupled to the electric machine rotor; wherein the hermetically sealed cavity of the electrical machine housing contains a gas at a pressure that is less than the pressure of a fluid entering the fluid end fluid rotor and less than a hydrostatic pressure of a fluid surrounding the housing of an electric machine when submerged to a specific depth; a magnet coupled to the fluid rotor and in magnetic interaction with the rotor magnet of an electric machine; and a non-magnetically conductive wall between the electric machine rotor magnet and the fluid rotor magnet.
[0002]
2. System according to claim 1, characterized in that: a fluid rotor drive end extends to an inner hole of the electric machine rotor and the fluid rotor magnet is coupled to an outer end of the end drive; the electric machine rotor magnet resides inside the hole of the electric machine rotor; and the wall, comprising a non-magnetically conductive cylinder, is disposed within the interior of the orifice of the electric machine rotor.
[0003]
3. System according to claim 2, characterized in that the cylinder comprises at least one of a gas-impermeable glass or ceramic inner sleeve within an outer sleeve of fiber matrix composite.
[0004]
4. System according to claim 3, characterized in that the outer sleeve compressively stretches the inner sleeve.
[0005]
5. System according to claim 2, characterized in that the cylinder comprises at least one between the inner sleeve of glass and the gas-impermeable ceramic inside an outer sleeve of fiber matrix composite, and at least one between the inner sleeve and the outer sleeve comprises a sealing surface on one end and a sealing surface on an opposite end.
[0006]
6. System according to claim 2, characterized in that the hermetically sealed cavity of the electrical machine housing contains a gas at a pressure close to atmospheric pressure and an interior of the cylinder contains a fluid at a pressure close to the pressure of fluid entering the fluid rotor from the fluid end.
[0007]
7. System according to claim 1, characterized in that the electric machine comprises a magnetic bearing supporting the electric machine rotor to rotate inside the electric machine stator, and the bearing is fully contained within the hermetically sealed cavity .
[0008]
8. System according to claim 1, characterized in that it further comprises a plurality of seals sealing the hermetically sealed cavity, and in which the seals are entirely static seals.
[0009]
9. System according to claim 8, characterized in that at least one of the seals comprises a metal-to-metal seal.
[0010]
10. System according to claim 1, characterized in that the electric machine rotor comprises a permanent magnet that interacts with the stator for at least one between rotating the electric machine rotor in relation to the stator or generating electricity when moved in relation to the stator.
[0011]
11. System according to claim 1, characterized in that the electrical machine comprises a motor and the fluid rotor comprises one or more between a pump rotor and a compressor.
[0012]
12. System according to claim 1, characterized in that the electrical machine comprises a generator.
[0013]
13. Method for coupling an electrical machine to a fluid end in a submersible fluid system, the method characterized in that it comprises: maintaining an electrical machine rotor in an area of a first pressure in a hermetically sealed cavity defined by housing of electric machine, the rotor being hermetically sealed from a fluid rotor of the fluid end in an area of a second, different pressure, the rotor comprising a permanent rotor magnet in the hermetically sealed cavity defined by the electric machine housing; and coupling the electric machine rotor to the fluid rotor with a magnetic coupling through a stationary wall between the electric machine rotor and the fluid rotor, where a first magnet of the magnetic coupling is within the area of first pressure and coupled to the rotor of the electrical machine and a second magnet of the magnetic coupling is within the area of second pressure and coupled to the fluid rotor; and wherein the first pressure is less than the second pressure and the first pressure is less than a hydrostatic pressure of a fluid surrounding the electrical machine housing when submerged to a specified depth.
[0014]
14. Method according to claim 13, characterized in that it comprises sealing the area containing the electric machine rotor from the area containing the fluid rotor entirely with static seals.
[0015]
15. Method according to claim 14, characterized in that it comprises maintaining a stator of the electrical machine in the area of the first pressure.
[0016]
16. Fluid system, characterized in that it comprises: a pump shaft contained in a submersible pump housing, the pump shaft having a permanent pump magnet; a rotor extending from one end of an electrical machine housing, the rotor having a permanent rotor magnet and residing in a hermetically sealed cavity defined by the electrical machine housing; and the pump permanent magnet residing close to the rotor permanent magnet communicating magnetic flux between the rotor permanent magnet and the pump permanent magnet and coupling the pump shaft with the rotor; wherein the hermetically sealed cavity of the electrical machine housing contains a gas at a pressure which is less than the pressure of a fluid entering the fluid end fluid rotor and less than a hydrostatic pressure of a surrounding fluid the electrical engine housing when submerged to a specified depth.
[0017]
17. System according to claim 16, characterized in that the rotor is configured to rotate inside a stator, and the magnetic coupling couples the rotor to the pump shaft to rotate the pump shaft at the same speed as the rotor.

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法律状态:
2018-12-11| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2020-02-04| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2021-02-02| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-04-20| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 12/09/2012, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

---

PCT/US2012/054843|WO2014042628A1|2012-09-12|2012-09-12|Coupling an electric machine and fluid-end|

---