Subsea pressure systems for fluid recovery

Systems and methods for recovering power fluid from a device under water and for pumping recovered power fluid to a surface of the water, the systems and methods, in certain aspects, including: flowing fluid from a subsurface apparatus to a subsurface recovery system, the fluid initially provided to the subsurface apparatus to power the subsurface apparatus; and the subsurface recovery system including pump apparatus for selectively pumping recovered fluid to a fluid container above a surface of the water. This abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims, 37 C.F.R. 1.72(b).

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to underwater accumulator systems which provide pressurized working fluid.

2. Description of Related Art

Deepwater power fluid systems provide pressurized working fluid for the control and operation of equipment, e.g. for blowout preventer operators; gate valves for the control of flow of oil or gas to the surface or to other subsea locations; hydraulically actuated connectors; and similar devices. The fluid to be pressurized is typically an oil based product or a water based product with added lubricity and corrosion protection, e.g., but not limited to hydraulic fluid. In certain prior art systems, once the power fluid has done its job in the operation of a device, it is exhausted into the water environment around the device.

U.S. Pat. Nos. 7,108,006; 6,202,753; 4,777,800; 4,649,704; and 3,677,001 are illustrative of various prior art subsea power fluid systems and are mentioned here not by way of limitation nor as exhaustive of the available prior art; and all said patents are incorporated fully herein for all purposes.

Certain prior art accumulators are precharged with pressurized gas to a pressure at or slightly below an anticipated minimum pressure required to operate equipment. Fluid can be added to the accumulator, increasing the pressure of the pressurized gas and the fluid. The fluid introduced into the accumulator is stored at a pressure at least as high as the precharge pressure and is available for doing hydraulic work.

Such prior art accumulators include: a bladder type with a bladder to separate the gas from the fluid; a piston type having a piston sliding up and down a seal bore to separate the fluid from the gas; and a float type with a float providing a partial separation of the fluid from the gas and for closing a valve when the float approaches the bottom to prevent the escape of gas.

In one particular example, a prior art system has accumulators that provide typical 3000 psi working fluid to surface equipment has a 5000 psi working pressure and contain fluid which raises the precharge pressure from 3000 psi to 5000 psi The efficiency of accumulators is decreased in deepwater; e.g., 1000 feet of seawater the ambient pressure is approximately 465 psi and, for an accumulator to provide a 3000 psi differential at 1000 ft. depth, it is precharged to 3000 psi plus 455 psi, or 3465 psi At slightly over 4000 ft. water depth, the ambient pressure is almost 2000 psi, so the precharge is required to be 3000 psi plus 2000 psi, or 5000 psi, i.e., the precharge equals the working pressure of the accumulator. Any fluid introduced for storage causes the pressure to exceed the working pressure, rendering the accumulator non-functional.

In the deepwater use of accumulators the ambient temperature can decrease to about 35 degrees F. For an accumulator precharged to 5000 psi at a surface temperature of 80 degrees F., about 416 psi precharge is lost simply because the temperature was reduced to 35 degrees F. The rapid discharge of fluids from accumulators and the associated rapid expansion of the pressurizing gas causes a natural cooling of the gas so that an accumulator is quickly reduced in pressure from, e.g., 5000 psi to 3000 psi without heat coming into the accumulator (adiabatic), experiences a pressure drop to 2012 psi

U.S. Pat. Nos. 7,108,006; 6,202,753; 4,777,800; 4,649,704; and 3,677,001 are illustrative of various prior art systems and are mentioned here not by way of limitation nor as exhaustive of the available prior art; and all said patents are incorporated fully herein for all purposes.FIG. 1illustrates a system as disclosed in U.S. Pat. No. 3,677,001 which shows a submerged pipeline10on which is arranged a valve housing11which contains a valve member to open and close pipeline10to control the flow of fluid therethrough. A valve stem housing is mounted on valve housing11. A valve stem13extends through the valve stem housing and connects to a piston14arranged in an actuator cylinder15. Piston14has fixed power and exhaust strokes. The valve stem housing is provided with packing seals17which surround and seal off fluid flow around valve stem13. A reduced internal diameter portion20of actuator cylinder15forms a cavity or chamber21and a seating shoulder23. A mating shoulder22formed on piston14is adapted to engage shoulder23. A static seal24which suitably may be an “O”-ring is arranged in a recess in shoulder23and seals off the space between shoulders22and23when piston14is at the end of its power stroke, as shown in the figure. A spring25is arranged in chamber21and functions to move piston14in its exhaust stroke. When the valve is fully open, piston14is at the end of its power stroke and when the valve is fully closed the piston is at the end of its exhaust stroke. When the valve (or other equipment) to be operated is located at a remote offshore location, a hydraulic power fluid reservoir30is provided with a floating piston31, compensated by sea water pressure. A diaphragm could be substituted for piston31A conduit34supplies a pump32with hydraulic control fluid from reservoir30. Pump32is operated by electrical power supplied from the water's surface through a conductor33. An accumulator35is connected to pump32to the exhaust stroke end of actuator cylinder15by means of a conduit40. The purpose of the accumulator is to provide a supply of power fluid available for immediate delivery to cylinder15. A bypass conduit41connects conduit40to reservoir30. A solenoid operated valve45controlled by electrical power supplied from the water's surface through a conductor46is connected into conduit41. Another solenoid operated valve47supplied with operating power from the water's surface through a conduit48is arranged between accumulator35and the junction of conduits40and41. An additional conduit50connects chamber21to reservoir30.

There has long been a need, recognized by the present inventor, for an effective accumulator systems and pressure compensation systems for underwater and subsea use. There has long been a need, recognized by the present inventor, for such systems which increase the amount of available pressurized gas to enhance the operation of subsea working fluid systems.

BRIEF SUMMARY OF THE INVENTION

The present invention, in certain aspects, discloses a fluid recovery system for recovering power fluid exhausted from a subsea apparatus (e.g. a BOP operator) and for then pumping the recovered power fluid to the surface. In certain aspects, the present invention discloses systems and methods for recovering power fluid from a device under water and for pumping recovered power fluid to a surface of the water, the methods and systems in certain aspects including: flowing fluid from a subsurface apparatus to a subsurface recovery system, the fluid initially provided to the subsurface apparatus to power the subsurface apparatus; and the subsurface recovery system including pump apparatus, the subsurface recovery system selectively pumping recovered fluid to a fluid container above a surface of the water.

The present invention, in certain aspects, discloses a pressure accumulator system for subsea operations that with one or more containers or “bottles” which have a primary gas-containing chamber for containing gas under pressure and, additionally, a secondary chamber or cavity for containing such gas, the secondary chamber in fluid communication with the primary chamber so that the total effective gas volume is increased to the extent of the volume of the secondary chamber. In one aspect, the secondary chamber is a cavity in part of a piston assembly.

The present invention, in certain aspects, discloses an accumulator system for subwater use, such systems having a body (e.g. a housing); a fluid chamber within the body for containing power fluid; a piston assembly movably disposed within the body; a gas chamber within the body for containing gas under pressure to move the piston assembly to move the power fluid out of the fluid chamber of the body; the piston assembly including a cavity therein for containing gas under pressure for assisting in movement of the piston assembly; and the cavity in fluid communication with the gas chamber.

The present invention, in certain aspects, discloses accumulator systems for subwater use, the systems having a body (e.g. a housing); a piston assembly movably disposed within the body, the piston assembly having an interior; a rod member passing through the body and extending into the interior of the piston assembly; a rod member end on an end of the rod member, the rod member end disposed within the interior of the piston assembly, the rod member end having a first side and a second side; a power fluid chamber in the interior of the piston assembly, the power fluid chamber adjacent the first side of the rod member; a gas chamber in the interior of the piston assembly, the gas chamber adjacent the second side of the rod member; and the piston assembly movable by gas in the chamber to move power fluid out of the power fluid chamber.

The present invention, in certain aspects, discloses a pressure compensation system for subsea apparatus which has one or more hydraulic power units used in an hydraulic fluid system. In certain aspects, such subsea apparatus employs one or more hydraulic fluid reservoirs and/or accumulators which releasably hold operational amounts of hydraulic fluid at a pressure slightly greater than the pressure of water exterior to the reservoir for selectively operating subsea equipment and systems, e.g. BOP's, coiled tubing units, valves, and subsea wellhead connectors. The reservoir and/or accumulator(s) can require a substantial amount (e.g. 50, 100, 500 gallons or more) of hydraulic fluid which can entail the flow of this substantial amount of fluid from a reservoir to the accumulator(s). In certain systems according to the present invention, a “seawater boost” is provided which includes exposing a piston end to the pressure of the seawater. This piston effectively boosts the force provided by another piston which is acted upon by compressed gas to move a power fluid out of the system. By using the seawater boost effect, the required number of containers or bottles for compressed gas is reduced. The seawater boost can boost the pressure on contained hydraulic fluid in addition to the pressure of gas on the fluid, thus reducing the amount of pressurized gas required to achieve a certain pressure on the hydraulic fluid.

In certain aspects, the reservoir is initially charged at a pressure slightly higher than the pressure of the water to be encountered at depth and the reservoir is pressure compensated so that at depth it is not damaged or destroyed.

Accordingly, the present invention includes features and advantages which are believed to enable it to advance subsea power fluid system technology. Characteristics and advantages of the present invention described above and additional features and benefits will be readily apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments and referring to the accompanying drawings.

What follows are some of, but not all, the objects of this invention. In addition to the specific objects stated below for at least certain preferred embodiments of the invention, there are other objects and purposes which will be readily apparent to one of skill in this art who has the benefit of this invention's teachings and disclosures. It is, therefore, an object of at least certain preferred embodiments of the present invention to provide:

Such systems for use with subsea blowout preventer operators; and

Such systems which can effectively provide and recover significantly large volumes of power fluid.

Certain embodiments of this invention are not limited to any particular individual feature disclosed here, but include combinations of them distinguished from the prior art in their structures, functions, and/or results achieved. Features of the invention have been broadly described so that the detailed descriptions that follow may be better understood, and in order that the contributions of this invention to the arts may be better appreciated. There are, of course, additional aspects of the invention described below and which may be included in the subject matter of the claims to this invention. Those skilled in the art who have the benefit of this invention, its teachings, and suggestions will appreciate that the conceptions of this disclosure may be used as a creative basis for designing other structures, methods and systems for carrying out and practicing the present invention. This invention includes any legally equivalent devices or methods which do not depart from the spirit and scope of the present invention.

The present invention recognizes and addresses the problems and needs in this area and provides a solution to those problems and a satisfactory meeting of those needs in its various possible embodiments and equivalents thereof. To one of skill in this art who has the benefits of this invention's realizations, teachings, disclosures, and suggestions, other purposes and advantages will be appreciated from the following description of certain preferred embodiments, given for the purpose of disclosure, when taken in conjunction with the accompanying drawings. The detail in these descriptions is not intended to thwart this patent's object to claim this invention no matter how others may later attempt to disguise it by variations in form, changes, or additions of further improvements.

The Abstract that is part hereof is to enable the U.S. Patent and Trademark Office and the public generally, and scientists, engineers, researchers, and practitioners in the art who are not familiar with patent terms or legal terms of phraseology to determine quickly from a cursory inspection or review the nature and general area of the disclosure of this invention. The Abstract is neither intended to define the invention, which is done by the claims, nor is it intended to be limiting of the scope of the invention or of the claims in any way.

It will be understood that the various embodiments of the present invention may include one, some, or all of the disclosed, described, and/or enumerated improvements and/or technical advantages and/or elements in claims to this invention.

Presently preferred embodiments of the invention are shown in the above-identified figures and described in detail below. It should be understood that the appended drawings and description herein are of preferred embodiments and are not intended to limit the invention or the appended claims. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the appended claims. In showing and describing the preferred embodiments, like or identical reference numerals are used to identify common or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.

As used herein and throughout all the various portions (and headings) of this patent, the terms “invention”, “present invention” and variations thereof mean one or more embodiment, and are not intended to mean the claimed invention of any particular appended claim(s) or all of the appended claims. Accordingly, the subject or topic of each such reference is not automatically or necessarily part of, or required by, any particular claim(s) merely because of such reference.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 2shows a system60according to the present invention in which power fluid from an hydraulic power unit is provided to a subsea blowout preventer operator (“BOP OPERATOR”). Hydraulic power fluid is pumped from a reservoir (“TANK”) by a pump (“PUMP”) through a check valve (“CHECK VALVE”) to a bank of accumulator containers at the surface (“ACCUMULATOR SYSTEM”). This fluid is then provided beneath a water level L through a check valve (“CHECK VALVE”) to an accumulator system according to the present invention with one or more depth compensated containers or conventional bladder bottles according to the present invention (“DEPTH COMPENSATED ACCUMULATOR SYSTEM”). A control valve (“DIRECTIONAL CONTROL VALVE”) selectively provides the power fluid from the depth compensated accumulator containers to operate a subsea device or apparatus, e.g. the BOP operator shown. Fluid exhausted from the BOP operator either flows into the water (“VENT”) or to a fluid recovery system (“FLUID RECOVERY SYSTEM”) from which it returns to the surface fluid reservoir (“TANK”). The containers of the depth compensated accumulator system may be any container or bottle according to the present invention, including, but not limited to, those ofFIGS. 5A-9B.

FIG. 3shows a subsea blowout preventer system80according to the present invention with multiple accumulator systems82according to the present invention.

FIGS. 5A,5B and5C illustrate a system100according to the present invention.FIG. 4shows schematically the system100as used to operate a BOP operator. Fluid from a surface hydraulic power system HP is stored in the system100for use through a directional control valve DV to a BOP operator BO. Fluid exhausted from the BOP operator either flows to a vent V or to a fluid recovery system FR for return to the surface. The systems ofFIGS. 6,7A,8A,9A and10A may be used in the scheme shown inFIG. 4instead of or in addition to a system100.

The system100has an outer housing102within which is movably mounted a piston assembly110which has a piston rod112with a first end114and a second end116. A piston end120with an interior cavity122is secured to the first end114of the rod112. A piston end130is secured to the second end of116of the rod112.

The piston rod112moves in a hole142in a gland140that divides a first chamber160(e.g. a chamber for hydraulic fluid) from a second chamber170(e.g. a chamber for gas udder pressure, e.g. nitrogen). A third chamber180(e.g., a vacuum chamber) is formed between the piston end130and an end cap190. Optionally, these chambers are interchanged with chamber160being a vacuum chamber and chamber180containing power fluid.

An end cap126secured in an opening124seals off the interior cavity122. A valve128permits gas under pressure, e.g. nitrogen, to be pumped into and through the cavity122, through a channel118extending through the length of the piston rod112, out through a channel119, and into the second chamber170to provide pressurized gas force against the piston end130. A recess132is provided in the piston end130so that the gas can flow into the second chamber130. Appropriate seals S1-S6seal the indicated structural interfaces.

The cavity122in the piston end120effectively increases the total amount of pressurized gas within the piston assembly110by the volume of the cavity122.

In one embodiment, the end cap126and the end surface of the piston end120are exposed to the pressure of water, e.g., sea water, when the system100is underwater. The force of this water pressure is additive with the force of the pressurized gas in the second chamber170and in the interior cavity122.

Power fluid, e.g. hydraulic fluid, is pumped from the first chamber160through a port162, e.g., to operate a BOP operator on a BOP.

Optionally, one, two, three, four or more (two shown) inserts146(solid or hollow, one solid shown, one hollow shown) may be placed within the interior cavity122to reduce the effective gas-containing volume of the cavity122; e.g. to optimize the minimum pressure (in terms of adiabatic or isothermal discharge).

FIG. 6illustrates a system300according to the present invention which has a movable piston with an inner member with a gas-containing cavity within the piston. This cavity is in fluid communication with a gas-containing chamber so that the effective total volume of gas is increased (as compared to having a gas-containing chamber alone) and, thus, the effective total volume of available gas is increased and, correspondingly, the available volume of power fluid is increased.

A piston302movable in a body304has an inner chamber306. An inner member310is secured to the body304with a beam or rod308. The inner member310is immobile and has a hollow part312with an inner cavity314that is in fluid communication with the chamber306via a channel318. Both the inner chamber306and the cavity314can contain gas under pressure. A cavity322can be evacuated so that a vacuum (or a very lower pressure is present or, alternatively, it can contain power fluid). A chamber320can contain power fluid, e.g. hydraulic fluid (or, alternatively, it can be evacuated so that a vacuum or a very low pressure is present). The pressure of water outside the body304can act on an outer surface324of the piston302and an outer surface328of the inner member310. Appropriate seals S101-S104seal the indicated interfaces.

As illustrated inFIG. 6, power fluid may exit through a port330(like the port162,FIG. 5A) to a control valve and on to an apparatus to be operated by the fluid. In this embodiment, there is a vacuum or very low pressure in the cavity322. Alternatively the power fluid may be in the cavity322and exit for use through a port340(shown in dotted lines) with a vacuum or very low pressure in the inner chamber306.

FIGS. 7A-7Fillustrate steps in a method of operation of a system like that ofFIG. 5Aaccording to the present invention.

InFIGS. 7A and 7B, no hydraulic power fluid has yet entered the system. The pressure of the seawater is applied to a piston top126of a piston assembly (that includes items130,142,120and126) and the pressure of gas in chambers122and170(in this case, nitrogen, “N2”) is applied to the piston end130. As shown inFIG. 7C, fluid PE from a surface hydraulic power unit flows from the port162into the chamber160moving the piston assembly and compressing the gas in the chambers122and170. This hydraulic power fluid enters the chamber160at a pressure sufficient to overcome the pressure of the seawater and the pressure of the gas.

As shown inFIG. 7D, the piston assembly has moved to the extent of its travel, and the chamber160is full of hydraulic fluid and fluid from port162ceases. A vacuum (or very low pressure, e.g. 14.7 psi) exists in the chamber180. In one particular example, the seawater pressure is 5348 psi; the gas pressure is 1272 psi; and the power fluid is at a pressure of 10211 psi. This hydraulic power fluid is now available to be moved from the system to power a device (e.g., but not limited to, a BOP operator).

FIG. 7Eillustrates the beginning of the provision of the power fluid from the chamber160to an external apparatus or control system. Power fluid flows from the chamber160through the port162. The force of the seawater and of the compressed gas, and the vacuum's force move the power fluid.

FIG. 7Fillustrates the discharge of the power fluid from the system. The system is now ready to again receive power fluid from the surface.

FIGS. 8A and 8Bshow a system200according to the present invention like the systems ofFIG. 5AandFIG. 7A, but with an interior chamber for water, e.g. seawater. As with the system shown inFIG. 5A, the system200is generally cylindrical, but only half is shown inFIGS. 8A and 8B.

A piston210, movably positioned on a housing208, has a gas chamber214for gas under pressure. The housing208may be two pieces secured together as shown (or a single piece). The piston210is mounted around and moves on a piston guide216which has an interior chamber218for additional gas under pressure. Hydraulic power fluid flows through a port232into a power fluid chamber230which is defined by part of an interior wall of the housing208and part of an exterior wall of the piston210. An interior vacuum chamber240(or chamber of relatively low pressure) is located at one end of the housing208. The lower end of the chamber218of the guide216is open to the chamber214.

Gas under pressure, e.g. nitrogen, is charged into the chambers214,218through a port250. Water from outside the system200flows into a chamber260through openings262. The pressure of the water acts on an end211of the piston210. The gas under pressure in the chambers214,218acts on an end213of the piston210. Seals SL seal various interfaces in the system.

Hydraulic power fluid at a pressure greater than the combined pressure of the gas in chambers214,218and the water in chamber260and the force of the vacuum in chamber240is introduced through the port232into the chamber230(e.g. for storage until it is used for a function, e.g. to operate a BOP operator). This moves the piston210(upwardly as shown inFIGS. 8A,8B). With the valve232shut, the power fluid remains in the chamber230. Upon opening of the valve232by a control system (not shown), the power fluid flows out from the chamber230(due to the vacuum, force of gas, and force of water).

FIGS. 9A and 9Bshow a system400according to the present invention like the systems ofFIG. 5A,FIG. 7A, but with an interior chamber for water, e.g. seawater and with a “tub” piston assembly movable within the housing. As with the system shown inFIG. 5A, the system400is generally cylindrical, but only half is shown inFIGS. 9A and 9B.

A piston410, movably positioned in a housing408, has a gas chamber414for gas under pressure. The piston410is a “tub” piston with exterior walls and an internal fluid containing space for containing power fluid and gas. The housing408may be two pieces secured together, or as shown a single piece. The piston410is mounted around and moves on a piston guide416and guide rod418. The guide rod418projects through an opening417in the piston410and through a top plate409of the housing408. Hydraulic power fluid (e.g. from a surface source) flows through a port439, through a channel433and through a port432into a power fluid chamber430which is defined by part of an interior wall of the piston410and part of an exterior wall of the guide rod418and top of the piston guide416. An interior vacuum chamber440(or chamber of relatively low pressure) is located at one end of the housing408.

Gas under pressure, e.g. nitrogen, is charged into the chamber414through a port450. Water from outside the system400flows into a chamber460through openings462. The pressure of the water acts on an end411of the piston410. The gas under pressure in the chamber414acts on an end413of the piston410. Seals SE seal various interfaces in the system.

Hydraulic power fluid at a pressure greater than the pressure of the gas in chamber414and the water in chamber460and the force of the vacuum in chamber440, is introduced through the port432into the chamber430. This moves the piston410(upwardly as shown inFIGS. 9A,9B). With no flow through the port432, the power fluid remains in the chamber430until it is used. Upon fluid flow from the port432, the power fluid flows out from the chamber430(due to the vacuum force, force of gas, and force of water). The systems200,300and400provide the water “boost” feature discussed above.

FIGS. 10A and 10Bshow a system500according to the present invention which has five interior chambers510,520,530,540and550. The system500is generally cylindrical, but only half is shown inFIG. 10A. The chamber510is a vacuum chamber (or chamber of very low pressure). The chamber520contains gas under pressure, e.g. nitrogen. The chambers530and540contain power fluid. The chamber550contains water, e.g. sea water.

Water enters the chamber550through holes552in a top plate501of a first housing502. Power fluid enters the chamber530through a port532and flows into the chamber540through a port542. Gas flows through a port522and through a channel524in a rod526to the chamber520. Seals503-509seal the interfaces where they are located.

The rod526is connected to or formed integrally with an end528. Part of the rod526and the end528are within a hollow member511in which are the chambers520and540(which, like other chambers in other embodiments herein, vary in volume depending on the position of other elements). The hollow member511is movable within a first housing502and a second housing513.

Connected to the first housing502, the second housing513contains part of the movable member511is in the second housing513. The seal505prevents water from impacting the exterior of the member511around the chamber520and thus the chamber520is always maintained with a positive internal pressure. The chamber510has a negative internal pressure. For this reason, the wall thickness of the second housing is relatively thicker than the wall thickness of the first housing. The first housing502includes the chambers530,540, and550in all of which a positive internal pressure is maintained. Adding the chamber530results in a relatively larger volume of available power fluid (as compared to a system in which there is no chamber530) and which provides the correct piston surface area ratios for operation.

The present invention, therefore, in at least some, but not necessarily all embodiments, provides an accumulator system, the accumulator system for subwater use, the accumulator system including: a body; a fluid chamber within the body for selectively containing power fluid; a piston assembly movably disposed within the body; a gas chamber within the body for containing gas under pressure to move the piston assembly to move the power fluid out of the fluid chamber of the body; the piston assembly including a cavity therein for containing gas under pressure for assisting in movement of the piston assembly; and the cavity in fluid communication with the gas chamber. Such a system may have one or some (in any possible combination) of the following: the piston assembly having a first piston end exposed exteriorly of the body for action thereupon of water pressure of water exterior to the body, said water pressure assisting in movement of the piston assembly to move power fluid from the fluid chamber out of the body; at least one insert removably located within the cavity for reducing the gas-containing capacity of the cavity; an apparatus to be operated by the power fluid, the fluid chamber having an exit port in fluid communication with the apparatus to be operated by the power fluid moved from the fluid chamber; the apparatus to be operated by the power fluid being a blowout preventer operator; the accumulator system located beneath water, a surface hydraulic power system at a surface above the water, the surface hydraulic power system for providing the power fluid to the fluid chamber of the body; the accumulator system located beneath water, a surface hydraulic power system at a surface above the water, the surface hydraulic power system for providing the power fluid to the fluid chamber of the body, and valve apparatus for controlling flow of power fluid to the apparatus from the surface hydraulic power system and for directing power fluid exhausted from the apparatus to a chosen line; the chosen line including any of a vent line or a line to a fluid recovery system; and/or a body having three interior chambers, including the fluid chamber, the gas chamber, and a third chamber, the body having a first body end with a first opening in the body, and a second body end with a second opening in the body, an amount of operational power fluid in the fluid chamber, an amount of pressurized gas in the gas chamber, a lower pressure in the third chamber, the piston assembly movably and sealingly mounted within the body, in the piston assembly a first piston end closing off the first opening and preventing hydraulic fluid from exiting through the first opening from the first chamber, the first piston end having an outer surface and an inner surface, the operational power fluid applying a first pressure against the first piston end's inner surface, water exterior to the accumulator system above to contact and to apply pressure to the outer surface of the first piston end to move the piston assembly in a direction toward the second body end, a piston rod with a first rod end and a second rod end, the first rod end connected to the first piston end, the second rod end connected to the second piston end, the piston assembly having a second piston end movably located in the second chamber, the second rod end connected to the second piston end, gas in the second chamber able to act on the second piston end to move the piston assembly in a direction away from the first opening, a channel through the piston rod and in fluid communication with the cavity and with the second chamber so that the gas within the cavity is flowable into the second chamber.

The present invention, therefore, in at least some, but not necessarily all embodiments, provides an accumulator system, the accumulator system for subwater use, the accumulator system including: a body; a fluid chamber within the body for selectively containing power fluid; a piston assembly movably disposed within the body; a gas chamber within the body for containing gas under pressure to move the piston assembly to move the power fluid out of the fluid chamber of the body; the piston assembly including a first piston end with a cavity therein for containing gas under pressure for assisting in movement of the piston assembly; the cavity in fluid communication with the gas chamber; the first piston end exposed exteriorly of the body for action thereupon of water pressure of water exterior to the body, said water pressure assisting in movement of the piston assembly to move power fluid from the fluid chamber out of the body; an apparatus to be operated by the power fluid; the fluid chamber having an exit port in fluid communication with the apparatus to be operated by the power fluid moved from the fluid chamber; the accumulator system located beneath water; a surface hydraulic power system at a surface above the water, the surface hydraulic power system for providing the power fluid to the fluid chamber of the body; the accumulator system located beneath water; a surface hydraulic power system at a surface above the water, the surface hydraulic power system for providing the power fluid to the fluid chamber of the body; valve apparatus for controlling flow of power fluid to the apparatus from the surface hydraulic power system and for directing power fluid exhausted from the apparatus to a chosen line; and wherein the chosen line can include any of a vent line or a line to a fluid recovery system.

The present invention, therefore, in at least some, but not necessarily all embodiments, provides a method for operating an apparatus located beneath water with power fluid, the method including storing power fluid in an accumulator system, the accumulator system as any according to the present invention, moving a piston assembly of the accumulator system to move power fluid out of a fluid chamber and to an apparatus, and powering the apparatus with the power fluid. Such a system may have one or some (in any possible combination) of the following: wherein the apparatus to be operated by the power fluid is a blowout preventer operator, the method including: operating the blowout preventer operator with the power fluid; wherein the accumulator system is located beneath water, a surface hydraulic power system at a surface above the water, the surface hydraulic power system for providing the power fluid to the fluid chamber of the body, the method including providing power fluid to the fluid chamber of the accumulator system; wherein the accumulator system includes valve apparatus for controlling flow of power fluid to the apparatus from the surface hydraulic power system and for directing power fluid exhausted from the apparatus to a chosen line, the method including controlling with the valve apparatus flow of power fluid to the apparatus; and/or wherein the chosen line can include any of a vent line or a line to a fluid recovery system, the method including: directing with the valve apparatus power fluid exhausted from the apparatus to any of a vent line or a fluid recovery system.

The present invention, therefore, in at least some, but not necessarily all embodiments, provides an accumulator system, the accumulator system for subwater use, the accumulator system including: a body; a piston assembly movably disposed within the body, the piston assembly having an interior; a rod member passing through the body and extending into the interior of the piston assembly; a rod member end on an end of the rod member, the rod member end disposed within the interior of the piston assembly, the rod member end having a first side and a second side; power fluid chamber in the interior of the piston assembly, the power fluid chamber adjacent the first side of the rod member; a gas chamber in the interior of the piston assembly, the gas chamber adjacent the second side of the rod member; and the piston assembly movable by gas in the chamber to move power fluid out of the power fluid chamber. Such a system may have one or some (in any possible combination) of the following: a low pressure chamber within the body and outside of the piston assembly, low pressure (e.g. but not limited to, a vacuum) within the low pressure chamber for assisting in moving power fluid from the power fluid chamber; a water chamber within the body and outside the piston assembly for receiving water from outside the body, pressure of said water for assisting in moving the piston assembly to move power fluid from the power fluid chamber; an apparatus to be operated by the power fluid; the power fluid chamber having an exit port in fluid communication with the apparatus to be operated by the power fluid moved from the fluid chamber and/or wherein the apparatus to be operated by the power fluid is a blowout preventer operator.

Accordingly, while preferred embodiments of this invention have been shown and described, many variations, modifications and/or changes of the system, apparatus and methods of the present invention, such as in the components, details of construction and operation, arrangement of parts and/or methods of use, are possible, contemplated by the patentee, within the scope of the appended claims, and may be made and used by one of ordinary skill in the art without departing from the spirit or teachings of the invention and scope of appended claims. Thus, all matter herein set forth or shown in the accompanying drawings should be interpreted as illustrative and not limiting, and the scope of the invention and the appended claims is not limited to the embodiments described and shown herein.

Certain fluid recovery systems according to the present invention have a pump system with one, two, or more pumps which pump to the surface power fluid exhausted from an apparatus powered by the power fluid. In a subsea environment, such a pump system according to the present invention is switched on and off. In one aspect the “switch” is provided by a piston apparatus, floating piston apparatus, or by a reserve capacity system with container(s) or bottle(s) with an inflatable bladder which, upon being inflated with seawater under pressure, is moved to contact part of a movable actuator within the bottle. The movable actuator is moved to operate a valve or switch which opens a fluid line to allow the flow of system (“TANK”) pressure to be applied to a piston of a pump. This occurs when the reserve capacity bottle is evacuated of power fluid.

One such system400is illustrated inFIG. 13Ain which a valve420controls the flow of fluid in a line404(fluid at system pressure supplied by a surface pumping system). When a housing414aof a reserve capacity bottle410ais evacuated of power fluid, seawater inflates a bladder412in the housing414a, the bladder412contacts an actuator418aand causes the an actuator418ato move down to operate the valve420. Optionally the actuator418acontacts and switches an electrical switch to actuate the valve420. The valve420stops the flow of fluid at the system pressure through the line404to a pump system430, stopping the pump system430(fluid flow in a line422to the surface ceases). A directional control valve434changes the direction of pumping of a pump or pumps in the system430. Check valves436and438provide a check valve function in the indicated lines.

FIG. 13Bshows a system400alike the system400,FIG. 13A(like numerals indicate like parts); but with a pump system430ahaving a pump with a piston431which can pump fluid to the surface from a first chamber432aor from a second chamber432b. The system400ahas check valves436,436a,438, and438a.

FIGS. 14A and 14Bshow a pump500according to the present invention which can be used in the pump system430a,FIG. 13B. The pump500has a body501ahousing a movable piston502a(like the piston431,FIG. 13B). The piston502ais movable to move power fluid from either of two chambers503a,504ato the surface. The piston502ahas two valve actuators505a,506awhich are movable to move bodies515,516to contact mechanical actuators507,508aof valves511a,512(respectively). Springs513a,514bias the bodies515,516away from the piston502ato assist in valve shifting and to “snap” the valve shut or open. The lines A, B, C shown inFIG. 14Acorrespond to the lines A, B, C shown inFIG. 17and the box labelled434ais a control valve corresponding to the valve434,FIG. 13B. The valves511a,512are mechanically actuated valves and may function, in one aspect, like the valves630,632,FIG. 16.

FIGS. 15A and 15Bshow a reserve capacity bottle410aaccording to the present invention which has a bladder412mounted within a housing414a. The bladder412is inflatable to contact and to move a body462aof an actuator rod464(which is movable to contact and operate a mechanically actuated valve, e.g. a valve420,FIG. 13A). The housing414ahas a lift ring452. Fluid enters the bladder412through holes454and a channel456. Exhausted power fluid enters an interior of the housing414athrough a bore458.

FIG. 16illustrates a system600according to the present invention utilizing a pump system602with a pump604(like the pumps ofFIGS. 13B and 14A). Two reserve capacity bottles610(like the bottle410a,FIG. 15A) receive power fluid exhausted from an apparatus powered by the power fluid (“FROM POD CAVITY RETURNS”) in a line606. Fluid under pressure pumped from a surface system (not shown) is provided in a line608to each of two mechanically operated valves611,612(which in turn control the provision of this fluid to operate the pump604). The pump604pumps power fluid to the surface in a line616from either of two chambers618,619in a body621. A valve630is mechanically actuated (e.g. as the valves511aor512,FIG. 14B) by contact with a piston640after the piton640has moved to pump power fluid from the chamber618. A valve632will be actuated upon contact by the piston640when the piston640has moved to expel power fluid from the chamber619into the line616. The valves630,632function similarly to the function of the valve434,FIG. 13A.

The dotted line642indicates the provision of a pilot signal from the valve632which shifts the valve630to allow fluid from a line618ato vent to line A which in turn allows the piston to move to the right (as viewed in theFIG. 16). The dotted line644indicates a similar provision of a pilot signal. Check valves643and645provide check valve functions in their respective lines633,635. The shuttle valve647provides a check valve function between the lines633,635. Power fluid enters the chamber618via a line618aand power fluid enters the chamber619via a line619a. Power fluid is expelled from the chamber618via a line618band power fluid is expelled from the chamber619via a line619b. Via a line617the pressure of the fluid from the line608is applied to the valves630,632to apply pressure on one side or the other of a piston to pump fluid to the surface.

FIG. 17illustrates a system700according to the present invention which uses a pump system (“PUMP SYSTEM”) according to the present invention, e.g., but not limited to, with a pump system as inFIG. 13A,13B, or16. The system700(“Power Fluid Recovery System”) has bottles (any disclosed herein or any suitable bottles) (“Reserve Capacity Bottles”) which recover hydraulic fluid from a blowout preventer operator (“BOP Operator”), flow to which is controlled by a control valve (“Control Valve”) which itself is controlled by a drive control (“Valve Drive Control”). The pump system (“Pump System”) has a valve system VS which receives fluid from the blowout preventer operator (in a line A) and pumps it in a line B back to a surface reservoir (“Tank”). An optional relief valve (“Relief Valve”) provides for equalization of pressure due to water density differentials. The pump system may have any desired number of pumps.

Check valves as indicated in the various lines (J, K, P, Q, X, Y) provide a check valve function. The two check valves labeled X and Y provide high pressure protection (valve X) and low pressure protection (valve Y). Accumulator containers at the surface (“Surface Bottles”) serve as containers for fluid pumped from the tank; and optional subsea containers (“Accumulator System”) provide an accumulator function at the level of the Power Fluid Recovery System.

The line C provides a constant flow of fluid under pressure to the Pump System's pump(s) which maintains a negative internal pressure in the pump. Via the line A, the pump receives fluid exhausted from the BOP operator and, via the line B, the pump pumps the fluid back to the surface. A piston movably disposed in a housing (e.g. a piston640) is movable in response to exhausted power fluid being introduced into the housing; and the piston is movable to pump the fluid into the line B and to the surface. The piston is movable to contact and move a valve actuator or actuators of a valve or valves in the valve system VS.

Once bladders are empty, the pumps are turned off.

The Reserve Capacity Bottles,FIG. 17, may be like the bottles610,FIG. 16; and the Pump System,FIG. 17, may be like the pump system602,FIG. 16.

FIG. 18Ashows the system400ofFIG. 13Awith various lines and check valves of the system ofFIG. 17. In such a system, the check valve438corresponds to the check valve P,FIG. 17; and the check valve436corresponds to the check valve Q,FIG. 17. The lines404and422correspond, respectively, to the lines C and B,FIG. 17.

The present invention, therefore, in at least certain embodiments, provides a method for recovering power fluid from a device under water and for pumping recovered power fluid to a surface of the water, the method including: flowing fluid from a subsurface apparatus to a subsurface recovery system, the fluid initially provided to the subsurface apparatus to power the subsurface apparatus; and the subsurface recovery system including pump apparatus for selectively pumping recovered fluid to a fluid container above a surface of the water. Such a method may one or some, in any possible combination, of the following: the subsurface recovery system including reserve capacity apparatus for receiving fluid from the subsurface apparatus and selectively providing the fluid to be pumped to the surface, the method further including selectively providing fluid from the reserve capacity apparatus to the pump; the pump apparatus pumps fluid in a line to the surface, the line to the surface including first check valve apparatus providing high pressure protection for the surface line and second check valve apparatus providing low pressure protection for the surface line, the method further including: protecting the line to the surface from high pressures with the first check valve apparatus; and protecting the line to the surface from high pressures with the second check valve apparatus; the pump apparatus pumps fluid in a line to the surface, the system including a relief valve on the line to the surface, the method further including: equalizing pressure due to water density differentials in the line to the surface with the relief valve; the subsurface recovery system includes pump valve apparatus for controlling fluid flow to the pump apparatus, the method further including: selectively providing fluid to the pump apparatus for pumping to the surface; a subwater accumulator system provides a flow of power fluid from the surface to the subsurface apparatus, the method further including: providing power fluid from the subwater accumulator system to power the subsurface apparatus; selectively providing fluid to the pump apparatus for pumping to the surface, providing a constant flow of fluid under pressure from the subwater accumulator system to maintain a negative internal pressure in the pump; pumping recovered fluid from the fluid container to the subsurface apparatus; pumping recovered fluid from the fluid container to surface accumulator apparatus; and pumping recovered fluid from the surface accumulator apparatus to the subsurface apparatus; the subsurface apparatus is a blowout preventer operator, a control valve controls fluid flow to the blowout preventer operator, a valve drive controls the control valve, and the method further including controlling fluid flow to the blowout preventer operator; the pump apparatus includes a two-chamber housing with a movable pumping piston therein, the two-chamber housing including a first chamber and a second chamber, the method further including: by moving the movable piston, pumping fluid in a line to the surface from the first chamber while the second chamber fills with fluid, and then pumping fluid to the surface from the second chamber while the first chamber fills with fluid; the pumping of fluid to the surface is continuous; a first reserve capacity apparatus selectively provides fluid to the first chamber or to the second chamber, and a second reserve capacity apparatus selectively provides fluid to the second chamber or to the first chamber, the method further including selectively providing fluid to the first chamber or to the second chamber from the first reserve capacity apparatus, and selectively providing fluid to the second chamber or to the first chamber from the second reserve capacity apparatus; first chamber valve apparatus controls fluid flow to the first, second chamber valve apparatus controls fluid flow to the second chamber, the method further including controlling fluid flow to the first chamber with the first chamber valve apparatus, and controlling fluid flow to the second chamber with the second valve apparatus; providing pilot signals from the first chamber and the second chamber to selectively vent fluid to facilitate reciprocation of the movable pumping piston; a secondary valve apparatus is in fluid communication with the first chamber valve apparatus and with the second chamber valve apparatus, and with the line to the surface, the method further including providing a check valve function with the secondary valve apparatus to selectively provide flow to the first chamber valve apparatus or to the second chamber valve apparatus; and/or pumping fluid to the surface through the secondary valve.

The present invention, therefore, in at least certain embodiments, provides a method for recovering power fluid from a device under water and for continuously pumping recovered power fluid to a surface of the water, the method including: flowing fluid from a subsurface apparatus to a subsurface recovery system, the fluid initially provided to the subsurface apparatus to power the subsurface apparatus; the subsurface recovery system including pump apparatus for selectively pumping recovered fluid to a fluid container above a surface of the water; selectively providing fluid to the pump apparatus for pumping to the surface; providing a constant flow of fluid under pressure from the subwater accumulator system to maintain a negative internal pressure in the pump; and wherein the pumping of fluid to the surface is continuous.

The present invention, therefore, in at least certain embodiments, provides a system for recovering power fluid from a device under water and for pumping recovered power fluid to a surface of the water, the system being a subsurface recovery system including pump apparatus for selectively pumping recovered fluid to a fluid container above a surface of water, the pump located for receiving fluid from a subsurface apparatus to a fluid initially provided to the subsurface apparatus to power the subsurface apparatus; reserve capacity apparatus for receiving fluid from the subsurface apparatus and selectively providing the fluid to the pump apparatus to be pumped to the surface; and pump valve apparatus for controlling fluid flow to the pump. Such a system may include a subwater accumulator for providing power fluid to the subsurface apparatus.

In conclusion, therefore, it is seen that the present invention and the embodiments disclosed herein and those covered by the appended claims are well adapted to carry out the objectives and obtain the ends set forth. Certain changes can be made in the subject matter without departing from the spirit and the scope of this invention. It is realized that changes are possible within the scope of this invention and it is further intended that each element or step recited in any of the following claims is to be understood as referring to the step literally and/or to all equivalent elements or steps. The following claims are intended to cover the invention as broadly as legally possible in whatever form it may be utilized. The invention claimed herein is new and novel in accordance with 35 U.S.C. §102 and satisfies the conditions for patentability in §102. The invention claimed herein is not obvious in accordance with 35 U.S.C. §103 and satisfies the conditions for patentability in §103. This specification and the claims that follow are in accordance with all of the requirements of 35 U.S.C. §112. The inventor may rely on the Doctrine of Equivalents to determine and assess the scope of the invention and of the claims that follow as they may pertain to apparatus not materially departing from, but outside of, the literal scope of the invention as set forth in the following claims. All patents and applications identified herein are incorporated fully herein for all purposes. What follows are some of the claims for some of the embodiments and aspects of the present invention, but these claims are not necessarily meant to be a complete listing of nor exhaustive of every possible aspect and embodiment of the invention. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function.