LOW COST DEEP WATER EFFICIENT BUOYANCY

Abstract: The present invention is directed to the formation of pressure resistant buoyancy structures with a given buoyancy efficiency at smaller sizes. The invention involves embedding into syntactic foam metallic spheres (10) which preferably are substantially hollow and comprise high strength, high performance, light weight metal alloys which can be precision forged. The weight per unit space of the metallic spheres is less than that of the syntactic foam. As a result, the metallic spheres can decrease the size of the structure required to achieve a desired amount of buoyancy.

Description: - 1 - LOW COST DEEP WATER EFFICIENT BUOYANCY The present invention relates to moldable subsea buoyancy structures comprising metallic spheres in syntactic foam and to a method of making such structures. All subsea vehicles and most subsea equipment require the use of a flotation system to make the vehicle or equipment either neutrally or positively buoyant. Typically, a castable material called syntactic foam is used for this purpose. This is especially true of subsea vehicles, such as Remotely Operated Vehicles (ROV's), and production oil and gas riser pipes (the piping that conducts oil and/or natural gas from the sea floor to a floating production platform at the surface of the ocean) . Syntactic foam is a mixture of epoxy or other suitable resin with hollow microspheres and sometimes "macrospheres" which typically are made of glass mixed evenly throughout the resin. "Macrospheres" are larger than microspheres, with sizes ranging up to about 3 inches (7.5cm) in diameter. The syntactic foam is cast and cured to form a block. Since the resins are liquid at room temperature, the foam can be cast into very complex shapes. The buoyancy efficiency of syntactic foam is defined as dry weight divided by the weight of a comparable volume of sea water. The smaller the buoyancy efficiency number, - 2 - the more efficient the buoyancy of the foam. At a rated depth of 3000 meters m the ocean, sufficient buoyancy can be provided if the foam density is roughly half the density of water (0.5 g per cm 3 or 32 pounds per cubic foot) . At deeper depths it is necessary to use foam having significantly higher density in order to provide sufficient strength against crushing; consequently the volume of foam required to provide a given amount of buoyancy is substantially increased. This means that - in deeper water - considerably more foam is required to provide the same amount of buoyancy. For an ROV that will operate at 3000 to 6000 meters ocean water depth (10,000 to 20,000 feet), the amount or size of the block of syntactic foam required to provide a desired amount of buoyancy can become a significant problem. At a design depth of 6000 meters, a typical Work Class ROV would require a foam block nearly twice as large as the foam block that would be required at 3000 meters. In addition to the problem of size, syntactic foam also is relatively expensive and lighter weight syntactic foams with greater buoyancy efficiency are subject to crushing at the pressures encountered m deep water. Syntactic foams are needed which are less expensive, which have increased buoyancy efficiency, and which have greater resistance to crushing in deep water. - 3 - According to the invention there is provided a pressure resistant buoyancy structure comprising a block of syntactic foam and metallic spheres embedded in the foam, the spheres having a weight per unit space less than said syntactic foam. The embedded metallic spheres may have a strength sufficient to maintain the buoyancy of the structure under pressures to which the structure will be exposed during use, those pressures being expected to be in excess of 1,000 psi (70 kg/cm 2 ) . The spheres are preferably substantially hollow and may each be formed from two hemispheres. The spheres are preferably formed from a precision forged high performance engineering structural metal. The spheres may for example be formed from an aluminium alloy, in particular one of the 7075, 7175 or 7050 series alloys. The spheres and the foam material may be of substantially equal bulk modulus. The spheres are preferably regularly spaced in the foam. The packing density of the spheres is preferably substantially the highest available packing density. The spheres preferably have a diameter greater than 20cm and, more preferably and particularly, an inner diameter greater than 24cm. Also the spheres preferably have a wall thickness that is small compared to their diameter. For example, the spheres may have a wall - 4 - thickness of the order of 0.4cm. The structure is especially suitable for deep water applications. Preferably the structure is able to withstand a pressure of 296 kg/cm 2 (4200 psi) and more preferably 423 kg/cm 2 (6000 psi). Preferably the spheres are able to withstand a wall stress of 5,000 kg/cm 2 (70,000 psi) and more preferably a wall stress of 7,000 kg/cm 2 (100,000 psi) . In another aspect, the invention provides a block of material and spheres embedded in the material, the spheres including spheres having a large diameter, preferably greater than 20cm. There may also be smaller spheres which may for example be an integral part of the material, which may be syntactic foam material. The invention further provides a method of forming a pressure resistant buoyancy structure comprising the steps of providing metallic spheres and molding syntactic foam around the spheres to form the structure, the spheres having a weight per unit volume less than the syntactic foam. The invention still further provides an apparatus comprising a pressure resistant buoyancy structure comprising a first block of syntactic foam comprising embedded metallic spheres, said syntactic foam and said metallic spheres - 5 - comprising materials and structure effective to produce a first buoyancy efficiency at a first size; wherein a pressure resistant buoyancy structure comprising said first buoyancy efficiency but comprising a second block of syntactic foam in the absence of said embedded metallic spheres comprises a second size which is larger than said first size. Similarly, the invention still further provides a method of reducing the size of a pressure resistant buoyancy structure required to achieve a first buoyancy, said method comprising: forming substantially hollow metal spheres comprising a high performance engineering structural metal; fixing said metallic spheres in a mold for said pressure resistant buoyancy structure; and pouring syntactic foam raw material into said mold and round said metallic spheres; and curing said syntactic foam. By way of example, an embodiment of the invention will be described with reference to the accompanying drawings, of which: Fig. 1A is a perspective view, partly cut-away, of a metallic sphere suitable for use in the present invention, Fig. IB is an exploded cross-sectional view of a preferred edge connection detail for each hemisphere of the - 6 - sphere shown in Fig. 1A, and Fig. 2 is a perspective view of metallic spheres in a mold for forming a buoyancy block. Preferred embodiments of the invention are concerned particularly with the manufacture of low cost, high strength, light weight, hollow metallic spheres that can be cast directly into a syntactic foam block. The spheres are preferably of relatively large diameter and are preferably thin walled. The spheres are lighter in weight per unit space than the foam that they replace, but cost approximately the same as the foam that they replace. The spheres may be made of any high performance engineering structural metal that can be precision forged. Suitable metals include, but are not necessarily limited to, aluminium and its alloys, steel, and titanium and its alloys. A preferred metal, for reasons of both cost and workability, is a high strength aluminium alloy such as 7075 or 7175, or one of the 7050 series alloys. The spheres preferably are manufactured by forging two hemispheres, machining the connection between the two hemispheres to allow them to be joined together, and then casting the hollow spheres into a block of syntactic foam. The diameter and thickness of the sphere is determined by the depth requirement for the buoyancy foam. The spheres may have substantially any diameter; however, for deepwater - 7 - environments of over 3000 meters, preferred diameters will range from about 10 inches (about 25cm) to about 24 inches (about 60cm) . The wall thickness of the sphere will typically be in the range of about 0.14 to about 0.16 inches (0.35cm to 0.41cm). In one particular example the sphere has a diameter of about 10 inches (25cm) and a wall thickness of about 0.15 inches (0.38cm). At a depth of 3000m the hydrostatic pressure is about 4200 psi (296 kg/cm 2 ) ; thus the stress in a block of syntactic foam at a depth of 3000m is about 4200 psi (296 kg/cm 2 ) . Because the metal spheres are hollow and have a very thin wall, the wall stress in the spheres will however be considerably higher; for example, in the case of a sphere of diameter 10 inches (25cm) and of wall thickness of about 0.15 inches (0.38cm), the wall stress resulting from a hydrostatic pressure of about 4200 psi (296 kg/cm 2 ) is about 70,000 psi (about 4932 kg/cm 2 ), and similarly, at a hydrostatic pressure of about 6,000 psi (423 kg/cm 2 ) the wall stress resulting from the hydrostatic pressure is about 100,000 psi (about 7046 kg/cm 2 ). Such a sphere can be provided by a traditional high strength aerospace aluminium forging alloy, such as 7175-T6. The spheres preferably should have roughly the same bulk modulus as the syntactic foam into which they are cast in order to keep interfacial stress to a low level. - 8 - When selecting dimensions for the sphere a safety factor of 1.5 may be employed. For example if a sphere is to be required to withstand wall stresses arising at a depth of 5,000m, it may be designed on the basis of calculations of stresses at a depth of 7,500m. The two hemispheres may be forged using a number of procedures, a preferred procedure being isothermal precision forging. In isothermal precision forging, a forging die with the desired hemispherical configuration is prepared. A blank of the metal to be forged is placed in the forging die, and both the forging die and the blank of metal are held at the same elevated temperature. The elevated temperature preferably should be sufficiently high to render the metal blank malleable enough for molding by the dies. Each metal alloy has a preferred temperature range for isothermal precision forging. The dies are closed on the blank of metal relatively slowly. Once the dies are closed, high tonnage is supplied on the dies to form the hemisphere. The hemispheres are then rough machined and heat treated according to the appropriate heat treating schedule for the alloy used. Persons of ordinary skill in the art will know the appropriate heat treating schedule. Typical heat treating schedules are available from the metal supplier, are described in the Metals Handbook, Vol. 5 (9th Ed. 1982), incorporated herein by - 9 - reference, and are described in various texts related to forging. After heat treating, the hemispheres are machined into their final shape by putting on edge connection detail to connect the two hemispheres. Although various edge connection configurations may be used, a preferred edge detail is shown in Figs 1A and IB. Referring to Figs. 1A and IB, each sphere 10 comprises two hemispheres 12, 14. The hemispheres 12, 14 are connected via mating annular shoulders and flanges. A first hemisphere 12 has an inner annular shoulder 15 and an outer annular flange 16. A second hemisphere 14 has an inner annular flange 17 and an outer annular shoulder 18. The inner annular flange 17 of the second hemisphere 14 mates with the inner annular shoulder 15 of the first hemisphere 12, and the outer annular flange 16 of the first hemisphere 12 mates with the outer annular shoulder 18 of the second hemisphere 14. The inner and outer surfaces of the hemispheres preferably are used in the as forged condition, without additional machining. After machining the edge detail, the two hemispheres 12, 14 are sealed together, preferably with the aid of a suitable adhesive, and the finished sphere is cast into a syntactic foam block. Referring to Fig. 2, a small amount of spacing preferably is provided between - 10 - spheres to avoid metal-to-metal contact. This spacing may be provided either with spacers glued to the spheres before casting, or a thin coating of the syntactic foam material may be applied and cured before the spheres are arranged in the block mold 20. The mold 20 preferably is treated with a suitable release agent before the spheres are fixed in the mold. Examples of suitable releasing agents or release films include, but are not necessarily limited to, FREEKOTE 700, 33 NC or 815 NC mold release agents. FREEKOTE is a U.S. federally registered trademark of The Dexter Corp. Thereafter, the spheres may be arranged and fixed in place in the block mold using any suitable means, such as a fixed lid mold 019 fixed grating unit that allows for the flow of syntactic foam but does not allow the spheres to move during casting. In order to maximise buoyancy efficiency, the spheres preferably are arranged in a regular manner at their highest packing density. After the spheres are fixed in the mold, the entire syntactic foam block is cast as a single unit. The starting materials for making syntactic foam include a suitable resin. The resin may be any suitable resin known to persons of ordinary skill in the art, including, but not necessarily limited to, synthetic organic resins such as an epoxy, a cyanate ester, or a polyimide resin. Silicones, - 11 - bismaleimides, and other thermosetting and thermoplastic resins also may be used. Preferred resins are epoxy resins . A preferred raw foam is entrained with air, and is commercially available under the name Low Cost Buoyancy Foam from Syntech Materials, P.O. Box 5242, Springfield, Virginia 22150. Microspheres or macrospheres (hereinafter "microspheres") are mixed with the foam. Substantially any available microspheres may be used. Suitable microspheres include, but are not necessarily limited to, polymer, glass, quartz, or carbon spheres, with preferred spheres being hollow glass spheres filed with a gas such as carbon dioxide and having a diameter in the range of from about 5 to about 200 microns. The microspheres may be mixed with the raw foam using any of the methods known in the art such as, for example, the vacuum mixing method or the vacuum impregnation method. The mixing may be performed either as a batch or continuous process. Once the raw foam and microspheres are thoroughly interspersed, the raw foam may be processed by molding and curing. The raw foam/microsphere mixture is poured into the mold until the raw foam surrounds and intimately contacts the resin coating or outer surface of the spheres. The mixture then is allowed to cure using known procedures. For a foam made from an epoxy resin where the material will - 12 - have a thickness in the range of from about two inches (about 5cm) to about six inches (about 15cm) , the raw o material is heated gradually [at a rate of about 0.18 C (1/2°F) per minute] to about 49°C (120°F), and held for o o about two hours, then heated to about 60 C (140 F) and held o o for about two hours, then heated to about 71 C (160 F) for up to about four hours. For material thicknesses greater than six inches (15cm) , the raw material is heated o o gradually [at a rate of about 0. 18 C (1/2 F) per minute] o o to about 41 C (105 F) and held for up to about four hours, then heated to about 49 C (120 F) for up to about two o o hours, then heated to about 60 C (140 F) for up to about o o two hours, then to about 71 C (160 F) for up to about four hours. The curing process can take place under a vacuum. If the resin contains entrained air, then the curing process does not take place under a vacuum. For a given depth rating, a block of syntactic foam having desired buoyancy and strength properties can be made in smaller dimensions using the embedded spheres of the present invention. If the spheres are well forged and intimately bonded to the foam, a block with embedded spheres will have a crush depth that is near the crush depth of a block of syntactic foam without embedded spheres . - 13 - The invention will be better understood with reference to the following Example, which is illustrative only, and is not intended to limit the scope of the present invention which is defined by the claims. EXAMPLE Preparation of Hollow Metallic Spheres Five hollow metallic spheres are forged using isothermal precision forging. A forging die is prepared having a diameter of about 10 inches (25cm) . A blank of about 1450g 7175 aluminium alloy is placed in the forging die, and both the forging die and the blank of metal are heated to about 370 C. The dies and metal blank are held at that temperature, and the dies are closed on the blank of metal relatively slowly. Once the dies are closed, approximately 2500 tons are supplied on the dies to form hemispheres having a thickness of about 0.15 inches (0.38cm) . The hemispheres are rough machined and heat treated by raising the temperature of the hemispheres to the "solutionizing" temperature, or to the point where the precipitation in the alloy goes back into solid solution in the metal. The hemispheres are then rapidly cooled or "quenched" to ensure that this solution remains. The - 14 - hemispheres are again heated to an "aging" temperature which is much lower than the solutionizing temperature, for a specified amount of time until the metal reaches its peak strength . After heat treating, the edge connection detail shown in Figs. 1A and IB is machined onto the edges of the appropriate opposing hemispheres. The inner and outer surfaces of the forging are used in the as forged condition. After machining, the "male and female" edges of the two hemispheres are joined, preferably using a cyanoacrylate adhesive or a room temperature setting epoxy adhesive. Casting of Foam Around the Spheres The mold is treated with FREEKOTE 700 before the spheres are affixed in the mold. FREEKOTE is a U.S. federally registered trademark of The Dexter Corp. In addition, a thin coating of the syntactic foam raw material is applied to the outer surface of the spheres and cured before the spheres are fixed in the block mold. The spheres are secured in place preferably using a grate, and are secured in the mold by entirely enclosing the flow mold cavity containing the spheres. In order to maximise buoyancy efficiency, the spheres are fixed in the mold at intervals - 15 - at their highest packing density. After the spheres are secured in the mold, raw foam material incorporating entrained air obtained from Syntech Materials is poured into the mold and the raw material is heated gradually (at a rate of about 0. 18°C (1/2°F) per minute to about 41 °C (105°F), then heated to about 49°C o o (120 F) for about two hours, then heated to about 60 C (140°F) for about two hours, then to about 71 °C (160°F) for about four hours . The resulting block is able to withstand hydrostatic pressures and has a buoyancy efficiency of approximately 0.40. Persons of ordinary skill in the art will recognise that many modifications may be made to the present invention without departing from the spirit and scope of the present invention. The embodiment described herein is meant to be illustrative only and should not be taken as limiting the invention, which is defined in the following claims .

Claims: - 16 - Claims 1. A pressure resistant buoyancy structure comprising a block of syntactic foam and metallic spheres embedded in the foam, the spheres having a weight per unit space less than said syntactic foam. 2. A structure according to claim 1, wherein said metallic spheres are substantially hollow. 3. A structure according to claim 1 or 2, wherein said metallic spheres are formed from a precision forged high performance engineering structural metal. 4. A structure according to any preceding claim, wherein said metallic spheres are formed from an aluminium alloy. 5. A structure according to any preceding claim, wherein said metallic spheres and said syntactic foam block are of substantially equal bulk modulus. 6. A structure according to any preceding claim, wherein said metallic spheres are regularly spaced in the foam. 7. A structure according to any preceding claim, wherein the packing density of the spheres is substantially the highest available density. 8. A structure according to any preceding claim, wherein said metallic spheres have an inner diameter of at least about 24cm. - 17 - 9. A structure according to any preceding claim, wherein said metallic spheres have wall thicknesses that are small compared to their diameters. 10. A structure according to claim 9, wherein the metallic spheres each have a wall thickness of the order of 0.4cm. 11. A structure according to any preceding claim, wherein said structure is able to withstand a pressure of 296 kg/cm 2 (4200 psi) . 12. A structure according to claim 11, wherein said structure is able to withstand a pressure of 423 kg/cm 2 (6000 psi) . 13. A structure according to any preceding claim, wherein said metallic spheres are able to withstand a wall stress of 5,000 kg/cm 2 (70,000 psi). 14. A structure according to any preceding claim, wherein said metallic spheres are able to withstand a wall stress of 7,000 kg/cm 2 (100,000 psi). 15. A pressure resistant buoyancy structure comprising a block of foam and spheres embedded in the foam, the spheres including spheres having a diameter greater than 20cm. 16. A method of forming a pressure resistant buoyancy structure comprising the steps of providing metallic spheres and molding syntactic foam around the spheres to form the structure, the spheres having a weight per unit volume less than the syntactic foam. - 18 - 17. A method according to claim 16, in which the structure is a structure according to any one of claims 2 to 15. 18. A method according to claim 16 or 17, said method including the steps of fixing spheres in a mold, pouring syntactic foam raw material into the mold and around the spheres and curing the syntactic foam. 19. An apparatus comprising a pressure resistant buoyancy structure comprising a first block of syntactic foam comprising embedded metallic spheres, said syntactic foam and said metallic spheres comprising materials and structure effective to produce a first buoyancy efficiency at a first size; wherein a pressure resistant buoyancy structure comprising said first buoyancy efficiency but comprising a second block of syntactic foam in the absence of said embedded metallic spheres comprises a second size which is larger than said first size. 20. A method of reducing the size of a pressure resistant buoyancy structure required to achieve a first buoyancy, said method comprising: forming substantially hollow metal spheres comprising a high performance engineering structural metal; fixing said metallic spheres in a mold for said pressure resistant buoyancy structure; and - 19 - pouring syntactic foam raw material into said mold and round said metallic spheres; and curing said syntactic foam.

Inventors: GOLAND LAWRENCE JON, HENKENER JERRY ALLEN, PATTON EDWARD MATTHEW, RENNICK TIMOTHY STEWART, GOLAND, LAWRENCE, JON, HENKENER, JERRY, ALLEN, PATTON, EDWARD, MATTHEW, RENNICK, TIMOTHY, STEWART
Applicants: GOLAND LAWRENCE JON, HENKENER JERRY ALLEN, PATTON EDWARD MATTHEW, RENNICK TIMOTHY STEWART, SAIPEM SPA, GOLAND, LAWRENCE, JON, HENKENER, JERRY, ALLEN, PATTON, EDWARD, MATTHEW, RENNICK, TIMOTHY, STEWART, SAIPEM S.P.A.
Application year: 1999
Main classification: B63B3
IPC codes: B63B3