Flush-Enabled Controlled Flow Drain

Abstract

A controlled flow drain having an upper flange coupled to a lower flange. The upper flange defines an inlet cavity and the lower flange defines a swirl chamber. The inlet cavity and swirl chamber are in fluid communication via a swirl nozzle defined within a swirl nozzle plate that separates the inlet cavity from the swirl chamber. After separating debris within the drain fluid, the drain fluid is accelerated through the swirl nozzle and discharged into the swirl chamber, and more debris is thereby separated and eventually settles into an annular groove. The drain fluid may then exit the lower flange via an exit control passage. The swirl chamber may be flushed with a series of flushing liquid injection ports symmetrically-arrayed about the annular groove. Flushing the swirl chamber removes fluidized debris and also remove any built up fouling present on the swirl nozzle and exit control passage.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is best understood from the following detailed description when read with the accompanying Figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

FIG. 1 illustrates a cross-sectional view of an exemplary drain, according to one or more embodiments disclosed.

FIG. 2A illustrates a side view of a debris fence and swirl nozzle, according to one or more embodiments disclosed.

FIG. 2B illustrates a plan view of a debris fence and swirl nozzle, according to one or more embodiments disclosed.

FIG. 3 illustrates a cross-sectional isometric view of the drain shown in FIG. 1.

FIG. 4 illustrates a close-up cross-sectional view of a portion of the drain shown in FIG. 1, according to one or more embodiments of the disclosure.

FIG. 5 illustrates a schematic method of controlling a drain flow, according to one or more embodiments of the disclosure.

DETAILED DESCRIPTION

It is to be understood that the following disclosure describes several exemplary embodiments for implementing different features, structures, or functions of the invention. Exemplary embodiments of components, arrangements, and configurations are described below to simplify the present disclosure; however, these exemplary embodiments are provided merely as examples and are not intended to limit the scope of the invention. Additionally, the present disclosure may repeat reference numerals and/or letters in the various exemplary embodiments and across the Figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various exemplary embodiments and/or configurations discussed in the various Figures. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. Finally, the exemplary embodiments presented below may be combined in any combination of ways, i.e., any element from one exemplary embodiment may be used in any other exemplary embodiment, without departing from the scope of the disclosure.

Additionally, certain terms are used throughout the following description and claims to refer to particular components. As one skilled in the art will appreciate, various entities may refer to the same component by different names, and as such, the naming convention for the elements described herein is not intended to limit the scope of the invention, unless otherwise specifically defined herein. Further, the naming convention used herein is not intended to distinguish between components that differ in name but not function. Additionally, in the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” All numerical values in this disclosure may be exact or approximate values unless otherwise specifically stated. Accordingly, various embodiments of the disclosure may deviate from the numbers, values, and ranges disclosed herein without departing from the intended scope. Furthermore, as it is used in the claims or specification, the term “or” is intended to encompass both exclusive and inclusive cases, i.e., “A or B” is intended to be synonymous with “at least one of A and B,” unless otherwise expressly specified herein.

FIG. 1 illustrates a cross-sectional view of an exemplary controlled flow drain 100, according to one or more embodiments disclosed herein. The drain 100 may be used to remove unwanted fluids and/or contaminants away from one or more contamination-sensitive cavities within a turbomachine (not shown), such as a motor-compressor. The drain 100 may be configured to simultaneously limit or otherwise preclude undesirable exiting of gas from the contamination-sensitive cavities. In at least one embodiment, the drain 100 may be employed in conjunction with a subsea motor-compressor configured to receive and compress a working fluid, such as a hydrocarbon gas, including but not limited to natural gas or methane.

The drain 100 may be embedded or otherwise defined within a modified high-pressure pipe flange, including an upper flange 102 and a lower flange 104. In at least one embodiment, the upper and lower flanges 102,104 may form a single-piece pipe flange. In the depicted embodiment, however, the upper and lower flanges 102, 104 may be coupled together as known by those skilled in the art, such as by mechanical fasteners (i.e., bolts), welding, brazing, or combinations thereof. An annular seal 103 may be disposed between the flanges 102, 104 and configured to sealingly engage the flanges 102, 104, thereby creating a fluid-tight seal therebetween. In one embodiment, the annular seal 103 may be an O-ring, but may also include other types of seals without departing from the scope of the disclosure.

The upper and lower flanges 102, 104 may be coupled to upper and lower drain pipes (not shown), respectively, of the accompanying turbomachine in order to channel and remove the unwanted fluids and/or contaminants from the liquid-sensitive cavities within the turbomachine. The unwanted fluids and/or contaminants may include liquids, such as water or hydrocarbon-based liquids, but may also include gases derived from the interior of the contamination-sensitive cavities described above.

To minimize plugging, the connecting upper and lower drain pipes may provide at least four times the flow area of the drain 100. In at least one embodiment, the connecting upper and lower drain pipes provide ten or more times the flow area of the drain 100. As depicted, the drain 100 may be oriented with respect to gravity having an inlet 106 at its upper extent defined within the upper flange 102, and an exit 108 at its bottom extent defined within the lower flange 104. Accordingly, drain fluid flow proceeds in a generally axial direction with respect to the drain's axis of symmetry Q, and as depicted by arrows A and B.

As the drain flow enters the inlet 106, it is directed through a director orifice 110 configured to centralize the incoming drain flow and direct it into an inlet cavity 112 and subsequently to the center of a succeeding swirl nozzle plate 114. The inlet cavity 112 may be an axisymmetric, profiled cavity formed within the upper flange 102 and partially defined at its base by the upper surface of the swirl nozzle plate 114. As the inlet cavity 112 receives the drain flow, particulate contamination or debris 116 contained within the drain flow is deposited or otherwise collected on the upper surface of the swirl nozzle plate 114. Typical debris 116 can include metallic pieces, rust, rock, sand, corrosion particles, sediment deposits, and/or combinations thereof.

A debris fence 118 is disposed within the inlet cavity 112 and may be welded to or otherwise milled into the swirl nozzle plate 114. As shown and described below with reference to FIGS. 2A and 2B, the debris fence 118 may surround a nozzle inlet 204 of a swirl nozzle 202. In operation, the debris fence 118 is at least partially configured to segregate the swirl nozzle 202 inlet area 204 from the debris 116 accumulating on the upper surface of the swirl nozzle plate 114. At the same time, the debris fence 118 allows drainage fluids to flow over the top of the debris fence 118 and into the swirl nozzle 202. Accordingly, the swirl nozzle 202 may provide fluid communication between the inlet cavity 112 and a swirl chamber 120, as will be described below.

Referring to FIGS. 2A and 2B, illustrated is the swirl nozzle 202 having a nozzle inlet 204 and a nozzle outlet 206. FIG. 2A depicts a side view of the swirl nozzle 202 and FIG. 2B depicts a plan view of the swirl nozzle 202. As illustrated, the swirl nozzle 202 may be defined or otherwise formed in the swirl nozzle plate 114, and the debris fence 118 may at least partially surround the nozzle inlet 204. The swirl nozzle 202 may include a prismatic cylindrical passage having a central axis R.

In one or more embodiments, the swirl nozzle 202 may be defined or otherwise arranged using compound declination angles. For example, as shown in FIG. 2A, the central axis R of the swirl nozzle 202 may be arranged at an angle α with respect to the horizontal X axis, thereby imparting a downward pitch to the swirl nozzle 202 with respect to horizontal. In at least one embodiment, the angle α may be about 20° or less. Moreover, as shown in FIG. 2B, the swirl nozzle 202 may be further arranged at an angle β with respect to the Z axis, thereby positioning the central axis R at an angle β with respect to a tangential discharge pitch circle in the radial plane. In other words, disposing the central axis R at an angle β effectively rotates the central axis R away from a purely tangential discharge position with respect to the sub-regions disposed below the swirl nozzle plate 114. In at least one embodiment, the angle β may be about 15°. As will be appreciated, however, the angle β may be adjusted in accordance with the desired diameter of the swirl nozzle 202. Accordingly, a broad range of diameters for the swirl nozzle 202 may be had simply by adjusting the angle β.

The use of double compound declination angles α and β allow for a compact geometry with both the nozzle inlet 204 and outlet 206 of the swirl nozzle 202 being contained within the same concentric circular boundary. Such a design maintains over 90% of the theoretical tangential swirl velocity as compared to the bulkier prior art designs described above that use a purely tangential swirl nozzle design.

In one or more embodiments, the overall thickness T (FIG. 2A) of the swirl nozzle plate 114 allows for the fully-cylindrical portion of the swirl nozzle 202 between its nozzle inlet 204 and outlet 206 breakout regions to be approximately equal to the nozzle 202 passage diameter in length. When concern about gas carry-under is the controlling constraint, the size of the swirl nozzle 202 may be fixed at the minimum diameter deemed acceptable by those skilled in the art for proof against blockage by possible fouling particles and debris. In at least one embodiment, an industrially-acceptable size of the swirl nozzle 202 may range from about ⅛ inch to about ¼ inch in diameter.

Referring again to FIG. 1, the drain 100 may further include a swirl chamber 120 formed or otherwise defined within the lower flange 104, the swirl chamber having its upper extent defined by the frustoconical, lower surface of the swirl nozzle plate 114 and its lower extent defined by a drain restrictor 122. The drain restrictor 122 may also have a generally frustoconical shape and include an exit control passage 124 centrally-defined therein. In at least one embodiment, the frustoconical, lower surface of the swirl nozzle plate 114 and the generally frustoconical shape of the drain restrictor 122 may be opposing parallel surfaces that are slightly angled to mirror each other. In one embodiment, the declination angle of the frustoconical, lower surface of the swirl nozzle plate 114 and the generally frustoconical shape of the drain restrictor 122 may be about 10°, but such angle may be modified to suit varying applications where fluids with differing flow coefficients are used. The frustoconical shape of the drain restrictor 122 may further generate a low point in the swirl chamber 120 where drain flow will accumulate and drain via the exit control passage 124. The frustoconical shape may also prevent incidental buildup of solids and/or liquids on the surface of the drain restrictor 122. This may be especially important for drainage when liquid is present with little or no pressure difference imposed across the drain restrictor 122.

The exit control passage 124 may be configured to minimize through-flow, and therefore act as a restrictor. In one embodiment, the exit control passage 124 includes sharp edges adapted to permit liquid drainage therethrough but concurrently control or otherwise restrict gas carry-under. The exit control passage 124 is in fluid communication with the downstream exit 108 discharge, which in turn fluidly communicates with the downstream exit piping system (not shown). In operation, the amount of flow through exit control passage 124 is generally controlled by the series combination of the pressure drops required to force the drain fluids through the swirl nozzle 202, the vortex flow generated by the swirl nozzle 202, and the general configuration of the exit control passage 124. In at least one embodiment, the diameter of the exit control passage 124 may be the same as the diameter of the swirl nozzle 202. As will be appreciated, however, the diameter of the exit control passage 124 may be greater than or less than the diameter of the swirl nozzle 202, without departing from the scope of the disclosure.

The swirl chamber 120 may be a generally cylindrical space configured to allow the drain flow exiting the swirl nozzle 202 (FIGS. 2A and 2B) to develop into a fully vortical fluid flow. Several novel features of the geometry of the swirl chamber 120 are directed at facilitating long service in difficult unattended subsea conditions. For example, in at least one embodiment, the geometry of the swirl chamber 120 includes a height roughly equal to the swirl nozzle 202 diameter. As can be appreciated, however, the height of the swirl chamber 120 may be modified to be greater or less than the swirl nozzle 202 diameter, without departing from the scope of the disclosure. In addition, to minimize the flow coefficient, the diameter of the swirl chamber 120 may be from about 5 to about 10 times the swirl nozzle 202 diameter.

Another significant feature of the swirl chamber 120 is the provision for the collection and removal of debris 116 from the swirl chamber 120 by flushing the debris 116 and any other fouling matter away from the swirl chamber 120. To accomplish this, the swirl chamber 120 may fluidly communicate with an annular groove 126 and a series of flushing liquid injection ports 128 (two shown in FIG. 1) symmetrically-arrayed about the annular groove 126. As illustrated, the annular groove 126 may be formed about the drain restrictor 122 on the lower surface and outer extent of the swirl chamber 120. The flushing liquid injection ports 128 may be configured to feed a flushing liquid from external piping connections (not shown) into the swirl chamber 120. In one embodiment, the flushing liquid may be water, but may also include liquids derived from hydrocarbons or other liquid sources known in the art. Until needed for flushing, the flushing liquid injection ports 128 are sealed and no fluid flow passes therethrough.

The vortical fluid flow exiting the swirl nozzle 202 into the swirl chamber 120 will force dense debris 116 disposed within the drain flow to the radially outer extent of the swirl chamber 120, where the debris 116 eventually settles into the annular groove 126 without obstructing the general area of swirl chamber 120 itself. At some point, during a duty cycle of the turbomachine, for example, the debris 116 accumulated within the annular groove 126 may be flushed out by injecting flushing liquid into the annular groove 126 via the flushing liquid injection ports 128. When flushing is carried out, the flushing liquid flows uniformly from these ports 128, pressurizes the swirl chamber 120, and thereby forces accumulated debris 116 out of the swirl chamber 120 and through the exit control passage 124. As can be appreciated, pressurizing the swirl chamber 202 may serve to fluidize at least a portion of the solid contaminants or debris settled in the annular ring 126. Once fluidized, the debris more easily exits the exit control passage 124.

The pressurized flushing liquid also serves to remove fouling that may have built up on the edges of the exit control passage 124. Moreover, because the swirl chamber 120 becomes pressurized, a fraction of the flushing liquid is simultaneously forced through the swirl nozzle 202 at a significant pressure. Consequently, flushing the swirl chamber 120 also dislodges debris 116 or fouling matter formed on the swirl nozzle 202, and such dislodged debris 116 and/or fouling matter can then be removed from the drain 100 via the exit control passage 124.

Referring now to FIG. 3, illustrated is a cross-sectional isometric view of the drain 100 shown in FIG. 1. As such, FIG. 3 may be best understood with reference to FIG. 1, where like numerals correspond to like elements and therefore will not be described again in detail. In exemplary operation, drain fluid enters the drain 100 via the inlet 106, as shown by arrow C. The director orifice 110 centralizes the incoming drain flow and directs it into the inlet cavity 112 and the succeeding swirl nozzle plate 114, as shown by arrow D. While the more dense debris 116 (FIG. 1) and other contaminating materials accumulate on the upper surface of the swirl nozzle plate 114, the less dense fluid flows over the top of the debris fence 118 and toward the swirl nozzle 202, as shown by arrow E.

As the drain flow channels through the swirl nozzle 202, it is accelerated and develops into a fully vortical fluid flow within the swirl chamber 120, as shown by arrow F. The vortical fluid flow exiting the swirl nozzle 202 forces dense debris and other contaminants within the drain flow to the radially outer extent of the swirl chamber 120 where they eventually settle into the annular groove 126, as shown by arrow G. By injecting flushing fluid via the flushing liquid injection ports 128 (one shown in FIG. 3), the debris and contaminants are removed or otherwise flushed from the annular groove 126 and to the frustoconical surface of the drain restrictor 122, as shown by arrow H. Flushing the swirl chamber 120 also serves to pressurize the swirl chamber, thereby forcing drain flow and unwanted contaminants down the exit control passage 124, as shown by arrow I. In at least one embodiment, a valve (not shown) located upstream from the inlet 106 to the drain 100 may be closed during flushing operations, thereby promoting the full pressurization of the drain and the consequential removal of debris 116 (FIG. 1) via the exit control passage 124.

Referring now to FIG. 4, illustrated is a partial cross-sectional view of the drain 100, and in particular a sectional view of the swirl chamber 120 and its interaction or fluid communication with the annular groove 126. In at least one embodiment, the upper periphery of the annular groove 126 where it meets the swirl chamber 120 may include a curved radius 402 about the circumference of the swirl chamber 120. As can be appreciated, the curved radius 402 may be configured to generally direct any flushed debris or contaminants toward the exit control passage 124, as shown by arrow J, and minimize potential reverse flow of collected debris through the swirl nozzle 202, as shown by arrow K.

It will be appreciated that the drain 100 as generally disclosed herein provides several advantages. For example, the combination of the inlet flow director orifice 110, the swirl nozzle plate 114, and the debris fence 116 allow prolonged operation in severe fouling or plugging service by shunting potential blocking matter away from the smaller downstream flow control passages, such as the exit control passage 124. Also, the compact topology of the swirl nozzle 202, including its unique compound angling, allows the drain 100 to be conveniently contained within a standard piping flange. Moreover, the integration of the annular ring 126 and uniformly-arrayed flushing liquid injection ports 128 disposed about the circumference of the annular ring 126 further extends severe service application of the drain 100, especially in subsea applications. Lastly, the conical endwalls on the swirl chamber 120 actively promote gravity assisted liquid drainage when little or no pressure differential exists across the drain 100, while simultaneously limiting deleterious gas migration through the exit control passage 124. Accordingly, this present disclosure allows reliable and efficient long-term operation of subsea devices requiring drainage maintenance.

Referring now to FIG. 5, depicted is a schematic method 500 of controlling a drain flow. The method 500 may include receiving a drain flow in a drain, as at 502. The drain flow may include an upper flange coupled to a lower flange, where the upper flange defines an inlet and the lower flange defines an exit. The drain flow may then be centralized within an inlet cavity with a director orifice, as at 504. The director orifice may be fluidly coupled to the inlet of the upper flange. Any debris within the incoming drain flow may then be segregated from a swirl nozzle, as at 506. The swirl nozzle may be defined within a swirl nozzle plate and provide fluid communication between the inlet cavity and a swirl chamber. The swirl chamber may be defined in the lower flange.

At least a portion of the drain flow may be accelerated through the swirl nozzle to generate a vortical fluid flow, as at 508. The vortical fluid flow may be configured to force any dense debris within the drain flow to a radially outer extent of the swirl chamber. Once separated from the drain flow, the dense debris may accumulate within an annular groove, as at 510. The annular groove may be fluidly coupled to the swirl chamber and defined within the lower flange. The drain flow may then be drained from the lower flange via an exit control passage, as at 512.

As used herein, “about” refers to a degree of deviation based on experimental error typical for the particular property identified. The latitude provided the term “about” will depend on the specific context and particular property and can be readily discerned by those skilled in the art. The term “about” is not intended to either expand or limit the degree of equivalents which may otherwise be afforded a particular value. Further, unless otherwise stated, the term “about” shall expressly include “exactly,” consistent with the discussion below regarding ranges and numerical data.

The foregoing has outlined features of several embodiments so that those skilled in the art may better understand the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions and alterations herein without departing from the spirit and scope of the present disclosure.

Claims

1. A controlled flow drain, comprising: an upper flange coupled to a lower flange, the upper flange defining an inlet fluidly coupled to an upper drain pipe, and the lower flange defining an exit fluidly coupled to a lower drain pipe;a director orifice fluidly coupled to the inlet of the upper flange and in fluid communication with an inlet cavity defined within the upper flange;a swirl nozzle plate disposed within the upper flange and configured to receive a drain flow via the inlet and director orifice and accommodate accumulation of debris thereon;a debris fence coupled to the swirl nozzle plate within the upper flange;a swirl nozzle defined within the swirl nozzle plate and at least partially surrounded by the debris fence, the swirl nozzle providing fluid communication between the inlet cavity and a swirl chamber;an annular groove fluidly communicable with the swirl chamber and defined within the lower flange, the annular groove having a series of flushing liquid injection ports symmetrically-arrayed thereabout; andan exit control passage defined within the drain restrictor and in fluid communication with the exit and the lower drain pipe.

2. The controlled flow drain of claim 1, wherein the debris fence segregates the swirl nozzle from the debris accumulating on the swirl nozzle plate.

3. (canceled)

4. The controlled flow drain of claim 1, wherein the swirl nozzle has a central axis extending from a nozzle inlet to a nozzle outlet.

5. The controlled flow drain of claim 4, wherein the central axis is arranged at an angle a with respect to horizontal, thereby imparting a downward pitch to the swirl nozzle.

6. The controlled flow drain of claim 5, wherein the central axis is arranged at an angle β with respect to the Z axis.

7. The controlled flow drain of aim 5, wherein the angle a may be about 20° or less.

8. The controlled flow drain of claim 6, wherein the angle β may be about 15°.

9. The controlled flow drain of claim 1, wherein the swirl chamber is defined in the lower flange by a lower surface of the swirl nozzle plate and a drain restrictor.

10. The controlled flow drain of claim 9, wherein the lower surface of the swirl nozzle plate and the drain restrictor are opposing parallel surfaces that are respectively frustoconical.

11. The controlled flow drain of claim 1 wherein the exit control passage includes sharp edges adapted to permit liquid drainage therethrough but concurrently restrict gas carry-under.

12. A method of controlling a drain flow, comprising: receiving the drain flow into an upper flange coupled to a lower flange, the upper flange defining an inlet and the lower flange defining an exit;centralizing the drain flow into an inlet cavity defined within the upper flange; segregating debris within the drain flow from a swirl nozzle defined within a swirl nozzle plate, the swirl nozzle providing fluid communication between the inlet cavity and a swirl chamber defined in the lower flange;accelerating the drain flow through the swirl nozzle to generate a vortical fluid flow that forces dense debris within the drain flow to a radially outer extent of the swirl chamber;accumulating the dense debris within an annular groove fluidly coupled to the swirl chamber and defined within the lower flange; anddraining the drain flow from the lower flange via an exit control passage.

13. The method of claim 12, further comprising flushing the swirl chamber with a flushing fluid ejected from a series of flushing liquid injection ports symmetrically-arrayed about the annular groove.

14. The method of claim 13, further comprising pressurizing the swirl chamber with the flushing fluid to force the drain fluid through the exit control passage.

15. The method of claim 14, further comprising fluidizing at least a portion of the dense debris such that the dense debris can be drained through the exit control passage.

16. The method of claim 14, further comprising removing built up fouling from the swirl nozzle and exit control passage with the flushing fluid.

17. A controlled flow drain, comprising: an upper flange coupled to a lower flange, the upper flange defining an inlet fluidly coupled to an upper drain pipe, and the lower flange defining an exit fluidly coupled to a lower drain pipe;an inlet cavity fluidly coupled to the inlet;a swirl chamber fluidly coupled to the exit;a swirl nozzle plate disposed between the inlet cavity and the swirl chamber and having a debris fence coupled thereto, the debris fence being disposed within the inlet cavity;a swirl nozzle defined within the swirl nozzle plate and providing fluid communication between the inlet cavity and the swirl chamber;an annular groove defined within the lower flange and in fluid communication with the swirl chamber, the annular groove having a curved radius defined about its upper periphery where the annular groove meets the swirl chamber; andan exit control passage defined within lower flange and in fluid communication with the exit and the lower drain pipe.

18. The controlled flow drain of claim 17, further comprising a series of flushing liquid injection ports symmetrically-arrayed about the annular groove.

19. The controlled flow drain of claim 18, wherein the swirl nozzle has a central axis arranged at an angle a with respect to horizontal, thereby imparting a downward pitch to the swirl nozzle.

20. The controlled flow drain of claim 19, wherein the central axis is arranged at an angle β with respect to the Z axis,

21-37. (canceled)