MODULARIZED TRANSFER PUMP SYSTEM FOR INCORPORATION INTO A SHIPPING CONTAINER STYLED SKID

Description

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims priority from U.S. Ser. No. 63/698,259 filed Sep. 24, 2024.

FIELD OF THE INVENTION

The present invention relates generally to modularized transfer pump skid (TPS) systems. More specifically, the present invention teaches an assembly combining a transfer pump system integrated into a modified shipping container enclosure for providing ease of fabrication, transport and setup when incorporating (alternatively termed “nippling up”) into an existing fluid network, such including without limitation produced water, fresh water systems crude oil and emulsion fluids.

BACKGROUND OF THE INVENTION

The prior art is documented with examples of transfer pump assemblies, such as which can be incorporated into a support skid or frame and prior to being transported to a worksite for installation into an existing fluid transfer network. Such pre-engineered systems, typically fabricated in a shop or other remote location upon a support frame or skid, includes any combination of pumps, motors, valves, instrumentation and other components. By combining all of the necessary components of the transfer pump system into a single, pre-assembled unit, the pump skids can save time and money during installation and operation when tied into, or “nippled up” into an existing fluid transfer network.

A pump skid, also known as a pump package or pump system, is a self-contained unit that integrates various components required for pumping fluids. It typically consists of a pump, motor, piping, valves, instrumentation, control systems, and other necessary accessories, all mounted on a single skid or platform.

As is further understood in existing application, a separate structure or enclosure is constructed around the skid supported transfer pump system once it is “nippled up” into the existing fluid transfer network. Aside from the time and effort expended in constructing the separate enclosure around the incorporated TPS system, provision must also be made for accessing the skid to service and replace worn out components. Given further the typical weight of the installed pumps and motors (such as can range to upwards of several thousand pounds) the current process of replacement includes removing the roof from the structure via crane or the like in order to access and replace and, once completed, the roof or access panel can be installed with the same process.

The purpose of a pump skid is to provide a complete and ready-to-install solution for fluid transfer, circulation, and control. The components within the skid are selected and designed based upon the type and flow requirements of the fluid network within which it is to be incorporated and so as to work together cohesively, ensuring optimal performance, efficiency, and reliability.

As indicated, pump skids are usually pre-engineered and pre-fabricated, which means they are built off-site and delivered as a single unit to the installation site. This approach significantly simplifies installation, reduces on-site construction time, and minimizes labor costs. It also allows for customization based on specific application requirements, ensuring that the pump skid is tailored to meet the needs of the industrial process or system it will be used for.

Pump Skids play a vital role in various applications, including fluid transfer, circulation, metering, blending, filtration, and more. These skids are designed to handle different types of fluids, ranging from water and chemicals to viscous or abrasive substances, depending on the industry and specific application. The integration of pumps, motors, valves, and control systems onto a single skid simplifies maintenance and troubleshooting processes which enables technicians access for making inspections, repairs, and replacements.

Overall, pump skid assemblies provide a compact, efficient, and reliable solution for fluid management in industrial applications which offer ease of installation, streamlined maintenance, and optimized performance, making them a preferred choice for various industries requiring efficient fluid handling systems.

As noted, a pump skid typically incorporates several key components to facilitate fluid transfer, circulation, and control. While the specific components may vary based on the application and requirements, the fundamental elements commonly found in a pump skid include each of:

Pump: The pump is the primary component responsible for generating fluid flow and can include any of a centrifugal pump, positive displacement pump, or another type, selected based on the specific application requirements such as flow rate, pressure, viscosity, and fluid properties.

Motor: The motor provides the power necessary to drive the pump. It can be an electric motor, diesel engine, or any other suitable power source, depending on the application and site conditions.

Piping and Valves: The pump skid includes an arrangement of piping and valves to facilitate the movement and control of fluids. Piping connects the pump inlet and outlet to the desired points of fluid transfer or circulation. Valves, such as gate valves, ball valves, or control valves, regulate the flow rate, pressure, and direction of the fluid within the system.

Instrumentation: Various instrumentation devices are incorporated into the pump skid to monitor and control the fluid parameters. These may include flow meters, pressure gauges, temperature sensors, level sensors, and other instruments that provide real-time data for process monitoring and control.

Control Systems: Pump skids often feature control systems, which can be simple or complex depending on the application. These systems provide automation and control capabilities, allowing operators to adjust and optimize the pump operation, monitor critical parameters, and respond to alarms or abnormal conditions.

Base or Skid: The base or skid serves as the foundation for mounting and supporting all the components of the pump skid. It is designed to provide stability and structural integrity while facilitating ease of transport, installation, and maintenance.

Safety Devices: Depending on the application and industry, pump skids may incorporate safety devices such as pressure relief valves, rupture discs, emergency shutdown systems, and other safety mechanisms to protect against overpressure, over-temperature, or other hazardous conditions.

Electrical and Control Wiring: The pump skid includes electrical wiring to connect the motor, control systems, and instrumentation devices. These wiring connections enable power supply, control signal transmission, and communication between different components of the skid.

Filters: Filters are used to remove impurities from the fluid before it enters the pump. This helps to protect the pump and to ensure that the fluid is clean.

Pressure gauges: Pressure gauges are used to monitor the pressure of the fluid in the pump skid. This helps to ensure that the pump is operating within its safe operating limits.

Accessories: Additional accessories may be included based on the specific requirements of the application. These can include strainers, dampeners, pressure regulators, heat exchangers, and other devices necessary for specific fluid conditioning or process needs.

In addition to these basic components, pump skids may also include other features such as insulation, vibration isolation, and weatherproofing. These features are typically added to protect the pump skid from harsh environmental conditions or to make it easier to transport.

Pump skid assemblies find application in diverse industries, owing to their versatility and adaptability. Some key areas where these assemblies are commonly utilized include each of:

Oil and Gas: Pump skid assemblies play a vital role in oil and gas exploration, production, and refining. They are used for well stimulation, water injection, pipeline transfer, and other critical processes.

Chemical and Petrochemical: In the chemical and petrochemical industries, pump skid assemblies handle various fluids such as acids, solvents, and hazardous materials. They ensure precise metering, blending, and transfer while adhering to strict safety standards.

Water and Wastewater: Pump skid assemblies are employed in water treatment plants, sewage systems, and desalination plants to facilitate water circulation, filtration, and transfer. These systems help maintain a consistent water supply and manage wastewater effectively.

Power Generation: From conventional power plants to renewable energy installations, pump skid assemblies play a crucial role in cooling systems, condensate extraction, fuel transfer, and boiler feed water applications.

Pharmaceuticals: In pharmaceutical manufacturing, pump skid assemblies offer precise control and sterile fluid handling, supporting critical processes like ingredient mixing, liquid transfer, and batch formulation.

Pulp and Paper: The pump skids in the pulp and paper industries are usually equipped with chemical metering and injection components.

SUMMARY OF THE INVENTION

The present invention teaches an assembly combining a transfer pump system including any suitable arrangement of components associated with a conventional skid supported modularized assembly, and which is integrated into a modified shipping container enclosure for providing ease of fabrication, transport and setup when incorporating (“nippling up”) into an existing fluid network, such including without limitation produced water, fresh water systems crude oil and emulsion fluids.

As will be further explained, the present invention provides a rigid and durable structure for environmentally protecting the transfer pump system components and which provides increased weight bearing capacity as compared to existing skids so as to avoid flexing movement which is typical of the components supported on less robust skid designs, which can cause damage such as to the motor, as well as causing misalignment of the pumps and stressing of the other components of the modularized transfer pump system.

In a non-limiting application, the modularized transfer pump system is integrated into an enclosed skid-style shipping container for incorporation into a fluid transfer network. The transfer pump system includes a prefabricated collection of components such as previously described in the background explanation and including one or more of a motor, valve, pump, electrical system, and heater integrated within a piping network including an inlet spool and an outlet spool.

The prefabricated collection of components is constructed within an interior of the container prior to transporting to an installation location with the fluid transfer network, with the inlet and outlet spools being accessible from first and second locations of the container for incorporating into the first and second locations of the existing fluid transfer network, while providing protection of the system components supported within the container interior enclosure.

In a first non-limiting embodiment, the inlet and outlet spools project through apertures configured at the first and second locations of the shipping container. Alternatively, the container can be designed with removable sections for accessing the inlet and outlet spools. An electrical connection is adapted to communicate through the container to an external power source located at the fluid transfer network.

The enclosed skid-style shipping container further includes a three dimensional rectangular shape with first and second sides, a top and a bottom, and first and second interconnecting ends. A side door opening (which can include a double opening) is formed into a selected one of the sides of the container, with a service access door formed into a selected one of the sides and ends of the container. An end of the container can also be openable, with an access opening can also be formed in the top of the container to provide crane access for removing and replacing larger or heavier components including the pump and motor. Other features include lift points engineered into the container to facilitate lifting and transport of the enclosed system.

Common applications of the fluid transfer network further include any of produced water, fresh water, crude oil and emulsion fluid. Other applications include lease automatic custody transfer for providing automatic measurement sampling and transfer of oil from a lease location into a pipeline associated with the fluid transfer network.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made to the attached drawings, when read in combination with the following detailed description, wherein like reference numerals refer to like parts throughout the several views, and in which:

FIG. 1 is a perspective view of a horizontally arrayed single transfer pump plumbing assembly according to a first non-limiting example and which can be integrated into a shipping style container for incorporating into an existing fluid network, such as via inlet and outlet spool components and a separate electrical connection;

FIG. 2 presents a perspective view of the transfer pump assembly of FIG. 1 incorporated into a shipping style container with a side and end wall of the container removed for ease of illustration;

FIG. 3 is a side plan view of the shipping container in FIG. 2;

FIG. 4 is an end plan view of the shipping container in FIG. 2 again showing the horizontally arrayed single transfer pump plumbing assembly of FIG. 1;

FIG. 5 presents a perspective view of a horizontally arrayed dual transfer pump plumbing assembly incorporated into a shipping style container again with side and end walls removed for ease of illustration;

FIG. 6 is a side plan view of the shipping container in FIG. 5;

FIG. 7 is an end plan view of the shipping container in FIG. 5 again showing the horizontally arrayed dual transfer pump plumbing assembly;

FIG. 8 is a perspective view of a single stack vertically oriented transfer pump plumbing assembly according to a further non-limiting example and which can be integrated into a shipping style container for incorporating into an existing fluid network, such as again via inlet and outlet spool components and a separate electrical connection;

FIG. 9 is an underside perspective view of a shipping style container integrating the transfer pump plumbing assembly of FIG. 8, again with side and end wall removed, for incorporating into an existing fluid network;

FIG. 10 is a perspective view of a double stack vertically configured pump assembly according to a still further non-limiting example for integrating into a shipping style container for incorporation into the existing fluid network; and

FIG. 11 is a perspective view of the shipping style container with side and end wall removed and integrating the transfer pump plumbing assembly of FIG. 10 for incorporating into the existing fluid network.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to the attached illustrations, the present invention discloses a skid system (also termed as a Modularized Transfer Pump Skid, or TPS System, integrated into a shipping container styled enclosure for providing ease of transport and setup when incorporating (nippling up) into an existing fluid network. As will be further explained, the present invention provides a rigid and durable structure for environmentally protecting the transfer pump system components and which provides increased weight bearing capacity as compared to existing skids so as to avoid flexing movement which is typical of the components supported on less robust skid designs, such as which can cause damage such as to the motor as well as causing misalignment of the pumps and stressing of the other components of the modularized transfer pump system.

In a non-limiting application, the modularized transfer pump system is integrated into an enclosed skid-style shipping container, such as generally shown at 20 in each of FIGS. 2-7 for incorporation into a fluid transfer network. As previously noted, and as will be further described, the transfer pump (TPS) system includes a prefabricated collection of components, such as previously described in the background explanation and typically including one or more of a motor, valve, pump, electrical system, and heater integrated within a piping network including an inlet spool and an outlet spool.

With reference to FIG. 1, a perspective view is shown of a horizontal transfer pump plumbing assembly according to a first non-limiting application, and which can be integrated into the shipping style container 20 for incorporating into an existing fluid network. Major components of the transfer pump system represented include each of a motor powered and horizontally configured water pump 1 (such further supported upon a platform), butterfly valves 6 and 10, flange filter pot 8, magnetic flow meter 12 (such as connected to pump 1, via an angled piping 3 at the pump outlet, and selected valve 10, as well as swing check valve 14 and port ball valve 15. Other features can include explosion proof heaters (not shown) or any other arrangement of components not limited to the background discussion of the TPS system which is suited for a given application.

Additional and ancillary support components are also depicted and include flex gaskets 2, 4 and 7, piping connection 5 connecting the valve 6 and upstream located filter pot 8 with inlet side of pump 1, additional outlet piping sections 11 (downstream of valve 10) communicating with flow meter 12 and communicating with further piping section 13 leading to the check valve 14 and ball valve 15. Finally, each of an inlet spool 9 and outlet spool 16 define opposite end components of the TPS system, with the afore-mentioned prefabricated collection of components being constructed and supported within the interior of the container 20 prior to transporting to an installation location with the fluid transfer network (not shown).

The inlet 9 and outlet 16 spools are configured so as to be accessible from first and second locations of the container 20 for incorporating into the corresponding first and second locations of the existing fluid transfer network, again while providing protection of the system components supported within the container interior enclosure. As previously noted, FIGS. 2-4 present a series of underside perspective, side plan and end plan views of a shipping style container integrating the transfer pump plumbing assembly of FIG. 1 for incorporating into the existing fluid network, with corresponding FIGS. 5-7 present a series of underside perspective, side plan and end plan views of a shipping style container integrating a related horizontally configured double transfer pump plumbing assembly for incorporating into the existing fluid network (with identical components being repetitively numbered).

In a first non-limiting embodiment, the inlet 9 and outlet 16 spools project through apertures/openings formed into or configured at the first and second locations of the shipping container, with the ends of the spools 9/16 projecting any distance through the side or end walls of the container 20 for tying into (“nippling up”) into the existing fluid transfer connections once the shipping container enclosure is emplaced. Alternatively, the container 20 can be designed with removable sections at the side or end wall locations for permitting installation of additional lengths of pipe associated with the fluid transfer network for accessing the inlet 9 and outlet 16 spools (such as which can be reconfigured to align with the removable sections).

An electrical connection, see as representative shown at 17 in FIG. 1, can tie into any of the powered components (e.g. illustrated as extending to motor component powering the water pump 1), and is adapted to communicate through the container 20 to an external power source (also not shown) located at the fluid transfer network.

Referring again FIGS. 2-7, the enclosed skid-style shipping container 20 is produced in either twenty or forty foot lengths, with the standard twenty foot container typically measuring twenty feet in length, eight feet in width, and eight and a half feet in height, with an internal width of around seven and three-quarter feet in dimension. In each instance, the container 20 exhibits a three dimensional rectangular shape with first 22 and second 24 sides, a top 26 and a bottom 28, and first 30 and second 32 interconnecting ends.

A side door opening 34 (which can include a double opening) is formed into a selected one of the sides 22 of the container, with a selected one of the ends 30 or 32 of the container also being openable in order to provide ease of access to the interior. An access opening can also be formed in the top 26 of the container to provide crane access for removing and replacing larger or heavier components including the pump and motor. Other features include lift points (see at 36 and 38) engineered into the container to facilitate lifting and transport of the enclosed TPS system.

Proceeding now to FIG. 8, shown is a perspective view of a single stack vertically oriented transfer pump plumbing assembly according to a further non-limiting example and which can likewise o be integrated into the shipping style container 20 for incorporating into an existing fluid network, such as again via inlet and outlet spool components and a separate electrical connection. As compared to FIG. 1, a similar arrangement of components in the TPS system are constructed between each of inlet 116 and outlet 110 spools.

These include vertical pump and motor 117, inlet side filter pot 115, butterfly valves 114, outlet side flow meter 112, port ball valve 118 and related gaskets and other miscellaneous components. It is also important to note that the arrangement of the TPS system in FIG. 8, as compared to as shown in FIG. 1 or FIG. 5, is optional and can include a suitable arrangement of flex gaskets 102, 104 and 106 and other components. FIG. 9 is a perspective view of the shipping style container 20 (again with side and end wall removed) integrating the transfer pump plumbing assembly similar to that shown in FIG. 8 for incorporating into the existing fluid network;

FIG. 10 presents a perspective view of a double stack vertically oriented pump assembly according to a still further non-limiting example for integrating into a shipping style container for incorporation into the existing fluid network, with FIG. 11 providing a corresponding underside perspective view of the shipping style container 20 integrating the transfer pump plumbing assembly similar to that shown in FIG. 10 for incorporating into the existing fluid network.

The arrangement of components for the TPS system provided in FIG. 10 is according to a yet further non-limiting combination of elements including a pair of vertical pump and motors 212, inlet (217, 205) and outlet side (207) valves. Other repetitive described components again include inlet side flange filter pot 218 and interconnecting inlet pipe sections 201 and 216 communicating with inlet spool 219, with outlet side of the vertical pumps and motors 112 including magnetic flow meter 214, port ball valve 215, and interconnecting pipe sections 208, 209 leading to outlet spool 210. Other features include flange blinds 213 and 220 located at dead ends of the inlet and outlet side pipe sections communicating with pairs of inlet and outlet side eccentric spools 203 leading to and from the vertical pumps and motors 212.

Common applications of the fluid transfer network again further include any of produced water, fresh water, crude oil and emulsion fluid. Other applications include lease automatic custody transfer for providing automatic measurement sampling and transfer of oil from a lease location into a pipeline associated with the fluid transfer network.

Accordingly, the present invention provides a rigid and durable structure which lasts longer than conventional unprotected skids upon which the TPS System is fabricated. Additionally, the weight supporting capacity of the shipping container is a multiple of what a conventional skid frame can support, with the container better suited for protecting the TPS System components.

Additionally, the shipping container provides a better transport option for moving the prefabricated modularized TPS System to the installation site without incidences of flexing movement associated with previous open skid supporting frames, such as which can cause damage to the motors, pump etc. of the assembly. Also, the shipping container style skid of the present invention additionally provides lifting points which are better suited for transport, such as being lifted on and off of a flatbed truck, rail car or the like, as well as providing weather tight protection of the mechanical and electrical equipment associated with the TPS System.

Having described my invention, other and additional preferred embodiments will become apparent to those skilled in the art to which it pertains, and without deviating from the scope of the appended claims. The detailed description and drawings are further understood to be supportive of the disclosure, the scope of which being defined by the claims. While some of the best modes and other embodiments for carrying out the claimed teachings have been described in detail, various alternative designs and embodiments exist for practicing the disclosure defined in the appended claims.

The foregoing disclosure is further understood as not intended to limit the present disclosure to the precise forms or particular fields of use disclosed. As such, it is contemplated that various alternate embodiments and/or modifications to the present disclosure, whether explicitly described or implied herein, are possible in light of the disclosure. Having thus described embodiments of the present disclosure, a person of ordinary skill in the art will recognize that changes may be made in form and detail without departing from the scope of the present disclosure. Thus, the present disclosure is limited only by the claims.

In the foregoing specification, the disclosure has been described with reference to specific embodiments. However, as one skilled in the art will appreciate, various embodiments disclosed herein can be modified or otherwise implemented in various other ways without departing from the spirit and scope of the disclosure. Accordingly, this description is to be considered as illustrative and is for the purpose of teaching those skilled in the art the manner of making and using various embodiments of the disclosure. It is to be understood that the forms of disclosure herein shown and described are to be taken as representative embodiments. Equivalent elements, materials, processes or steps may be substituted for those representatively illustrated and described herein. Moreover, certain features of the disclosure may be utilized independently of the use of other features, all as would be apparent to one skilled in the art after having the benefit of this description of the disclosure. Expressions such as “including”, “comprising”, “incorporating”, “consisting of”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural.

Further, various embodiments disclosed herein are to be taken in an illustrative and explanatory sense and should in no way be construed as limiting of the present disclosure. All joinder references (e.g., attached, affixed, coupled, connected, and the like) are only used to aid the reader's understanding of the present disclosure, and may not create limitations, particularly as to the position, orientation, or use of the systems and/or methods disclosed herein. Therefore, joinder references, if any, are to be construed broadly. Moreover, such joinder references do not necessarily infer that two elements are directly connected to each other.

Additionally, all numerical terms, such as, but not limited to, “first”, “second”, “third”, “primary”, “secondary”, “main” or any other ordinary and/or numerical terms, should also be taken only as identifiers, to assist the reader's understanding of the various elements, embodiments, variations and/or modifications of the present disclosure, and may not create any limitations, particularly as to the order, or preference, of any element, embodiment, variation and/or modification relative to, or over, another element, embodiment, variation and/or modification.

It will also be appreciated that one or more of the elements depicted in the drawings/figures can also be implemented in a more separated or integrated manner, or even removed or rendered as inoperable in certain cases, as is useful in accordance with a particular application. Additionally, any signal hatches in the drawings/figures should be considered only as exemplary, and not limiting, unless otherwise specifically specified.