Composite Subsea Compressor Casing for Lower Weight Handling
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Solution Overview
Problem
The existing subsea motorcompressor casings made of metal are heavy, leading to high handling costs and reduced reliability due to the need for large vessels and prolonged intervention times, especially in offshore applications.
Innovation Solution
A dual-layer casing design comprising an inner layer of corrosion-resistant material, such as nickel base alloy, and an outer layer of lightweight composite material, like PEEK reinforced with continuous carbon fibers, to reduce weight and enhance handling capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the casing is made of metal to ensure structural integrity and corrosion resistance, then the strength and corrosion resistance are improved, but the weight increases significantly
Solution Approach 1:
The casing employs a composite structure consisting of an inner metal layer providing corrosion resistance and structural integrity, and an outer composite material layer reducing overall weight. This composite approach allows the casing to maintain strength while significantly reducing weight compared to traditional full-metal construction.
Solution Approach 2:
The casing applies different material properties to different regions - the inner layer uses metal material specifically where corrosion resistance and structural strength are critical, while the outer layer uses lighter composite material where weight reduction is prioritized. This localized material selection optimizes the balance between strength and weight.
2Reliability
If the casing is made of metal to ensure corrosion resistance, then the reliability is improved, but the handling capability deteriorates due to heavy weight
Solution Approach 1:
The composite casing structure maintains corrosion resistance through the inner metal layer while the outer composite layer reduces weight to improve handling capability. This allows the casing to be both reliable in corrosive environments and easier to handle during installation and maintenance operations.
Solution Approach 2:
The invention changes the material composition parameters of the casing from 100% metal to a composite structure, fundamentally altering the weight-to-strength ratio and enabling both corrosion resistance and improved handling characteristics.
3Ease of operation
If a heavy load vessel is used to handle the motorcompressor to ensure safe handling, then the handling safety is improved, but the intervention time increases
Solution Approach 1:
By reducing the casing weight through composite materials, the motorcompressor can be handled by lighter vessels with smaller lifting capacities, enabling faster deployment and retrieval operations while maintaining safety through proper engineering of the lighter handling system.
4Strength
If the casing is made of metal to ensure durability, then the structural integrity is improved, but the handling cost increases
Solution Approach 1:
The composite casing structure reduces weight while maintaining structural integrity, directly lowering the lifting capacity requirements of handling vessels and reducing associated operational costs for transportation, installation, and maintenance operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The dual-layer casing design significantly reduces the weight and simplifies handling and servicing operations, lowering downtime and associated costs while maintaining structural integrity.
Implementation Method 1
The main body also comprises an outer layer applied over the inner layer and made of a composite material
Implementation Method 2
The inner layer is made of corrosion and/or erosion resistant material
Data Source
Figure 1~2
Figure 2a
Figure 2b
AI summary
A casing (1) for a subsea compressor comprises a main body (2) having a central axis (A); a plurality of interconnection flanges (4) attached to the main body (2); wherein the main body (2) comprises an inner layer (5) made of corrosion resistant material; an outer layer (6) applied over the inner layer (5) and made of a composite material; wherein the outer layer (6) extends along the entire length of said main body (2).