Underwater excavation apparatus

Abstract

There is disclosed an excavation apparatus (5), such as an underwater excavation apparatus, having means for producing, in use, at least one vortex, spiral or turbulent flow in a laminar flow of fluid, e.g. water. The excavation apparatus (5) comprises a rotor (10) having a rotor rotation axis (A), wherein, in use, flow of fluid past or across the rotor (10) is at a first angle (a) from the axis of rotation (A). The excavation apparatus (5) comprises the rotor (5) and means or an arrangement for dampening reactive torque on the apparatus (5) caused by rotation of the rotor (10), in use. The turbulent flow is provided within, such as within a (transverse) cross-section, of the laminar flow.

Claims

1. An excavation apparatus, comprising: at least one rotor; at least one stator comprising stator blades, the stator blades comprising a plurality of larger primary stator blades and a plurality of smaller secondary or splitter blades provided between adjacent pairs of the larger primary stator blades; and a torque dampening arrangement for dampening reactive torque caused by rotation of the rotor, the torque dampening arrangement comprising the stator blades.

2. The excavation apparatus as claimed in claim 1, wherein the at least one rotor comprises a single rotor.

3. The excavation apparatus as claimed in claim 1, wherein the torque dampening arrangement does not comprise a second rotor.

4. The excavation apparatus as claimed in claim 1, wherein the torque dampening arrangement does not comprise a second rotor counter-rotating to the at least one rotor.

5. The excavation apparatus as claimed in claim 1, wherein the rotor comprises a first body and a plurality of rotor blades disposed on the first body.

6. The excavation apparatus as claimed in claim 1, wherein the at least one stator comprises a single stator.

7. The excavation apparatus as claimed in claim 6, wherein the at least one stator comprises a second body and the stator blades are disposed on the second body.

8. The excavation apparatus as claimed in claim 1, further comprising a housing comprising a hollow body, the housing comprising an inlet and an outlet.

9. The excavation apparatus as claimed in claim 8, wherein the excavation apparatus is operable in an excavation mode, and in the excavation mode the outlet faces an area to be excavated and the inlet is provided above the outlet.

10. The excavation apparatus as claimed in claim 8, wherein the excavation apparatus is operable in a suction mode, and in the suction mode the inlet faces an area which has been excavated and to be cleared, and the inlet is provided below the outlet.

11. The excavation apparatus as claimed in claim 8, wherein the rotor and the stator are provided in the housing, the housing comprises an axis, the rotor and the stator are arranged coaxially upon the axis, the housing is provided upon the axis, and the rotor is provided proximal the inlet and the stator is provided proximal the outlet.

12. The excavation apparatus as claimed in claim 1, wherein the torque dampening arrangement comprises one or more anti-rotation vanes.

13. The excavation apparatus as claimed in claim 12, wherein the one or more anti-rotation vanes comprise aerofoils.

14. The excavation apparatus as claimed in claim 12, further comprising a housing comprising an inlet and an outlet, and wherein the one or more anti-rotation vanes are provided between the rotor and the outlet, and the one or more anti-rotation vanes are provided between the stator and the outlet.

15. The excavation apparatus as claimed in claim 12, further comprising a housing comprising an inlet and an outlet, and wherein the one or more anti-rotation vanes are provided at or adjacent the outlet.

16. The excavation apparatus as claimed in claim 12, further comprising a housing having a hollow body, and wherein the one or more anti-rotation vanes are provided within the housing.

17. The excavation apparatus as claimed in claim 16, further comprising a ring provided within the housing and having an outer surface, wherein each anti-rotation vane of the one or more anti-rotation vanes has an outer end that is connected to an inner surface of the housing, and wherein each anti-rotation vane of the one or more anti-rotation vanes has an inner end that is connected to the outer surface of the ring provided within the housing.

18. An excavation apparatus comprising: a housing comprising an inlet and an outlet; a rotor comprising a first body and a plurality of blades disposed on the first body; a stator comprising a second body and a plurality of further blades disposed on the second body; and wherein the further blades comprise a plurality of larger primary stator blades and smaller secondary or splitter blades provided between adjacent pairs of the plurality of larger primary stator blades.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) Embodiments of the present invention will now be described by way of example only, with reference to the accompanying drawings, which are:

(2) FIG. 1 a schematic diagram illustrating fluid flow through a hollow body of an excavation apparatus according to an embodiment of the present invention;

(3) FIG. 2(a) a schematic view of stator blades;

(4) FIG. 2(b) a schematic view of stator blades of an excavation apparatus according to an embodiment of the present invention;

(5) FIG. 3 a schematic side view of anti-rotation vanes of an excavation apparatus according to an embodiment of the present invention;

(6) FIG. 4 a further schematic side view of the anti-rotation vanes of FIG. 3;

(7) FIG. 5 a schematic side view of an excavation apparatus according to an embodiment of the present invention;

(8) FIG. 6 a perspective view from below and to one side of an exit nozzle of the excavation apparatus of FIG. 5;

(9) FIG. 7(a) a partial sectional side view of an excavation apparatus according to an embodiment of the present invention;

(10) FIG. 7(b) a partial sectional side view of the excavation apparatus of FIG. 7(a) to an enlarged scale;

(11) FIG. 8 a perspective view from below and to one side of an exit nozzle or outlet of an excavation apparatus according to an embodiment of the present invention;

(12) FIG. 9 a sectional view from above of the exit nozzle of the excavation apparatus of FIG. 8;

(13) FIG. 10 a sectional side view of an excavation apparatus according to an embodiment of the present invention;

(14) FIG. 11 a perspective view from above and to one side of a rotor of an excavation apparatus according to an embodiment of the present invention;

(15) FIG. 12 a perspective view from above and to one side of a stator of an excavation apparatus according to an embodiment of the present invention.

(16) FIG. 13 a cross-sectional side view of an exit nozzle of an excavation apparatus according to an embodiment of the present invention illustrating laminar flow and turbulent flow exiting the exit nozzle, in use; and

(17) FIG. 14 a cross-sectional end view of the exit nozzle of the excavation apparatus of FIG. 13 illustrating the laminar flow and turbulent flow exiting the exit nozzle, in use.

DETAILED DESCRIPTION OF DRAWINGS PREFERRED EMBODIMENTS

(18) Embodiments of the present invention will now be described with reference to the accompanying drawings.

(19) According to embodiments of the present invention there is provided an excavation apparatus 5, such as an underwater excavation apparatus, comprising a rotor 10 having a rotor rotation axis A, wherein, in use, flow of fluid past or across the rotor 10 is at a first angle α from the axis of rotation A.

(20) This arrangement is beneficial in allowing excavation and/or suction modes of the apparatus 5. In excavation mode and suction mode, fluid flows from an inlet 25 to an outlet 30 of the excavation apparatus 5.

(21) In use, fluid flow past or across the rotor 10 is non-axial to the axis of rotation A of the rotor 10.

(22) The excavation apparatus 5 comprises a housing or hollow body 20. The housing 20 comprises inlet 25 and outlet 30. In a first mode of operation, e.g. excavation mode, the outlet 30 is directed towards or faces an area or region to be excavated. In such mode the inlet 25 is, at least in use, typically provided higher than or above, e.g. directly above, the outlet 30. In an alternative or second mode of operation, e.g. suction mode, the inlet 25 is directed towards or faces an area or region excavated and/or requires to be cleared. In such mode the inlet 25, is at least in use, provided lower than or below, e.g. directly below, the outlet 30.

(23) The rotor 10 comprises a first body 39, e.g. a first cone member. The first angle α diverges away from the axis A in a direction away from the inlet 25 and towards the outlet 30. An apex of the rotor 10 faces the inlet 25. The rotor 10 comprises a plurality of impellers or blades 35, e.g. aerofoil blades, which are disposed, e.g. circumferentially disposed, on the rotor cone.

(24) The excavation apparatus 5 further comprise a stator 15. The stator 15 is coaxial with the rotor 10. The stator 15 is provided between the rotor 10 and the outlet 30.

(25) Row of fluid past or across the stator 15 is at a second angle β from the axis of rotation of the rotor 10. The stator 15 comprises a second body 40, e.g. a second cone member. The second angle β converges towards the axis A in a direction away from the inlet 25 and towards the outlet 30.

(26) An apex of the stator 15 faces the outlet 30. The stator 15 comprises a plurality of vanes or blades 45, e.g. aerofoil blades, which are disposed on the stator cone.

(27) The first angle α is in the range of 45° to 55°, and beneficially around 50°.

(28) The second angle β is in the range of 5° to 15°, and preferably around 10°.

(29) The excavation apparatus 5, such as an underwater excavation apparatus, comprises at least one rotor 10 and means or an arrangement for dampening reactive torque on the apparatus 5 caused by rotation of the rotor 10, in use. Beneficially the at least one rotor 10 comprises a single rotor 10. The torque dampening means does not comprise a second rotor, e.g. second rotor counter-rotating to the at least one (single) rotor 10.

(30) The excavation apparatus 5 comprises at least one rotor 10. In beneficial embodiments the at least one rotor 10 comprises a single rotor 10.

(31) The excavation apparatus 5 may comprise at least one stator 15. In beneficial embodiments the at least one stator 15 comprises a single stator 15.

(32) The excavation apparatus comprises a housing or hollow body 20. The housing 20 comprises inlet 25 and outlet 30. In a first mode of operation, e.g. excavation mode, the outlet 30 is directed towards or faces an area or region to be excavated. In such mode the inlet 25, at least in use, is typically provided above, e.g. directly above, the outlet 30. In an alternative or second mode of operation, e.g. suction mode, the inlet 25 is directed towards or faces an area or region excavated and/or requires to be cleared. In such mode the inlet 25, is at least in use, provided lower than or below, e.g. directly below, the outlet 30.

(33) The rotor 10 and/or the stator 15 are provided in the housing 20. The housing 20 comprises an axis. The rotor 10 and the stator 15 are arranged coaxially, e.g. upon the axis A. The housing 20 is provided upon the axis A. The rotor 10 is provided proximal the inlet 25 and the stator 15 is provided proximal the outlet 30. The rotor 10 comprises a first body 39, e.g. cone body, and a plurality of blades 35, disposed on, e.g. circumferentially around, the first body 30.

(34) The stator 15 comprises a second body 40, e.g. a further cone body, and a plurality of further blades 45, disposed on, e.g. circumferentially around, the second body 40. The torque dampening means comprises or includes the further blades 45. The stator blades 45 comprises a plurality of primary stator blades 46 and secondary or splitter blades 47 provided between adjacent pairs of primary stator blades 46.

(35) The torque dampening means comprise or include one or more anti-rotation vanes 50. The anti-rotation vanes 50 comprise aerofoils. The anti-rotation vanes 50 are provided between the rotor 10 and the outlet 30. The anti-rotation vanes 50 are provided between the stator 15 and the outlet 30. The anti-rotation vanes 50 are provided at or adjacent the outlet 30. The anti-rotation vanes 50 are provided within the housing 20, e.g. circumferentially disposed within the housing 20.

(36) An outer end of each anti-rotation vane 50 is connected to an inner surface of the housing 20. An inner end of each anti-rotation vane 50 is connected to an outer surface of a ring 55 provided within the housing 20.

(37) An inside and/or an outside of the housing 20 diverges from the inlet 25 towards the rotor 10. An inside and/or an outside of the housing 20 converges from the stator 15 towards the outlet 30. The housing 20 is circumferentially symmetrical about the axis.

(38) In preferred embodiments the fluid flowing through or exiting the excavation apparatus 5 typically has a pressure of around 35 to 120 KPa and a volume flow rate of 1 to 8 m.sup.3/S.

(39) In the disclosed embodiment, the excavation apparatus 5, such as an underwater excavation apparatus, has means or an arrangement 60 for producing, in use, at least one vortex or spiral in a flow of fluid, e.g. water.

(40) The at least one vortex can comprise a plurality of vortexes which together can comprise a closed shape, e.g. circular, oval, elliptical or the like. The vortex producing means 60 hereinafter can be referred to as a vortex generator(s). The vortex producing means 60, in use, cause a spiraling movement of fluid flowing out of or into the excavation apparatus 5. The excavation apparatus 5 comprises at least one rotor 10 or impeller, and beneficially comprises a (i.e. a single) rotor 10. The excavation apparatus 5 comprises at least one stator 15, and beneficially comprises a (i.e. a single) stator 15.

(41) The excavation apparatus 5 comprises housing or hollow body 20. The housing 20 comprises inlet 25 and outlet 30. In a first mode of operation, e.g. excavation mode, the outlet 30 is directed towards or faces an area or region to be excavated. In such mode the inlet, at least in use, is provided above, e.g. directly above, the outlet 30. In an alternative or second mode of operation, e.g. suction mode, the inlet 25 is directed towards or faces an area or region excavated and/or requires to be cleared. In such mode the inlet 25, is at least in use, provided lower than or below, e.g. directly below, the outlet 30.

(42) The rotor 10 and/or the stator 15 is provided in the housing 20. The housing 20 comprises axis A. The rotor 10 and the stator 15 are arranged coaxially, e.g. upon the axis A. The rotor 10 is provided proximal the inlet 25 and the stator is provided proximal the outlet 30.

(43) The vortex producing means 60 are provided in, on or adjacent the outlet 30.

(44) In one embodiment the vortex producing means 60 are provided on an inner surface of the housing 20. In an alternative embodiment the vortex producing means 60 are provided on a body 65, e.g. within the housing 20, e.g. within the outlet of the housing 20. The body 65 is provided on the housing axis, e.g. coaxially with the rotor 10 and stator 15.

(45) In one embodiment the vortex producing means 60 is provided on an outer surface of the body 65. In an alternative embodiment the vortex producing means 60 is provided on an inner surface of a tube or hollow body or can comprise a ring 55.

(46) The vortex generating means 60 comprises at least one pair, and preferably a plurality of pairs, of vortex generating means 60. One member of a pair generates a vortex spiraling in one direction, while another member of said pair generates a vortex spiraling in another or counter direction. The vortex generating means 60, e.g. pairs of vortex generating means 60, are circumferentially disposed, e.g. on the housing or body 20. Beneficially there are provided six (6) pairs of vortex generating means 60.

(47) Each vortex generating means 60 comprises a planar member or tooth, e.g. a triangular planar member. An edge of the planar member is attached to the housing or body 20. Each planar member is disposed on the housing or body 20 such that said edge of the planar member is disposed at an angle (e.g. acute angle) relative to the axis of the housing 20. Planar members of each pair of vortex generating means 60 are disposed at opposing angles.

(48) In use, e.g. in an excavation mode, a fluid flow, exits the outlet 30. Vortexes produced by the vortex generating means 60 are provided within a cross-section of the said fluid flow.

(49) The body 65 is attached to the housing 20, e.g. by one or more blades 50 which are circumferentially disposed.

Laminar Flow/Turbulent Flow

(50) Referring now to FIGS. 13 and 14, according to embodiments of the present invention hereinbefore described, the excavation apparatus 5, such as an underwater excavation apparatus, comprises means or an arrangement for producing a laminar flow LF and means or an arrangement for producing a turbulent flow TF or vortex or spiral flow, the turbulent flow being provided within the laminar flow LF. In this example the turbulent flow TF is provided within a cross-section (transverse cross-section) of the laminar flow LF.

(51) The laminar flow LF is represented by arrows or dots, while the turbulent flow TF is represented by spiral/looped lines.

(52) As can be seen from FIGS. 13 and 14, a flow direction of the turbulent flow TF is substantially parallel to a flow direction of the laminar flow LF. Also, in this embodiment, the flow direction of the laminar flow LF and/or flow direction of the turbulent flow TF is/are substantially parallel to a longitudinal axis A of the excavation apparatus 5.

(53) As can also be seen from FIGS. 13 and 14, the turbulent flow TF comprises a closed shape within a transverse cross-section of the laminar flow LF, i.e. perpendicular to the flow direction. Also, in this embodiment, the closed shape of the turbulent flow TF is substantially centred within the laminar flow LF and within the outlet 30.

Non-Axial Rotor Fluid Flow

(54) Hydrodynamic performance of subsea flow excavation devices is determined by factors such as: internal shape of the hollow body (or housing or shroud) which houses the impeller(s); impeller design; inlet and outlet design; and use of guide vanes within the device.

(55) Known mass flow devices typically house impellers within simple tubular forms of hollow body and are designed so that the impellers receive and discharge the fluid with very little change of direction. See, for example, GB 2 240 568 A (SILLS), GB 2 297 777 A (DIKKEN) and EP 1 007 796 B1 (SUSMAN). In such prior art the impellers receive and discharge the flow in a purely axial direction. In SUSMAN a change of direction occurs after the fluid is discharged from the impeller. This axial configuration limits the amount of pressure that mass flow devices can impart from the impeller into the fluid. To generate the higher fluid speed and higher pressure within the controlled flow excavator according to the present invention, the impeller blade passages (formed by the combination of impeller hub, impeller blades and impeller shroud) as well as causing the fluid to rotate in a circumferential motion, also divert the fluid in a partly radial, partly axial direction (see FIG. 1). The partly radial nature of the impeller blades means that the circumferential speed at the trailing edge of the blade is higher than at the leading edge, thus imparting more kinetic energy into the fluid than an axial impeller blade running at the same speed. Use of an ‘aerofoil’ blade shape improves the hydrodynamic efficiency of the rotor blades.

(56) In the controlled flow excavator according to the present invention the fluid leaves the impeller blades with a significant circumferential velocity, but also with both axial and radial velocities (see FIG. 1). Downstream of the impeller blade, the shape of the controlled flow apparatus flow passage, created by the housing and hub profiles, removes the radial component of the flow by turning from a mixed radial and axial direction to a purely axial direction. The fluid then travels axially but still with significant circumferential velocity and high kinetic energy at a relatively large radius. Blade passages of a stator section remove the circumferential component of flow, converting some of the kinetic energy into pressure energy, and bring the fluid back to a smaller radius for ejection from the excavator in a relatively small-diameter concentrated flow or jet.

Reactive Torque Dampening

(57) Another feature of typical mass flow excavators is the means by which such cope with reactive torque transmitted from a drive mechanism into the fluid passing through the device. The fluid in turn exerts an equal and opposing torque on the housing in the opposite direction (reactive torque) which if not cancelled would make the body of the excavation device rotate in the opposite direction from the impeller, making the excavation device unstable in use. SILLS uses a number of clump weights deployed with the device to counteract the reactive torque; DIKKEN and SUSMAN employ two counter rotating impellers so that each impeller counteracts the reaction of the other.

(58) To avoid the need for complex devices to counteract reactive torque the controlled flow device of the invention provides guide vanes in a stator section after an impeller to straighten fluid flow. Substantially removing any circumferential motion or swirl caused by the impeller before the fluid exits the device substantially removes reactive torque from the excavator device. Because the fluid entering the stator has relatively high circumferential velocity compared to a conventional mass flow excavator, the stator blades must turn the fluid through significantly higher angles. This is achieved by a relatively higher number of stator blades of a relatively longer length, with a relatively higher blade angle at the LE (leading edge), and the use of a splitter blade. The higher the blade angle at the LE, the higher is the blockage caused by the blades, as shown in FIG. 2(a). This blockage effect limits the number of stator blades that can be efficiently used. As the fluid is turned, however, and the blades approach a more axial aspect, the effective gap between the blades increases, reducing the effectiveness of the blades in straightening the flow. A splitter blade, which is a small blade between each main blade, is therefore used to address this problem. The splitter blades increase the blading and hence help to straighten the flow but do not increase the blockage to an unacceptable level because they are only present in the area where the blade angles are smaller.

(59) Particularly for operation in shallow water, it is important to seek to minimise a height of the controlled flow device, and while it would be simplest and less costly to house the stator blades in a purely cylindrical passage, i.e. one where the diameters do not change, in order to minimise length the stator is housed in a converging section, i.e. one where the diameter is reducing, so that the tasks of firstly removing the circumferential velocity from the fluid and converting kinetic into pressure energy, and secondly of bringing the fluid back to a smaller diameter for ejection through the nozzle, are combined in one section.

(60) The controlled flow excavator seeks to achieve stability in the water by careful hydrodynamic stator blade design which seeks to ensure that when the excavation apparatus is running at designed operating parameters, the stator blades remove most if not all of the angular momentum from the fluid. Therefore, there is little residual reactive torque on the housing of the excavator. However, at ‘off-design’ conditions, i.e. where the excavator apparatus is being used with significantly greater or smaller rotor speeds than ideal operating point, there may remain a residual swirl in the fluid leaving the excavator apparatus. This means that the reactive torque may not have been fully eliminated by the stator blading. Anti-rotation blades attached to inside faces of nozzles near their outer diameter, as shown in FIG. 3, help to reduce or minimise any residual reactive torque. These anti-rotation blades convert some or all of any remaining rotational velocity in the fluid into torque in the opposite direction to the reactive torque which such residual swirl would produce. The anti-rotation blades are typically purely axial in profile with no camber (i.e. such are symmetrical about a chord-line running through the blade), which together with the use of an aerofoil profile induces lift in the desired direction regardless of which direction the fluid is swirling in. Hence a torque on the excavator housing is produced, in use, which partially or wholly offsets the reactive torque, as shown in FIG. 4. To reduce manufacturing costs, the anti-rotation blades may also be plane flat plates, and may for example be constructed from thick plate metal with, for example, rounded leading edges and sharpened trailing edges.

Vortex Generation

(61) To further enhance the cutting capability of the controlled flow excavation apparatus, the exit nozzle of the apparatus can comprise a series of vortex generators to produce pairs of counter rotating vortexes. Vortex generators can be of a half delta wing profile or can be as simple as triangular or rectangular plates which are placed within the exit nozzle and are inclined to the flow to produce a strong vortex at the trailing edge of the vortex generator. The power of the vortex hitting the seabed locally weakens the area of the seabed to enable greater penetration by the controlled flow.

(62) By using counter rotating pairs each vortex helps contain and preserve the rotation of a neighbouring vortex(es) to produce more stable vortexes and avoid the creation of unwanted reactive torque as the torque from each vortex is cancelled by its neighbour (see FIG. 9).

(63) The anti-rotation vanes can also be used in conjunction with vortex generators as described below, particularly to locate and support a ring of vortex generating pairs.

(64) The number of vortex pairs can be maximised by placement of the vortex generators at the outer diameter of the exit nozzle (see FIG. 6).

(65) Such placement has potential to cause mixing of the exiting fluid from the controlled flow device and the body of fluid in which the device is being used, thereby slowing and causing dispersal of the controlled flow.

(66) In an alternative embodiment (see FIGS. 7(a) and 7(b)), the vortex generators can be placed substantially in a centre of the exit nozzle, e.g. on a feature created to hold the vortex generators. However this arrangement allows for only a more limited number of pairs of vortex generators.

(67) In a further alternative embodiment (see FIG. 8), the vortex generators can be placed on a ring within the exit nozzle so that a greater number of pairs may be used, while maintaining the vortexes wholly within the high speed flow from the controlled flow devices. Maintaining the vortexes wholly within the high speed flow helps to create stable vortexes. Supports which attach the vortex ring to the nozzle may be in the form of anti-rotation blades as discussed above.

(68) When used in suction mode the exit of the controlled flow apparatus can be connected to a pipe or hose for transportation of a slurry mix of fluid and seabed material (or spoil) away from the excavation site. Operating in this mode, the vortex generators in the exit of the controlled flow apparatus aid the transport of seabed material by mixing of the fluid which maintains the collected material in suspension.

(69) It will be understood that in order to transport the excavated material along the transportation pipe that the ratio of seabed material to water being transported should preferably not exceed a ratio of approximately 15% to 20% solids to water. This ratio can be controlled by varying the power supplied to the controlled flow apparatus.

(70) To transport material over long distances, say 200 meters or further, it may be necessary to add another controlled flow apparatus in series either directly coupled after the first controlled flow apparatus or some distance along the transportation pipe.

(71) It will be appreciated that the embodiments of the invention hereinbefore described are given by way of example only, and are not meant to be limiting of the invention in any way.

(72) It will be appreciated that modifications may be made to the disclosed embodiments. For example, the turbulent means or vortex producing means or vortex generator(s) may be provided on the anti-rotation vanes, e.g. on an inner edge(s) of the anti-rotation vanes.