U.S. patent application number 14/061694 was filed with the patent office on 2014-02-20 for modular, distributed, rov retrievable subsea control system, associated deepwater subsea blowout preventer stack configuration, and methods of use.
This patent application is currently assigned to Oceaneering International, Inc.. The applicant listed for this patent is Oceaneering International, Inc.. Invention is credited to Greg R. Boyle, Robert A. Johnigan, Graeme E. Reynolds.
Application Number | 20140048274 14/061694 |
Document ID | / |
Family ID | 50099254 |
Filed Date | 2014-02-20 |
United States Patent
Application |
20140048274 |
Kind Code |
A1 |
Reynolds; Graeme E. ; et
al. |
February 20, 2014 |
Modular, Distributed, ROV Retrievable Subsea Control System,
Associated Deepwater Subsea Blowout Preventer Stack Configuration,
and Methods of Use
Abstract
A distributed function control module adapted for use in a
modular blowout preventer (BOP) stack for use subsea comprises a
housing adapted to be manipulated by a remotely operated vehicle
(ROV) with a stab portion adapted to be received into a BOP stack
control module receiver. Control electronics, adapted to control a
predetermined function with respect to the BOP stack, are disposed
within the housing and connected to one or more controllable
devices by a wet mateable connector interface. It is emphasized
that this abstract is provided to comply with the rules requiring
an abstract which will allow a searcher or other reader to quickly
ascertain the subject matter of the technical disclosure. It is
submitted with the understanding that it will not be used to
interpret or limit the scope of meaning of the claims.
Inventors: |
Reynolds; Graeme E.;
(Houston, AU) ; Boyle; Greg R.; (Camarillo,
CA) ; Johnigan; Robert A.; (Houston, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Oceaneering International, Inc. |
Houston |
TX |
US |
|
|
Assignee: |
Oceaneering International,
Inc.
Houston
TX
|
Family ID: |
50099254 |
Appl. No.: |
14/061694 |
Filed: |
October 23, 2013 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
12729929 |
Mar 23, 2010 |
8607879 |
|
|
14061694 |
|
|
|
|
11205893 |
Aug 17, 2005 |
7216714 |
|
|
12729929 |
|
|
|
|
60603190 |
Aug 20, 2004 |
|
|
|
Current U.S.
Class: |
166/338 ;
166/351 |
Current CPC
Class: |
E21B 34/16 20130101;
E21B 33/064 20130101; E21B 33/038 20130101; E21B 33/0355 20130101;
E21B 33/0385 20130101 |
Class at
Publication: |
166/338 ;
166/351 |
International
Class: |
E21B 33/064 20060101
E21B033/064; E21B 33/038 20060101 E21B033/038 |
Claims
1. A modular blowout preventer stack non-electric failsafe
mechanical module, comprising: a. a housing adapted to be received
into a complementary blowout preventer stack receiver; and b. an
accumulator disposed within the housing, the accumulator configured
to activate a hydraulic pilot signal from an ROV mechanically
activated handle.
2. The modular blowout preventer stack non-electric failsafe
mechanical module of claim 1, further comprising a hydraulic port
configured to receive an ROV hydraulic stab and receive hydraulic
fluid for control as well as to recharge the accumulator.
3. The modular blowout preventer stack non-electric failsafe
mechanical module of claim 1, further comprising a non-electric
controller configured to control a predetermined modular blowout
preventer stack function.
4. A modular blowout preventer stack non-electric failsafe
mechanical module, comprising: a. a housing configured to be
received into a complementary blowout preventer stack receiver; b.
an interface to an external coupler disposed at least partially
within the housing; and c. a predetermined set of function
controllers.
5. The modular blowout preventer stack non-electric failsafe
mechanical module of claim 4, wherein the interface comprises at
least one of an interface to an external power coupler and an
interface to an external communications coupler.
6. The modular blowout preventer stack non-electric failsafe
mechanical module of claim 5, wherein the predetermined set of
function controllers comprises at least one of a data provider and
a power provider.
7. The modular blowout preventer stack non-electric failsafe
mechanical module of claim 6, further comprising an interface to a
special function box.
8. The modular blowout preventer stack non-electric failsafe
mechanical module of claim 7, wherein the interface to a special
function box comprises at least one of a data interface and a power
interface.
9. A method of providing control to a non-functional or improperly
functioning module in a subsea modular blowout preventer,
comprising: a. locating a receiver in a subsea modular blowout
preventer; and b. inserting a re-router into the receiver; and c.
performing a predetermined function at the receiver.
10. The method of claim 9, where in the receiver is at least one of
a spare receiver or a non-important receiver.
11. The method of claim 9, wherein the predetermined function
comprises at least one of providing data or providing power to a
second modular blowout preventer function non-electric, fail-safe
mechanical module.
12. The method of claim 9, wherein the predetermined function
comprises providing hydraulic control to a blowout preventer
hydraulic assembly.
Description
RELATION TO OTHER APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 12/729,929 filed on Mar. 23, 2010 which was a
continuation of U.S. patent application Ser. No. 11/205,893, filed
on Aug. 17, 2005 now U.S. Pat. No. 7,216,714, issued May 15, 2007
which claims the benefit of U.S. Provisional Application No.
60/603,190, filed on Aug. 20, 2004.
FIELD OF THE INVENTION
[0002] The inventions relate to offshore drilling operations and
more specifically, to a deepwater subsea blowout preventer stack
configuration and its control system architecture, system
interface, and operational parameters.
BACKGROUND OF THE INVENTION
[0003] When drilling in deepwater from a floating drilling vessel,
a blowout preventer stack (BOP Stack) is typically connected to a
wellhead, at the sea floor, and a diverter system, which is mounted
under the rig sub-structure at the surface via a marine riser
system. Although pressure containing components, connectors,
structural members, reentry guidance systems, load bearing
components, and control systems have been upgraded for the
operational requirement, the overall system architecture has
remained common for more than two decades.
[0004] The BOP Stack is employed to provide a means to control the
well during drilling operations and provide a means to both secure
and disconnect from the well in the advent of the vessel losing
position due to automatic station keeping failure, weather, sea
state, or mooring failure.
[0005] A conventionally configured BOP Stack is typically arranged
in two sections, including an upper section (Lower Marine Riser
Package) which provides an interface to a marine riser via a riser
adapter located at the top of the package. The riser adapter is
secured to a flex-joint which provides angular movement, e.g. of up
to ten degrees (10.degree.), to compensate for vessel offset. The
flex-joint assembly, in turn, interfaces with a single or dual
element hydraulically operated annular type blowout preventer
(BOP), which, by means of the radial element design, allows for the
stripping of drill pipe or tubulars which are run in and out of the
well. Also located in the Lower Marine Riser Package (or upper
section) is a hydraulically actuated connector which interfaces
with a mandrel, typically located on the top of the BOP Stack lower
section. The BOP Stack lower section typically comprises a series
of hydraulically operated ram type BOPs connected together via
bolted flanges in a vertical plane creating a ram stack section. In
turn, the ram stack section interfaces to a hydraulically latched
wellhead connector via a bolted flange. The wellhead connector
interfaces to the wellhead, which is a mandrel profile integral to
the wellhead housing, which is the conduit to the wellbore.
[0006] Conduit lines integral to the marine riser provide for
hydraulic fluid supply to the BOP Stack Control System and
communication with the wellbore annulus via stack mounted gate
valves. The stack mounted gate valves are arranged in the ram stack
column at various positions allowing circulation through the BOP
Stack column depending on which individual ram is closed.
[0007] The unitized BOP Stack is controlled by means of a control
system containing pilot and directional control valves which are
typically arranged in a control module or pod. Pressure regulators
are typically included in the control pod to allow for operating
pressure increase/decrease for the hydraulic circuits which control
the functions on the unitized BOP Stack. These valves, when
commanded from the surface, either hydraulically or
electro-hydraulically direct pressurized hydraulic fluid to the
function selected. Hydraulic fluid is supplied to the BOP Stack via
a specific hydraulic conduit line. In turn, the fluid is stored at
pressure in stack-mounted accumulators, which supply the function
directional control valves contained in redundant (two (2)) control
pods mounted on the lower marine riser package or upper section of
the BOP Stack.
[0008] Currently, most subsea blowout preventer control systems are
arranged with "open" circuitry whereby spent fluid from the
particular function is vented to the ocean and not returned to the
surface.
[0009] A hydraulic power unit and accumulator banks installed
within the vessel provide a continuous source of replenishment
fluid that is delivered to the subsea BOP Stack mounted
accumulators via a hydraulic rigid conduit line and stored at
pressure. The development and configuration of BOP Stacks and the
control interface for ultra deep water applications has in effect
remained conventional as to general arrangement and operating
parameters.
[0010] Recent deepwater development commitments have placed
increased demands for well control systems, requiring dramatic
increases in the functional capability of subsea BOP Stacks and, in
turn, the control system operating methodologies and complexity.
These additional operational requirements and complexities have had
a serious effect on system reliability, particularly in the control
system components and interface.
[0011] Although redundancy provisions are provided by the use of
two control pods, a single point failure in either control pod or
function interface is considered system failure necessitating
securing the well and retrieving the lower marine riser package,
containing the control pods, or the complete BOP Stack for
repair.
[0012] Retrieving any portion of the BOP Stack is time consuming
creating "lost revenue" and rig "down time" considering the
complete marine riser must be pulled and laid down.
[0013] Running and retrieving a subsea BOP Stack in deepwater is a
significant event with potential for catastrophic failure and
injury risk for personnel involved in the operation.
[0014] In addition, vessel configuration, size, capacity, and
handling equipment has been dramatically increased to handle,
store, and maintain the larger more complex subsea BOP Stacks and
equipment. The configuration and pressure rating of the overall BOP
Stack requires substantial structural members be incorporated into
the assembly design to alleviate bending moment potential,
particularly in the choke and kill stab interface area between the
Lower Marine Riser Package and BOP Stack interface. These stab
interfaces may see in excess of two hundred and seventy five
thousand (275,000') ft/lbs. separating forces, again requiring
substantial section modulus in the structural assemblies, which
support these components.
[0015] Further, a lower marine riser package apron or support
assembly size has increased to accommodate the contemporary
electro-hydraulic control pods and electronic modules necessary to
control and acquire data from an overall Unitized BOP Stack
assembly.
[0016] Substantial increases in the overall weight and size of high
pressure BOP Stacks has created problems for drilling contractors
who have a high percentage of existing vessels, which will not
accommodate these larger stacks without substantial modifications
and considerable expense. In most cases, the larger, heavier and
more complex units are requiring by operators for "deep water"
applications and reduce the potential for negotiating a contract
for the particular rig without this equipment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The various drawings supplied herein are representative of
one or more embodiments of the present inventions.
[0018] FIG. 1 is a view in partial perspective of a subsea BOP
Stack comprising a riser connector, a BOP assembly, and a modular
retrievable element control system;
[0019] FIG. 2 is a view in partial perspective of a riser
connector;
[0020] FIG. 3 is a view in partial perspective of a riser
connector;
[0021] FIG. 4 is a view in partial perspective of a control
module;
[0022] FIG. 5 is a view in partial perspective of a control module
mated to a receiver;
[0023] FIG. 6 is a view in partial perspective cutaway of a control
module;
[0024] FIG. 7 is a view in partial perspective of an interface
between a stab of control module and receiver on a BOP
assembly;
[0025] FIG. 8 is a flowchart of an exemplary method of use;
[0026] FIG. 9 is a schematic of an exemplary diagnostic modular BOP
stack receiver diagnostic tool;
[0027] FIGS. 10 and 10a are schematics of an exemplary modular
blowout preventer stack module comprising a predetermined modular
blowout preventer function non-electric, fail-safe mechanical
module (FIG. 10) and a re-router (FIG. 10a);
[0028] FIG. 11 is a schematic of an exemplary modular blowout
preventer stack module comprising a predetermined modular blowout
preventer function non-electric, fail-safe mechanical module;
[0029] FIG. 12 is a schematic of an exemplary modular carrier which
comprises one or more module carrier receivers; and
[0030] FIG. 13 is a view in partial perspective of a special
function unit.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTIONS
[0031] Referring now to FIG. 1, the present inventions comprise
elements that, when assembled and unitized, form a reconfigured
subsea Blowout Preventer Stack (BOP Stack) 1 including modular
retrievable element control system 200. Variations of the
architecture and components of modular retrievable element control
system 200 may be utilized subsea, e.g. in production tree,
production riser, and subsea manifold control interface
applications.
[0032] In a preferred embodiment, BOP Stack 1 comprises riser
connector 10, BOP assembly 100, and wellhead connector 50.
[0033] BOP assembly 100 includes control modules 200 that, in a
preferred embodiment, are arranged in a vertical array and
positioned adjacent to the particular function each control module
200 controls, such as hydraulic functions. Composition of control
module 200 sections preferably include materials that are
compatible on both the galvanic and galling scales and be suitable
for long term immersion in salt water.
[0034] BOP assembly 100 is configured to accept and allow the use
of distributed functional control modules 200 which are remotely
operated vehicle (ROV) retrievable (the ROV is not shown in the
figures). The use of this modular distributed control system
architecture in subsea BOP Stack applications allows for the
re-configuration of existing BOP stack arrangement designs to
reduce weight and complexity in the integration and unitization of
the elements required to form the overall BOP Stack 1.
[0035] BOP assembly 100 may be unitized and may comprise elements
such as a hydraulic connector to interface to the subsea wellhead,
one or more blowout preventers 115 (e.g. ram type blowout
preventers), annular 110 or spherical type blowout preventers, a
plurality of hydraulic connectors to interface to a marine riser
(not shown in the figures) and hydraulically operated gate type
valves for isolation and access for choke and kill functions.
[0036] Riser connector 10 comprises riser adapter 11,
guideline-less reentry assembly 14, and multi-bore connector 15.
Flex joint 13 is disposed intermediate riser adapter 11 and
multi-bore connector 15. One or more flex loops 12 may be present
and in fluid communication with ports on riser adapter 11.
Multi-bore connector 15 provides an interface to BOP assembly
100.
[0037] BOP assembly 100 may be further adapted to receive one or
more control modules 200 into docking stations 202 as well as other
modules, e.g. annular preventer 110, RAM preventer 115, blowout
preventers (not specifically shown), connectors (not specifically
shown), "Fail Safe" gate valves (not specifically shown), sub
system interface values (not specifically shown), or the like, or
combinations thereof. One or more lines 120, e.g. kill and/or choke
lines, may be present as well as various control pathways such as
hydraulic conduit 101 and/or MUX cables (e.g. cables 26 in FIG.
2).
[0038] Hang-off beams 102 may be provided to allow for support of
BOP assembly 100 during certain operations, e.g. in a moon pool
area such as for staging and/or testing prior to running.
[0039] Referring now to FIG. 2, riser connector 10 is typically
adapted to provide a connector, such as riser adapter 11, to
interface with a marine riser (not shown in the figures). In a
preferred embodiment, riser connector 10 comprises one or more MUX
cables 26 and hydraulic conduit hoses 25. Riser connector 10 may
also incorporate integral connection receptacles for choke/kill,
hydraulic, electric, and boost line conduit interfaces. In a
preferred embodiment, riser connector 10 is configured with
connector 15 as a multi-bore connector rather than single bore
connector, although either configuration may be used. This allows
for riser connector 10 to absorb loading and separating forces as
well as bending moments within its body where substantial section
modulus exists. Further, it decreases the need for a substantial
fabricated structure to alleviate the potential for separation of a
line holding a high pressure, e.g. line 120 (FIG. 1).
[0040] In a preferred embodiment, one or more subsea wet mateable
connectors 21 are also integrated into riser connector 10 for
interfacing with BOP assembly 100 (FIG. 1). This interface may be
used to supply power and/or communications to control modules 200
(FIG. 1) located on BOP assembly 100. In a preferred embodiment,
the marine riser and its interfaces, such as choke/kill, hydraulic,
electric, and boost, may be disconnected or reconnected in one
operation from riser connector 10.
[0041] In certain embodiments, riser connector 10 may also include
riser connector control module 28 which comprises one or more
junction boxes and subsea electronics module which may be integral
with junction box 27. Using riser connector control module 28 may
allow control of riser connector 10 and lower marine riser package
functions independent of the BOP stack in the event the marine
riser must be disconnected from BOP stack 100 (FIG. 1) and pulled
back to the surface.
[0042] In a preferred embodiment, subsea electronics module 27 may
provide for connections such as electrical connections and may be
equipped with connector receptacles for interfacing to ROV devices,
e.g. ROV retrievable control modules 200 (FIG. 1) such as to
facilitate control of riser connector functions.
[0043] In a preferred embodiment, subsea electronics module 27
provides one or more interfaces from main multiplex cables 26 to a
lower marine riser package which contains multibore riser connector
15. Wet make/break electrical connectors which may be present, e.g.
21, may be integral to riser connector 15, e.g. via pressure
balanced, oil-filled cables.
[0044] Apron plate 30, which is of sufficient area to provide for
mounting of junction boxes 27, may be present to provide a
transition from main multiplex control cable connectors to the wet
mateable assemblies located in multi-bore connector 15. Power and
other signals to riser connector control module 28 may be effected
via an oil filled pressure compensated cable assembly (not shown)
that is connected to electrical junction boxes 27 mounted on apron
plate 30. In a preferred embodiment, two junction boxes 27 are
provided for redundancy and each may be distinguished from the
other, e.g. labeled or provided with different colors. Apron plate
30 may be attached to guideline-less reentry funnel 16 (FIG.
3).
[0045] In a preferred embodiment, riser connector 10 includes flex
joint 13 and one or more flex loops 12, e.g. to allow for angular
movement to compensate for vessel offset. The upper flange adapter
or flex-joint top connection typically interfaces to a flange of
riser adapter 11 containing kick-out flanged assemblies for
connection of lines 120 (FIG. 1) interfacing with the marine riser,
e.g. formed hard pipe flow-loops that interface choke and kill line
120 to the main marine riser.
[0046] Referring now to FIG. 3, riser connector 10 interfaces with
BOP assembly 100 (FIG. 1) using guideline-less receiver assembly 24
and connector mandrel 19. Connector mandrel 19 is typically
connected to BOP assembly 100 through riser connector mandrel
flange 23 which may be further adapted to provide mounting for
choke/kill, hydraulic, MUX cable, boost, electric connectors and
stabs, and the like, or a combination thereof
[0047] In a preferred embodiment, riser connector mandrel flange 23
is of the API ring-groove type and interfaces with a matching
flange which forms the lower connection of flex-joint assembly 13
or additional elements, e.g. annular blowout preventers which may
be mounted on lower marine riser package.
[0048] Guideline-less receiver assembly 24 comprises guideline-less
reentry funnel 16 and guideline-less reentry receiver 17.
Multi-bore connector 15 may be arranged to reside in guideline-less
reentry funnel 16 and guideline-less reentry receiver 17 may be
attached to the top of BOP assembly 100 (FIG. 1). In a preferred
embodiment, guideline-less reentry funnel 16 is configured with a
funnel portion that interfaces with a corresponding funnel portion
of guideline-less reentry receiver 17.
[0049] In further configurations, orientation dogs 20 and
corresponding orientation slots 29 may be used to align riser
connector 10 with respect to BOP assembly 100 (FIG. 1). This
alignment system provides correct orientation of multi-bore
connector 15 and its integral peripheral receptacles with
corresponding receptacles of BOP assembly 100, e.g. hydraulic stab
18 and/or choke stab 22, during reentry operations.
[0050] The connector upper flange of multi-bore connector 15 may be
of an API ring groove type and interface with a matching flange
which forms a lower connection of flex joint 13.
[0051] In a preferred embodiment, the bottom or lower flex loop
connection 12 interfaces to multi-bore connector 15, e.g. a studded
ring groove connection, via an API flange.
[0052] Referring to FIG. 4, control module 200 includes electronics
housing 220 connected to compensator housing 222 which is in
communication with or otherwise connected to pressure compensated
solenoid housing 218. Pilot valve 216 is located between pressure
compensated housing 218 and sub plate mounted (SPM) valve 224. In
certain embodiments, pilot valve 216 is adapted to interface with
and actuate a predetermined function of SPM valve 224, e.g. via
hydraulic activation.
[0053] Hydraulic fluid is typically supplied to control module 200
via supply manifold 226. Control module 200 communicates with BOP
assembly 100 (FIG. 1) through electrical cable 232 (FIG. 5) in
communication with wet mateable connector 228.
[0054] Control module 200 is connected to BOP assembly 100 (FIG. 1)
via stab 212 that includes a hydraulic seal 210. In a preferred
embodiment, hydraulic seal 210 comprises a molded elastomer with an
integral reinforcing ring element. Hydraulic seal 210 may be
retained in stab 212 via tapered seal retainers which are screw cut
to match a female thread profile machined into the stab port
interface.
[0055] In an embodiment, hydraulic seals 210, also called packer
seals, mount into stab 212 and are positioned and retained in a
machined counterbore which is common to the hydraulic porting
through the body of stab 212. When mated, the stab internal ports
containing packer seals 210 align and interface with the matching
ports contained in female receptacle 270 (FIG. 7) that are machined
on the outside to accept flanged subsea connections. These flanged
subsea connections may be retained by SAE split flanges and
fasteners and may be provided with weld sockets for pipe, screw cut
for tubing connectors, or various hose connectors (i.e., JIC, SAE,
or NPT) terminating methods.
[0056] In preferred embodiments, wet mateable connector 228
comprises conductors or pins to supply power, data signals, or both
to electronics (not shown) within control module 200, for example
induction couplers, fiber optic couplers, or the like, or
combinations thereof. In addition, a fiber optic conductor
connection interface (not shown) may be included for signal command
or data acquisition requirements depending on the functional
application of the particular module assignment.
[0057] SPM valve 224 may further include vent port 214. SPM valve
224 (FIG. 4) typically includes a flanged, ported body cap or top
member which contains an actuating piston and one or more integral
pilot valves 216. Pilot valve 216 may be solenoid actuated and may
be a pressure compensated, linear shear-seal type arranged as a
three-way, two position, normally closed, spring return pressure
compensated with a five thousand p.s.i. working pressure (WP).
[0058] Supply manifold 226 porting and arrangement may vary for
valve operation in normally open or normally closed modes.
Hydraulic fluid is supplied to pilot valves 216 through a dedicated
port through the stab 212. Pressure regulators integral to the
supply manifold 226 are provided for supply to function circuits
requiring reduced or regulated pressures.
[0059] Pilot valves 216 interface with solenoid actuators that are
contained in pressure compensated solenoid housing 218. Pressure
compensated solenoid housing 218 is preferably filled with
di-electric fluid providing a secondary environmental protection
barrier.
[0060] Referring to FIG. 5, control module 200 is typically
inserted into receiver 238 and may be released by actuating a
hydraulic lock dog release 230. Receiver 238 is part of BOP
assembly 100 and may be integral to a mounting plate which is
permanently mounted to a BOP assembly frame.
[0061] SPM valve 224 (FIG. 4) on control module 200 may comprise
one or more SPM directional control valves 240 whose manifold
pockets may be investment cast from stainless steel with the
porting arranged for supply, outlet, and vent functions of
three-way, two position, piloted SPM directional control valves
240.
[0062] Modern manufacturing techniques, such as investment casting,
may be employed for components such as the SPM valve 240, SPM valve
224, and supply manifold 226 providing substantial weight reduction
and machining operations.
[0063] Referring to FIG. 6, retrievable control modules 200 include
atmosphere chamber 260 containing electronics control input/output
(I/O) modules, such as an electronic board 256, and one or more
power supplies. In a preferred embodiment, atmosphere chamber 260
is maintained at one atmosphere. In currently preferred
embodiments, control module 200 further includes one or more
pressure compensating bladders 262, pilot valve actuating solenoids
266, pilot valves 216 (FIG. 4), and poppet valve type SPM valves
240 (FIG. 5) which are piloted from solenoid operated pilot valves
216.
[0064] Pressure compensating bladder 262 is contained within
pressure compensated solenoid housing 218 to aid in equalizing the
housing internal pressure, e.g. with seawater head pressure. An
open seawater port 254 may be provided and a relief valve (not
shown), e.g. a ten p.s.i. relief valve, may be contained within
pressure compensated solenoid housing 218 to limit pressure build
up inside pressure compensated solenoid housing 218, allowing
equalization of the compensator bladder 262 volume against pressure
compensated solenoid housing 218 volume, including a pressure
compensated chamber 250. Pressure compensated chamber 250 may be
accessed through an oil fill port 252.
[0065] A mandrel, e.g. conduit 268, may be disposed more or less
centrally through pressure compensated solenoid housing 218 to
provide a conduit, at preferably one atmosphere, for
electrical/fiber optic conductors from a wet make/break connector
half located in stab 212 (FIG. 4). In addition, the internal
profile of mandrel 268 may be machined with a counterbore shoulder
that is drilled with preparations to accept molded epoxy filled,
male connectors for an electrical wiring attachment. In turn, the
wiring attachment may terminate at corresponding male connectors at
solenoids 266, e.g. via boot seals and/or locking sleeves 264.
[0066] Pressure compensated solenoid housing 218 interfaces with
atmosphere chamber 260 containing the electronics module. In an
embodiment, atmosphere chamber 260 mates to pressure compensated
solenoid housing 218 via a bolted flange, which is machined with an
upset mandrel containing redundant radial seals. In addition, the
internal wire/fiber optic conduit, e.g. conduit 268, mates to an
internal counterbore profile via a matching male mandrel also
containing redundant radial a-ring seals. Atmosphere chamber 260
may further be equipped with flanged top providing access to the
electronics chassis, wiring harness, and pigtail wiring connection.
In embodiments, the flanged top is also provided with an upset
mandrel containing redundant O-ring seals which interface to the
top of atmosphere chamber 260.
[0067] In a preferred embodiment, all seal interfaces are machined
with test ports to provide a means to test the internal and
external O-ring seals to ensure integrity prior to module
installation. In addition, housing 260 is typically equipped with
"charge" and "vent" ports 258 for purging housing 260, such as with
dry nitrogen, providing further environmental protection for the
electronics components. Each port 258 may further be equipped with
a shut-off valve and secondary seal plug.
[0068] In deep subsea use, electrical/electronic interface
integrity may be assured by the environmental protection of
electrical or fiber optic conductors using a stainless steel
conduit spool equipped with redundant seal sub type interface, or
the like.
[0069] FIG. 7 illustrates a preferred embodiment of the interface
between stab 212 (FIG. 4) of control module 200 (FIG. 4) and
receiver 238 (FIG. 5) on BOP assembly 100 (FIG. 1). Stab 212
includes male stab 272 that correspond to female receptacle 270 on
receiver 238. Female receptacles 270 may contain ports for
hydraulic supply 234, 236, 242, 244 (FIG. 5), which provide input
and outlets to an assigned blowout preventer stack. Connector body
through-bores for female receptacle 270 are machined with
preparations to accept poly-pack type radial seal assemblies to
seal on male stabs 272.
[0070] In a preferred embodiment, the base of male stab 272 is
machined with a counterbore profile to accept the male half of the
connector insert containing male pins. The counterbore is recessed
deep enough to allow the insert to be set back in the stab body
providing protection for the individual pins and alleviating the
potential for damage during handling.
[0071] A corresponding male mandrel profile is machined into the
female receptacle base to accept the female half of a connector
pair. Both the male mandrel in female receptacle 270 and female
counterbore in the male stab 272 are machined with matching tapers,
which provide a centering function and positive alignment for the
male/female connector halves when stab 272 enters female receptacle
270. In addition, this centering/alignment method further assures
correct hydraulic port, equal packer seal alignment, squeeze and
loading when male stab 272 is mated in female receptacle 270.
[0072] The connection between male stab 272 and female receptacle
270 is maintained by a hydraulic latch 278, and communication is
achieved through a wet mateable connector assembly 284, which is
preferably of the wet make/break type. Hydraulic communication
between male stab 272 and female receptacle 270 is maintained
through packer seal assemblies 282.
[0073] Male stab 272 interfaces with SPM valve 240 (FIG. 5) through
supply channel 274 or function channel 276 which contain redundant
O-ring seals with back-up rings. The seal subs locate the manifold
element to the stab body via counterbores in each member. Conduit
268 may interface with receiver 238 through conduit mandrel
286.
[0074] Additionally, fitting 280 may be present to terminate a
cable at receptacle 270. For example, fitting 280 may be an
SAE.-to-J.I.C. adapter fitting to terminate a pressure balanced,
oil filled cable at receptacle 270.
[0075] Referring now to FIG. 9, when all portions of BOP Stack 1
(FIG. 1) are operational all is good. However, when a component is
not operating correctly, a diagnostic tool can be used to
troubleshoot the problem. If the problem is in a removable control
module 200 (FIG. 1) it can be replaced by ROV 300. However, if the
problem is on BOP Stack 1 in the form of an electrical or hydraulic
problem, that problem may be diagnosed using the modular BOP stack
receiver diagnostic tool 500.
[0076] Referring now to FIG. 9, in certain embodiments, BOP stack
receiver diagnostic tool 500 comprises housing 220 configured to be
removably received into modular blowout preventer stack module
receiver 238 and components such as BOP stack receiver diagnostic
electronics 510, disposed within housing 220. Modular BOP stack
receiver diagnostic tool 500, as discussed above, may comprise
annular preventer 110 (FIG. 1), RAM preventer 115 (FIG. 1), blowout
preventers (not specifically shown), connectors (not specifically
shown), "Fail Safe" gate valves (not specifically shown), sub
system interface valves (not specifically shown), or the like, or
combinations thereof or be configured to operatively interface with
a predetermined modular blowout preventer function generator such
as annular preventer 110, RAM preventer 115, one or more blowout
preventers (not specifically shown), one or more connectors (not
specifically shown), one or more "Fail Safe" gate valves (not
specifically shown), one or more sub system interface valves (not
specifically shown), or the like, or combinations and perform one
or more analysis functions selected from a predetermined set of
analytic functions with respect to a specific predetermined modular
blowout preventer function. These functions may comprise a
hydraulic operation, a power operation, a data communication
operation, or the like, or a combination thereof. As also discussed
herein, housing 220 may be configured to be maneuvered into modular
blowout preventer stack module receiver 238 by a remotely operated
vehicle (ROV) 300 to be installed subsea by using ROV 300.
[0077] Modular BOP stack receiver diagnostic tool 500 typically
further comprises a mechanical component such as one or more
solenoids 543, valves 541, pressure transducers 540 operatively in
communication with modular BOP stack receiver diagnostic tool
electronics 510, or the like, or a combination thereof. Any of
these mechanical components may also be configured to be exercised
hydraulically and/or electrically. If hydraulically exercised,
modular blowout preventer stack diagnostic module 500 may further
comprise hydraulic coupler 544 operatively in fluid communication
with the mechanical component and configured to operatively couple
with an ROV hydraulic stab 306 or similar ROV hydraulic source such
as a source provided by ROV skid 302.
[0078] One or more fluid couplers 503, 504 (two being illustrated
in FIG. 9) may be present to allow modular BOP stack receiver
diagnostic tool 500, once mated in modular blowout preventer stack
module receiver 238, to operatively interface with hydraulic lines
in BOP stack 1 (FIG. 1). Communications interface 501 and power
interface 502 may also be present and operatively interface with
modular BOP stack receiver diagnostic tool electronics 510 and a
source of communications and/or power such as via coupler 21
present in BOP stack 1 which is operatively in communication with
interface coupler 521. As noted above, coupler 21 and interface
coupler 521 may comprise one or more connectors such as wet
mateable couplers, inductive couplers, fiber optic couplers, or the
like, or a combination thereof. Additional data communication
and/or power may be provided by ROV 300 such as through link 304.
Interface coupler 521 may be present to provide a data
communication and/or power connector between modular BOP stack
receiver diagnostic tool electronics 510 and ROV 300 such as
directly, via a second matched set of interface couplers 521, or
the like, or a combination thereof.
[0079] In embodiments, modular blowout preventer stack diagnostic
module 500 may further a plurality of controllable hydraulic
functions. In other embodiments, modular blowout preventer stack
diagnostic module 500 may further comprise analog feedback sensors
(not shown in figures) disposed within or proximate to BOP stack
receiver diagnostic electronics 510 providing pressure, voltage,
current, and other diagnostic information. In other embodiments,
modular blowout preventer stack diagnostic module 500 may have no
hydraulic control and might simply be a data acquisition module
that collects feedback from one or more sensors. It is understood
that modular BOP stack receiver diagnostic tool 500 may be fitted
to belly skid 302 that fits under ROV 300 where ROV 300 maneuvers
belly skid 302 proximate BOP stack 1 and mates modular BOP stack
receiver diagnostic tool 500 into modular blowout preventer stack
module receiver 238.
[0080] Referring now to FIGS. 10 and 10a, in other contemplated
configurations, modular blowout preventer stack module 600
comprises a predetermined modular blowout preventer function
non-electric, fail-safe mechanical module 600 disposed within
housing 220. Modular blowout preventer function non-electric,
fail-safe mechanical module 600 typically further comprises
electrically activated controller 650 configured to perform one or
more predetermined functions such as re-routing a failed electrical
modular blowout preventer function generator, such as annular
preventer 110, RAM preventer 115 (FIG. 1) to a predetermined
alternative modular blowout preventer function generator annular
preventer 110, RAM preventer 115 such as by using modular blowout
preventer function non-electric, fail-safe mechanical module 600 to
select one or the other of fluid couplers 503, 504.
[0081] As illustrated in FIG. 10a, modular blowout preventer
function non-electric, fail-safe mechanical module 640 may function
as a re-router and may further comprise one or more interfaces to
external power and/or communications such as interface coupler 521.
If a module is non-functional or functioning improperly, such as at
receiver 238ba, modular blowout preventer function non-electric,
fail-safe mechanical module 640 may be inserted to perform a
predetermined set of functions at receiver 238a. As illustrated, a
second modular blowout preventer function non-electric, fail-safe
mechanical module 640 may be inserted into a spare or otherwise
non-important receiver 238b and provide data and/or power to the
first modular blowout preventer function non-electric, fail-safe
mechanical module 640.
[0082] Referring now to FIG. 11, in still other contemplated
configurations, modular blowout preventer stack module 200 is
configured as a modular blowout preventer stack non-electric
failsafe mechanical module 600 and comprises accumulator 612
disposed within housing 220. In these configurations, modular
blowout preventer stack non-electric failsafe mechanical module 600
may further comprise non-electric controller 651 configured to
control a predetermined modular blowout preventer stack function.
Typically, no electric power is present or needed and all control
is obtained mechanically.
[0083] Additionally, accumulator 612 may be configured to activate
a function upon activation of accumulator such as a hydraulic pilot
signal from ROV mechanically activated handle 614. Accordingly,
modular blowout preventer stack non-electric failsafe mechanical
module 600 may further comprise one or more hydraulic ports 613
configured to receive ROV hydraulic stab 306 and receive hydraulic
fluid through hydraulic ports 613 to aid in or otherwise allow for
control as well as to recharge accumulator 612.
[0084] ROV mechanically activated handle 614 may be operatively
connected to one or more ports, valves, and/or controllers such as
non-electric controller 600 which may, in turn, be operatively
connected to fluid lines 503, 504. Turning ROV mechanically
activated handle 614 can, for example, control one or more such
non-electric controller 600 and operatively open or close fluid
flows 503,504.
[0085] Referring additionally to FIG. 11, in certain embodiments
one or more modular blowout preventer stack modules 200, 500, 600
may be lowered proximate BOP stack 1 (FIG. 1) using modular carrier
310 which comprises one or more module carrier receivers 312 into
which a desired modular blowout preventer stack module 200, 500,
600 may be placed for use by ROV 300 or into which a retrieved
modular blowout preventer stack module 200, 500, 600 may be placed
by ROV 300.
[0086] In the operation of a preferred embodiment, distributed
function control module 200 (FIG. 1) may be installed subsea by
using an ROV to position distributed function control module 200
proximate control module receiver 238 (FIG. 5) in BOP stack 100
(FIG. 1) installed subsea. Once positioned, the ROV inserts stab
end 272 (FIG. 7) of distributed function control module 200 into
distributed function control module receiver 238 which is adapted
to receive stab end 272. At a predetermined time, as the insertion
occurs, first wet mateable electrical connector 228 (FIG. 5)
disposed proximate stab end 272 is mated to second wet mateable
electrical connector 228 (FIG. 5) disposed proximate receiver 270
(FIG. 7). As described herein above, wet mateable connector 228 may
supply power, signals, or both to electronics (not shown) within
control module 200, by way of example and not limitation such as by
induction couplers, fiber optic couplers, or the like, or
combinations thereof. Once mated, electrical connectivity between
control electronics 256 (FIG. 7) disposed within distributed
function control module 200 is enabled between control electronics
256 and an electronic device disposed outside distributed function
control module 200.
[0087] As the need arises, e.g. for maintenance or repair, an ROV
may be positioned proximate end 220 (FIG. 5) of the inserted
distributed function control module 200 (FIG. 1) distal from stab
end 272 (FIG. 7) and distributed function control module 200
disengaged from receiver 270 (FIG. 7), i.e. by withdrawing
distributed function control module 200 from receiver 270.
[0088] Referring again to FIG. 9, at times a failing or failed
control module 200 (FIG. 1) may be retrieved and removed using ROV
300 and replaced with another control module 200 into stack
receiver 238. However, at other times a further method of
responding to a modular blowout preventer stack condition using a
modular blowout preventer stack module, remotely operative vehicle
(ROV) 300 may be used to install modular BOP stack receiver
diagnostic tool 500 into modular blowout preventer stack module
receiver 238 subsea, where modular BOP stack receiver diagnostic
tool 500 is as described above. Alternatively, modular BOP stack
receiver diagnostic tool 500 may be fitted to belly skid 302 that
fits under ROV 300 where ROV 300 maneuvers belly skid 302 proximate
BOP stack 1 and mates modular BOP stack receiver diagnostic tool
500 into modular blowout preventer stack module receiver 238. Thus,
ROV 300 may be used to remove a failed or failing control module
200 and store, discard, or otherwise set it aside. ROV 300 can then
retrieve up an appropriate modular BOP stack receiver diagnostic
tool 500 which may be stored in skid 302 disposed underneath ROV
300 or which ROV 300 can retrieve or guide into BOP stack receiver
238 (FIG. 5).
[0089] Once installed in modular blowout preventer stack module
receiver 238, modular BOP stack receiver diagnostic tool
electronics 510 is interfaced to the predetermined modular blowout
preventer function generator such as annular preventer 110, RAM
preventer 115 (FIG. 1) and data may be then be obtained via modular
BOP stack receiver diagnostic tool electronics 510 regarding the
predetermined modular blowout preventer function generator. These
data may be used for, and sufficient to aid in, verifying or
diagnosing whether or not the predetermined modular blowout
preventer function generator is working for a predetermined
function such as verifying correct operation of the predetermined
modular blowout preventer function generator, diagnosing a faulty
operation of the predetermined modular blowout preventer function
generator, effecting control of the predetermined modular blowout
preventer function generator, or the like, or a combination
thereof.
[0090] Additionally, modular BOP stack receiver diagnostic tool 500
may be used to help in determining, or otherwise autonomously
determine, the existence of faulty operation of the predetermined
modular blowout preventer function generator such as annular
preventer 110, RAM preventer 115 (FIG. 1). If faulty operation is
determined, modular BOP stack receiver diagnostic tool 500 may be
removed and replaced with failsafe mechanical module 600 (FIG.
10).
[0091] As an example, if the predetermined function comprises a
hydraulic operation, testing the hydraulic operation may further
comprise using ROV 300 to monitor module inlet pressure and the
output pressure of each hydraulic function when controlled from BOP
stack 1 (FIG. 1). If no hydraulics is present or the hydraulic
functions are not working as required, when commanded from modular
blowout preventer stack module receiver 238 ROV 300 may be used to
provide inlet pressure and exercise the hydraulic functions to
verify that modular blowout preventer stack module receiver 238 is
the problem.
[0092] Once interfaced, modular BOP stack receiver diagnostic tool
500 may be used to continue to monitor the obtained data. If the
predetermined function comprises a power operation, the monitoring
may further comprise using modular BOP stack receiver diagnostic
tool electronics 510 to test electrical power in modular blowout
preventer stack module receiver 238.
[0093] As a further example, modular BOP stack receiver diagnostic
tool 500 may be connected to ROV 300 through one or more of
communications interfaces 501 (FIG. 9), power interfaces 502 (FIG.
9), and/or hydraulics connectors 503,504,505 (FIG. 9). ROV 300 then
inserts modular BOP stack receiver diagnostic tool 500 into a
specific BOP stack receiver 238 where modular BOP stack receiver
diagnostic tool 500 connects to the BOP through communications
interfaces 501 (FIG. 9), power interfaces 502 (FIG. 9), and/or
hydraulics connectors 503,504,505. After insertion, BOP 110 (FIG.
1) or ROV 300 (FIG. 9) can control modular BOP stack receiver
diagnostic tool 500. This duality allows for troubleshooting what
is wrong by allowing one side to control and the other side monitor
and vice versus.
[0094] Modular BOP stack receiver diagnostic tool 500 may contain
electronics such as analyzer 510 that can get its power and/or data
communications from BOP 100 (FIG. 1) or ROV 300. For example, one
or more electronics controls solenoids 543 (FIG. 9) may be used to
control hydraulic flow when commanded from BOP 100 or ROV 300.
These electronics can also read back the pressure from the pressure
transducers 540 (FIG. 9) and send data back to the BOP side and the
ROV side. If BOP 100 has failed power or data communications,
modular BOP stack receiver diagnostic tool 500 will be electrically
dead from the BOP side. However, ROV 300 can still control modular
BOP stack receiver diagnostic tool 500 from the ROV side and verify
the BOP side electrical is out, such as by using the solenoids and
reading the pressure transducers in modular BOP stack receiver
diagnostic tool 500. When ROV 300 activates these functions, BOP
100 should also be able to verify these hydraulic functions on the
BOP side. If the hydraulic supply is out on the BOP side, ROV 300,
with the aid of modular BOP stack receiver diagnostic tool 500, can
control selected BOP hydraulic functions, such as by supplying
hydraulic fluid from ROV 300. This can aid in verifying that the
problem is on the BOP Stack Receiver, e.g. in its hydraulic
supply.
[0095] ROV 300 can then remove modular BOP stack receiver
diagnostic tool 500. If the BOP Stack Receiver is working
correctly, then the problem was in the removable electronic module
which can be replaced with a new electronic module. If the problem
on the BOP stack is electrical, ROV 300 can insert a non-electrical
fail safe mechanical module such as modular blowout preventer stack
module 600. The functions of modular blowout preventer stack module
600 are controlled by ROV 300 either through manual control of
handle 614 or through hydraulic activation of selected functions
from ROV 300. If the problem on the BOP stack is its hydraulic
supply, ROV 300 can insert modular blowout preventer stack module
600 where accumulator 612 or ROV 300 provides the hydraulic source.
BOP 100 (FIG. 1) may then control hydraulic output functions
through electrical circuitry, e.g. solenoids 543 (FIG. 9), or it
may be controlled mechanically from ROV 300.
[0096] Referring to FIG. 12, in a further case the entire BOP 100
(FIG. 1) loses electrical power. One or more modular blowout
preventer stack modules 200, 500, 600 (module 600 being illustrated
in FIG. 12) including fail safe fail safe modular blowout preventer
stack modules 200, 500, 600, may be lowered proximate BOP stack 1
(FIG. 1) using modular carrier 310 which comprises one or more
module carrier receivers 312 into which desired modular blowout
preventer stack modules 200, 500, 600 have been placed for use and
installation by ROV 300.
[0097] Referring now generally to FIGS. 10 and 11, if BOP stack
receiver 238 fails at a location of an important function, such as
a blind shear ram, a re-router module such as modular blowout
preventer stack module 640 (FIG. 10a) or modular blowout preventer
function non-electric, fail-safe mechanical module 600 (FIG. 10 or
11) can receive power and/or data communications from a spare or
non-important function on BOP 100 (FIG. 1) and provide control of
hydraulics where the important function is located.
[0098] In a further scenario, involving special function box 400
(FIG. 13) not connected to BOP 100 (FIG. 1), BOP stack receiver
238, comprising a spare or non-important function, can be used to
send power and/or data communications via special function box 400
not connected to BOP 100, where special function box 400 is
operatively in communication with an appropriate device such as
modular blowout preventer stack module 600 or the like and can send
a signal such as a power signal, a data signal, or the like, or a
combination thereof between special function box 400 and modular
blowout preventer stack module 600.
[0099] The foregoing disclosure and description of the inventions
are illustrative and explanatory. Various changes in the size,
shape, and materials, as well as in the details of the illustrative
construction and/or an illustrative method may be made without
departing from the spirit of the invention.
* * * * *