METHOD AND APPARATUS FOR FASTENING A BLOWOUT PREVENTER (BOP) STACK CONTAINMENT ASSEMBLY TO AN OCEAN FLOOR
A valve assembly is described for containing an oil spill caused by a defective blowout preventer. The valve assembly may include a hollow cavity having a floor, a ceiling and a wall, and a valve that protrudes through the ceiling and the floor of the hollow cavity. The hollow cavity may be configured to be reinforced by filling the hollow cavity with cement. The valve assembly may have a cylindrical geometric configuration. The valve may be configured to be maintained in an open position while the valve assembly is lowered below a surface of an ocean. The valve assembly may be positioned above a blowout preventer located on a floor of the ocean.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 12/822,324, filed Jun. 24, 2010, which is incorporated by reference as if fully set forth herein.
TECHNICAL FIELDThis application generally relates to a method and apparatus for containing an oil and/or gas spill originating from the bottom of an ocean.
BACKGROUNDAn offshore platform, often referred to as an oil platform or an oil rig, is a large structure used in offshore drilling to house workers and machinery needed to drill wells in the ocean bed, extract oil and/or natural gas, process the produced fluids, and ship or pipe them to shore. Depending on the circumstances, the platform may be fixed to the ocean floor, may consist of an artificial island, or may float.
Remote subsea wells may also be connected to a platform by flow lines and by umbilical connections. These subsea solutions may consist of single wells or of a manifold center for multiple wells.
The Deepwater Horizon oil spill, also called the BP oil spill, the Gulf of Mexico oil spill or the Macondo blowout, was a massive oil spill in the Gulf of Mexico, and is considered the largest offshore spill to ever occur in U.S. history. The spill stemmed from a sea floor oil gusher that started with an oil well blowout on Apr. 20, 2010. The blowout caused a catastrophic explosion on the Deepwater Horizon offshore oil drilling platform that was situated about 40 miles (64 km) southeast of the Louisiana coast in the Macondo Prospect oil field. The explosion killed 11 platform workers and injured 17 others. Another 98 people survived without serious physical injury.
Although numerous crews worked to block off bays and estuaries, using anchored barriers, floating containment booms, and sand-filled barricades along shorelines, the oil spill resulted in an environmental disaster characterized by petroleum toxicity and oxygen depletion, thus damaging the Gulf of Mexico fishing industry, the Gulf Coast tourism industry, and the habitat of hundreds of bird species, fish and other wildlife. A variety of ongoing efforts, both short and long term, were made to contain the leak and stop spilling additional oil into the Gulf, without immediate success.
After the Deepwater Horizon drilling rig explosion on Apr. 20, 2010, a BOP should have activated itself automatically to avoid an oil spill in the Gulf of Mexico. The oil spill originated from a deepwater oil well 5,000 feet (1,500 m) below the ocean surface. A BOP is a large valve that has a variety of ways to choke off the flow of oil from a gushing oil well. If underground pressure forces oil or gas into the wellbore, operators can close the valve remotely (usually via hydraulic actuators) to forestall a blowout, and regain control of the wellbore. Once this is accomplished, often the drilling mud density within the hole can be increased until adequate fluid pressure is placed on the influx zone, and the BOP can be opened for operations to resume. The purpose of BOPs is to end oil gushers, which are dangerous and costly.
Underwater robots were sent to manually activate the Deepwater Horizon's BOP without success. BP representatives suggested that the BOP may have suffered a hydraulic leak. However, X-ray imaging of the BOP showed that the BOP's internal valves were partially closed and were restricting the flow of oil. Whether the valves closed automatically during the explosion or were shut manually by remotely operated vehicle work is unknown.
BOPs come in a variety of styles, sizes and pressure ratings, and usually several individual units compose a BOP stack. The BOP stack used for the Deepwater Horizon is quite large, consisting of a five-story-tall, 300-ton series of oil well control devices.
The amount of oil that was discharged after the Deepwater Horizon drilling rig explosion is estimated to have ranged from 12,000 to 100,000 barrels (500,000 to 4,200,000 gallons) per day. The volume of oil flowing from the blown-out well was estimated at 12,000 to 19,000 barrels (500,000 to 800,000 gallons) per day, which had amounted to between 440,000 and 700,000 barrels (18,000,000 and 29,000,000 gallons). In any case, an oil slick resulted that covered a surface area of over 2,500 square miles (6,500 km2). Scientists had also discovered immense underwater plumes of oil not visible from the surface.
Various solutions have been attempted to control or stop an undersea oil and/or gas spill. One solution is to use a heavy (e.g., over 100 tons) container dome over an oil well leak and pipe the oil to a storage vessel on the ocean surface. However, this solution has failed in the past due to hydrate crystals, which form when gas combines with cold water, blocking up a steel canopy at the top of the dome. Thus, excess buoyancy of the crystals clogged the opening at the top of the dome where the riser was to be connected.
Another solution is to attempt to shut down the well completely using a technique called “top kill”. This solution involves pumping heavy drilling fluids into the defective BOP, causing the flow of oil from the well to be restricted, which then may be sealed permanently with cement. However, this solution has not been successful in the past.
It would be desirable to have a method and apparatus readily available to successfully contain oil and/or gas spewing from a defective BOP stack, until an alternate means is made available to permanently cap or bypass the oil and/or gas spill, or to repair/replace the defective BOP stack.
SUMMARYA method and apparatus are described for fastening a blowout preventer (BOP) stack containment assembly to an ocean floor. A primary containment assembly is lowered below a surface of the ocean. The primary containment assembly includes a bottom opening and a top opening, wherein the top opening is narrower than the bottom opening. The bottom opening of the primary containment assembly is positioned on a portion of the ocean floor that circumvents the defective BOP stack. The bottom opening is fastened to the ocean floor by using a self-fastening mechanism, while allowing at least one of oil or gas spewing from the defective BOP stack to rise through the top opening to a secondary containment assembly. The self-fastening mechanism may include at least one of a plurality of fastening devices or sealing devices that fasten the primary containment assembly to the ocean floor when activated, or at least one blade that rotates when activated to burrow a portion of the primary containment assembly below the ocean floor.
The self-fastening mechanism may include a series of small explosive charges that, when detonated, force the fastening elements to project from the fastening devices and fasten the primary containment assembly to the ocean floor.
Each sealing device of the self-fastening mechanism may include sealant that is released from the sealing device, when activated, and fastens the primary containment assembly to the ocean floor.
The portion of the ocean floor that circumvents the defective BOP stack may be graded, before the primary containment assembly is positioned, by at least one remotely operated vehicle (ROV).
The secondary containment assembly may be configured to be fastened between the primary containment assembly and at least one containment vessel floating on the ocean surface.
The secondary containment assembly may comprise a flexible ducting hose, or a plurality of flexible ducting hose sections that are interconnected.
The secondary containment assembly may comprise at least one of a plurality of sections or components that are interconnected.
The secondary containment assembly may comprise a riser assembly having a first opening that is directly attached to the top opening of the primary containment assembly, and a second opening that is that is either directly or indirectly attached to the containment vessel.
A more detailed understanding may be had from the following description, given by way of example in conjunction with the accompanying drawings wherein:
The present invention described herein proposes the undertaking of a potentially expensive method and apparatus, due to the substantially large size of a defective BOP stack that must be circumvented and sealed under thousands of feet of water in response to a catastrophic event, such as the Deepwater Horizon oil spill. However, it has recently been discovered that there are currently no procedures or apparatus available for effectively dealing with such events, and that the consequences of other similar events occurring over a period of time have the potential to destroy life on Earth as we know it.
Instead of tapping off various points of the defective BOP stack 120′, the present invention uses its various embodiments to substantially isolate the BOP stack 120′ from the ocean by completely circumventing and encasing the defective BOP stack 120′. Thus, the amount of ocean that mixes with the spewing oil and/or gas 210 is minimized. Furthermore, a combination of one or more heating elements and measurement equipment, as well as the addition of one or more valves, allow the present invention to better contain and/or control the spewing oil and/or gas 210.
The present invention proposes a method and apparatus for containing oil from a subsea oil and/or gas blowout. An apparatus constructed from this design will mitigate the spread of oil slicks from subsea oil and/or gas blowouts, with the benefit of allowing oil and/or gas exploration to proceed with diminished risk of environmental damage. The present invention has particular application where coastal wetlands or other delicate ecosystems may potentially be damaged by an oil spill. There currently appears to be no alternative method or apparatus for containing the oil from such blowouts. The present invention has market potential in basins subject to offshore oil exploration where deepwater rigs are active.
The reinforcement material mentioned herein, such as cement, is used underwater for many purposes including, for example, in pools, dams, piers, retaining walls and tunnels. There are many factors that must be controlled for successful application of cement underwater. Of these, the hardening time, that between mixing and solidification, is particularly important because, if it is too long, the cement does not solidify at all but simply dissolves in the surrounding water, herein the environmental water. Compositions containing exothermic micro particles have been found very advantageous for underwater cement applications. The exothermic micro particles produce very high rates of exothermic heating when combined with base cement and water. The exothermic heat produced is sufficient to raise the reaction temperature to a point where the cement composition solidifies underwater, even in cold environmental water.
A more sophisticated system of mud flaps 340 may be implemented, whereby the mud flaps 340 may be located at different heights along the outer wall 320 of the cylindrical containment assembly 300, and may be remotely activated (either wirelessly or via a wired or hydraulic connection from a vessel on the ocean surface 105) to protrude or retract, or be raised or lowered, to control the depth of the cylindrical containment assembly 300 as more weight is added on top of it in order to contain the spewing oil and/or gas 210. Furthermore, the mud flaps 340 may be designed to break off, based on how much weight is applied to the top perimeter 328 (see
The cylindrical containment assembly 300 is lowered below the ocean surface 105 and positioned on a portion of the ocean floor 115 that circumvents the defective BOP stack 120′. Although it may be possible to lower the cylindrical containment assembly 300 over the defective BOP stack 120′ if the riser assembly 125 remains in a vertical position by letting the riser assembly 125 pass through the center of the cylindrical containment assembly 300, the riser assembly 125 needs to be disconnected (i.e., cut off) near the top of the defective BOP stack 120′ if a catastrophic event caused the riser assembly 125 to collapse (i.e., fold over), as what occurred due to the Deepwater Horizon drilling rig explosion (see
Alternatively, the cylindrical containment assembly 300 may consist of a plurality of sections and/or components that are assembled below the ocean surface 105. The sections and/or components of the cylindrical containment assembly 300 would be constructed and stored onshore close to areas where deepwater rigs are active. The sections and/or components may include seals and/or gaskets, and the sections and/or components may be assembled together as they are immersed just under the ocean surface 105.
When the cylindrical valve assembly 350 is lowered below the ocean surface 105 onto the reinforced cylindrical containment assembly 300′, the valve 355 is maintained in a fully open position such that the oil and/or gas 210 spewing from the defective BOP stack 120′ is allowed to pass through the valve 355. By leaving at least one valve 355 of a suitable diameter in a fully open position, buoyancy problems due to the pressure of the spewing oil and/or gas 210 may be minimized, while the hollow cavity 375 of the cylindrical valve assembly 350, surrounding the valve 355, is filled with reinforcement material (e.g., cement). Preferably, the valve 355 may be configured to be remotely controlled (either wirelessly or via a wired or hydraulic connection from a vessel on the ocean surface 105) to maintain an open position, a partially open position or a closed position, as desired. A ROV may be used to assist in the lowering and positioning of the cylindrical valve assembly 350.
A riser assembly 125 may be attached between the large diameter valve 355 and a containment vessel on the ocean surface 105. The large diameter valve 355 may then be opened to allow the at least one of oil and gas 210 to be stored by the containment vessel.
The pressure of the at least one of oil or gas 210 may be monitored by the pressure monitor unit 388 after the large diameter valve 355 is closed. The large diameter valve 355 may be automatically opened by the pressure monitor unit 388 when the pressure within the reinforced cylindrical containment assembly 300′ reaches or exceeds a predetermined threshold.
The wide hollow wall 305 of the reinforced cylindrical containment assembly 300′ may be of such a large width (e.g., 10 feet or more), that it may be unlikely that the reinforced cylindrical containment assembly 300′ would sink very far below the ocean floor 115, and thus the mud flaps 340 may not be necessary. However, the extreme weight applied to the top perimeter 328 (see
In step 405 of the procedure 400 of
In step 420 of the procedure 400 of
As an example, the diameter of the cylindrical containment assembly 300 may be on the order of 80 feet, and the height of the cylindrical containment assembly 300 may be on the order of 60 feet. The width of the hollow wall 305 of the cylindrical containment assembly 300 may be on the order of 10 feet. The diameter of the cylindrical valve assembly 350 may be equal to or greater than the diameter of the cylindrical containment assembly 300, and the height of the cylindrical valve assembly 350 may be on the order of 80 feet. Thus, the hollow cavity 375 of the of the cylindrical valve assembly 350 may be able to hold on the order of 400,000 cubic feet of reinforcement material (e.g., cement). Depending upon the type of reinforcement material used, which may range from 90 to 140 pounds per cubic foot, and how much is poured into the hollow cavity 375 of the cylindrical valve assembly 350, the weight applied to the top perimeter 328 of the reinforced cylindrical containment assembly 300′ to counter the pressure of the spewing oil and/or gas 210 may be on the order of 25,000 tons. The enormous mass of the reinforced cylindrical valve assembly 350′, combined with the large mass of the cement-filled reinforcement cavity 310 of the reinforced cylindrical containment assembly 300′, should insure that the oil and/or gas 210 would not be able to pass through the bottom of the reinforced cylindrical containment assembly 300′, since the annular rim 380 would be applying a huge force to the ocean floor 115, causing it to compress and form an watertight seal with the bottom of the reinforced cylindrical containment assembly 300′.
The diameter of the valve 355 is critical to the first embodiment of the present invention, and may be on the order of six feet. For example, the diameter of the valve 355 may be similar to the diameter of jet flow gates used for dams, such as the Hoover Dam, which may range in diameter from 68 to 90 inches. The valve 355 is designed to operate under high pressure (e.g., 10,000 pounds per square inch (PSI)), and may include a steel plate that may be opened or closed to either prevent or allow the spewing oil and/or gas 210 to be discharged.
As would be known by one of ordinary skill, smaller or larger dimensions may be applicable to the components used to implement the various embodiments of the present invention in accordance with the particular BOP failure situation that the assemblies 300 and 350 are designed for. For example, initial tests and analysis should be performed in a laboratory setting to determine more precise dimensions that may be applicable to a particular BOP stack failure situation.
The first embodiment of the present invention, as described above in conjunction with
Still referring to
Still referring to
The primary containment assembly 500/550 is lowered below the ocean surface 105 and positioned on a portion of the ocean floor 115 that circumvents the defective BOP stack 120′. Although it may be possible to lower the primary containment assembly 500/550 over the defective BOP stack 120′ if the riser assembly 125 remains in a vertical position by letting the riser assembly 125 pass through the first opening 505/555 and the second opening 525/570 of the primary containment assembly 500/550, the riser assembly 125 needs to be disconnected (i.e., cut off) near the top of the defective BOP stack 120′ if a catastrophic event caused the riser assembly 125 to collapse (i.e., fold over), as what occurred due to the Deepwater Horizon drilling rig explosion.
Preferably, it would be desirable to grade the portion of the ocean floor 115 that circumvents the defective BOP stack 120′ before the primary containment assembly 500/550 is positioned, in order to optimize the reduction of the pollution of the ocean caused by the oil and/or gas 210 spewing from the defective BOP stack 120′. Such ocean floor grading may be performed by at least one ROV. Furthermore, the ROV may be used to assist in the lowering and positioning of the primary containment assembly 500/550.
Alternatively, the primary containment assembly 500/550 may consist of a plurality of sections and/or components that are assembled below the ocean surface 105. The sections and/or components of the primary containment assembly 500/550 would be constructed and stored onshore close to areas where deepwater rigs are active. The sections and/or components may include seals and/or gaskets, and the sections and/or components may be assembled together as they are immersed just under the ocean surface 105.
In accordance with a fourth embodiment of the present invention,
Claims
1-20. (canceled)
21. A valve assembly comprising:
- a hollow cavity including a floor, a ceiling and a wall; and
- a valve that protrudes through the ceiling and the floor of the hollow cavity.
22. The valve assembly of claim 21 wherein the hollow cavity is configured to be reinforced by filling the hollow cavity with cement.
23. The valve assembly of claim 21 wherein the valve assembly has a cylindrical geometric configuration.
24. The valve assembly of claim 23 further comprising:
- at least one seal mounted along a perimeter of the floor of the hollow cavity.
25. The valve assembly of claim 21 wherein the valve that protrudes through the ceiling and the floor of the hollow cavity is configured to be maintained in an open position while the valve assembly is lowered below a surface of an ocean.
26. The valve assembly of claim 21 further comprising:
- at least one heating element configured to heat up the valve that protrudes through the ceiling and the floor of the hollow cavity.
27. The valve assembly of claim 21 further comprising:
- at least one cement input valve.
28. The valve assembly of claim 21 further comprising:
- a pressure monitor unit configured to monitor the pressure of at least one of oil or gas in a containment assembly on which the valve assembly is positioned on.
29. The valve assembly of claim 21 wherein the valve assembly is configured to be positioned above a blowout preventer located on a floor of an ocean.
30. A valve assembly comprising:
- a cement filled cavity; and
- a valve that protrudes through the cement filled cavity.
31. The valve assembly of claim 30 wherein the cavity includes a floor, a ceiling and a wall, and the valve protrudes through the ceiling and the floor of the cement filled cavity.
32. The valve assembly of claim 31 wherein the valve assembly has a cylindrical geometric configuration.
33. The valve assembly of claim 32 further comprising:
- at least one seal mounted along a perimeter of the floor of the hollow cavity.
34. The valve assembly of claim 30 wherein the valve that protrudes through the cement filled cavity is configured to be maintained in an open position while the valve assembly is lowered below a surface of an ocean.
35. The valve assembly of claim 30 further comprising:
- at least one heating element configured to heat up the valve that protrudes through the cement filled cavity.
36. The valve assembly of claim 30 further comprising:
- at least one cement input valve.
37. The valve assembly of claim 30 further comprising:
- a pressure monitor unit configured to monitor the pressure of at least one of oil or gas in a containment assembly on which the valve assembly is positioned on.
38. The valve assembly of claim 30 wherein the valve assembly is configured to be positioned above a blowout preventer located on a floor of an ocean.
39. A valve assembly comprising:
- a valve; and
- a hollow cavity circumventing the valve, wherein the hollow cavity is configured to be filled with cement.
40. The valve assembly of claim 39 wherein the valve assembly is configured to be positioned above a blowout preventer located on a floor of an ocean.
Type: Application
Filed: Jul 30, 2010
Publication Date: Dec 29, 2011
Applicant: Subsea IP Holdings LLC (Sewell, NJ)
Inventor: Scott Wolinsky (Sewell, NJ)
Application Number: 12/847,326
International Classification: E02D 5/74 (20060101);