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.

Description

RELATION TO OTHER APPLICATIONS

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

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

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.

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.

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°), 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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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

The various drawings supplied herein are representative of one or more embodiments of the present inventions.

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;

FIG. 2 is a view in partial perspective of a riser connector;

FIG. 3 is a view in partial perspective of a riser connector;

FIG. 4 is a view in partial perspective of a control module;

FIG. 5 is a view in partial perspective of a control module mated to a receiver;

FIG. 6 is a view in partial perspective cutaway of a control module;

FIG. 7 is a view in partial perspective of an interface between a stab of control module and receiver on a BOP assembly;

FIG. 8 is a flowchart of an exemplary method of use;

FIG. 9 is a schematic of an exemplary diagnostic modular BOP stack receiver diagnostic tool;

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);

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;

FIG. 12 is a schematic of an exemplary modular carrier which comprises one or more module carrier receivers; and

FIG. 13 is a view in partial perspective of a special function unit.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTIONS

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.

In a preferred embodiment, BOP Stack 1 comprises riser connector 10, BOP assembly 100, and wellhead connector 50.

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.

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.

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.

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.

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).

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

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).

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.

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.

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.

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.

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).

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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).

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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).

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.

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).

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.

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.

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.

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.

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.

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.

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.

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.

The foregoing disclosure and description of the invention is 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.

Claims

1. A modular blowout preventer stack module, comprising:

a. a housing configured to be removably received into a modular blowout preventer stack module receiver; and

b. a modular BOP stack receiver diagnostic tool electronics disposed within the housing, the modular BOP stack receiver diagnostic tool comprising an analyzer configured to operatively interface with a predetermined modular blowout preventer function generator and perform a predetermined set of analytics with respect to the predetermined modular blowout preventer function.

2. The modular blowout preventer stack diagnostic module of claim 1, wherein the housing is configured to be maneuvered into the modular blowout preventer stack module receiver by a remotely operated vehicle (ROV).

3. The modular blowout preventer stack diagnostic module of claim 1, wherein the modular BOP stack receiver diagnostic tool further comprises a mechanical component.

4. The modular blowout preventer stack diagnostic module of claim 3, wherein the mechanical component further comprises at least one of a solenoid, a valve, and a pressure transducer operatively in communication with the diagnostic tool.

5. The modular blowout preventer stack diagnostic module of claim 3, wherein the mechanical component is configured to be exercised hydraulically and/or electrically.

6. The modular blowout preventer stack diagnostic module of claim 5, wherein the mechanical component comprises a mechanical component configured to be hydraulically exercised, the modular blowout preventer stack diagnostic module further comprising a hydraulic coupler operatively in fluid communication with the mechanical component and configured to operatively couple with an ROV hydraulic stab.

7. A modular blowout preventer stack module, comprising:

a. a housing configured to be removably received into a modular blowout preventer stack module receiver; and

b. a predetermined modular blowout preventer function non-electric, fail-safe mechanical module.

8. The modular blowout preventer stack module of claim 7, wherein the non-electric, fail-safe mechanical module further comprises an electrically activated controller configured to re-route a failed electrical modular blowout preventer function generator to a predetermined alternative modular blowout preventer function generator.

9. A method of responding to a modular blowout preventer stack condition using a modular blowout preventer stack module, comprising:

a. using a remotely operative vehicle (ROV) to install a modular blowout preventer stack module into a modular blowout preventer stack module receiver subsea, the modular blowout preventer stack module comprising: i. a housing configured to be removably received into a modular blowout preventer stack module receiver; and ii. a modular BOP Stack receiver diagnostic tool disposed within the housing, the modular BOP Stack receiver diagnostic tool configured to operatively interface with a predetermined modular blowout preventer function generator and perform a predetermined set of analytics with respect to the predetermined modular blowout preventer function;

b. interfacing the analyzer to the predetermined modular blowout preventer function generator; and

c. obtaining data regarding the predetermined modular blowout preventer function generator at the analyzer, the data sufficient to aid in verifying or diagnosing whether or not the predetermined modular blowout preventer function generator is working for a predetermined function.

10. The method of claim 9, wherein the predetermined function comprises at least one of a hydraulic operation, a power operation, and a data communication operation

11. The method of claim 9, wherein the predetermined function further comprises at least one of verifying correct operation of the predetermined modular blowout preventer function generator, diagnosing a faulty operation of the predetermined modular blowout preventer function generator, and effecting control of the predetermined modular blowout preventer function generator.

12. The method of claim 9, further comprising:

a. determining the existence of faulty operation of the predetermined modular blowout preventer function generator;

b. removing the modular blowout preventer stack module; and

c. replacing the modular blowout preventer stack module with a failsafe mechanical module.

13. The method of claim 9, further comprising:

a. determining the existence of faulty operation of the predetermined modular blowout preventer function performed by a replaceable blowout preventer function module;

b. removing the blowout preventer function module; and

c. replacing the blowout preventer function module with a failsafe mechanical module,

14. The method of claim 9, wherein the predetermined function comprises a hydraulic operation.

15. The method of claim 14, wherein testing the hydraulic operation further comprises:

a. using an ROV to monitor module inlet pressure and the output pressure of each hydraulic function when controlled from the BOP stack;

b. if no hydraulics is present or the hydraulic functions are not working when commanded from the modular blowout preventer stack module receiver, using the ROV to provide inlet pressure and exercise the hydraulic functions to verify that the modular blowout preventer stack module receiver is the problem.

16. The method of claim 9, further comprising monitoring the obtained data.

17. The method of claim 16, wherein:

a. the predetermined function comprises a power operation; and

b. the monitoring comprises using the analyzer to test electrical power in the modular blowout preventer stack module receiver.

18. The method of claim 9, further comprising:

a. positioning a special function box 400 not connected to the blowout preventer proximate the modular blowout preventer stack module 600;

b. interfacing the special function box into communication with the modular blowout preventer stack module 600; and

c. sending a signal between the special function box 400 and the modular blowout preventer stack module 600.

19. The method of claim 18, wherein the signal comprises at least one of a power signal and a data signal.