Patent Application
20120241160
Not Applicable.
Not Applicable.
1. Field of the Invention
The present invention relates to disaster prevention system for offshore oil wells and in particular to a supplemental disaster preventive system to provide means to insure human, equipment and environmental safety and associated cost avoidance during the offshore well drilling process under all conceived/feasible accidents/failures conditions. The overall system design concept, related procedures/processes and many associated system components to provide major cost reduction benefits for the entire life cycle (drilling, completion, production and abandonment) for both accident/failure and normal/uneventful operations.
2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98
Shortly after the 2010 offshore oil well catastrophe in the Gulf of Mexico, it became obvious that British Petroleum (BP), the entire oil industry, and/or the US Government were unprepared to effectively stop the gushing oil or the means to clean it up.
Throughout the first two plus months of the disaster numerous re-sealing, capturing, clogging, killing and capping techniques were unsuccessfully attempted and several high risk/cost ‘normal’ well drilling processes were brought to light.
The successful 20 July re-seal, capture and cap ‘Rube Goldberg’/‘Kluge’ (said with admiration) was a simplistic but effective temporary solution for the catastrophic symptoms of the problem—where the primary operative phrase is ‘temporary solution for the catastrophic symptoms’.
The enormous somewhat/sometimes unquantifiable costs of the (or of a future) incident includes:
Human life
Drilling platform
Well (the equipment and the associated labor and its potential production)
Equipment and labor associated with the numerous re-seal, capture, and cap ‘quick fixes’
Equipment and labor associated with the relief/kill wells
Gulf clean-up
Tourist and fishing industry
Local community
Public opinion relating to the oil industry and the government
Nation and international financial markets
The prior art ‘blowout prevender’ (BOP) is intended to close off the well in case of an uncontrolled/emergency condition (blowout). It's a multi mega-buck, multi-ton device installed on the seafloor having various means/methods, with the design intent of closing a well. The most technically difficult is if/when a pipe and/or pipes (drill, casing, etc.) are within the well. The BOP must ‘ram’ through the pipe(s) and close off the well. That seems difficult, but add the extreme water pressure and low temperatures, the more extreme oil pressure and high temperatures and the prior art BOP is likely not going to work. After the Macondo's well was finally closed, the BOP was pulled up and evaluated—it was functional but did not do the job.
As offshore oil drilling/production continues in the future it seems only rational that the government as well as oil industry itself would demand, as a prime priority the development of improved equipment/systems and processes.
Whatever the cause(s) (human neglect/error, equipment failure, etc.) of the 2010 oil well disaster and whatever means are developed to insure no such similar failure and/or related impacts reoccurs, there are potentially more likely and more damaging events—specifically natural disasters and (accidental or deliberate) human intervention that must also be addressed.
The focus of the ‘quick fix’ was to stop/control the symptoms of the immediate catastrophe—the gushing oil.
What is needed is an overall systems design and implementation approach that provides the means to reduce/eliminate the causes and impacts of any conceived/realistic threats to oil wells in the future and further provides more reliable, practical and cost effective means to accomplish the oil well drilling task.
The primary design objective of the present invention was to provide an offshore oil well improvement system using an overall systems design and implementation approach that provides the means to reduce/eliminate the causes and impacts of any conceived/realistic threats to oil wells in the future and further provide more reliable, practical and cost effective means to accomplish oil well drilling.
As the present invention design evolved it became apparent that many related procedures/processes and many associated system components provide major cost reduction benefits for the oil well's entire life cycle (drilling, completion, production and abandonment) in either problem or normal operations.
The present invention is composed of two functional and physically integrated subsystems, the Multi-Function Well Subsystem (MFWS) and the Intrusion Detection and Response Subsystem (ID&RS).
The MFWS is presented in two basic configurations, the ‘Fundamental’ & the ‘Advanced’. Both configurations modify the sea-floor and in-well equipment to provide maintenance access and unique tools to provide the means to: cap the well, seal/re-seal the well, drill/re-drill the well, kill the well from the top, improve BOP reliability, add BOP functional redundancy, improve the cementing process, incorporate a sea-floor pressure relief/diversion function and improves the well's life cycle safety.
The Advanced MFWS includes a unique dome top cylindrical sidewall structure enclosing the well's sea-floor equipment providing improved structural strength as well as passive protection from natural/human induced disasters.
The ID&RS provides the means to detect, track and classify the 3D aspects of air/surface/sub-surface objects about a specific oil well or group of oil wells and provides the means to evaluate and eliminate threats.
As all elements are based on existing simplistic proven technology, the development cost risk is minimum.
As the system design includes a major focus on the physical implementation and operation, the implementation and operational cost risk is minimum
Considering the pure human and environmental safety, the pure dollar and cents (or multi-million/billion dollar) cost avoidance and/or the potential cost savings/reductions (for any or all such reasons) it is a significant understatement to suggest that features of the present invention should be integrated with other planned improvements, and incorporated on all oil wells.
These and other details of the present invention will be described in connection with the accompanying drawings, which are furnished only by way of illustration and not in limitation of the invention.
The drawings are intended to provide an introductory overview of major system/system elements that along with other unique system supporting devices are comprehensively defined in the ‘Detailed Description Of The Invention’.
The drawing further depicts the addition of two additional items, an Adjunctive BOP/Valve Assembly (AVA) (7) and a Platform to Well Interface Assembly (P-WIA) (8) in series with the ‘typical’ well's interface of (6) & (9).
These two units are further shown on
Note the drawing does not depict the drill pipe, drill bit or various casings that may be going into the well from the drill platform during the drilling stage. When in use these would be feed through items (9, 8, 7, 6, 5, 4, 3 & 2).
It is further noted that the full ‘functional redundancy of the BOP’ is not yet complete in that the BOP can (by intent but with poor reliability) ram through an obstruction and close the well.
The full ‘functional redundancy’ is provided by one of two alternate means. The first is the Enclosed Pipe Cutter within (7) and the second is the remote Pipe Coupling/De-Coupling device as shown on
The Advanced MFWS differs by replacement the Production Valve Assembly with a unique Domed Assembly (DA) structurally enclosing the well's sea-floor equipment. The DA consists of a Dome Cylindrical Sidewall (4), a Dome Top (3), and the Dome Interior Plate (5). The DA's lower section further includes Leveling Devices (11), Floor/Footing (12), & Vent Pipes (13).
The Dome Top (3) includes parallel well outputs for the Normal Capture Valve & Pipe (111) & the Pressure Relief/Diversion Valve & Pipe (110) (functionally identical to 11 & 10 on
The DA upper section further includes a large ROV Access Port (7) that can be converted to the smaller port size of a normal BOP feed thru access by installing the Access Port Adaptor (APA) (8).
Two sets of AVA's (1) & P-WIA, s (2) are provided in series with the Normal Well Drill & Return Pipe (109). One set is connected to the BPO (105) via the BOP Output Adaptor (OPA) (10) and a Pipe Mounting Adaptor (PMA) (9). The other set is connected to the APA (8).
The Dome Interior Plate (5) includes a Cable/Tube Access Hole and an associated Cable/Hole Sealer (13) (further shown on
The interior area between the Dome Top (3) & Dome Interior Plate (5) and further enclosed by 13, 8, 9, 10110 & 111 is the Reservoir Area (6) sealed form the exterior sea water and is capable of holding well pressure.
The Housing (1) includes a physical area (2) below the Access Valve (3) that incorporates the EPC. The mechanical aspects of the EPC are shown on
As a general reference the BOP Access Area (7) is shown as dashed lines. As a specific reference to the Advanced MFWS relating to the lower (ref.
In the case of the Fundamental MFWS the unit is directly connected to the Production Valve Assembly and the upper set of AVA & P-WIA of the Advanced MFWS directly connects to the APA (ref.
Item 1 is a flat circular/donut shaped turn-table connected to the AVA housing via ball bearings.
Item 2 (in dashed lines) reference to the BOP's access area depicting the required centered opening of item 1.
Item 3 is the turn-table motor assembly consisting of a motor, gearing, encoder & associated housing. The motor housing is attached to the AVA housing. The motor shaft, gearing & encoder interface with the turn-table.
Items 4 (in dashed lines) represents the AVA housing under the turn-table.
Items 6s are three circular saw blades each including a motor & tachometer.
Item 7s are three wedges.
Items 8 & 9 are details of items 5.
Item 8 is the fixed member of item 5. It is affixed to the turn-table and includes a lateral drive motor, an encoder, slides & gearing.
Item 9 is the lateral sliding member of item 5 and includes slides & gearing. The dashed lines at item 9 indicate this member at its extended position.
Item 1 depicts the housing.
Item 2 depicts the return flow opening/path.
Item 3 is the remotely controlled by-pass valve allowing (return) flow around a sealed pipe outer wall to return.
Items 4 are remotely controlled expandable ‘o’ ring gaskets capable of closing the area between the interior pipes outer sidewall and the AVA's housing (the return path). The dashed lines at items 4 show the said gasket expanded.
Item 5 is a sample pipe within the AVA.
Item 6 is a reference to the Normal Well Return Pipe going to the drill platform. This reference is applicable to the Fundamental MFWS & the upper P-WIA of the Advanced MFWS. The lower P-WIA of the Advanced MFWS is opened to the Reservoir.
Item 7 (in dashed lines) is a reference to the BOP's access feed-thru area.
Item 1 is the Containment/Separator Tank. Although not shown it is assumed internal elements would provide enhanced oil-water-mud-gas separation beyond that obtained by a simplistic internally opened tank.
Item 2 is the Ballast required to stabilize the tank to the Sea-Floor (3) as the tank takes on different elements (initially filled with sea water and latter replaced with mud, oil & gas).
Item 4 is a reference to the Pressure Relief/Diversion Valve shown on
Item 5 is the pipe/tubing coming from the well as seen on
Item 6 is a composite of numerous controls and internal tank monitoring/sensors interfacing with the surface equipment.
Items 7 are pipes/tubes to further divert and/or capture the tank's separated holdings. It is assumed the different separated outputs would go to different places (such as oil to a surface containment area or capture vehicle while the gas may be diverted to a further safer area father away from the oil containment/capture area).
Items 8, 9 & 10 are remotely controlled valves.
Item 8 is the Sea Water/Mud Valve and would initially be opened in conjunction with the Pressure Relief/Diversion Valve to allow the tank to extract its initial sea water and accept the wells output. As sensors indicate the tank no longer contains sea water/mud the valve would be closed.
Item 9 is the Gas Valve. If gas is sensed within the tank this valve would be opened.
Item 10 is the Oil Release Valve. As oil is sensed within the tank this valve would be opened.
Items 1 are the upper end & lower end of the upper & lower coupling pipes. These ends have standard pipe to pipe coupling means.
Item 2 (in dashed lines) indicates the inside wall.
Item 4 is the smaller diameter upper pipe coupling surface that fits within the lower coupling pipe as indicated by the dashed lines of Item (10).
Item 9 depicts a tapered the bottom portion of item 4 allowing it to initially align/fit into the lower section.
Item 3 is the upper pipe's mounting flange & gasket that mates to the lower pipes mounting flange item 11.
Item 12 is a unique threaded element in the interior sidewall of the lower pipe. The ‘unique’ threads have a stepping characteristic as shown on Detail ‘B’ item 13. The width of the individual steps are slightly larger than the width of the remote controlled Spring Loaded Grabbing Device (SLGD), item 5.
Items 5 are installed on the upper coupling pipe via Pivots (7) and normally extends out from the sidewall via its internal spring. When compressed the SLGD fits into the pipe's sidewall per item 8. Detail ‘A’, item 14 indicates a sloped mating (mating the slope of item 13) of the SLGP.
As the upper & lower sections are joined the SLGDs compress into the sidewall and springs in & out of the different levels of the stepped threaded element. When the mounting flanges bottom-out the upper pipe is turned clockwise (where it ratchet into, further tightens and locks into the threaded—stepped element.
The pipes de-couple via energizing the SLGD remote control mechanism, item 6 where the SLGD is pulled into its sidewall unlatching/freeing the two pipe sections.
The system of the present invention comprises two functional and physically integrated subsystems, the Multi-Function Well Subsystem (MFWS) and the Intrusion Detection and Response Subsystem (ID&RS).
Both MFWS configurations (Fundamental and Advanced) utilize ‘other’ (not shown on Figures) unique support devices including:
The Production Hard Cap (PHC) is a simplistic device. It is round as viewed from the top and has a mounting surface compatible with both the Production Valves and the Production Ports. The PHC is utilized to provide means to cap each individual unused Production Port and/or Valve.
The Remote Monitor and Control Unit (RM&CU) is a platform mounted specialized device associated with the Multi-Function Well Subsystem (MFWS).
The RM&CU will provide the surface platform to sea-floor and in-well equipment man-machine monitor & control interface.
The RM&CU will include processing capability to provide operator recommendations and warnings, as well as an automatic mode to control the sea-floor and in-well equipment for critical/emergency situations.
Although specific operational displays, modes, functions or controls are not specified in detail at this time, it is assumed the RM&CU equipment (such as monitors, computers and interface devices) matching/exceeding the system requirements are commercially/off-the-shelf available.
The Re-Case End Pipe (R-CEP) is a pipe section smaller in diameter than the installed well pipe/casing in need of repair when the drill pipe is not in the well. It will have a remotely controlled initially closed bottom end valve, a remotely controlled expandable ‘o-ring’/gasket around its outer circumference near the closed end. It will further have a remotely controlled sidewall gate valve located slightly above the said gasket. Prior to installing the R-CEP the number of sections of Re-Casing Pipe (R-CP) required to repair the well must be determined. At a point above where the existing well pipe is in need of repair but below the BOP, a pair of remotely controlled Coupling/De-Coupling Pipes shall be joined, followed by additional sections of R-CP from above the bottom of the BPO to the surface platform. The R-CEP and R-CP would be lowered through the ‘normal outer/return drill pipe’ to the desired location.
The R-CEP gasket would be energized sealing/closing/choking the pipe to pipe area. The sidewall remotely controlled gate valve will be opened and mud followed by concrete would be pumped directly into the re-casing pipe. The mud/concrete flows through the opened gate valve and into the pipe/casing in need of repair to seal the pipe to pipe/casing area. The concrete will flow through said area until cement is detected in the pipe to pipe area above the last (highest) section of well pipe that needed repair. The concrete pumping will stop, the sidewall gate valve will be closed and the concrete will be removed from the interior of the Re-Case Pipe.
The bottom remotely controlled closed end valve will then be opened. The concrete is let to set between the pipe to pipe areas. The Re-Case Pipe (below the BOP and above the well pipe that require repair) will be uncoupled via the Coupling/De-Coupling Pipe (or will be cut and extracted).
The Re-Case Pipe (R-CP) is similar to the lowest section of the installed faulty well pipe/casing except:
The Bottom Kill End Pipe (BKEP) is similar to the R-CEP except:
The Kill Pipe (KP) is similar to the R-CP except the ‘selected sections’(the uppermost as a minimum) shall incorporate remotely monitored interior (as well as exterior) pressure, oil, water, mud and cement sensors.
The Modified Conversion Float Valve (MCFV) changes the release method/mechanism from the present dropped ball, semi obstructing the flow through a pipe holding the valve opened causing a delta pressure. When/if the delta pressure and flow meet a pre-selected criterion, the said pipe releases and converts the device to a one-way valve.
The modification converts the valve to an electrical remote controlled device—activating a solenoid. The opening valve will further be spring loaded and its opening will be sensed and reported and remotely monitored as flow-rate.
The Modified Casing (MC) incorporates remote controlled sidewall gate valves near the top of the casing. Although the MC is primarily intended for the lower most casing, it could be desirable for other casing sections as well. The said valves would be initially being held closed. Upon command the valves will allow one-way flow, from the pipe into the well-bore. This will allow cementing from the top of the casing to the bottom, reducing the required pressure and further provides a more positive void/bore fill.
The Modified Reamer Shoe/Drill Shaft (MRS/DS) modifications combine the functional elements of the R-CEP and the BKEP with the following alterations:
The ‘Fundamental’ MFWS provides maintenance access, redundancy, sea-floor pressure relief/diversion means and utilizing common unique and in-use apparatus and tools, used in conjunction with a newly devised oil well access to provide the means to:
The ‘Advanced’ MFWS includes all the features of the above, and further includes a unique dome top, cylindrical sidewall assembly/structure enclosing the well's sea-floor equipment providing improved structural strength and protection from natural/human induced disasters.
Either the Fundamental or Advanced MFWS configurations could be modified to include an additional Adjunctive BOP/Access Valve Assembly (AVA) installed below the BOP providing further redundancy.
Design.
Notes/Requirements:
The objective of the Intrusion Detection and Response Subsystem (ID&RS) is to protect the surface and underwater oil well elements from deliberate human intervention. It is assumed a 3D restrictive zone will be established about an individual or group of oil wells.
The ID&RS provides the means to detect, track and classify the 3D aspects (bearing, range, and depth) of air/surface/sub-surface objects about a specific oil well or group of oil wells. It also provides the means to evaluate potential threats and ‘Hard and/or Soft Kill’ threats.
The ID&RS elements are identified in four categories as follows:
1. Major existing military type platform equipment that provides short range AAW, ASUW and ASW capability including such items as:
Many of the terms such as ‘short range’ and ‘weapons’ are quite subjective and since the primary threat is considered to be quite rudimentary the following are identified as design guidance:
The acoustic sensors and arrays are conceptually based on USN ASUW and ASW detection and processing techniques. The subsurface piggy-back depth angle sensor and the related arrays depth determination is unique but based on the triangular processing of the bearing and range. It is anticipated the sensed ‘depth angle’ will be compromised by sea-floor and surface reflections/bounce, but it is assumed that integrating over time and averaging the three differently located sensors data will provide tangible results. The tracking, classification, threat analysis and threat response recommendations are also based on USN processing.
The RF, IR and acoustic generators and corner reflector(s), and their associated array, are conceptually based on USAF and USN air tactical counter-measures (stand-off jammers and gate stealers) and USN submarine counter-measures (decoys).
The Light Airborne Multi-Purpose System (LAMPS) operations are based on the USN LAMPS MK111 ASW and ASUW techniques.
The following describe a single well installation utilizing a USN or USCG Ship for the ‘Major existing military type platform equipment that provides short range AAW, ASUW and ASW capability’.
It is assumed alternative interfaces, operations and array configurations could be derived for well platform based equipment and/or multiple well implementations.
The Radar and associated IFF and Electromagnet (passive detection) Sensor (EMS) are the ‘eyes’ for above the surface, while the passive acoustic sensors are the ‘eyes’ for below the surface.
The acoustic sensor array provides subsurface and surface detection data and the means required to triangulate the sensors detections to determine Bearing, Range and Depth.
The outputs of the acoustic sensors* and control signals for all generators (RF, IR and acoustical) interface with (via cable) an Array Distribution Unit (ADU). The ADU (data/controls) interfaces (via cable) with to the Data and Signal Formatter (D&SF). D&/SF on a (oil well) platform digitizes and serializes the signals. The digitized and serialized signal is sent to the platforms RF Data Link and then the ship's RF Data Link. The data is then sent to the Processor where is processed for display monitoring and display interface, detection support (bearing, range and depth determination for acoustic contacts) and tracking, classification, threat analysis and related recommendations, as well as historical storage for air, surface and subsurface contacts.
The processed data and information is then sent to the Display Monitor and Control Unit. A trained Operator views/reviews the data and information and determines and initiates appropriate actions.
The processing will include an operator selectable auto threat-quick reaction ‘soft-kill’/decoy mode, allowing the program to automatically control the RF, IR, acoustical generators and corner reflectors.
The controls are sent to the appropriate selected unit(s) (specific sensor and/or generator) via the Processor, RF Data Link, Data Formatter, Array Distribution Unit and then to the appropriate unit. LAMPS Helicopter interfaces via its own data link.
If ROV actions are required, a stand alone interface, monitor and control system identical to the existing ROV's will be used.
If the Ship has a sonobuoy receiver system compatible with the number and type of sonobuoys in the array the sensors could directly (via RF) interface with the ship.
It is assumed the sensor (RADAR, IFF, and ESM etc.) and weapons on a USN or USCG Ship identified as short range AAW, ASUW and ASW capable would well serve this mission, particularly as supplemented.
The RF and IR Generators/Decoys are standard simplistic active noise or repeater source similar to numerous such devices used by the USN and USAF. The device shall be externally stimulated and controlled by the Processor to produce outputs capable of:
The Passive Acoustic Sensor (PAS) is derived from a modification of the standard AN/SSQ 53 Directional Frequency Analysis and Recording (DIFAR) Sonobuoy.
The low-tech modifications include:
The Acoustic Generator (AG) is a simplistic active acoustic noise source similar to numerous such devices used by the USN.
The device shall be externally stimulated and controlled by the Processor to produce outputs capable of:
The Acoustic Corner Reflector (ACR) is a simplistic passive decoy type device. It is basically composed of two flat acoustical reflective crossing plains (crossing in the center) at 90 degrees that reflects an acoustical signal back in the same angle it was received. The ACR further includes a remote controlled element that rotates (from the center) one of the plains to form a dual flat surface. The ACR is deployed with weighs on the sea-floor and/or tethered at different depths.
The PAS and AG units will be connected (via cable or be physically joined) and typically deployed in functional sets of three or four typically @ equal distance from each other and equal distance about a specific well (or in other functional sets about a group of wells).
Each of the PAS, AG and/or ACR units will be tethered from the sea-floor to pre-determined depths. The RF & IR generators will be tethered to the sea surface.
The said tethered cables could include various combinations of sensors/decoys.
The sea-floor will hold the tethered cable with weights capable of insuring it does not change its position (depth, lat. and long.). The cable length from the tethered weight to the sea-floor to platform shall be the planned distance plus about one and a half times the sea depth (for future recovery/maintenance). A single (non-joined) AG will be mounted on the underside of the surface platform providing the means to calculate (via the processor) the exact position and aspect of the joined PAS and AG devices.
The ROV(s) is identical to such devices used by the oil industry for deep off-shore drilling but this unit's interface cables will be lengthened so it can travel greater than two miles from the platform. The ROV(s) provide the means to view, evaluate and move delayed fused under-sea explosives.
The Array Distribution Unit (ADU) function only acts as a convenient physical wire/cable distribution center.
The Data and Signal Formatter (D&SF) is an active electronic data and signal formatting device located on the platform.
The ‘formatting includes:
It is assumed devices matching/exceeding these requirements are available ‘off-the shelf’ (from Industry/US Government). The RF Data Link is a common device used by industry and the government. The device converts serial (cable media) electronic data/signals to RF for transmission to another location via an antenna and likewise receives RF and converts it to serial electronic data/signals.
The capacity (bandwidth) must be compatible with the required data/signals of the system, as identified for the D&SF.
It is assumed devices matching/exceeding these requirements are available ‘off-the shelf’ (from Industry/US Government).
*The above assumes a separate in-place ship to helicopter (LAMPS) data link.
The Processor includes a computer and specialized computer programs. The Processor provides critical functions related to the surface/sub-subsurface objects:
The processor also provides interface for the Display Monitor and Control Unit. The processor further provides for sensor position and aspect calibration, operator training via simulation and historical operational recording.
It is assumed the computers are in-place on the ship, or a computer matching/exceeding the required process capacity and speed are available ‘off-the shelf’ commercially.
The ‘specialized computer programs would have to be developed, but the USN utilizes similar functional software for their AAW, ASUW and ASW mission. If such were made available the development (time, cost and risk) would be reduced by an order of magnitude.
The Display Monitor and Control Unit (DM&CU) provides for the operator to system interface.
The Light Airborne Multi-Purpose System (LAMPS) is identical to that used by the USN for surface and sub-surface detection, localization and engagements.
Although specific operational displays, modes, functions or controls are not specified in detail at this time, it is assumed the DM&CU is in-place on the ship or a unit matching/exceeding the requirements is commercially available—large touch-screen monitor would well serve the all requirements.
It is understood that the preceding description is given merely by way of illustration and not in limitation of the invention and that various modifications may be made thereto without departing from the spirit of the invention as claimed.
The present utility patent application claims the benefit of provisional application No. 61/459,895 filed Dec. 20, 2010.
| Number | Date | Country | |
|---|---|---|---|
| 61459895 | Dec 2010 | US |
