1. Field of Invention
This disclosure relates in general to oil and gas equipment, and to a power and communications hub (PCH) for use in oil and gas equipment. In particular, the disclosure provides systems and methods that utilize one or more PCHs to distribute power and communications in blowout preventer (BOP) subsea applications.
2. Related Technology
BOP systems are hydraulically-controlled systems used to prevent blowouts from subsea oil and gas wells. Subsea BOP equipment typically includes a set of two or more redundant control systems with separate hydraulic pathways to operate a specified BOP function on a BOP stack. The redundant control systems are commonly referred to as blue and yellow control pods. In known systems, a communications and power cable sends information and electrical power to an actuator with a specific address. The actuator in turn moves a hydraulic valve, thereby opening a fluid path to a series of other valves/piping to control a portion of the BOP.
Historically, power and communications connections have been centralized on BOP control pods subsea. However, subsea safety standards have become more stringent, including a higher demand for subsea condition monitoring. These increased safety and industry standards increase the complexity, and therefore the complications, involved with the interface with subsystems, surface systems, and the subsea control pods.
By separating BOP electrical interface requirements from subsea control pod(s) on a BOP stack, the present disclosure provides for a modular design with two or more separate PCHs. In certain embodiments, this modular design of the PCH allows a reduction in the requirements on the control pod, such that the control pod controls only hydraulic functions. Thus, separating out the interface system from the control pods according to embodiments of the disclosure increases design expandability and flexibility for current and future designs. In some embodiments, the modular design can prevent time consuming redesign of sophisticated control pods, where new design requirements can be handled by the PCH, such as due to a requirement to add a new condition monitoring subsystem.
In some embodiments, a PCH includes four objectives: multiplexer (MUX) interface; power distribution; communication distribution; and combined power/communications distribution. The PCH absorbs these interfaces from the control pod requirements, thus reducing the complexity of the control pod. In addition, by separating the interfaces from the control pod, a PCH enables design flexibility and increases system reliability.
In certain embodiments, a PCH interfaces with a MUX cable break out device and serves as the central power and communication system for subsea controls. Communication links can be terminated from the MUX output and linked to their appropriate interface. The PCH includes a power system and a communication system. In certain embodiments, the PCH power system converts delta 3 phase 480 volt alternating current (VAC) 60 Hz to 24 volt direct current (VDC) to serve as the primary voltage for a BOP subsea control. In certain embodiments, the PCH communication system serves as a gateway for subsea communications. The PCH communication system can provide a communication crossover to and from the coinciding PCH. The communication crossover can serve as a means of a redundant communication link. In certain embodiments, the PCH can provide fiber optic (FO) monitoring where degradation in optical signal can trigger an automatic switchover to a redundant fiber optic communications pathway.
In some embodiments, the PCH can allow for multiplexer (MUX) communications from a lower BOP stack to surface systems, resulting in a significant simplification from previous designs. In some embodiments, having redundant PCHs can enable the distribution of crossover power, which gives redundant power to the control pod from both MUX cables, and such redundant power can increase reliability. The technology of the present disclosure can reduce the vulnerability of the control pod to non-critical subsystem failures and the need for major redesigns due to downstream changes, as are required in a control pod only system.
Therefore, disclosed herein is a power and communications hub (PCH) for oil and gas operations. The PCH includes, a port operable to provide electrical power to a device for use in oil and gas operations; a port operable to provide electrical communications for use in oil and gas operations; a multiplexer (MUX) interface for connection to a MUX cable; a PCH connection interface for connection to at least one additional PCH; and a PCH body. The PCH body is operable to be disposed proximate a blowout preventer (BOP) stack, and the PCH body is physically disposed apart from but in electrical communication with at least one control pod on the BOP stack.
Also disclosed is a PCH system for subsea oil and gas operations. The PCH system includes a first LMRP PCH. The first LMRP PCH includes a port operable to provide electrical power to a device for use in oil and gas operations; a port operable to provide electrical communications for use in oil and gas operations; a MUX interface for connection to a MUX cable; a PCH connection interface for connection to at least one additional PCH; and a PCH body, wherein the PCH body is operable to be disposed proximate a BOP stack, and wherein the PCH body is physically disposed apart from but in electrical communication with at least one control pod on the BOP stack; a second LMRP PCH; a first lower stack (LS) PCH; and a second LS PCH.
Also disclosed is a method for decentralizing power and communications in subsea BOP stack control pods. The method includes the steps of: introducing at least one PCH to a BOP stack, wherein the PCH is operable to provide power and communications for existing BOP stack components and future BOP stack components; and operating the PCH to provide required power and communications to components on the BOP stack from surface controls, wherein the PCH is physically disposed apart from but in electrical communication with at least one control pod on the BOP stack.
These and other features, aspects, and advantages of the present disclosure will become better understood with regard to the following descriptions, claims, and accompanying drawings. It is to be noted, however, that the drawings illustrate only several embodiments of the disclosure and are therefore not to be considered limiting of the disclosure's scope as it can admit to other equally effective embodiments.
So that the manner in which the features and advantages of the embodiments of PCH systems and methods, as well as others, which will become apparent, may be understood in more detail, a more particular description of the embodiments of the present disclosure briefly summarized previously may be had by reference to the embodiments thereof, which are illustrated in the appended drawings, which form a part of this specification. It is to be noted, however, that the drawings illustrate only various embodiments of the disclosure and are therefore not to be considered limiting of the present disclosure's scope, as it may include other effective embodiments as well.
Referring first to
Lower stack 104 can include shuttle panel 134, as well as a blind shear ram BOP 136, a casing shear ram BOP 138, a first pipe ram 140, and a second pipe ram 142. BOP stack 100 is disposed above a wellhead connection 144. Lower stack 104 can further include optional stack-mounted accumulators 146 containing a necessary amount of hydraulic fluid to operate certain functions within BOP stack 100.
As noted previously, power and communications connections historically have been centralized on BOP control pods subsea, such as control pods 108, 110. However, subsea safety standards have become more stringent, including a higher demand for subsea condition monitoring. These increased safety and industry standards increase the complexity, and therefore the complications, involved with the interface with subsystems, surface systems, and the subsea control pods. The disclosure provides the ability to separate power and communication connections from the control pods. For example, with power and communication connections, such as a PCH, located proximate the lower stack 104 additional monitoring is possible. Additional monitoring devices can be connected to one or more PCHs on lower stack 104, rather than running a connection through wedges 128, 130 to control pods 108, 110. One or more PCHs can be used to provide power and communications on either or both LMRP 102 and lower stack 104.
Referring now to
Blue LMRP PCH 204 interfaces with a MUX cable at blue MUX direct/blue MUX-XO connection interface 214, and yellow LMRP PCH 206 interfaces with a MUX cable at yellow MUX direct/yellow MUX-XO connection interface 216. In the embodiment shown, blue LMRP PCH 204 and yellow LMRP PCH 206 serve as the central power and communication system for subsea controls. The LS PCHs 210, 212 interface, via subsea cable and connector, with the lower stack stab and serve as an extension of the LMRP PCHs for lower stack subsystems and instrumentation. Additionally, in the embodiment shown, the LMRP PCHs 204, 206 feed power and communication to safety instrumented systems (SIS)-pod(s) 218 located on the LMRP.
Between LMRP subsystem 202 and LS subsystem 208, blue LMRP PCH 204 is operably coupled with blue LS PCH 210 by blue wedge connector 220. Between LMRP subsystem 202 and LS subsystem 208, yellow LMRP PCH 206 is operably coupled with yellow LS PCH 212 by yellow wedge connector 222. LMRP subsystem 202 further includes a first blue subsea electronics module (SEM) 224, a second blue SEM 226, a first yellow SEM 228, a second yellow SEM 230, an auxiliary LMRP connection 232, an acoustic monitoring system 234, and a new services connection for the LMRP 236. The blue LMRP PCH 204 provides for a primary connection to the first blue SEM 224, and a secondary connection to the second yellow SEM 230. The yellow LMRP PCH 206 provides for a primary connection to the first yellow SEM 228, a secondary connection to the second blue SEM 226, and a connection to acoustic monitoring system 234.
The blue LS PCH 210 further includes an accumulator pressure transducer 238, a high pressure/high temperature (HPHT) probe 240, and an auxiliary lower stack connection 242. The yellow LS PCH 212 provides an accumulator pressure connection 244, an HPHT probe connection 246, and acoustic monitoring LS connection 248. LS subsystem 208 also provides for an interface to a remotely operated vehicle (ROV) display 250 and LS new services connection 252.
In PCH system 200, the power system provides power as follows: six 24 volts direct current (VDC) buses for each SEM 224, 226, 228, 230 at the pods; two 24 VDC buses for RAM monitoring; four 24 VDC buses for future extensions (new services); one 24 VDC bus for acoustic monitoring connected to yellow LMRP PCH 206; one 24 VDC bus for acoustic monitoring connected to yellow LS PCH 212; one 24 VDC bus for non-safety critical future extensions connected to blue LMRP PCH 204; one 24 VDC bus for non-safety critical future extensions connected to blue LS PCH 210; and two 24 VDC buses for stack mounted instrumentation at the LS.
In PCH system 200, the communication system will provide communications as follows: one individual communication link to each SEM; two individual communication links for RAM monitoring; two individual communication links for future extensions (new services); one individual communication link to the acoustic monitoring system connected to yellow LMRP PCH 206; one individual communication link to acoustic monitoring connected to the yellow LS PCH 212; one individual communication link to a non-safety critical future service connected to blue LMRP PCH 204; one individual communication link to a non-safety critical future service connected to the blue LS PCH 210; two individual communication links to additional monitoring; two individual communication links for stack mounted instrumentation at the LS; and acoustic monitoring and other non-critical BOP subsystems shall have isolated communication links.
BOP system 300 includes a fiber 320 that is a pass through for the LMRP SIS pod. A fiber cluster 322 with 3 fibers provides no connection to surface controls and is terminated at the surface. Fiber cluster 322 includes fibers from surface data infrastructure electronics to a network switch for data infrastructure. A fiber cluster 324 with 3 fibers provides a connection to surface controls. Fiber cluster 324 includes fibers from a blue central command unit (CCU) connecting to a network switch for direct control. A fiber cluster 326 with 3 fibers provides a connection to surface controls. Fiber cluster 326 includes fibers from the blue CCU connecting to a network switch for crossover control. Communications for direct and crossover control are based on industrial network protocols (e.g. Modbus/Transmission Control Protocol (TCP)) for primary (blue) and redundant (yellow) controls.
BOP system 300 includes a fiber 328 that is a pass through for the LMRP SIS pod. A fiber cluster 330 with 3 fibers provides fibers connecting to an acoustic monitoring server. A fiber cluster 332 with 3 fibers provides a connection to surface controls. Fiber cluster 332 includes fibers from the yellow CCU connecting to a network switch for direct control. A fiber cluster 334 with 3 fibers provides a connection to surface controls. Fiber cluster 334 includes fibers from the yellow CCU connecting to a network switch for crossover control. Communications for direct and crossover control are based on industrial network protocols (e.g. Modbus/TCP) for primary (yellow) and redundant (blue) controls.
Referring now to
In
In the various embodiments of the disclosure described, a person having ordinary skill in the art will recognize that alternative arrangements of components, units, conduits, and fibers could be conceived and applied to the present invention.
The singular forms “a,” “an,” and “the” include plural referents, unless the context clearly dictates otherwise.
Examples of computer-readable medium can include but are not limited to: one or more nonvolatile, hard-coded type media, such as read only memories (ROMs), CD-ROMs, and DVD-ROMs, or erasable, electrically programmable read only memories (EEPROMs); recordable type media, such as floppy disks, hard disk drives, CD-R/RWs, DVD-RAMs, DVD-R/RWs, DVD+R/RWs, flash drives, memory sticks, and other newer types of memories; and transmission type media such as digital and analog communication links. For example, such media can include operating instructions, as well as instructions related to the systems and the method steps described previously and can operate on a computer. It will be understood by those skilled in the art that such media can be at other locations instead of, or in addition to, the locations described to store computer program products, e.g., including software thereon. It will be understood by those skilled in the art that the various software modules or electronic components described previously can be implemented and maintained by electronic hardware, software, or a combination of the two, and that such embodiments are contemplated by embodiments of the present disclosure.
This application is a non-provisional application claiming priority to U.S. Provisional Application No. 62/093,029, filed Dec. 17, 2014, which is hereby incorporated herein by reference in its entirety.
Number | Name | Date | Kind |
---|---|---|---|
3902554 | Hooper | Sep 1975 | A |
4109938 | Mitchell et al. | Aug 1978 | A |
4618173 | Dopyera et al. | Oct 1986 | A |
4709726 | Fitzgibbons | Dec 1987 | A |
5314024 | Rodgers et al. | May 1994 | A |
5778918 | McLelland | Jul 1998 | A |
5781192 | Kodimer | Jul 1998 | A |
5867150 | Bricklin et al. | Feb 1999 | A |
6040969 | Winch et al. | Mar 2000 | A |
6041804 | Chatufale | Mar 2000 | A |
6835292 | Sato et al. | Dec 2004 | B2 |
6957205 | Liongosari | Oct 2005 | B1 |
6961226 | Mason, Jr. et al. | Nov 2005 | B2 |
6990498 | Fenton et al. | Jan 2006 | B2 |
7000890 | Bell et al. | Feb 2006 | B2 |
7111874 | Smith, III | Sep 2006 | B2 |
7113668 | Sorum et al. | Sep 2006 | B2 |
7216715 | Reynolds | May 2007 | B2 |
7261162 | Deans et al. | Aug 2007 | B2 |
7337848 | Fraser et al. | Mar 2008 | B2 |
7558684 | Patten et al. | Jul 2009 | B2 |
7571772 | Reams | Aug 2009 | B2 |
7760670 | Causier | Jul 2010 | B2 |
7832706 | Judge | Nov 2010 | B2 |
7849599 | Huff et al. | Dec 2010 | B2 |
7887103 | Evans et al. | Feb 2011 | B2 |
7913767 | Larson et al. | Mar 2011 | B2 |
7975770 | Keener | Jul 2011 | B2 |
8020623 | Parks et al. | Sep 2011 | B2 |
8054593 | Reid et al. | Nov 2011 | B2 |
8157025 | Johnson | Apr 2012 | B2 |
8157295 | Krywitsky | Apr 2012 | B2 |
8230735 | Chouzenoux et al. | Jul 2012 | B2 |
8322436 | Maa | Dec 2012 | B2 |
8388255 | Larson et al. | Mar 2013 | B2 |
8403053 | Judge | Mar 2013 | B2 |
8464797 | Singh et al. | Jun 2013 | B2 |
8469048 | Bresnahan | Jun 2013 | B2 |
8602108 | Mathis | Dec 2013 | B2 |
8708054 | Dailey, Jr. | Apr 2014 | B2 |
8724957 | Oisel et al. | May 2014 | B2 |
8781743 | McKay et al. | Jul 2014 | B2 |
8812274 | Virkar et al. | Aug 2014 | B2 |
8944403 | Jurena et al. | Feb 2015 | B2 |
9057751 | Spencer et al. | Jun 2015 | B2 |
9085948 | Egeland | Jul 2015 | B2 |
9151794 | Radan | Oct 2015 | B2 |
20080264642 | Horton | Oct 2008 | A1 |
20100300696 | McCalvin et al. | Dec 2010 | A1 |
20110114329 | Emecheta et al. | May 2011 | A1 |
20110266002 | Singh et al. | Nov 2011 | A1 |
20120233128 | Solmer | Sep 2012 | A1 |
20120312546 | Bussear et al. | Dec 2012 | A1 |
20120318517 | Christensen et al. | Dec 2012 | A1 |
20130054034 | Ebenezer | Feb 2013 | A1 |
20130118755 | Kotrla et al. | May 2013 | A1 |
20130228371 | Farrar | Sep 2013 | A1 |
20130253872 | Curtis et al. | Sep 2013 | A1 |
20130255956 | Gilmore et al. | Oct 2013 | A1 |
20130283919 | Coonrod et al. | Oct 2013 | A1 |
20140061516 | Gustafson et al. | Mar 2014 | A1 |
20140064029 | Jaffrey | Mar 2014 | A1 |
20140321341 | Kristiansen | Oct 2014 | A1 |
20140361785 | Radan | Dec 2014 | A1 |
20150015066 | Dong et al. | Jan 2015 | A1 |
20150041122 | Valsecchi | Feb 2015 | A1 |
20150101674 | Gustafson | Apr 2015 | A1 |
20150129233 | Gaude et al. | May 2015 | A1 |
20150184505 | Panicker-Shah | Jul 2015 | A1 |
20150198001 | McWhorter et al. | Jul 2015 | A1 |
20150233202 | Caldwell et al. | Aug 2015 | A1 |
20150260203 | Launonen et al. | Sep 2015 | A1 |
20160042154 | Goldberg | Feb 2016 | A1 |
20180073320 | Holmes et al. | Mar 2018 | A1 |
Number | Date | Country |
---|---|---|
2 427 171 | Apr 2003 | CA |
201250646 | Jun 2009 | CN |
2 383 429 | Nov 2011 | EP |
2 458 143 | May 2012 | EP |
2 447 331 | Sep 2008 | GB |
0001915 | Jan 2000 | WO |
2013192494 | Dec 2013 | WO |
Entry |
---|
McCord, “A Multiplex System for a Small Remotely Manned Submersible”, IEEE Ocean 1975, pp. 361-364, 1975. |
Hickok, “Practical Experience of Control Valve Behavior”, Subsea Control and Data Acquisition: Proceedings of an international conference, London, UK, pp. 195-203, Apr. 4-5, 1990. |
Martin et al., “A Proven Oil/Water/Gas Flowmeter for Subsea, Offshore Technology Conference”, Offshore Technology Conference, Houston, pp. 589-596, May 6-9, 1991. |
Ali et al., “Subsea Valve Actuator for Ultra Deepwater”, Offshore Technology Conference, Houston, Texas, 1996 proceedings, pp. 799-809, May 6-9, 1996. |
Altamiranda et al., “Intelligent Supervision and Integrated Fault Detection and Diagnosis for Subsea Control Systems”, OCEANS 2007 Europe, pp. 1-6, Jun. 18-21, 2007. |
Wang et al., “Water Hammer Effects on Water Injection Well Performance and Longevity”, Society of Petroleum Engineers, SPE International Symposium and Exhibition on Formation Damage Control,Lafayette, Louisiana, USA, pp. 1-10, Feb. 13-15, 2008. |
Vetcogray, “Capital Drilling Equipment”, retrieved from http://site.ge-energy.com/businesses/ge_oilandgas/en/literature/en/downloads/capital_drilling_equipment.pdf, pp. 1-15, 2008. |
Altamiranda et al., “Condition Monitoring and Diagnosis for Subsea Control Systems. A Subsystem Prototype”, OCEANS 2009 Europe, pp. 1-6, May 11-14, 2009. |
Whitby et al., “20KSI BOP Stack Development”, SPE International, pp. 1-5, Feb. 2-4, 2010. |
Tang et al., “A Dynamic Simulation Study of Water Hammer for Offshore Injection Wells to Provide Operation Guidelines”, SPE Production & Operations, vol. No. 25, Issue No. 4, pp. 509-523, Nov. 2010. |
Shanks et al., “OTC 23473 New Generation Control System for 20 KSI Subsea BOP”, Offshore Technology Conference, pp. 1-12, May 3, 2012. |
Levine et al., “BSEE and BOEM Workshop with Government of Israel Application for Permit to Drill”, pp. 1-40, Jul. 24, 2012. |
Cai et al., “Reliability Analysis of Subsea Blowout Preventer Control Systems Subjected to Multiple Error Shocks”, Journal of Loss Prevention in the Process Industries, vol. No. 25, Issue No. 6, pp. 1044-1054, Nov. 1, 2012. |
Cai et al., “Application of Bayesin Networks to Reliability Evaluation of Software Systems for Subsea Blowout Preventers”, International Journal of Control and Automation, pp. 47-60, Feb. 28, 2013. |
Umofia., “Risk-Based Reliability Assessment of Subsea Control Module for Offshore Oil and Gas production”, Cranfield University, School of Engineering, Department of Offshore, Process and Energy Engineering, pp. 1-284, Sep. 2014. |
Chazal et al., “Enhancements in Fraction Measurements and Flow Modeling for Multiphase Flowmeters” Society of Petroleum Engineers, SPE Annual Technical Conference and Exhibition, pp. 1-19, Oct. 27-29, 2014. |
PCT Search Report and Written Opinion issued in connection with Related Application No. PCT/US2015/053238 dated Feb. 1, 2016. |
PCT Search Report and Written Opinion issued in connection with Related Application No. PCT/US2015/055915 dated Feb. 2, 2016. |
GE Oil & Gas, “GE's 20-ksi” BOP Completely Re-Engineered to Meet Demands of HPHT Reservoirs, Drilling Contractor, pp. 1-2, Feb. 17, 2016. |
Cameron., “Mark III Subsea MUX BOP Control System”, Drilling Pressure Control Equipment, retrieved from http://www.c-a-m.com/products-and-services/drilling/drilling-pressure-control-equipment/mark-iii-subsea-mux-bop-control-system, pp. 1-4, Feb. 19, 2016. |
International Search Report and Written Opinion issued in connection with corresponding PCT Application No. PCT/US2015/066374 dated Mar. 21, 2016. |
International Preliminary Report on Patentability issued in connection with corresponding PCT Application No. PCT/US2015/066374 dated Jun. 20, 2017. |
Holmes, J.S. et al., High Pressure bop system, GE Pending U.S. Appl. No. 62/065,431, filed Oct. 17, 2014. |
Number | Date | Country | |
---|---|---|---|
20160177700 A1 | Jun 2016 | US |
Number | Date | Country | |
---|---|---|---|
62093029 | Dec 2014 | US |