1. Technical Field
Embodiments of the subject matter disclosed herein generally relate to methods and systems and, more particularly, to mechanisms and techniques for displaying/retrieving sensor information of a subsea device.
2. Discussion of the Background
During the past years, with the increase in price of fossil fuels, the interest in developing new production fields has increased dramatically. However, the availability of land-based production fields is limited. Thus, the industry has now extended drilling to offshore locations, which appear to hold a vast amount of fossil fuel.
The existing technologies for extracting the fossil fuel from offshore fields use a System 10 as shown in
However, during normal drilling operation, unexpected events may occur that could damage the well and/or the equipment used for drilling. One such event is the uncontrolled flow of gas, oil or other well fluids from an underground formation into the well. Such event is sometimes referred to as a “kick” or a “blowout” and may occur when formation pressure inside the well exceeds the pressure applied to it by the column of drilling fluid. This event is unforeseeable and if no measures are taken to prevent it, the well and/or the associated equipment may be damaged. Although the above discussion is directed to subsea oil exploration, the same is true for ground oil exploration.
Thus, a blowout preventer (BOP) might be installed on top of the well to seal the well in case that one of the above mentioned events occurs and threatens the integrity of the well. The BOP is conventionally implemented as a valve to control the pressure either in the annular space between the casing and the drill pipe or in the open hole (i.e., hole with no drill pipe) during drilling or completion operations. More recently, a plurality of BOPs has been installed on top of the well for various reasons.
The BOPs are provided in a BOP stack 45 as shown in
Various sensors and valves are provided on the BOP stack to monitor its status and the surrounding environment. Information associated with the sensors and valves need to be provided to the operator on the vessel for controlling the BOP stack. Thus, as shown in
However, in case of an unexpected loss of control of the MUX POD, for example, explosion of the rig or vessel, even when all information related to the BOP stack is lost the sensors and/or valves are still functional and able to generate the information.
Therefore, it is desired to provide a capability to overcome the above noted problems.
According to one exemplary embodiment, there is a subsea sensors display system configured to display data about a blowout preventer (BOP) stack. The subsea sensors display system includes a display panel having plural universal subsea displays, each universal subsea display being configured to display a value measured by a sensor attached to the BOP stack; and a J-box (junction box) electrically connected to the display panel and configured to provide electrical power to the display panel and to receive data from the display panel. The electrical power is provided from a pod provided on the BOP stack or from a battery when the pod is not available or from a remote operated vehicle (ROV) when connected to the display panel.
According to another exemplary embodiment, there is a subsea sensors display system configured to display data about a blowout preventer (BOP) stack. The subsea sensors display system includes a display panel having plural universal subsea displays, each universal subsea display being configured to display a value measured by a sensor attached to the BOP stack; a J-box electrically connected to the display panel and configured to provide electrical power to the display panel and to receive data from the display panel; a battery connected to the J-box; and plural sensors connected to the display panel. The electrical power is provided from a pod provided on the BOP stack or from the battery when the pod is not available or from a remote operated vehicle (ROV) when connected to the display panel.
According to still another exemplary embodiment, there is a method for displaying measurements associated with sensors provided on a blowout preventer (BOP) stack. The method includes a step of providing electrical power from a battery or a remove operated vehicle (ROV) to a J-box when a pod of the BOP stack is not available; a step of transmitting the electrical power from the J-box to a display panel; a step of activating the display panel with the ROV; a step of transmitting the electrical power from the display panel to plural sensors after being activated by the ROV; a step of receiving readings from the plural sensors to the display panel; and a step of displaying the reading on universal subsea displays mounted on the display panel. The system is also capable of transmitting the sensor data through the ROV connection as a RS485 feed that can be transmitted to the surface through the ROV and accessed with a laptop provided with required software.
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate one or more embodiments and, together with the description, explain these embodiments. In the drawings:
The following description of the exemplary embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims. The following embodiments are discussed, for simplicity, with regard to the terminology and structure of a BOP stack having a MUX POD undersea. However, the embodiments to be discussed next are not limited to these systems, but may be applied to other BOPs that may be used, for example, inland.
Reference throughout the specification to “an exemplary embodiment” or “another exemplary embodiment” means that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in an exemplary embodiment” or “in another exemplary embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
According to an exemplary embodiment, a new or an existing BOP stack may be configured to provide data indicative of the state of the stack even when a MUX POD is out of order. A subsea display system may be implemented (added, retrofitted, built) on the BOP stack for providing access to desired sensors of the stack in case that power and/or communication through the MUX POD is lost. In one application, a remote operated vehicle (ROV) is used to either connect to the subsea display system for retrieving the sensor data or to retrieve the data without physical contact with the subsea display system.
According to an exemplary embodiment illustrated in
Sensor 106 in
As noted above, the subsea sensors display system 120 may include the display panel 116 and the J-box 114. The display panel 116 may be configured to have the default status as inactive, i.e., minimal power is consumed and no data is displayed in order to conserve the battery energy. However, when a need arises for reading the data, the ROV 130 may approach the display panel 116 and shine light on it to activate the display gauges 140, 142 and 144 mounted on the display panel 116. Such display gauges are produced by Perry Slingsby Systems (Houston, Tex.) and have a power input of 3.5V to 35V, have a depth rating of 4000 m, are configured to accept a sensor input of 4 to 20 mA analog current, and are designed to work with sensors related to pressure, proximity, potentiometer, rotary/linear encoders and strain gauge bridges (or equivalent).
Thus, such a display panel 116 has various display gauges or universal subsea display (USD) units 140, 142, and 144, each configured to display a value measured by a corresponding sensor. The display panel 116 may have any number of USDs. The ROV may connect to the display panel via a wet-made connector 146 so that data can be transferred (e.g., via a RS485 signal) to an internal memory 132 of the ROV 130 or directly transferred to the surface via a cable 134 and viewed, for example, on a laptop equipped with relevant software.
As the subsea sensors display system 120 is configured to operate as an alternative system when the regular MUX POD system fails, this system may be equipped with the battery 118 or may be provided with electrical power directly from the ROV 132. For these cases, the subsea sensors display system 120 is configured to power up the sensors 106 and 110. The battery 118 may be recharged either through the ROV or when the MUX POD is available. The battery 118 may be a seabattery power module as those produced by Deepsea Power & Light (San Diego, Calif.), e.g., type 24V-40AH, having a molded polyethylene case and having a depth rating of 11,000 m.
The J-box 114 is connected between the RTU unit 112 and the subsea sensors display system 120. The J-box is configured to provide the RS485 signals from the USDs 140, 142 and 144 to the wet-mate connector 146, to provide electrical power from the wet-mate connector to the subsea sensors display system 120, or the battery 118 or the sensors 106 and 110 or any combination of these elements. The J-box is configured to control the power and communications flow to and from different components of the system 100 and may be handled by a printed circuit board housed inside the junction box 114. Also, the J-box may have a module 150 that controls the charging voltage of the battery 118, a module 152 for shut-off of the battery or the system 120, and a module 154 for temperature adjustments (related to the ocean depth). The J-box may be implemented in software, hardware or a combination thereof as will be discussed later.
The subsea sensors display system 120 is shown in more details in
The J-box 114 is also configured to detect when the MUX POD 102 and/or 104 fails and to take appropriate action. For example, when the MUX PODs fail, the J-box 114 is configured to automatically provide energy from the battery 118 to the display panel 116 and/or sensors 106 and 110. The amount of time during which energy is provided from the battery varies, from minutes to hours and will depend upon the capacity of the battery and the number of components that draw power from it. After a predetermined time (e.g., five minutes), the display panel 116 is configured to shut down which also determines the shutdown of sensors 106 and 110. These operations may be controlled by module 154 of the J-box 114 or preset before the deployment of the unit subsea.
In one application, a storage device (data logger) may be provided on the BOP stock (e.g., the J-box) and configured to receive the information from the sensors when the MUX PODs have failed and store this data for later retrieval via the ROV.
After a certain time, the ROV 130 arrives at the display panel 116. The ROV may be configured to activate the display panel 116, for example, by shining light on a certain area 160 of the display panel 116. This area may include a light sensor 162. Alternatively, each individual USD may be equipped with light sensors which can be activated by the ROV by shining light above a certain thresh hold value. Other mechanisms may be envisioned, e.g., acoustic sensor, mechanical touch, etc. Once activated, the display panel 116 provides voltage to the sensors so that the sensors can perform their measurements. It is noted that although
After the sensors have been powered (from the RTU 112 or from the battery 118 or from the ROV 130 via the display panel 116), the results are displayed, e.g., digitally, on the USD 140, 142, 144. The ROV may read these values by using a video camera, in which case no direct connection between the ROV and the display system 120 is necessary. Alternatively, if the connection 146 has been made, the ROV may directly connect to the display system 120 and may start to download the measured values on a local storage device 130 or provide the readings directly to the vessel above through cable 134. The display system 120 may be configured to read the analog output of the sensors and convert it into an RS485 signal to be provided to the ROV. The J-box houses the connectors and a circuit board that includes modules 152 and 154. The internals of the junction box may be housed in an enclosure maintained at 1 atm pressure or could be oil filled pressure compensated to prevent sea water from contacting the circuit board.
If the ROV connects to the display system 120, the battery 118 is charged from the ROV and also the display panel 116 and the sensors are configured to receive electrical power from the ROV. In this case, the ROV could provide the energy for the display system 120 for days if not months (dependent on the capacity of the ROV that is available). When not activated the USD goes into sleep mode after a predetermined amount of time.
In this way, critical data about the BOP stack, even if it failed, could be accessed and remedies for shutting the well may be implemented. The system is designed that even if some of the sensors are destroyed, the remaining sensors still transmit their measurements to the display panel 116 as long as the sensors can be powered by alternate means. This novel system may also be used to monitor the BOP stack when the MUX POD is disconnected for various reasons. The number of sensors to be monitored by the novel system is not limited. The system can be activated by an ROV even when the MUX Pod is working and the power at that time is provided to the system by the MUX Pod through the RTU 112. Under normal working conditions the battery is trickle charged through the connection to the RTU and keeps it fully charged compensating for any power that is self discharged or any power consumed by different components during the sleep mode.
According to another exemplary embodiment illustrated in
Another embodiment is now discussed with regard to
The RTU 302 is connected to RTU 90 (shown in
According to an exemplary embodiment illustrated in
In the above example, it is shown how readings from the blind RAM 410 and the shear RAM 412 can be used with the subsea display system. Other types of RAM may be used. By manipulating the signals in the RTU 20, e.g., using electrical circuits, the analog signals can be duplicated and one set can be sent to the subsea display panel 402 and read with the help of the USDs while the other set can be sent to a traditional RTU 422 and then to the operator through the PODs (not shown). For reading the position from two of the RAMs on the display panel, four USDs may be used. Each of the USDs read one sensor and displays a position and pressure reading. More USDs will be required to read data from additional RAMs. Various connectors (e.g., 6/36 pie connector) may be used with the RTU 420 for handling the signals. While
According to an exemplary embodiment illustrated in
As discussed above, the J-box may include various hardware, software or a combination of the two for controlling the various elements to which it is connected. An example of a control system capable of carrying out operations in accordance with the exemplary embodiments of
The exemplary control system 1000 suitable for performing the activities described in the exemplary embodiments may include server 1001, which may include blocks 152 and 154 shown in
The server 1001 may also include one or more data storage devices, including hard and floppy disk drives 1012, CD-ROM drives 1014, and other hardware capable of reading and/or storing information such as DVD, etc. In one embodiment, software for carrying out the above discussed steps may be stored and distributed on a CD-ROM 1016, diskette 1018 or other form of media capable of portably storing information. These storage media may be inserted into, and read by, devices such as the CD-ROM drive 1014, the disk drive 1012, etc. The server 1001 may be coupled to a display 1020, which may be any type of known display or presentation screen, such as LCD displays, plasma display, cathode ray tubes (CRT), etc. A user input interface 1022 is provided, including one or more user interface mechanisms such as a mouse, keyboard, microphone, touch pad, touch screen, voice-recognition system, etc.
The disclosed exemplary embodiments provide a display system and a method for providing information regarding a BOP stack when the MUX POD is not available. It should be understood that this description is not intended to limit the invention. On the contrary, the exemplary embodiments are intended to cover alternatives, modifications and equivalents, which are included in the spirit and scope of the invention as defined by the appended claims. Further, in the detailed description of the exemplary embodiments, numerous specific details are set forth in order to provide a comprehensive understanding of the claimed invention. However, one skilled in the art would understand that various embodiments may be practiced without such specific details.
Although the features and elements of the present exemplary embodiments are described in the embodiments in particular combinations, each feature or element can be used alone without the other features and elements of the embodiments or in various combinations with or without other features and elements disclosed herein.
This written description uses examples of the subject matter disclosed to enable any person skilled in the art to practice the same, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims.
This is a Non-Provisional application which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 61/480,123 filed on Apr. 28, 2011 the entire contents of which are hereby incorporated by reference into the present application.
Number | Date | Country | |
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61480123 | Apr 2011 | US |