1. Field of the Invention
The invention relates generally to subsea wellheads and techniques for containment of any leaking fluids from such wellheads.
2. Description of the Related Art
In a subsea well leak, significant amounts of crude oil, gases, salt water and other fluids may be released into the sea. Conventional techniques for responding to such leaks generally seek to install a plug or sealing cap within or upon the subsea well head or within the flowing tubular in order to close off flow of hydrocarbon fluids out of the wellbore. However, it may be difficult to install a plug or sealing cap in many situations due to the differential pressures between the wellbore pressure and the surrounding sea. In addition, the depth and remoteness of the wellhead may make it difficult to install such a plug or sealing cap effectively or in a timely manner.
The invention provides systems and methods for at least temporarily containing a subsea wellhead and controlling fluid outflow from the wellhead until a more permanent method of closing off the well can be completed. In one embodiment, the invention provides a containment system having a containment vessel that defines an interior chamber that is shaped and sized to fit over a subsea well head housing in a loose manner. The In one embodiment, the vessel generally includes three openings that provide access between the interior chamber and the exterior of the vessel. One opening interconnects the interior chamber with a riser or other deployment means, which extends to surface. A second opening interconnects the interior chamber with a flow conduit that leads to a collection sump or holding tank. In a described embodiment, the flow conduit communicates through a side wall of the containment vessel so that well fluids are flowed laterally out of the interior chamber. At least one fluid pump, such as a variable-speed centrifugal pump, is associated with the flow conduit to flow fluid from the interior chamber to the collection sump. In some embodiments, a third opening is provided in the vessel. A second flow conduit is interconnected with this third opening and is used to flow one or more chemicals, such as methanol, into the interior chamber which prevent hydrate solids or ice crystals from forming.
According to methods of operation, the containment system is assembled and launched from a rig, ship or other platform at the surface of the water. Preferably, the containment vessel is affixed to a riser and then is disposed downwardly from the platform or vessel toward the leaking wellhead. The first and second flow conduits are preferably also secured to the containment vessel and riser during running at the surface prior to launch. However, they may also be interconnected with the containment vessel at a later time using remotely operated vehicles (ROVs). Alternatively, the first and second flow conduits may be integrated into the riser. The containment vessel is moved proximate to and preferably surrounding the wellhead, such that leaking oil is released into the interior chamber of the vessel. It is not essential or even intended that the containment vessel creates a high-pressure seal with or even completely encloses the well head. Seawater inflow into the interior chamber is limited by pressure differential. The fluid pump of the containment system is then actuated to flow leaking hydrocarbon fluid through the first flow conduit and to the collection sump.
According to embodiments of the invention, a controller controls the speed or flow volume of the fluid flow device to maintain a predetermined pressure or flow/fluid interface within the interior chamber, or a pressure at the wellhead annulus site (or PWAS) based upon a set point that is at, above or below seabed pressure. The controller is used to balance fluid flow from the containment vessel with the fluid pump. In one manner of operation, the controller controls the fluid pump to maintain the pump PWAS at a set point that is at, above or below sea bed pressure. Seabed pressure may be measured by a sensor that is carried on the containment vessel or an ROV. Alternatively, seabed pressure may be calculated based upon the wellhead depth and the controller programmed with a set point based upon such calculated sea bed pressure.
In accordance with some embodiments of the invention, leaking well fluids are blocked from flow into the riser during containment by a blocking valve that is operably associated with the riser. According to one method of operation, the riser and containment vessel are disposed into the water and lowered to depth with the blocking valve open to permit fluid flow into the riser and pressure equalization. When the containment vessel is moved proximate the leaking well head, the blocking valve is then closed to prevent flow of leaking well fluids into the riser and thereby prevent an uncontrolled flow of leaking fluids up the riser toward the platform. In an alternative to the blocking valve, the riser may be pressurized from the surface to prevent leaking well fluids from flowing up the riser in an uncontrolled manner.
In alternative embodiments of the invention, fluid flow into the riser is not blocked, and the presence and/or amount of well fluids within the riser is monitored. Alternatively, the location of the point of contact or interface between oil and water within the riser is monitored. Based upon one or more of these determinations, the speed of the pump and flow rate from the containment vessel to the sump is adjusted.
Containment operations are preferably maintained until a relief well is successfully deployed and the well is sealed below the sea floor or another permanent solution to the leaking well head can be implemented. In certain embodiments, the containment system of the present invention may be used while still allowing access to the well through the riser, icy containment vessel and into the leaking well with conventional drill pipe. This is advantageous since the access can be used to pump additional chemicals and/or to deploy additional pumps into the containment vessel or to facilitate other work over operations.
The advantages and further aspects of the invention will be readily appreciated by those of ordinary skill in the art as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference characters designate like or similar elements throughout the several figures of the drawing and wherein:
A containment system 31 in accordance with the present invention includes a containment vessel 32 is affixed to the lower end of the riser 26. An exemplary containment vessel 32 with associated components is depicted in greater detail in
A fluid pump 50 is incorporated into the flow conduit 48. In one embodiment, the pump 50 comprises a centrifugal pump with a variable speed motor and power supply. Depending upon the output of the leaking wellhead 10, there may be more than one flow conduit 48 and pump 50. Pumps can be exchanged by ROV and by cable deployment. Additionally, the size of the flow conduit 48 and the capacity of the pump 50 may be adjusted as necessary to handle the amount of leaking fluids from the wellhead 10. As can be seen in
A second flow conduit 58 extends from chemical tank 60 on the platform 14 to the third opening 46 of the containment vessel 32. The chemical tank 60 is supplied with a pump, as is known in the art, for flowing chemicals from the tank 60 to the interior chamber 36 of the containment vessel 32. In one embodiment, the tank 60 contains one or more chemicals that prevent the formation of undesirable solids, such as solid hydrates and to scales, within the interior chamber 36. Suitable chemicals for this application include methanol. In an embodiment, a fluid distributing ring header 61 is located within the containment vessel 32 and is interconnected to the second flow conduit 58. An exemplary ring header 61 is depicted in
According to one method of operation, the containment system 31 is assembled by affixing the containment vessel 32 to the riser 26 at the platform 14. In addition, the flow conduit 48 and fluid conduit 58 are preferably interconnected with the containment vessel 32 at the platform 14. The hoisting system 22 then extends the riser 26 downwardly through the moonpool 24 in the direction indicated by the arrow 65 in
It is noted that the containment vessel 32 is not intended to fully cap off the well head 10 or even to necessarily fully enclose the well head 10. Rather, it is intended that the vessel 32 be brought proximate the wellhead 10 so that leaking well fluids 11 which are escaping the well head 10 will be drawn by the pump 50 into the interior chamber 36 of the vessel 32 and via the flow conduit 48 to the sump 28. The open lower end 37 of the vessel 32 does not form a seal against the well head 10. The opening 37 is typically large enough so that there is significant spacing between the well head 10 and the vessel 32. However, the containment vessel 32 may be moved downwardly to the point that the lower end 37 will be pushed into an sealed with the mud line of the sea bed 12, as depicted in
According to one method of operation, the controller 54 controls the pump 50 to maintain the pump suction pressure at a set point that is at a predetermined level above, at or below sea bed pressure. The controller 54 is programmed to compare the suction pressure (PWAS) detected by the sensor 52 with the set point, thereby enabling control of flowing pressure. Exemplary set points are those that are generally about 5-10% below the is sea bed pressure. However, the actual amount of difference below or above sea bed pressure can be optimized to minimize the amount of surrounding sea water intake through the opening between the well head 10 and the containment vessel's open end 37. The set point should not be too far below sea bed pressure, which could encourage sea water to flow into the chamber 36, or too far above sea bed pressure, which could encourage well fluids 11 to flow out of the chamber 36 into the surrounding sea 18.
Referring now to
In yet another embodiment of the invention, operators aboard the platform 14 visually examine any fluids leaving the riser 26 of
In instances where the well head 10 is very deep, ice crystals and solid hydrates tend to form. In order to prevent such solids from forming within the interior chamber 36, chemicals are flowed from the tank 60 via conduit 58 to the chamber 36 during a containment operation as described previously. As noted previously, the distribution ring header 61 is useful to ensure relatively consistent distribution of chemicals from tank 60 within the chamber 36.
The containment systems 31 and 31′ are typically to be operated as described previously on a temporary basis until a more permanent solution to the leaking well head 10 can be implemented, such as a relief well completed.
It is pointed out that the containment system 31′ (
The foregoing description is directed to particular embodiments of the present invention for the purpose of illustration and explanation. It will be apparent, however, to one skilled in the art that many modifications and changes to the embodiment set forth above are possible without departing from the scope and the spirit of the invention.
Number | Name | Date | Kind |
---|---|---|---|
1858241 | Giles | May 1932 | A |
1859606 | Fredrick et al. | May 1932 | A |
3745773 | Cunningham | Jul 1973 | A |
4318442 | Lunde et al. | Mar 1982 | A |
4323118 | Bergmann | Apr 1982 | A |
4358218 | Graham | Nov 1982 | A |
4416565 | Ostlund | Nov 1983 | A |
4440523 | Milgram et al. | Apr 1984 | A |
4456071 | Milgram | Jun 1984 | A |
4568220 | Hickey | Feb 1986 | A |
5107931 | Valka et al. | Apr 1992 | A |
6176317 | Sepich | Jan 2001 | B1 |
6415877 | Fincher et al. | Jul 2002 | B1 |
6615923 | Lay, Jr. et al. | Sep 2003 | B1 |
6648081 | Fincher et al. | Nov 2003 | B2 |
6719496 | Von Eberstein | Apr 2004 | B1 |
6817417 | Blair et al. | Nov 2004 | B2 |
6845815 | Hergarden et al. | Jan 2005 | B2 |
6854532 | Fincher et al. | Feb 2005 | B2 |
7051804 | Arning | May 2006 | B1 |
7600571 | Smith | Oct 2009 | B2 |
7987903 | Prado Garcia | Aug 2011 | B1 |
8322437 | Brey | Dec 2012 | B2 |
20030146000 | Dezen et al. | Aug 2003 | A1 |
20070034379 | Fenton et al. | Feb 2007 | A1 |
20120325489 | Beynet et al. | Dec 2012 | A1 |
Number | Date | Country | |
---|---|---|---|
20120087729 A1 | Apr 2012 | US |