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.

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.