Suction Pile Wellhead Closure System for Deepwater Flow Containment

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Solution Overview

Problem

Conventional flow control and emergency shut-off procedures for deepwater well drilling are inadequate, particularly when the blowout preventer fails, leading to uncontrollable hydrocarbon flows that are difficult and time-consuming to manage, as seen in incidents like the Macondo prospect well in the Gulf of Mexico.

Innovation Solution

The development of underwater wellhead closure systems utilizing pre-approved, pre-designed suction pile designs and templates with anchoring ports, suction piles, and suction caps that can be rapidly deployed to secure the ocean floor and contain hydrocarbon flows, incorporating suction pumps and redundant piping configurations to manage pressure and flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional blowout preventer systems are used for deepwater well control, then the system can provide basic flow control, but the system fails when the BOP fails leading to uncontrollable flows that are time-consuming to manage

Engineering Contradiction:

Improvewell control reliabilityVSAvoidtime to contain flow

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The suction pile system is pre-installed at the wellhead location before drilling operations begin. The template with anchoring ports and the suction pile structure are prepared in advance, allowing for rapid deployment of the containment system without requiring time-consuming installation during an emergency situation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system provides a pre-configured backup containment solution that cushions against the failure of the primary BOP system. The suction pile structure is designed beforehand to provide an alternative flow control mechanism, ensuring that if the BOP fails, there is already a ready-made containment system in place.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Adaptability or versatility

If drilling operations extend to increasingly deeper waters, then exploration capabilities are expanded, but conventional flow control procedures become inadequate

Engineering Contradiction:

Improvedeepwater drilling capabilityVSAvoidflow control effectiveness

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The system is divided into separate functional components: a template with anchoring ports for securing the structure, a suction pile for providing hold-down force and containment, and integration points for connection to the wellhead. This segmentation allows each component to be optimized for its specific function and facilitates rapid assembly and deployment in deepwater environments.

Inventive Principle:

Principle #1Segmentation

3Ease of operation

If a pre-installed blowout preventer is used, then emergency shut-off capability is provided, but the system becomes time-consuming to implement when drilling relief wells

Engineering Contradiction:

Improveemergency shut-off capabilityVSAvoidtime to implement relief well solution

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The suction pile containment system is pre-installed and positioned at the wellhead location before any emergency occurs. The template is secured to the seabed in advance, and the suction pile structure is ready for immediate activation, eliminating the need to wait for relief well drilling operations to begin.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

These systems enable timely and economical containment of uncontrollable deepwater wellhead flows, potentially shutting in the flow within 72 hours, leveraging pre-configured designs based on site-specific data and existing infrastructure, ensuring rapid deployment and effective shut-in of hydrocarbon flows.

Implementation Method 1

the open end of the pile is embedded into the seabed by hydrostatic pressure

Methodology Applied

Scientific EffectHydrostatic pressure: Pressure Increase

Implementation Method 2

a suction cap that can be disposed about a pre-installed BOP stack and that can contain pressure and flow

Methodology Applied

Scientific EffectSuction: Suction

Data Source

PatentUS8950500B2Suction pile wellhead and cap closure system

Publication Date: 2015.02.10 FLUOR TECH CORP

AI summary

Various embodiments of underwater wellhead closure systems are described that include a template having first and second anchoring ports and that is configured to be secured to a floor of a body of water. A suction pile having a cylindrical body with a head portion and an open bottom can be coupled to the first anchoring port, such that the suction pile can provide additional hold down force to the template. The system can also include a suction cap coupled to the second anchoring port, and having a cylindrical body with an open bottom and a head portion having at least one suction pump.