WO2014142853A1

WO2014142853A1 - Subsea material separation and collection system

Info

Publication number: WO2014142853A1
Application number: PCT/US2013/031070
Authority: WO
Inventors: Hans Smit; Craig MARSTON
Original assignee: Neptune Minerals, Inc.
Priority date: 2013-03-13
Filing date: 2013-03-13
Publication date: 2014-09-18

Abstract

A subsea material separation system includes a hydrocyclone having an inlet, the hydrocyclone configured to receive drilling material from a subsea drilling device via the inlet while the subsea material separation system is positioned on a sea floor; and a plurality of containers configured to move relative to the hydrocyclone. The hydrocyclone is configured to separate the drilling material into at least first and second portions and direct the first portion to at least one of the plurality of containers.

Description

SUBSEA MATERIAL SEPARATION AND COLLECTION SYSTEM

BACKGROUND

[0001] The present disclosure relates generally to the field of subsea mining and the separation of drilled subsea material from the corresponding drilling fluid and other fluids or materials, and more specifically, to systems and methods related to a subsea material separation and collection system that utilizes a hydrocyclone and a carousel assembly in a subsea environment to separate and collect materials obtained through subsea drilling and similar operations.

[0002] Conventional underwater drilling operations often operate to obtain samples of solid materials below the sea floor for analysis, evaluation, etc. There are many challenges associated with effectively and efficiently retrieving such materials from the sea floor.

[0003] As such, various embodiments disclosed herein relate to a subsea material separation and collection system that utilizes a hydrocyclone and a carousel assembly that address many existing challenges.

SUMMARY

[0004] One embodiment relates to a subsea material separation system comprising a hydrocyclone comprising an inlet, the hydrocyclone configured to receive drilling material from a subsea drilling device via the inlet while the subsea material separation system is positioned on a sea floor; and a plurality of containers configured to move relative to the hydrocyclone; wherein the hydrocyclone is configured to separate the drilling material into at least first and second portions and direct the first portion to at least one of the plurality of containers.

[0005] Another embodiment relates to a subsea material separation system for separation of drilling materials in a subsea environment, the system comprising a material separator configured to receive drilling material from a subsea drilling device and separate the drilling material into at least first and second portions; and a carousel assembly coupled to the material separator and comprising a plurality of containers, the carousel assembly configured to be moveable relative to the material separator such that the material separator directs successive amounts of the first portion of drilling material to successive ones of the plurality of containers.

[0006] Another embodiment relates to a method of separating drilling material in a subsea environment, the method comprising receiving drilling material from a subsea drilling operation at a material separator supported on a sea floor; separating the drilling material into first and second portions at the material separator; directing the first portion of the drilling material to a plurality of containers rotatably secured relative to the material separator; and directing the second portion of the drilling material out of the material separator separate from the first portion of the drilling material.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIG. 1 is a schematic representation of a subsea drilling and material separation operation according to an exemplary embodiment.

[0008] FIG. 2 is a perspective view of a material separation assembly usable in connection with the subsea drilling and material separation operation of FIG. 1 according to an exemplary embodiment.

[0009] FIG. 3 is another perspective view of the material separation assembly of FIG. 2 according to an exemplary embodiment.

[0010] FIG. 4 is an exploded view of the material separation assembly of FIG. 2 according to an exemplary embodiment.

[0011] FIG. 5 is a perspective view of a carousel assembly usable with the materials separation system of FIG. 2 according to an exemplary embodiment.

[0012] FIG. 6 is an exploded view of the carousel assembly of FIG. 5.

[0013] FIG. 7 is a detailed perspective view showing a portion of the material separation system of FIG. 2 according to an exemplary embodiment.

[0014] FIG. 8 is a detailed perspective view of a container being inserted and/or removed from the material separation system of FIG. 2 according to an exemplary embodiment. [0015] FIG. 9 is a top view of a drive system usable with the material separation system of FIG. 2 according to an exemplary embodiment.

[0016] FIG. 10 is a block diagram of a method of separating materials in a subsea environment according to an exemplary embodiment.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0017] Referring to the FIGURES generally, various embodiments disclosed herein related to a drilling and cuttings collection system that may utilize, for example, a remote operated vehicle (ROV) operated hydrocyclone subsea cutting collections carousel that enables collection of drill cuttings in increments (e.g., one meter increments) corresponding to the size of a sample tube, such that a carousel of sample tubes may accommodate a total of 20 meters of drill hole or more.

[0018] Referring to FIG. 1, a subsea mining and/or drilling and material collection system 10 is shown according to an exemplary embodiment. Generally, system 10 is intended to provide drilling and material collection capabilities in a subsea environment (e.g., at depths of 2500 feet or more) such that drill cuttings from subsea drilling operations may be effectively and efficiently separated (e.g., separated from the drill fluid), collected, and recovered (e.g., for assay and geotechnical analysis, etc.).

[0019] As shown in FIG. 1, system 10 includes a drilling system 12, a material collection system 14, and a surface vessel 16. In one embodiment, during operation, drilling system 12 operates to remove drilling material from beneath the sea floor. The drilling material is transferred from drilling system 12 to material collection system 14 by way of a subsea pipe 18 (e.g., a pipe, hose, conduit, transfer device, etc.). Material collection system 14 separates the drilling material into separate portions (e.g., to separate the solid drill cuttings from the drilling fluid, etc.) and stores a portion (e.g., the solid drill cuttings) of the drilling material such that the stored portion of drilling material can be raised to surface vessel 16 for analysis, processing, etc. It should be understood that according to various alternative embodiments, system 10 may include more or fewer components than those shown in FIG. 1, and all such configurations are within the scope of the present disclosure. [0020] According to an exemplary embodiment, drilling system 12 includes a drilling device 20 (e.g., a subsea drilling and/or material extraction device, etc.) that may be controlled via a remote operated vehicle (ROV) 24. Drilling device 20 and/or ROV 24 may be controlled from surface vessel 16 via an umbilical 22 or other means. In other embodiments, other configurations of operating a drilling device such as drilling device 20 may be used. In operation, drilling device 20 removes drilling material from beneath the sea floor and transfers the drilling material to material collection system 14 via subsea pipe 18. Drilling device 20 may provide a variety of drill bore sizes, cuttings size, cuttings density, etc., and the sizing of the components of material collection system 14 may be varied accordingly.

[0021] Referring further to FIG. 1, according to an exemplary embodiment, material collection system 14 includes a collection assembly 28 that may be controlled from surface vessel 16 via an ROV 32 and umbilical 30. As with drilling system 12, other configurations for operating collection assembly 28 may be utilized. For example, the ROV or umbilical functions for drilling and collecting material may be integrated into a single ROV and/or umbilical device. Other configurations are possible according to various other

embodiments. In operation, material collection system 14 receives, separates, and stores at least a portion of the drilling material received from drilling system 12 via subsea pipe 18. The separation and collection of the drilling materials is discussed in greater detail below.

[0022] Referring to FIGS. 2-4, in one embodiment, collection assembly 28 includes a lift assembly 34, a carousel assembly 36, and a housing assembly 38. Collection assembly 28 further includes a material separation device, shown as hydrocyclone assembly 40, that directs a portion of the drilled material (e.g., the solid drill cuttings) to a number of collection or sample tubes 42 arranged within or around carousel assembly 36. A hose basket 44 may be provided and coupled to housing assembly 38 and be usable to transport and/or store various hoses, tooling, etc. A camera assembly 46 may also be provided adjacent hydrocyclone assembly 40 to monitor the separation operation during use.

[0023] Lift assembly 34 provides a secure means for raising and lowering collection assembly 28 to/from the sea floor and moving the position of collection assembly 28. As shown in FIG. 2, lift assembly 34 may include an A-frame type shape to facilitate coupling of lift assembly 34 to an umbilical, winch, or similar device. Lift assembly 34 may be configured to be pivotable relative to housing assembly 38 such that lift assembly 34 can lie flat, or generally horizontally, during use of collection system 14 (see, e.g., FIG. 2), and extend generally upward, or vertically, during raising and lowering of collection system 14 (see, e.g., FIG. 3). According to various other embodiments, other types of lift assemblies may be utilized.

[0024] Referring to FIG. 3, housing assembly 38 includes a top frame assembly 80, a bottom frame assembly 82, and a number of sidewalls 84, 86 extending between top frame assembly 80 and bottom frame assembly 82. Housing assembly 38 is coupled to lift assembly 34 by way of top frame assembly 80 (e.g., by way of one or more pivot joints, etc.). In some embodiments, top frame assembly 80 may include one or more support members 90 that are coupled to a top housing member 92. Top housing member 92 defines an aperture 94 (see, e.g., FIG. 7) through which drilled material from hydrocyclone assembly 40 can pass to sample tubes or containers 42. Top housing member 92 further includes a central aperture and a top bushing such that a portion of carousel assembly 36 (e.g., central shaft 76) can rotate relative to top housing member 92 to provide the necessary movement for carousel assembly 36.

[0025] Bottom frame assembly 82 includes one or more supports 108 (see FIG. 3), a bottom member 110, a central aperture 112, and a bearing member 114. Aperture 112 and bearing member 114 are intended to facilitate rotation of central shaft 76 of carousel assembly 36 during use. Bottom member 110 is a generally planar member that provides support for carousel assembly 36. While top and bottom frame assemblies 80, 82 are shown as having generally octangular peripheral shapes, according to various other embodiments, the peripheries of top and bottom frame assemblies 80, 82 may vary (e.g., be circular, square, multi-sided, irregularly-shaped, etc.).

[0026] In one embodiment, a drive mechanism 96 may be configured to rotate carousel assembly 36 relative to housing assembly 38 such that successive containers 42 can be aligned with aperture 94 in top housing member 92 to receive drilled material. For example, as shown in FIG. 9, in one embodiment, drive mechanism 96 may include a motor 98, one or more sprockets 100, and a roller chain 102, such that motor 98 rotates sprockets 100 which in turn rotate carousel assembly 36 by way of roller chain 102. In other embodiments, other types of drive mechanisms may be used to provide various types of movement (e.g., rotational, linear, combinations thereof, etc.) for carousel assembly 36. All such configurations are understood to be within the scope of the present disclosure.

[0027] Referring now to FIGS. 5-6, carousel assembly 36 is shown in greater detail according to an exemplary embodiment. Generally, carousel assembly 36 provides a structure for holding containers 42, and is moveable such that successive containers can be positioned so as to receive drilled material from hydrocyclone assembly 40. In one embodiment, carousel assembly 36 includes a top plate assembly 48, a bottom plate assembly 50, and an intermediate structure 52. Intermediate structure 52 extends between top plate assembly 48 and bottom plate assembly 50 and provides a mounting structure for containers 42. As shown in FIG. 6, top and bottom plate assemblies 48, 50 are generally circular in shape, but according to various other embodiments, top and bottom plate assemblies 48, 50 may take other shapes (e.g., multi-sided, irregularly-shaped, etc.).

[0028] According to one embodiment, top plate assembly 48 includes a plate member 58, a number of ports 60, and a shaft aperture 62. Ports 60 are arranged so as to align with containers 42. According to one embodiment, ports 60 may be formed as through holes in plate member 58. In other embodiments, ports 60 may be cylindrical in shape (e.g., formed as relatively short, tubular members) that direct material from hydrocyclone assembly 40 into containers 42. In general, the number of ports 60 corresponds to the number of containers 42, such that each port 60 is aligned with a corresponding container 42. As shown in FIG. 4, ports 60 are generally equally spaced about the peripheral portion of plate member 58 in a generally circular manner. In alternative embodiments, ports 60 may be otherwise spaced (e.g., unequally spaced, etc.) and be positioned in other configurations.

[0029] Intermediate structure 52 is positioned between and coupled to top plate assembly 48 and bottom plate assembly 50. As shown in FIG. 6, intermediate structure 52 includes a number of baffles 70 extending radially outward from the center of the structure (e.g., outward from central shaft 76). A number of cross-members 72 connect adjacent baffles 70 together at the upper and outer portions of the baffles. As shown in FIG. 6, one or more struts 74 extend downward from each cross-member and act as supports for individual ones of containers 42. In addition, one or more support straps 78 (e.g., bungee cord, elasticized member, etc.) may be coupled to each strut 74 and be configured to wrap around or otherwise secure a container to the strut. [0030] In one embodiment, one strut 74 is positioned generally aligned with each baffle 70, and two struts 74 are provided between adjacent baffles and extending from cross- members 72, resulting in 24 total struts (which in turn can support 24 containers 42). In other embodiments, the size, number, and arrangement of the baffles, cross-members, struts, and other components may be varied to accommodate more or fewer containers, different arrangements of containers, etc.

[0031] According to an exemplary embodiment, bottom plate assembly 50 includes a bottom plate member 64, a shaft aperture 68, and a number of recesses 66. As shown in FIG. 6, recesses 66 are provided around the outer portion of plate member 64, and are sized and spaced such that each recess 66 is configured to receive a corresponding projection on one of the containers 42 (e.g., to assist in securing the containers into proper positions). As such, the number of recesses 66 generally corresponds to the number of struts 74, and in turn, the number of containers 42 supported by carousel assembly 36. As noted above, the size, spacing etc. of the various components may be varied to suit a particular application.

[0032] Referring to FIG. 7, hydrocyclone assembly 40 (e.g., a material separator, etc.) includes an inlet 116, a separation chamber 118, a first outlet 120, and a second outlet 122. Drilling material is received at inlet 116 from drilling system 12 by way of, for example, subsea pipe 18. Separation chamber 118 receives the drilling material from inlet 116 and separates the drilling material into a first, relatively heavier component or portion (e.g., the solid drilling cuttings, etc.), and a second, relatively lighter component or portion (e.g., the drilling fluid, etc.). The heavier portion exits hydrocyclone assembly 40 via first outlet 120 and is directed into a sample container 42 by way of ports 60. The lighter portion exits the hydrocyclone assembly 40 via second outlet 122.

[0033] Referring to FIG. 8, according to an exemplary embodiment, sample containers 42 are generally positioned between top plate assembly 48 and bottom plate assembly 50 of carousel assembly 36. Containers 42 may be "tipped" to be removed from carousel assembly 36. As shown in FIG. 8, ports 60 may extend into the interior of containers 42 when the containers are mounted to carousel assembly 36 (e.g., to assist in guiding material from hydrocyclone assembly 40 to containers 42).

[0034] Referring now to FIG. 10, the use of material collection system 10 according to an exemplary embodiment will be discussed in greater detail. First, drilling system 12 and materials collection system 14 are positioned on a sea floor (step 130). As discussed above, the operations disclosed herein may take place at depths of 2500 feet or more below the surface. The various components, including the drilling and collection systems, may be raised and/or lowered to the surface by any suitable means, such as the use of an umbilical, winch, etc. On the sea floor, drilling system 12 and material collection system 14 are coupled together via a material transfer device such as subsea pipe 18, or a similar material transfer system or means. In some embodiments, drilling system 12 and material collection system 14 may be combined into a single, integrated drilling and material collection system.

[0035] Drilling system 12 drills material from beneath the sea floor (step 132). Any suitable deep sea drilling device may be utilized, and the depth of drilling and amount of material extracted from beneath the sea floor may be varied to suit a particular operation. As discussed above, a drilling device may be controlled by way of an ROV and/or umbilical operated by way of a surface vessel, or by any other suitable means. In some embodiments, drilling system 12 is configured to drill in approximately 1 meter increments that are stored in corresponding sample containers, enabling a single carousel assembly of multiple sample containers to collect 20 meters or more of sample material.

[0036] The drilling material is transferred from the drilling system to the material separation system (step 134). The drilling material is in one embodiment transferred using a subsea pipe such as subsea pipe 18, while other transfer methods may be used according to other alternative embodiments. As mentioned above, in some embodiments subsea pipe 18 may be unnecessary should the material collection system be integrated into the drilling system. Any suitable conduit, etc. may be used as subsea pipe 18.

[0037] At the material collection system, the drilling material is separated into different portions (step 136). In one embodiment, a hydrocyclone is utilized to separate the relatively heavier material (e.g., the solid drill cuttings, etc.) from the relatively lighter material (e.g., the drill cutting fluid, etc.). As such, the hydrocyclone receives drilling material, for example, by way of sub sea pipe 18, and separates the drilling material into, for example, a first, heavier portion, and a second, lighter portion.

[0038] The first, heavier portion of the drilling material is then deposited by the hydrocyclone into one of a number of sample containers, or tubes, such as sample containers 42 (step 138). In one embodiment, the containers are arranged about the perimeter of a carousel assembly and are successively rotated into position to receive material from the hydrocyclone. The carousel assembly continues to rotate containers into position until all of the containers on the carousel assembly are filled.

[0039] Upon all of the containers on the carousel assembly being filled with a portion of the drilling material, the collection system may be transported, or raised, back to the sea surface and surface vessel 16 (step 140). An umbilical, cable, or other device may be used to raise the collection system back to the surface by way of, for example, a lift system such as lift assembly 34. Once at surface vessel 16, the drilling material may be safely unloaded from the collection system and further processed, analyzed, etc. The collection system may then be returned to the sea floor to collect additional sample material. In some

embodiments, multiple collection systems may be utilized such that while one collection system is being raised to the surface for unloading, one or more other collection systems may continue to separate and/or collect drilling material.

[0040] It should be understood that the construction and arrangement of the elements of the drilling and material collection system shown in the exemplary embodiments are illustrative only. Although only a few embodiments of the present disclosure have been described in detail, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements. Some like components have been described in the present disclosure using the same reference numerals in different figures. This should not be construed as an implication that these components are identical in all embodiments; various modifications may be made in various different embodiments. It should be noted that the components and/or assemblies of the drilling and material collection system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and

combinations.

Claims

WHAT IS CLAIMED IS:

1. A subsea material separation system comprising:

a hydrocyclone comprising an inlet, the hydrocyclone configured to receive drilling material from a subsea drilling device via the inlet while the subsea material separation system is positioned on a sea floor; and

a plurality of containers configured to move relative to the hydrocyclone; wherein the hydrocyclone is configured to separate the drilling material into at least first and second portions and direct the first portion to at least one of the plurality of containers.

2. The system of claim 1, further comprising a carousel assembly coupled to the hydrocyclone, wherein the plurality of containers are arranged in a generally circular manner about the carousel and are configured to rotate relative to the hydrocyclone.

3. The system of claim 2, wherein the carousel assembly comprises a central shaft and a plurality of container supports, each container support configured to provide support for a corresponding one of the plurality of containers.

4. The system of claim 3, wherein the carousel assembly comprises a top plate and a bottom plate, the top plate comprising a plurality of apertures, each aperture configured to be substantially aligned with an opening in an end in a corresponding one of the plurality of containers, the bottom plate configured to support a bottom portion of each of the plurality of containers.

5. The system of claim 4, wherein the bottom portion of each of the plurality of containers comprises a projection, and wherein the bottom plate of the carousel assembly comprises a plurality of recesses, each of the plurality of recesses configured to receive the projection on a corresponding one of the plurality of containers.

6. The system of claim 2, further comprising an outer housing, wherein the top and bottom plates of the carousel assembly are provided within the outer housing.

7. The system of claim 6, wherein the outer housing comprises: a top portion;

a bottom portion; and

a plurality of side portions extending between the top and bottom portion, wherein at least one of the plurality of side portions is moveable to provide access to the plurality of containers.

8. The system of claim 2, further comprising a drive assembly configured to rotate the central shaft of the carousel assembly to cause a corresponding rotation of the plurality of containers and enable successive ones of the plurality of containers to receive the first portion of material from the hydrocyclone.

9. The system of claim 1, further comprising a lift assembly configured to enable raising and lowering of the subsea material separation system.

10. The system of claim 1, further comprising a camera configured to capture images of the system during operation.

11. A subsea material separation system for separation of drilling materials in a subsea environment, the system comprising:

a material separator configured to receive drilling material from a subsea drilling device and separate the drilling material into at least first and second portions;

a carousel assembly coupled to the material separator and comprising a plurality of containers, the carousel assembly configured to be moveable relative to the material separator such that the material separator directs successive amounts of the first portion of drilling material to successive ones of the plurality of containers.

12. The subsea material separation system of claim 11, wherein the material separator comprises:

an inlet configured to receive the drilling material from the subsea drilling device;

a first outlet configured to direct the first portion of the drilling material to the plurality of containers; and

a second outlet configured to direct the second portion of the drilling material out of the material separator separate from the first portion.

13. The system of claim 12, wherein the material separator comprises a hydro cyclone.

14. The system of claim 11, wherein the carousel assembly comprises a drive system and a carousel, wherein the carousel supports the plurality of containers, and wherein the drive system is configured to rotate the carousel and the plurality of containers relative to the material separator.

15. The system of claim 14, wherein each of the plurality of containers comprises a tube-shaped container having a closed end and an open end opposite the closed end, the open end configured to face generally upward during operation of the material separator.

16. A method of separating drilling material in a subsea environment, the method comprising:

receiving drilling material from a subsea drilling operation at a material separator supported on a sea floor;

separating the drilling material into first and second portions at the material separator;

directing the first portion of the drilling material to a plurality of containers rotatably secured relative to the material separator; and

directing the second portion of the drilling material out of the material separator separate from the first portion of the drilling material.

17. The method of claim 16, wherein the material separator comprises a hydro cyclone.

18. The method of claim 17, further comprising rotating the plurality of containers relative to the hydrocyclone such that successive ones of the plurality of containers receive successive amounts of the first portion of drilling material from the hydrocyclone.

19. The method of claim 18, wherein rotating the plurality of containers relative to the hydrocyclone comprises rotating a carousel assembly, the carousel assembly supporting the plurality of containers in a generally circular configuration.

20. The method of claim 16, further comprising:

lowering the material separator to the sea floor prior to directing the first portion of the drilling material to the plurality of containers; and

raising the material separator from the sea floor to a surface vessel after directing the first portion of the drilling material to at least a portion of the plurality of containers.