Modular, distributed, ROV retrievable subsea control system, associated deepwater subsea blowout preventer stack configuration, and methods of use

1. A modular blowout preventor (BOP) stack for use subsea, comprising:

a. a receptacle base, further comprising a wet make/break electrical connector; and

b. a distributed functional control module adapted for use with a remotely operated vehicle (ROV), the functional control module further comprising:

i. an interface to a predetermined controllable function, the interface further comprising an interface to a receiver receptacle; and

ii. a mateable top portion removably connectable to the receptacle base;

iii. an interface to a female receiver receptacle, the female receiver receptacle in fluid communication with a hydraulic supply input and comprising an output to an assigned BOP operator function port;

iv. an electronics module; and

v. a mateable bottom portion mated to the receptacle base and adapted to receive a tubular therethrough.

2. The BOP stack of claim 1 , wherein the receptacle base is a female receptacle base.

3. The BOP stack of claim 1 , wherein the distributed functional control module is a plurality of distributed functional control modules.

4. The BOP stack of claim 1 , wherein the distributed functional control module is disposed proximate the predetermined controllable device to be controlled by the distributed functional control module.

5. The BOP stack of claim 1 , wherein:

a. the mateable top portion is adapted to receive a tubular therethrough; and

b. one mateable top portion of a first distributed functional control module of the plurality of distributed functional control modules is mated with one mateable bottom portion of a second distributed functional control module of the plurality of distributed functional control modules.

6. The BOP stack of claim 5 , wherein the female receiver receptacle comprises at least one of (i) a hydraulic supply input port or (ii) an outlet for a predetermined BOP port.

7. The BOP stack of claim 5 , wherein the wet make/break electrical connector further comprises conductors adapted to supply the electronics module with at least one of (i) power or (ii) signal.

8. The BOP stack of claim 1 , wherein the distributed functional control module further comprises:

a. a one atmosphere chamber in which an electronics control input/output (I/O) module and power supply are disposed;

b. a pressure compensated housing chamber further comprising:

i. a compensating bladder; and

ii. a pilot valve actuating solenoid;

c. a hydraulic chamber comprising:

i. a pilot valve; and

ii. a function sub plate mounted valve (“S.P.M.”) type poppet valve piloted from the pilot valve actuating solenoid; and

d. a male stab assembly chamber, adapted for interfacing with the statically mounted female receptacle base, further comprising:

i. a base machined with a counterbore profile comprising a taper, the base adapted to accept a male portion of a connector insert comprising male pins;

ii. an interface packer type hydraulic seal positioned and retained in the machined counterbore profile; and

iii. a wet make/break connector portion.

9. The BOP stack of claim 1 , wherein the distributed functional control module further comprises:

a. a one atmosphere chamber in which an electronics control input/output (I/O) module and power supply are disposed;

b. a pressure compensated housing chamber further comprising:

i. a compensating bladder; and

ii. a pilot valve actuating solenoid;

c. a hydraulic chamber comprising:

i. a pilot valve; and

ii. a function sub plate mounted valve (“S.P.M.”) type poppet valve piloted from the pilot valve actuating solenoid; and

d. a mate stab assembly chamber, adapted for interfacing with the statically mounted female receptacle base, further comprising:

i. a base machined with a counterbore profile comprising a taper, the base adapted to accept a male portion of a connector insert comprising mate pins;

ii. an interface packer type hydraulic seal positioned and retained in the machined counterbore profile; and

iii. a wet make/break connector portion.

10. A method of installing a distributed function control module subsea, comprising:

a. using a remotely operated vehicle (ROV) to position a distributed function control module as claimed in claim 1 proximate a control module receiver disposed in a blowout preventer (BOP) stack installed subsea;

b. once positioned, using the ROV to insert a stab end of the distributed function control module into a mating end of a desired distributed function control module receiver which is adapted to receive the stab end.

11. The method of installing a distributed function control module subsea of claim 10 , further comprising:

a. mating a first wet mateable electrical connector disposed proximate the stab end to a second wet mateable electrical connector disposed the proximate receiver at a predetermined insertion point; and

b. once mated, establishing electrical connectivity between control electronics disposed within the distributed function control module and an electrode device disposed outside the distributed function control module.

12. A method of repairing a distributed function control module subsea disposed within a blowout preventer (BOP) stack installed subsea, comprising:

a. positioning a remotely operated vehicle (ROV) proximate an end of a distributed function control module as claimed in claim 1 which has been installed in a BOP, the end located distally from a stab end;

b. disengaging the distributed function control module from a control module receiver with which the distributed function control module is in communication by withdrawing the distributed function control module from the control module receiver;

c. using the ROV to position a replacement distributed function control module as claimed in claim 1 proximate the control module receiver; and

d. once positioned, using the ROV to insert a stab end of the replacement distributed function control module into a mating end of the control module receiver.

13. A modular blowout preventor (BOP) stack for use subsea, comprising:

a. a receptacle base, further comprising a wet make/break electrical connector; and

b. a distributed functional control module adapted for use with a remotely operated vehicle (ROV), the functional control module further comprising:

i. an interface to a predetermined controllable function, the interface further comprising an interface to a receiver receptacle;

ii. a mateable top portion removably connectable to the receptacle base;

iii. an electronics housing selectively engageable with the wet make/break electrical connector;

iv. a connector housing connected to the electrodes housing, and;

v. a pressure compensated housing chamber in fluid communication with the connector housing, the pressure compensated housing further comprising:

i. a compensating bladder disposed within the pressure compensated housing and adapted to aid in equalizing internal pressure of the control module; and

ii. a pilot valve actuating solenoid.

14. The BOP stack of claim 13 , wherein the receptacle base is a female receptacle base.

15. The BOP stack of claim 13 , wherein the distributed functional control module is a plurality of distributed functional control modules.

16. The BOP stack of claim 13 , wherein the distributed functional control module is disposed proximate the predetermined controllable device to be controlled by the distributed functional control module.

17. The BOP stack of claim 13 , wherein:

a. the functional control module interface further comprises an interface to a female receiver receptacle, the female receiver receptacle in fluid communication with a hydraulic supply input and comprising an output to an assigned BOP operator function port;

b. the functional control module further comprises:

i. an electronics module; and

ii. a mateable bottom portion mated to the receptacle base and adapted to receive a tubular therethrough;

c. wherein

i. the mateable top portion is adapted to receive a tubular therethrough; and

ii. one mateable top portion of a first distributed functional control module of the plurality of distributed functional control modules is mated with one mateable bottom portion of a second distributed functional control module of the plurality of distributed functional control modules.

18. The BOP stack of claim 17 , wherein the female receiver receptacle comprises at least one of (i) a hydraulic supply input port or (ii) an outlet for a predetermined BOP port.

19. The BOP stack of claim 17 , wherein the wet make/break electrical connector further comprises conductors adapted to supply the electronics module with at least one of (i) power or (ii) signal.