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Perdido, the world's deepest
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production
and drilling platform.
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What we do is like the space
program in the other direction.
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To push engineering frontiers
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to the absolute limit...
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These machines can easily work
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at 10,000-foot depths
or greater.
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Engineers look to
the pioneering innovators
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of the past...
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What once was the wall
has now become the floor.
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So the intumescent paint
now is charring
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due to a chemical reaction.
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That made
the impossible possible.
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Captions by vitac...
www.Vitac.Com
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captions paid for by
discovery communications
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Since the 1940s,
the Gulf of Mexico has provided
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a vital source
of energy for America.
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Almost 2 million barrels
of liquid fuel
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are produced there every day,
and almost half of the country's
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entire petroleum-refining
capacity is on the Gulf coast.
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The challenge of
accessing deep-water reserves
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gets harder and harder.
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We're exhausting the supply
or access to the easy barrels.
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With every new
discovery and development,
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it gets more challenging
and it gets deeper.
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That's what causes us to push
the frontiers of technology.
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To access these
deep-water fuel reserves,
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200 miles from shore
is the revolutionary Perdido,
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the deepest production and
drilling facility in the world.
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It's a $3 billion
engineering colossus.
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The structure itself stands
as tall as the Eiffel Tower
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from the bottom of the spire
all the way to the top
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of the drilling rig.
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Weighing over 60,000 tons,
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00:02:01,020 --> 00:02:04,020
the world's deepest production
and drilling platform
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00:02:04,020 --> 00:02:07,260
is anchored to the sea floor
by nine 2-mile-long
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steel and polyester
mooring lines.
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00:02:10,700 --> 00:02:13,930
Oil and gas from
35 newly discovered Wells,
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00:02:13,930 --> 00:02:17,740
some as far as seven miles away
from the platform,
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00:02:17,740 --> 00:02:19,670
are pumped to the surface.
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00:02:19,670 --> 00:02:24,410
At 550 feet long
and 118 feet in diameter,
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this floating spar
provides the base
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for the three decks where
the oil and gas are processed.
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There's space for
two helicopters, a restaurant,
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a gym, and multiple cabins
to house the crew of 150-plus,
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00:02:38,760 --> 00:02:41,790
who live and work
on this record-breaking platform
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for 14 days at a time.
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Perdido is
an engineering achievement
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once thought impossible.
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You're going into
a frontier area
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00:02:56,540 --> 00:03:01,580
in what we call
the ultra-deep water.
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00:03:01,580 --> 00:03:06,620
We are going in reservoirs that
had not truly been tested before
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in new plays
for the oil and gas industry
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in the Gulf of Mexico.
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You are going into
one of the most severe
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environmental conditions
as you can imagine,
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in 7,800 feet of water.
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00:03:17,530 --> 00:03:19,830
Making Perdido possible required
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00:03:19,830 --> 00:03:24,640
a giant technological leap.
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00:03:24,640 --> 00:03:27,770
Oil and gas fields wouldn't
exist without the death
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of tiny plants and creatures.
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00:03:35,650 --> 00:03:37,580
While dinosaurs
roamed the earth,
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gazillions of dead plankton
and algae built up
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on the sea floor...
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Oh, crikey.
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00:03:43,520 --> 00:03:49,360
Before a crust of rock
formed over the top.
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00:03:49,360 --> 00:03:52,030
Millions of years of pressure
and the earth's heat
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essentially cooked this
into an energy-rich soup.
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00:03:56,400 --> 00:03:58,540
But getting to it underwater
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00:03:58,540 --> 00:04:01,170
has never been easy.
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00:04:05,850 --> 00:04:08,750
Because it had to operate
at an unprecedented depth
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of 7,800 feet,
engineers determined Perdido
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00:04:12,790 --> 00:04:15,750
couldn't have legs
like a standard oil rig.
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00:04:15,760 --> 00:04:18,320
The reason we couldn't use
a conventional
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00:04:18,330 --> 00:04:22,260
tension leg platform was because
the water depth was so great
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00:04:22,260 --> 00:04:25,060
that those tension legs
would be too heavy
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00:04:25,070 --> 00:04:28,500
for any structure
to be able to support.
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To go this deep,
Perdido's designers drew on
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00:04:31,810 --> 00:04:34,170
a breakthrough
military technology
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called the floating
instrument platform.
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In San Diego, California,
mechanical engineer Dan Dickrell
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is exploring one of history's
most unique vessels.
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00:04:59,900 --> 00:05:02,600
In the early 1960s,
the U.S. Navy was looking for
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00:05:02,600 --> 00:05:05,840
a new type of research platform
from which to take precise
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00:05:05,840 --> 00:05:07,710
underwater
acoustic measurements.
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00:05:07,710 --> 00:05:09,770
Now, the submarines
they'd been using previously
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00:05:09,780 --> 00:05:11,740
were deemed unstable
due to their shape.
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00:05:11,750 --> 00:05:14,180
They would yaw in the water,
making it impossible
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00:05:14,180 --> 00:05:16,480
for the scientists on board
to take the precise measurements
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00:05:16,480 --> 00:05:19,250
they needed.
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00:05:19,250 --> 00:05:21,550
Oceanographer
and underwater explorer
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00:05:21,550 --> 00:05:24,690
Fred Spiess developed
a more balanced solution
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00:05:24,690 --> 00:05:28,330
that changed deep-sea
exploration forever.
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00:05:28,330 --> 00:05:31,230
After months
of testing various designs,
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Spiess and his team came up
with this, the R.P. Flip,
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00:05:34,900 --> 00:05:40,510
a floating instrument platform.
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00:05:40,510 --> 00:05:42,670
But flip
earns its name in another,
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00:05:42,680 --> 00:05:45,240
more extraordinary way.
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00:05:50,120 --> 00:05:53,990
This one-of-a-kind,
350-foot-long spar buoy
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00:05:53,990 --> 00:05:58,090
can go from horizontal to
vertical in just 30 minutes.
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00:06:03,860 --> 00:06:06,900
But how does this work
with crew on board?
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00:06:12,970 --> 00:06:15,040
During the flip itself,
everyone comes,
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00:06:15,040 --> 00:06:16,940
stands out on the outside decks.
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00:06:16,940 --> 00:06:21,010
As the process occurs,
the decks and the bulkheads
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00:06:21,010 --> 00:06:22,680
exchange places throughout
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00:06:22,680 --> 00:06:25,150
the horizontal-to-vertical
transformation.
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00:06:33,460 --> 00:06:35,630
Most rooms on board
have two doors...
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00:06:35,630 --> 00:06:39,600
One horizontal orientation,
and another door
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00:06:39,600 --> 00:06:42,270
for the vertical orientation
of the platform.
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00:06:42,270 --> 00:06:44,840
Now, in the configuration
it is right now,
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00:06:44,840 --> 00:06:46,370
we're in
the horizontal position.
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00:06:46,370 --> 00:06:48,810
But imagine what happens
when the flip occurs.
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00:06:48,810 --> 00:06:53,110
What once was the wall
has now become the floor,
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00:06:53,110 --> 00:06:58,150
and what once was the floor
has now become the wall.
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00:06:58,150 --> 00:06:59,550
Everything on flip
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00:06:59,550 --> 00:07:03,320
is designed in two
configurations...
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00:07:03,320 --> 00:07:04,720
Look at this.
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00:07:04,720 --> 00:07:06,790
It's a sink.
It's a bathroom sink.
119
00:07:06,790 --> 00:07:09,690
But, oh, it pivots.
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00:07:09,700 --> 00:07:11,800
How bizarre is that?
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00:07:11,800 --> 00:07:14,430
From rotating
condiment racks in the galley
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00:07:14,430 --> 00:07:18,640
to tables on the walls.
123
00:07:18,640 --> 00:07:21,270
To maintain its stable position
in the horizontal,
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00:07:21,270 --> 00:07:22,840
there are huge concrete blocks
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00:07:22,840 --> 00:07:24,910
underneath what is
now the floor.
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00:07:24,910 --> 00:07:27,910
But when it's time to change
and flip from horizontal
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00:07:27,910 --> 00:07:30,880
to vertical,
tons of seawater are pumped into
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00:07:30,880 --> 00:07:33,120
those ballast chambers slowly
129
00:07:33,120 --> 00:07:36,920
that changes from horizontal
to perfectly vertical.
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00:07:36,920 --> 00:07:39,960
It's so cool.
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00:07:39,960 --> 00:07:41,430
When flipped vertically,
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00:07:41,430 --> 00:07:44,960
amazing stability is provided
by the 800 tons of water
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00:07:44,960 --> 00:07:47,930
inside a ballast tank
in the long spar
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00:07:47,930 --> 00:07:49,870
sitting below the surface.
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00:07:49,870 --> 00:07:55,670
Flip is so steady it can deal
with swells up to 275 feet high
136
00:07:55,680 --> 00:07:58,440
and is still in use today.
137
00:07:58,440 --> 00:08:02,080
Oh, this platform is too crazy.
138
00:08:13,830 --> 00:08:16,360
Engineers in Finland
built on the principles
139
00:08:16,360 --> 00:08:19,230
of Spiess' flip design
to construct the world's
140
00:08:19,230 --> 00:08:21,230
biggest floating spar.
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00:08:29,710 --> 00:08:33,440
The spar itself is
constructed quite ingeniously.
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00:08:33,450 --> 00:08:35,610
It's done in slices.
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00:08:35,620 --> 00:08:37,450
You cut it into slices.
144
00:08:39,990 --> 00:08:43,320
And it's from the top
of it to the can section,
145
00:08:43,320 --> 00:08:46,160
and then the truss section
you do.
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00:08:46,160 --> 00:08:49,560
And then it's welded
together slice by slice.
147
00:08:51,700 --> 00:08:53,700
Each of the seven-ring sections
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00:08:53,700 --> 00:08:56,230
has 12 self-contained
compartments,
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00:08:56,240 --> 00:08:59,440
so if disaster strikes
and a compartment is punctured,
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00:08:59,440 --> 00:09:04,140
then only that compartment
would flood with water.
151
00:09:04,140 --> 00:09:07,980
On the end of the can section,
an open truss of pipe works
152
00:09:07,980 --> 00:09:10,620
and the ballast area are added
153
00:09:10,620 --> 00:09:14,320
to complete
this massive structure.
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00:09:14,320 --> 00:09:17,660
Perdido's spar
is about 550 feet.
155
00:09:17,660 --> 00:09:20,890
In diameter, it's 118 feet.
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00:09:26,100 --> 00:09:28,570
Then the spar
was delivered by ship
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00:09:28,570 --> 00:09:31,870
to the Perdido site
in the Gulf of Mexico.
158
00:09:34,770 --> 00:09:40,110
To reach depths of 7,800 feet,
plugs are pulled to let seawater
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00:09:40,110 --> 00:09:44,450
into the ballast, and then,
like Fred Spiess' flip ship,
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00:09:44,450 --> 00:09:47,290
Perdido's spar slowly
begins the process
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of switching from
horizontal to vertical.
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00:09:52,630 --> 00:09:55,930
So they also pump water
into the tanks
163
00:09:55,930 --> 00:09:59,460
inside the can section,
and that lowers it to give it
164
00:09:59,470 --> 00:10:05,970
that stability to allow the
pitch and the roll to stabilize.
165
00:10:05,970 --> 00:10:09,110
Once upended,
the spar must then be secured
166
00:10:09,110 --> 00:10:14,350
to brace against storms, or
so-called tropical disturbances.
167
00:10:14,350 --> 00:10:17,780
We have a long duration...
Relatively long duration
168
00:10:17,780 --> 00:10:19,620
before we can get to storm-safe.
169
00:10:19,620 --> 00:10:23,350
The first disturbance is
predicted to be here within
170
00:10:23,360 --> 00:10:27,220
about seven to eight days.
171
00:10:27,230 --> 00:10:30,160
Nine supersized
mooring lines had to be tethered
172
00:10:30,160 --> 00:10:32,600
to the floating spar
to the sea floor,
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00:10:32,600 --> 00:10:38,970
totaling around
20 miles of chain and rope.
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00:10:38,970 --> 00:10:42,270
So what we do in order
to secure the structure
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00:10:42,280 --> 00:10:44,940
floating on the surface is
we connect the suction anchors
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00:10:44,940 --> 00:10:48,180
on the sea floor
with 2-mile-long,
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00:10:48,180 --> 00:10:52,150
huge polyester mooring lines,
about 25 inches thick,
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00:10:52,150 --> 00:10:58,320
and massive steel chains on
either side of the mooring line.
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00:10:58,320 --> 00:11:00,760
For maximum
protection from storms,
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00:11:00,760 --> 00:11:05,430
the lines fan out for more than
1 1/2 miles around the spar.
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00:11:09,470 --> 00:11:11,540
Now, it's still sitting
pretty high in the water,
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00:11:11,540 --> 00:11:15,640
so they put a weight in the
bottom, essentially iron ore.
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00:11:15,640 --> 00:11:19,340
They pump into a tank at the
bottom of that truss section,
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00:11:19,350 --> 00:11:23,850
so you have a lot of weight
at the bottom tank.
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00:11:23,850 --> 00:11:26,280
With the additional
weight and the mooring lines,
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Perdido's spar
is finally storm-safe.
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00:11:34,760 --> 00:11:37,800
But this was just the first step
in creating the world's
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00:11:37,800 --> 00:11:41,600
deepest production
and drilling facility.
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00:11:41,600 --> 00:11:43,570
It was critical
to get the top sides
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00:11:43,570 --> 00:11:46,870
to be a certain weight
because we wanted to do
191
00:11:46,870 --> 00:11:50,810
the top sides' installation
with a single lift.
192
00:11:50,810 --> 00:11:53,610
To do this,
the team had to produce
193
00:11:53,610 --> 00:11:55,680
more engineering
breakthroughs...
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00:11:55,680 --> 00:11:58,580
You just can't
get people down there,
195
00:11:58,580 --> 00:12:01,690
yet a considerable amount
of work has to still be done
196
00:12:01,690 --> 00:12:04,160
at these water depths.
197
00:12:04,160 --> 00:12:06,420
To deliver this
record-breaking feat
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00:12:06,430 --> 00:12:08,660
of impossible engineering.
199
00:12:19,970 --> 00:12:21,470
Perdido.
200
00:12:21,470 --> 00:12:25,840
About 200 miles off the Texas
coastline in the Gulf of Mexico,
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00:12:25,840 --> 00:12:28,940
the world's deepest production
and drilling platform
202
00:12:28,950 --> 00:12:34,020
is at the cutting edge of
ultra-deep water operations.
203
00:12:34,020 --> 00:12:37,250
Moored in waters
nearly 1 1/2 miles deep,
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00:12:37,250 --> 00:12:40,320
the rig extracts oil
from 35 Wells
205
00:12:40,320 --> 00:12:43,190
across three
newly discovered oil fields,
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00:12:43,190 --> 00:12:48,630
producing 100,000 barrels
of oil each day.
207
00:12:48,630 --> 00:12:56,070
But creating a rig like this
called for daring engineering.
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00:12:56,070 --> 00:12:58,970
Once workers anchored
the world's biggest spar,
209
00:12:58,980 --> 00:13:03,580
the next step was to connect
the all-important top side.
210
00:13:03,580 --> 00:13:06,280
What we call the top side
is all of the equipment
211
00:13:06,280 --> 00:13:09,880
that sits on
the structure in the water
212
00:13:09,890 --> 00:13:14,320
that allows us to produce
the oil and gas.
213
00:13:14,320 --> 00:13:16,660
It was critical to get
the top sides to be
214
00:13:16,660 --> 00:13:19,690
a certain weight because
we wanted to do
215
00:13:19,700 --> 00:13:22,330
the top sides' installation
with a single lift
216
00:13:22,330 --> 00:13:25,630
in the interest of doing it
efficiently and safely.
217
00:13:25,640 --> 00:13:28,900
Traditionally,
these multi-story megaplants
218
00:13:28,910 --> 00:13:30,770
are assembled at sea.
219
00:13:30,770 --> 00:13:33,440
But a location
as remote as Perdido's
220
00:13:33,440 --> 00:13:36,410
called for a different solution.
221
00:13:36,410 --> 00:13:39,080
The top sides were
constructed at Ingleside, Texas,
222
00:13:39,080 --> 00:13:42,620
and they were done one layer
at a time, like a birthday cake,
223
00:13:42,620 --> 00:13:44,820
and there are three layers
on the deck of Perdido.
224
00:13:44,820 --> 00:13:47,960
All that was done
in the construction yard,
225
00:13:47,960 --> 00:13:51,090
and then you had
a heavy-lifting device
226
00:13:51,090 --> 00:13:54,500
that took that entire
three-deck layer
227
00:13:54,500 --> 00:13:59,900
and put it on a barge
and shipped it offshore.
228
00:13:59,900 --> 00:14:03,170
With the final weight
around 11,000 tons,
229
00:14:03,170 --> 00:14:08,410
the top side began its journey
deep into the Gulf of Mexico,
230
00:14:08,410 --> 00:14:11,880
where the giant crane vessel,
the Thialf, was waiting
231
00:14:11,880 --> 00:14:16,620
to begin the biggest single lift
ever attempted there.
232
00:14:16,620 --> 00:14:21,420
This was the moment of truth,
when engineers attempted
233
00:14:21,420 --> 00:14:25,460
to connect the spar
to the top side.
234
00:14:25,460 --> 00:14:28,360
Remember, these things,
they were built separately,
235
00:14:28,360 --> 00:14:32,200
one in Finland and one in Texas,
and all by measurements,
236
00:14:32,200 --> 00:14:34,200
and all of a sudden,
this was the first time
237
00:14:34,200 --> 00:14:38,340
they said, "things
better mate together."
238
00:14:38,340 --> 00:14:40,510
And there's a lot
of very anxious moments
239
00:14:40,510 --> 00:14:46,550
as that crane is lifting
that top side on to that hull.
240
00:14:46,550 --> 00:14:47,820
As the lift began,
241
00:14:47,820 --> 00:14:53,890
the top sides were
pivoted into position.
242
00:14:53,890 --> 00:14:55,760
And they fit perfectly.
243
00:14:59,700 --> 00:15:05,330
To see those pins go in,
it's a wonderful feeling.
244
00:15:05,330 --> 00:15:09,340
At last, the spar
settled into its new draft.
245
00:15:13,480 --> 00:15:16,640
With this mammoth construction
milestone complete,
246
00:15:16,650 --> 00:15:20,310
the Perdido team had to focus on
installing production equipment
247
00:15:20,320 --> 00:15:22,180
on the sea floor.
248
00:15:22,190 --> 00:15:25,850
But at 7,800 feet
below the surface,
249
00:15:25,860 --> 00:15:29,790
with a terrain resembling
a mountain range,
250
00:15:29,790 --> 00:15:34,960
this is a seemingly impossible
working environment.
251
00:15:34,960 --> 00:15:36,730
It's extreme amount of pressure.
252
00:15:36,730 --> 00:15:38,370
In addition to that,
it's really, really cold
253
00:15:38,370 --> 00:15:40,800
down there, so you're talking
temperatures in the order of
254
00:15:40,800 --> 00:15:44,970
38 degrees Fahrenheit, so, very,
very cold, and there's no light.
255
00:15:44,970 --> 00:15:47,780
So it's very hostile conditions
in terms of the pressures
256
00:15:47,780 --> 00:15:50,040
we have down there.
257
00:15:50,050 --> 00:15:52,750
With sophisticated
deep-sea hardware needed
258
00:15:52,750 --> 00:15:55,650
on the sea floor,
physically interacting with it
259
00:15:55,650 --> 00:15:57,920
is practically impossible.
260
00:15:57,920 --> 00:16:01,720
You just can't get people down
there, yet a consider amount
261
00:16:01,720 --> 00:16:06,190
of work has to still be done
at these water depths.
262
00:16:06,200 --> 00:16:08,460
In an environment
where even fish
263
00:16:08,460 --> 00:16:12,030
struggle to survive,
how do you carry out
264
00:16:12,030 --> 00:16:14,240
some of the most advanced
engineering work
265
00:16:14,240 --> 00:16:16,370
at these high-pressure depths?
266
00:16:16,370 --> 00:16:20,010
This problem required
another ingenious innovation
267
00:16:20,010 --> 00:16:21,510
from the past...
268
00:16:21,510 --> 00:16:23,310
Check this out. Look at this.
269
00:16:23,310 --> 00:16:31,190
That arm right in there
exactly mimics my actions.
270
00:16:31,190 --> 00:16:33,790
Cool.
271
00:16:33,790 --> 00:16:37,160
To make the impossible possible.
272
00:16:49,830 --> 00:16:51,730
The Perdido platform.
273
00:16:51,730 --> 00:16:55,000
In the Gulf of Mexico,
this engineering giant
274
00:16:55,000 --> 00:16:59,840
is the deepest production and
drilling platform on the planet.
275
00:16:59,840 --> 00:17:03,470
But to drill at the staggering
depth of 7,800 feet
276
00:17:03,480 --> 00:17:08,050
in the water, engineers had to
look to an ingenious innovation
277
00:17:08,050 --> 00:17:12,980
from the past,
the telemanipulator.
278
00:17:18,930 --> 00:17:22,790
In the 1950s, America was
at the forefront of developing
279
00:17:22,800 --> 00:17:26,560
nuclear power for peacetime use.
280
00:17:26,570 --> 00:17:29,600
Crucial to this movement
was Chicago's vast
281
00:17:29,600 --> 00:17:32,240
Argonne national laboratory.
282
00:17:36,810 --> 00:17:39,510
And professor Eric Lima
is here to reveal
283
00:17:39,510 --> 00:17:43,210
the breakthrough telemanipulator
technology that lets scientists
284
00:17:43,220 --> 00:17:46,780
safely handle
radioactive material.
285
00:17:46,790 --> 00:17:52,290
And so, what they would use
are these incredible arms,
286
00:17:52,290 --> 00:17:53,590
and this is really cool.
287
00:17:53,590 --> 00:17:54,960
Look at this.
288
00:17:54,960 --> 00:17:59,900
On the other side of that glass,
it does exactly what I do.
289
00:17:59,900 --> 00:18:02,730
And not only does it
move back and forth, in and out,
290
00:18:02,740 --> 00:18:03,870
but check this out.
291
00:18:03,870 --> 00:18:05,170
Look at this.
292
00:18:05,170 --> 00:18:12,680
That arm right in there
exactly mimics my actions.
293
00:18:12,680 --> 00:18:14,310
Cool.
294
00:18:14,310 --> 00:18:18,120
Called mechanical
master slave manipulators,
295
00:18:18,120 --> 00:18:22,790
or MSMS, these devices allowed
technicians to transfer
296
00:18:22,790 --> 00:18:24,990
basic movements to a second arm
297
00:18:24,990 --> 00:18:27,860
from behind the safety
of a glass wall.
298
00:18:27,860 --> 00:18:33,930
But their dexterity and strength
was still limited.
299
00:18:33,930 --> 00:18:38,170
That is, until 1954,
when engineer Raymond Goertz
300
00:18:38,170 --> 00:18:41,770
added a motor to each arm,
connected by an electric cable,
301
00:18:41,780 --> 00:18:45,380
spawning the powerful
telemanipulator.
302
00:18:45,380 --> 00:18:48,450
It's actually
a force multiplier.
303
00:18:48,450 --> 00:18:51,680
So, I could pick up something
very heavy just like
304
00:18:51,690 --> 00:18:54,420
I was gripping it with
my hand and move it over.
305
00:18:54,420 --> 00:18:55,920
Well, look.
There's another arm right there.
306
00:18:55,920 --> 00:18:57,160
I could use both of them.
307
00:18:58,690 --> 00:19:00,960
It's, like, right out
of some cyborg thing.
308
00:19:00,960 --> 00:19:01,930
Whoa.
309
00:19:01,930 --> 00:19:03,130
It's making noises.
310
00:19:03,130 --> 00:19:06,300
That's the servo motors
up there.
311
00:19:06,300 --> 00:19:09,270
The motors
not only multiplied force.
312
00:19:09,270 --> 00:19:13,910
They also allowed the operator
to feel the movements.
313
00:19:13,910 --> 00:19:17,340
Improved precision was matched
by greater flexibility,
314
00:19:17,340 --> 00:19:20,280
and the electrical cable
connection allowed engineers
315
00:19:20,280 --> 00:19:24,780
to separate the master
and slave arms.
316
00:19:24,780 --> 00:19:28,320
Goertz was able to decouple
the arms, and what that means
317
00:19:28,320 --> 00:19:32,390
is they can be as far apart and
in any location that we want,
318
00:19:32,390 --> 00:19:34,960
so we could actually have
the slave arm coming up
319
00:19:34,960 --> 00:19:38,000
from the floor or coming at
some weird angle to get us
320
00:19:38,000 --> 00:19:39,660
right where we want it to go.
321
00:19:44,000 --> 00:19:45,840
Over the following decades,
322
00:19:45,840 --> 00:19:48,910
Goertz's remote technology
was further finessed,
323
00:19:48,910 --> 00:19:51,880
producing a series of
telemanipulators
324
00:19:51,880 --> 00:19:53,580
that combined safety...
325
00:19:53,580 --> 00:19:55,510
Okay.
326
00:19:55,520 --> 00:19:58,520
With robotic precision.
327
00:19:58,520 --> 00:20:00,450
So, thanks to Goertz
and his work
328
00:20:00,450 --> 00:20:01,950
at Argonne national laboratory,
329
00:20:01,960 --> 00:20:03,990
developing these
telemanipulators,
330
00:20:03,990 --> 00:20:06,260
we are able to go, as humans,
331
00:20:06,260 --> 00:20:11,660
in places that we've never
been able to go before.
332
00:20:19,340 --> 00:20:22,140
Resembling a scene
from a Sci-Fi novel,
333
00:20:22,140 --> 00:20:26,210
engineers at Perdido are using
telemanipulator technology
334
00:20:26,210 --> 00:20:32,480
to work at sea depths that
were once thought impossible.
335
00:20:32,490 --> 00:20:36,520
This fleet of remote-operated
vehicles, or R.O.V.S,
336
00:20:36,520 --> 00:20:40,790
sweep the sea floor
beneath the platform.
337
00:20:40,790 --> 00:20:43,130
This is exactly
the type of R.O.V.
338
00:20:43,130 --> 00:20:44,460
That we would use on Perdido.
339
00:20:44,460 --> 00:20:47,330
This is a 1,000-pound
thrust machine.
340
00:20:47,330 --> 00:20:49,470
One of the main reasons we use
them is simply because
341
00:20:49,470 --> 00:20:51,700
below about
600-foot water depth,
342
00:20:51,700 --> 00:20:53,140
it gets really, really dicey,
343
00:20:53,140 --> 00:20:55,570
really, really risky
to have humans at those depths.
344
00:20:55,580 --> 00:20:57,040
Enter the R.O.V.
345
00:20:57,040 --> 00:21:00,410
These machines can easily work
at 10,000-foot water depth
346
00:21:00,410 --> 00:21:03,010
or greater, and we can always
get them back,
347
00:21:03,020 --> 00:21:07,120
and they never get hurt.
348
00:21:07,120 --> 00:21:13,690
These sub-aqua robots
are equipped for serious work.
349
00:21:13,690 --> 00:21:16,260
These are our hands
that actually connect and attach
350
00:21:16,260 --> 00:21:18,030
all the different
equipment we need.
351
00:21:18,030 --> 00:21:20,530
And here is our eyes.
352
00:21:20,530 --> 00:21:22,070
This camera,
this high-definition camera
353
00:21:22,070 --> 00:21:26,940
is how we see what
we have going on down there.
354
00:21:26,940 --> 00:21:30,110
A leap forward
from Goertz's telemanipulators,
355
00:21:30,110 --> 00:21:33,210
these R.O.V.S can be
operated by a joystick
356
00:21:33,210 --> 00:21:37,280
using a fly-by wire system
back on board the rig.
357
00:21:37,280 --> 00:21:41,850
That allows a R.O.V. To fly out
on excursions and move about
358
00:21:41,860 --> 00:21:44,460
the well pattern to go from
one well to the next,
359
00:21:44,460 --> 00:21:49,060
so they can survey
the entire subsea system.
360
00:21:50,860 --> 00:21:53,130
Installation,
drilling, and maintenance
361
00:21:53,130 --> 00:21:55,570
can all be achieved remotely.
362
00:21:55,570 --> 00:21:58,900
But there was one daunting task
the R.O.V. Engineers
363
00:21:58,910 --> 00:22:02,840
had to overcome...
Getting the oil to shore.
364
00:22:02,840 --> 00:22:07,480
So, you're 150 miles
offshore of the coast of Texas.
365
00:22:07,480 --> 00:22:10,680
And you had to get that oil
and gas back to the beach.
366
00:22:10,680 --> 00:22:12,720
Most of the oil pipelines
that you have
367
00:22:12,720 --> 00:22:15,820
in the Gulf of Mexico
start in less than 5,000 feet
368
00:22:15,820 --> 00:22:17,960
of water depth,
so we had to connect
369
00:22:17,960 --> 00:22:21,690
from Perdido's location
to oil pipelines
370
00:22:21,690 --> 00:22:22,990
and gas pipelines that are
371
00:22:23,000 --> 00:22:25,830
further up
in the shallower water.
372
00:22:28,740 --> 00:22:30,840
Connecting to a live export line
373
00:22:30,840 --> 00:22:33,770
at these depths
had never been attempted.
374
00:22:33,770 --> 00:22:36,910
The pipe had to be cut
and connector installed
375
00:22:36,910 --> 00:22:41,250
with extraordinary precision,
and at nearly 5,000 feet,
376
00:22:41,250 --> 00:22:45,650
it was completely
out of human reach.
377
00:22:45,650 --> 00:22:49,020
Over a two-year period,
the Perdido team designed
378
00:22:49,020 --> 00:22:53,060
and rehearsed for this
procedure with the R.O.V.
379
00:22:53,060 --> 00:22:58,430
And when they made
the attempt, it worked.
380
00:22:58,430 --> 00:23:01,600
To be able to do all that
with remote-operated vehicles
381
00:23:01,600 --> 00:23:03,830
and the water depth
that they did that at Perdido
382
00:23:03,840 --> 00:23:04,700
was world-class.
383
00:23:04,700 --> 00:23:08,610
Never been done before.
384
00:23:11,440 --> 00:23:14,110
This state-of-the-art
solution is opening up
385
00:23:14,110 --> 00:23:17,280
the depths of the sea.
386
00:23:17,280 --> 00:23:20,320
But to tap into the world's
deepest oil reserves,
387
00:23:20,320 --> 00:23:25,090
Perdido's engineers
had to look to the past...
388
00:23:25,090 --> 00:23:26,660
The moment I flip this switch,
389
00:23:26,660 --> 00:23:29,090
something very exciting
is going to happen.
390
00:23:29,100 --> 00:23:33,230
To produce more
impossible engineering.
391
00:23:46,900 --> 00:23:49,200
The Perdido platform
is the deepest
392
00:23:49,210 --> 00:23:52,770
offshore production and drilling
facility ever built.
393
00:23:52,780 --> 00:23:59,080
It has pushed the boundaries
of offshore engineering.
394
00:23:59,080 --> 00:24:03,020
This deep-sea hub
has 22 Wells directly underneath
395
00:24:03,020 --> 00:24:06,560
its structure,
and its reach is far greater.
396
00:24:06,560 --> 00:24:10,060
An additional 13 Wells
across three oil fields
397
00:24:10,060 --> 00:24:14,600
transport crude through a nearly
200-mile web of pipeline.
398
00:24:18,140 --> 00:24:23,370
But creating ultra-deep
offshore Wells is no easy task.
399
00:24:23,370 --> 00:24:25,440
So, when you're offshore,
drilling's a little bit
400
00:24:25,440 --> 00:24:27,440
different than
if you're on land.
401
00:24:27,440 --> 00:24:30,710
In Perdido's Wells,
the total well depth
402
00:24:30,710 --> 00:24:34,620
was somewhere
around 17,000 feet.
403
00:24:34,620 --> 00:24:37,350
But almost half of that,
7,800 feet of it,
404
00:24:37,350 --> 00:24:39,620
was just the water column.
405
00:24:39,620 --> 00:24:42,860
Each new well
must be drilled with precision,
406
00:24:42,860 --> 00:24:45,660
keeping the water out
and the oil in,
407
00:24:45,660 --> 00:24:48,160
or both the project
and the environment
408
00:24:48,170 --> 00:24:50,430
could be irreversibly damaged.
409
00:24:50,430 --> 00:24:53,500
To prevent the oil from leaking,
engineers look to
410
00:24:53,500 --> 00:24:58,840
a revolutionary innovation,
the conductor pipe.
411
00:25:09,320 --> 00:25:12,690
Andrew Smyth is exploring
Titusville, Pennsylvania,
412
00:25:12,690 --> 00:25:15,660
to discover how the conductor
pipe paved the way
413
00:25:15,660 --> 00:25:19,530
for an economic boom
of black gold.
414
00:25:19,530 --> 00:25:21,700
The moment I flip this switch,
415
00:25:21,700 --> 00:25:24,070
something very exciting
is going to happen.
416
00:25:28,270 --> 00:25:29,800
Here it comes. You can see it.
417
00:25:29,810 --> 00:25:32,840
Pennsylvania crude.
418
00:25:32,840 --> 00:25:35,380
It was here in the small town
of Titusville
419
00:25:35,380 --> 00:25:39,310
that the hunt for oil took off
at a scale never before seen,
420
00:25:39,320 --> 00:25:46,150
and all because
of one man's simple innovation.
421
00:25:46,160 --> 00:25:49,930
In 1859,
railway worker Edwin Drake
422
00:25:49,930 --> 00:25:52,560
gambled his life savings on
a small stake
423
00:25:52,560 --> 00:25:57,970
of the newly formed Pennsylvania
rock and oil company.
424
00:25:57,970 --> 00:26:01,600
Drake, as a stakeholder and now
employee, was sent here,
425
00:26:01,610 --> 00:26:05,140
to this very site, where
he began his search for oil.
426
00:26:05,140 --> 00:26:08,640
But early attempts
were met with mixed results.
427
00:26:12,320 --> 00:26:15,050
So, at the time,
the practice in drilling
428
00:26:15,050 --> 00:26:17,690
was to use something
called percussion drilling,
429
00:26:17,690 --> 00:26:21,490
where the drill is just hammered
down through the soil
430
00:26:21,490 --> 00:26:24,630
until you reach your oil.
431
00:26:24,630 --> 00:26:27,200
But Titusville's
water-sodden ground
432
00:26:27,200 --> 00:26:30,670
thwarted his plans at extracting
the oil effectively.
433
00:26:30,670 --> 00:26:34,440
As you withdrew the drill,
the problem would be
434
00:26:34,440 --> 00:26:38,540
that the water would rush into
that space and contaminate
435
00:26:38,540 --> 00:26:41,010
the oil he was
trying to pump out.
436
00:26:41,010 --> 00:26:44,480
To overcome this problem, Drake
and his assistant, Billy Smith,
437
00:26:44,480 --> 00:26:48,950
came upon the idea of connecting
lengths of cast-iron pipe
438
00:26:48,950 --> 00:26:51,750
to encase the freshly dug hole,
439
00:26:51,760 --> 00:26:57,730
preventing the ingress
of the water.
440
00:26:57,730 --> 00:27:00,760
Called a conductor
pipe, they continued to drill
441
00:27:00,760 --> 00:27:04,100
through this now-watertight
space through the ground,
442
00:27:04,100 --> 00:27:07,140
the bedrock, and down
to the oil reservoir.
443
00:27:07,140 --> 00:27:10,970
After drilling 69 feet,
they waited.
444
00:27:17,010 --> 00:27:19,610
Overnight, it happened.
445
00:27:19,620 --> 00:27:22,550
Clean oil had risen up
through the pipe
446
00:27:22,550 --> 00:27:24,890
to a point which
it could now be collected.
447
00:27:24,890 --> 00:27:27,260
Drake's plan had worked.
448
00:27:30,560 --> 00:27:33,300
By the following year,
oil Wells using
449
00:27:33,300 --> 00:27:37,000
Drake's innovative technique
sprang up all over the region,
450
00:27:37,000 --> 00:27:41,600
producing several
hundred thousand barrels.
451
00:27:41,610 --> 00:27:43,910
The nation's
oil bonanza had begun,
452
00:27:43,910 --> 00:27:47,310
and huge fortunes would be made.
453
00:27:56,290 --> 00:27:59,690
To drill to unrivaled
depths, Perdido engineers
454
00:27:59,690 --> 00:28:02,560
have taken the principle
of Drake's conductor pipe
455
00:28:02,560 --> 00:28:06,390
200 miles offshore.
456
00:28:06,400 --> 00:28:08,860
And like that
first well in Titusville,
457
00:28:08,870 --> 00:28:11,030
one thing is crucial.
458
00:28:11,030 --> 00:28:14,600
The processes for drilling
are designed around
459
00:28:14,600 --> 00:28:18,670
keeping the oil in the pipe.
460
00:28:18,680 --> 00:28:23,410
So, you start with big diameter
pipes, and as you go deeper,
461
00:28:23,410 --> 00:28:30,050
you get smaller and smaller
concentric sizes of pipe.
462
00:28:32,620 --> 00:28:36,420
To begin, a hole is
drilled for the conductor pipe.
463
00:28:36,430 --> 00:28:39,590
Then another drill bores
a few hundred feet
464
00:28:39,600 --> 00:28:42,430
before a casing pipe
is installed.
465
00:28:42,430 --> 00:28:45,900
This is followed
by a smaller drill and casing.
466
00:28:45,900 --> 00:28:52,210
The process is repeated until
the oil reservoir is reached.
467
00:28:52,210 --> 00:28:54,740
But with the sea floor
resembling the landscape
468
00:28:54,750 --> 00:28:58,410
of the Grand Canyon, being able
to hit the target area
469
00:28:58,420 --> 00:29:01,350
with the drill is no easy task.
470
00:29:01,350 --> 00:29:04,350
Most of the
locations that we have to drill
471
00:29:04,350 --> 00:29:07,420
are quite far away from the rig,
and we have to use
472
00:29:07,420 --> 00:29:11,730
directional drilling techniques
in order to get there.
473
00:29:11,730 --> 00:29:14,060
The scale that we're
talking about, to be able to
474
00:29:14,060 --> 00:29:17,830
land a well in the exact place
that we need it,
475
00:29:17,830 --> 00:29:21,200
if you were in a typical room,
the thickness of a human hair
476
00:29:21,200 --> 00:29:23,770
from the ceiling
all the way down to the floor,
477
00:29:23,770 --> 00:29:26,880
hitting a square inch,
is the kind of accuracy
478
00:29:26,880 --> 00:29:30,610
that we're talking about.
479
00:29:30,610 --> 00:29:33,110
To tap reservoirs
spread across nearly
480
00:29:33,120 --> 00:29:37,250
30 square miles of sea floor,
GPS-drilling motors
481
00:29:37,250 --> 00:29:41,920
guided the drill string
within a foot of its target.
482
00:29:41,930 --> 00:29:45,290
In all, 35 separate Wells
were created,
483
00:29:45,300 --> 00:29:50,230
feeding five risers
leading up to the rig.
484
00:29:50,230 --> 00:29:53,270
But for the engineering team,
perhaps the biggest challenge
485
00:29:53,270 --> 00:29:58,970
of all is lifting the crude oil
up these risers to the surface.
486
00:29:58,980 --> 00:30:00,410
The reservoirs are low-pressure,
487
00:30:00,410 --> 00:30:02,640
lower than you normally would
find in the Gulf of Mexico.
488
00:30:02,650 --> 00:30:06,250
That required us to add energy
to the system in order
489
00:30:06,250 --> 00:30:09,280
to produce fluids
up to the surface.
490
00:30:09,290 --> 00:30:10,920
To do that, we had to pump.
491
00:30:10,920 --> 00:30:13,350
We had to use
electrical, submersible pumps.
492
00:30:13,360 --> 00:30:17,960
Well, these pumps
don't like gas.
493
00:30:17,960 --> 00:30:20,230
Normally the gas, oil, and water
494
00:30:20,230 --> 00:30:22,200
are separated on the surface.
495
00:30:22,200 --> 00:30:25,400
But to bring Perdido's oil
up to the platform,
496
00:30:25,400 --> 00:30:29,070
engineers had to remove
the gas at the source itself,
497
00:30:29,070 --> 00:30:32,670
over 1 1/2 miles
below on the sea floor.
498
00:30:32,680 --> 00:30:36,740
At the base of each riser,
a unit separates the components.
499
00:30:36,750 --> 00:30:43,250
The gas naturally ascends and is
then pumped to the surface.
500
00:30:43,250 --> 00:30:46,150
The engineering leap for
Perdido was really in two areas.
501
00:30:46,160 --> 00:30:48,460
One was the depth in water
in which we were working.
502
00:30:48,460 --> 00:30:50,290
The other and more significant
503
00:30:50,290 --> 00:30:56,630
was the first ever
subsea process.
504
00:30:56,630 --> 00:31:00,300
After decades of
innovation, in march 2010,
505
00:31:00,300 --> 00:31:06,070
oil from the world's deepest
offshore Wells finally emerged.
506
00:31:06,080 --> 00:31:08,610
We are all piped in via camera
507
00:31:08,610 --> 00:31:13,820
to the guys who are
actually offshore doing it.
508
00:31:13,820 --> 00:31:16,990
And then you start watching the
pressure in the pressure gauges,
509
00:31:16,990 --> 00:31:19,550
and you see the pressure
start falling,
510
00:31:19,560 --> 00:31:21,820
meaning that
it's starting to flow.
511
00:31:21,830 --> 00:31:24,830
It's been a long road, boys.
512
00:31:24,830 --> 00:31:27,400
You know, you've just
done something that,
513
00:31:27,400 --> 00:31:32,700
in Perdido's case,
nobody had ever done before.
514
00:31:32,700 --> 00:31:36,400
We were pumping and separating
on the subsea floor from day 1.
515
00:31:36,410 --> 00:31:43,180
And it all worked,
and that was incredible.
516
00:31:45,180 --> 00:31:48,550
Perdido's engineers
are succeeding in procuring oil
517
00:31:48,550 --> 00:31:51,950
from deep within
the earth's crust.
518
00:31:51,960 --> 00:31:54,890
But to ensure
this operation remains safe,
519
00:31:54,890 --> 00:31:57,590
engineers had to
look to the past...
520
00:31:57,590 --> 00:31:59,990
Let's see what happens
when I light them.
521
00:32:00,000 --> 00:32:03,600
To create
more impossible engineering.
522
00:32:18,200 --> 00:32:21,040
The Perdido oil platform.
523
00:32:21,040 --> 00:32:23,170
It's the first of its kind
to operate
524
00:32:23,170 --> 00:32:28,140
in ultra-deep water depths
at nearly 8,000 feet.
525
00:32:28,150 --> 00:32:33,020
When it started operations,
172 workers spent two weeks
526
00:32:33,020 --> 00:32:36,250
at a time extracting enough oil
to fill more than
527
00:32:36,250 --> 00:32:40,860
six Olympic-size swimming pools
each and every day.
528
00:32:40,860 --> 00:32:42,690
As you fly up to Perdido,
529
00:32:42,690 --> 00:32:44,890
it's 200 miles
away from the coast.
530
00:32:44,900 --> 00:32:47,760
There's pretty much
nothing around it,
531
00:32:47,770 --> 00:32:50,700
and it's almost a 2-hour flight
on the chopper,
532
00:32:50,700 --> 00:32:54,170
and as you get into the range
of where Perdido is,
533
00:32:54,170 --> 00:32:56,870
you see this monument
to what's possible
534
00:32:56,880 --> 00:33:00,040
out in the middle of nowhere,
and it's really satisfying
535
00:33:00,040 --> 00:33:05,210
to land on that and see
what we've accomplished.
536
00:33:05,220 --> 00:33:07,320
But Perdido's isolation creates
537
00:33:07,320 --> 00:33:09,190
logistical challenges.
538
00:33:09,190 --> 00:33:11,550
It's a 24-hour boat journey.
539
00:33:11,560 --> 00:33:14,720
So, while much of
the resupplying happens by ship,
540
00:33:14,730 --> 00:33:18,560
the biweekly turnover of staff
from 200 miles away
541
00:33:18,560 --> 00:33:20,930
is carried out by helicopter.
542
00:33:20,930 --> 00:33:23,500
We're flying these
really large helicopters,
543
00:33:23,500 --> 00:33:26,940
like this s-92 you have, which
can hold up to 19 passengers.
544
00:33:26,940 --> 00:33:29,410
Although we'll fly
with about 15 or 16.
545
00:33:29,410 --> 00:33:31,810
In the event
that helicopter goes down,
546
00:33:31,810 --> 00:33:34,510
that's a lot of people
that we need to take care of.
547
00:33:37,180 --> 00:33:39,820
But when you're
potentially processing more than
548
00:33:39,820 --> 00:33:42,520
100,000 barrels of oil a day,
549
00:33:42,520 --> 00:33:47,420
one hazard above all others
comes to the forefront.
550
00:33:47,430 --> 00:33:49,830
Fire protection
on an offshore installation
551
00:33:49,830 --> 00:33:51,360
is of Paramount importance.
552
00:33:51,360 --> 00:33:52,900
We design for safety.
553
00:33:52,900 --> 00:33:57,570
It's the number-one thing
we have to get right.
554
00:33:57,570 --> 00:33:59,300
The worst thing
that can happen on a rig
555
00:33:59,300 --> 00:34:01,240
or a production facility
in the event of a fire
556
00:34:01,240 --> 00:34:03,010
is it gets out of control.
557
00:34:03,010 --> 00:34:05,610
It gets to be very large
and very catastrophic,
558
00:34:05,610 --> 00:34:08,480
and in that event, we're going
to abandon the facility.
559
00:34:08,480 --> 00:34:10,350
We're going to put people
in lifeboats that they've been
560
00:34:10,350 --> 00:34:13,150
trained to use, and we'll put
those lifeboats in the water
561
00:34:13,150 --> 00:34:16,420
and get people away from the
fire and abandon the platform.
562
00:34:18,490 --> 00:34:21,720
Fire isn't just
a hazard to the workforce.
563
00:34:21,730 --> 00:34:25,160
A hydrocarbon Blaze can reach
such high temperatures,
564
00:34:25,160 --> 00:34:30,400
it has the potential to deform
or even destroy solid steel.
565
00:34:30,400 --> 00:34:33,440
As we become more complex
and remote with these types
566
00:34:33,440 --> 00:34:36,910
of developments, the safety
systems that we need in order
567
00:34:36,910 --> 00:34:41,210
to support them
become ever more critical.
568
00:34:41,210 --> 00:34:44,410
So how can you protect
Perdido's vast surface areas
569
00:34:44,420 --> 00:34:46,850
against the threat
of extreme heat?
570
00:34:46,850 --> 00:34:50,050
Engineers look to
a chemical used for safety
571
00:34:50,050 --> 00:34:55,290
in 19th-century
show business, boron.
572
00:35:02,730 --> 00:35:06,500
If, hundreds of years ago,
fire-safety expert Luke Bisby
573
00:35:06,500 --> 00:35:09,140
visited a theater like this,
he might have been
574
00:35:09,140 --> 00:35:11,210
taking his life in his hands.
575
00:35:11,210 --> 00:35:14,340
At the time, oil lamps
were used for lighting,
576
00:35:14,350 --> 00:35:20,380
so curtains and fabrics
were frequently set ablaze.
577
00:35:20,390 --> 00:35:23,420
But in the early 1800s,
following a string
578
00:35:23,420 --> 00:35:27,390
of tragic fires,
French chemist Joseph Gay Lussac
579
00:35:27,390 --> 00:35:30,630
worked to fireproof
France's theaters.
580
00:35:30,630 --> 00:35:33,200
He began experimenting
with boron, a compound now used
581
00:35:33,200 --> 00:35:34,800
in detergents and cosmetics.
582
00:35:34,800 --> 00:35:36,300
And to demonstrate
how effective it is,
583
00:35:36,300 --> 00:35:37,770
I'm going to do an experiment.
584
00:35:37,770 --> 00:35:40,470
Here, I have a stage,
and it has two curtains.
585
00:35:40,470 --> 00:35:42,440
One of them has been
soaked in boron solution,
586
00:35:42,440 --> 00:35:45,210
and the other one
is just normal fabric.
587
00:35:45,210 --> 00:35:47,540
So let's see what happens
when I light them.
588
00:35:53,620 --> 00:35:56,450
And you can see that the curtain
on the right-hand side
589
00:35:56,450 --> 00:35:59,290
is burning quite vigorously,
whereas the one on the left,
590
00:35:59,290 --> 00:36:01,390
you can clearly see
the effect of the boron,
591
00:36:01,390 --> 00:36:04,060
which is helping the curtains
to prevent flaming.
592
00:36:04,060 --> 00:36:08,900
I mean, I'm impressed,
and I'm a fire-safety person.
593
00:36:08,900 --> 00:36:12,100
The boron helps form
a protective layer of char,
594
00:36:12,100 --> 00:36:16,870
which acts as a buffer
between the fire and the fabric.
595
00:36:16,870 --> 00:36:19,540
But this element alone
isn't enough to protect
596
00:36:19,540 --> 00:36:23,880
the steel platform from being
subsumed by fire.
597
00:36:23,880 --> 00:36:26,450
To protect this
gargantuan platform,
598
00:36:26,450 --> 00:36:32,660
engineers needed to take another
page from engineering history...
599
00:36:32,660 --> 00:36:34,260
So, the intumescent paint now
600
00:36:34,260 --> 00:36:36,660
is charring due to
a chemical reaction.
601
00:36:36,660 --> 00:36:41,830
It's swelling and turning
into a thick char.
602
00:36:41,830 --> 00:36:45,200
To make the impossible possible.
603
00:37:00,260 --> 00:37:03,730
Perdido is the deepest
production and drilling platform
604
00:37:03,730 --> 00:37:07,030
on the planet.
605
00:37:07,030 --> 00:37:10,630
But to keep this colossal
platform and its crew safe
606
00:37:10,630 --> 00:37:15,270
from the outbreak of fire,
engineers had to look to
607
00:37:15,270 --> 00:37:19,440
another fire-safety development
that works on steel...
608
00:37:19,440 --> 00:37:24,250
Intumescent paint.
609
00:37:29,420 --> 00:37:32,990
The charring effect pioneered by
Gay Lussac's use of boron
610
00:37:32,990 --> 00:37:35,620
is also evident
in the modern fire-resistant
611
00:37:35,630 --> 00:37:37,460
intumescent paint.
612
00:37:37,460 --> 00:37:40,000
At Edinburgh university's
fire lab,
613
00:37:40,000 --> 00:37:42,560
Luke Bisby
will put it to the test.
614
00:37:42,570 --> 00:37:44,400
And what we're gonna do is
we're gonna subject
615
00:37:44,400 --> 00:37:47,400
these two steel plates, which
are identical to each other,
616
00:37:47,410 --> 00:37:49,200
to the heat from the flame.
617
00:37:49,210 --> 00:37:51,040
The plate on the left
is coated just with
618
00:37:51,040 --> 00:37:53,740
a household emulsion paint,
and the plate on the right
619
00:37:53,740 --> 00:37:56,210
is coated with a fire-protection
intumescent paint.
620
00:37:56,210 --> 00:37:58,250
All right, so, here we go.
621
00:38:04,690 --> 00:38:07,490
So, the intumescent paint now
is charring due to
622
00:38:07,490 --> 00:38:13,000
a chemical reaction and swelling
and turning into a thick char.
623
00:38:13,000 --> 00:38:15,160
As with Gay Lussac's
boron coating,
624
00:38:15,170 --> 00:38:18,370
this charring looks dramatic,
but temperature monitoring
625
00:38:18,370 --> 00:38:22,940
reveals just how
effective it is.
626
00:38:22,940 --> 00:38:28,680
The untreated steel plate
heats up to 650 degrees.
627
00:38:28,680 --> 00:38:33,480
But the one with intumescent
plate burns under 212 degrees.
628
00:38:36,890 --> 00:38:40,760
As the intumescent paint's
chemical reaction accelerates,
629
00:38:40,760 --> 00:38:44,460
expanding bubbles insulate
this plate's surface.
630
00:38:44,460 --> 00:38:47,260
So, a massive amount of thermal
protection for the steel.
631
00:38:47,260 --> 00:38:48,830
While it's visually
kind of ugly,
632
00:38:48,830 --> 00:38:51,000
it's exactly what
we wanted to see happen.
633
00:39:03,980 --> 00:39:06,850
In the Gulf of Mexico,
the Perdido oil platform
634
00:39:06,850 --> 00:39:11,590
has its key components
coated in an intumescent paint.
635
00:39:11,590 --> 00:39:13,520
So, intumescent
paint that we've used
636
00:39:13,520 --> 00:39:16,890
on Perdido, it's an epoxy
coating on the steel,
637
00:39:16,890 --> 00:39:19,160
and if it comes
into contact with heat,
638
00:39:19,160 --> 00:39:21,430
it'll form a charred layer,
and that'll provide
639
00:39:21,430 --> 00:39:24,730
a heat barrier between
the fire and the steel itself.
640
00:39:24,740 --> 00:39:28,200
So the intumescent paint system
buys you time to either
641
00:39:28,210 --> 00:39:31,340
fight the fire and get it under
control or protect people
642
00:39:31,340 --> 00:39:33,740
to the point where if you need
to get off the platform
643
00:39:33,740 --> 00:39:38,080
and evacuate,
you've got that time.
644
00:39:38,080 --> 00:39:41,380
Above all,
the platform and its workforce
645
00:39:41,390 --> 00:39:45,390
are geared up to stopping fire
breaking out in the first place.
646
00:39:45,390 --> 00:39:47,260
What we do to train
our people to combat a fire,
647
00:39:47,260 --> 00:39:48,690
it starts with prevention.
648
00:39:48,690 --> 00:39:51,060
It's always about prevention,
just like you learned in school.
649
00:39:51,060 --> 00:39:53,000
Prevent the fire to start with.
650
00:39:53,000 --> 00:39:55,860
We have a ton of monitoring
equipment out there
651
00:39:55,870 --> 00:39:58,570
to always be on watch,
24 hours a day,
652
00:39:58,570 --> 00:40:01,640
watching for fires or potential
sources of fires,
653
00:40:01,640 --> 00:40:03,770
like a gas leak.
654
00:40:03,770 --> 00:40:07,480
Perdido is covered by
hundreds of sensors and alarms.
655
00:40:07,480 --> 00:40:10,680
It is rigged with twin
5,000-gallon-per-minute
656
00:40:10,680 --> 00:40:14,050
firewater pumps,
and an automatic foam system
657
00:40:14,050 --> 00:40:20,490
that covers the entire platform,
including the heliport.
658
00:40:20,490 --> 00:40:23,530
All of this is designed
to protect the environment,
659
00:40:23,530 --> 00:40:28,030
the workers, and this remarkable
engineering pioneer.
660
00:40:38,880 --> 00:40:42,280
It's been more than a century
since humanity first dared
661
00:40:42,280 --> 00:40:44,610
to attempt offshore drilling.
662
00:40:44,620 --> 00:40:49,790
Now, in 7,800 feet of water
in the Gulf of Mexico,
663
00:40:49,790 --> 00:40:52,490
a new generation
of bold engineers
664
00:40:52,490 --> 00:40:59,330
has put the Perdido platform
into the record books.
665
00:40:59,330 --> 00:41:02,060
For me personally, that
was the single biggest project
666
00:41:02,070 --> 00:41:04,070
I had ever worked on,
and I've worked on
667
00:41:04,070 --> 00:41:07,100
some good projects,
but I have tremendous pride
668
00:41:07,100 --> 00:41:09,270
in what we did with Perdido.
669
00:41:09,270 --> 00:41:12,240
I think everyone who worked on
that project team feels
670
00:41:12,240 --> 00:41:14,440
they had done something
in the oil industry
671
00:41:14,450 --> 00:41:16,280
that had never been done before
672
00:41:16,280 --> 00:41:22,990
and really set the stage
to move into ultra-deep water.
673
00:41:22,990 --> 00:41:25,250
By looking at
engineering history
674
00:41:25,260 --> 00:41:27,760
and making
the innovations high-tech,
675
00:41:27,760 --> 00:41:30,290
the team behind
the Perdido platform
676
00:41:30,290 --> 00:41:35,330
is rewriting the map and
exploring brand-new frontiers.
677
00:41:35,330 --> 00:41:37,200
What we do is like
the space program
678
00:41:37,200 --> 00:41:39,400
in the other direction,
to be able to push
679
00:41:39,400 --> 00:41:41,540
the boundaries
of what's possible
680
00:41:41,540 --> 00:41:44,070
and achieve more
than you thought you could.
681
00:41:44,070 --> 00:41:46,940
It just gives
a huge sense of satisfaction,
682
00:41:46,940 --> 00:41:49,880
and it provides inspiration
to the next generation
683
00:41:49,880 --> 00:41:53,580
who have to push the boundaries
even further than we did.
684
00:41:53,580 --> 00:41:55,580
Engineers have succeeded
685
00:41:55,590 --> 00:42:00,520
in making
the impossible possible.
686
00:42:00,570 --> 00:42:05,120
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