Automated Pressure Testing for Blowout Preventers
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Solution Overview
Problem
The existing methods for internally pressure testing blowout preventers and pressurized vessels are time-consuming and disruptive to drilling operations, often requiring manual procedures that can take hours or days, delaying the drilling process and increasing costs.
Innovation Solution
A method utilizing a programmable logic controller (PLC) to estimate and calculate the volume of additional liquid needed to achieve a maximum test pressure, automating the pressure testing process by controlling the influx of liquid and monitoring pressure, allowing for faster and more accurate testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual pressure testing is used, then operational simplicity is maintained, but testing time increases significantly
Solution Approach 1:
The patent replaces manual mechanical operation with an automated control system that uses electronic sensors, actuators, and a controller to execute the pressure testing sequence, eliminating the need for manual pumping and observation while significantly reducing test duration
Solution Approach 2:
The pressure testing system performs self-service through automatic detection of pressure conditions, self-regulation of fluid flow rates, and self-monitoring of test parameters, allowing the system to execute the complete testing protocol without continuous manual intervention
2Productivity
If automated control is implemented, then testing speed increases, but device complexity increases
Solution Approach 1:
The control system is designed as a multi-functional integrated unit that combines pressure sensing, flow control, data logging, and test sequence management in a single system, eliminating the need for multiple separate devices and reducing overall system complexity despite increased automation
Solution Approach 2:
The patent introduces a controller as an intermediary component that mediates between the various system elements (pump, sensor, display, memory), coordinating their operations and simplifying the interaction between complex subsystems through a centralized control architecture
3Ease of operation
If manual observation of pressure volumes is used, then measurement simplicity is maintained, but testing accuracy decreases
Solution Approach 1:
The patent replaces manual visual observation and measurement with electronic sensors that automatically detect and record pressure and volume data, eliminating human error in reading instruments and ensuring consistent, accurate measurements throughout the testing process
Solution Approach 2:
The system implements continuous feedback by monitoring actual pressure and volume readings, comparing them against target values, and automatically adjusting test parameters to maintain measurement accuracy, ensuring that the recorded data precisely reflects the actual test conditions
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method significantly reduces the time required for pressure testing, enhances accuracy, and minimizes disruptions to drilling operations by automating the process, thereby improving operational efficiency and reducing costs.
Implementation Method 1
calculating a volume of additional liquid necessary to bring the enclosed space to the maximum test pressure
Data Source
AI summary
The present disclosure provides a method for conducting a pressure test on an apparatus. The method may include selecting a maximum test pressure for the pressure test, providing a first volume of liquid in the enclosed space and estimating a volume of gas in the enclosed space. The method may further include calculating a volume of additional liquid necessary to bring the enclosed space to the maximum test pressure, providing the volume of additional liquid in the enclosed space, and observing pressure of the enclosed space.