Blowout Preventer Control Pod Redundancy for Downtime Reduction
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Solution Overview
Problem
Current blowout preventer systems in offshore drilling face challenges with unproductive downtime and economic costs due to the need to return equipment to the surface for repairs or replacements, especially when one control pod becomes unavailable, leading to suspended operations and increased operational time.
Innovation Solution
The implementation of an additional control pod connected to a separate surface control system provides redundancy, allowing continued operation even if one control pod is unavailable, reducing the need for equipment retrieval and minimizing downtime by offering a standalone backup system with quicker response times compared to traditional acoustic or ROV-based systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional control pod systems are used with only two pods (Blue and Yellow), then device complexity is reduced, but reliability deteriorates when one pod becomes unavailable requiring equipment retrieval to surface
Solution Approach 1:
The patent introduces a third control pod (Red) as a pre-configured standby unit that can immediately replace either the Blue or Yellow pod if needed. This preliminary preparation of an additional backup unit eliminates the need for equipment retrieval to surface when a pod fails, directly resolving the reliability improvement while avoiding excessive complexity through targeted redundancy
Solution Approach 2:
The system implements beforehand cushioning by pre-positioning the Red control pod as a protective buffer against potential failures of the Blue or Yellow pods. This prior cushioning ensures continuous operational availability without requiring complex retrieval procedures, balancing enhanced reliability with controlled system complexity
2Ease of repair
If equipment is retrieved to surface for repairs or replacements, then ease of repair is improved, but productivity deteriorates due to unproductive downtime
Solution Approach 1:
The patent creates a redundant copy (Red control pod) of the control system that can immediately substitute for failed Blue or Yellow pods. This copying approach allows the operational system to continue without interruption while the failed pod can be replaced with the pre-positioned Red pod, eliminating unproductive downtime while maintaining ease of repair through simple pod substitution
Solution Approach 2:
The system enables discarding of failed control pods (Blue or Yellow) and recovering operational continuity through the Red pod. The failed pod can be discarded and replaced with the Red pod without requiring surface retrieval, thus improving productivity by eliminating downtime while maintaining ease of repair through modular pod replacement
3Speed
If acoustic or ROV-based backup systems are used, then device complexity is reduced, but speed deteriorates due to slower response times
Solution Approach 1:
The patent replaces acoustic or ROV-based mechanical/remote control systems with a direct electrical/electronic connection between the Red control pod and the BOP stack. This substitution enables immediate response times comparable to the primary Blue/Yellow pods, achieving high speed while managing complexity through standardized pod architecture rather than complex remote communication systems
Data Source
AI summary
the present invention relates to a blowout preventer system comprising, a lower blowout preventer (BOP) stack comprising a number of hydraulic components, and a lower marine riser package (LMRP) comprising a first control pod and a second control pod adapted to provide, during use, redundant control of hydraulic components of the lower blowout preventer stack where the first and the second control pods are adapted to being connected, during use, to a surface control system and to be controlled, during use, by the surface control system, wherein the blowout preventer system further comprises at least one additional control pod connected to at least one additional surface control system and to be controlled, during use, by the additional surface control system. In this way, an improved blowout preventer system is provided.