Subsea BOP Control System Reconfiguration for Redundancy
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Solution Overview
Problem
Subsea blowout preventer (BOP) systems face downtime and repair challenges due to hydraulic element failures, which result in loss of redundancy and require costly operations, as existing systems are hard-plumbed and not easily reconfigurable or repairable, with previous solutions degrading system performance.
Innovation Solution
The method involves isolating leaking hydraulics by reassigning electric controls to spare subsea valves and re-routing hydraulic fluid, maintaining system redundancy and performance without changing the user interface, and incorporating a parallel configuration of regulators and hydraulic manifolds for redundancy, allowing for reconfiguration and adaptation of control systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional hard-plumbed hydraulic systems are used, then system structure is simple and easy to manufacture, but the system cannot be readily re-configured or repaired when hydraulic elements fail
Solution Approach 1:
The hydraulic system is divided into modular segments with isolated hydraulic circuits. Each control pod contains separate hydraulic pathways that can be independently isolated and reconfigured. This segmentation allows faulty sections to be disconnected while maintaining functionality in other sections, enabling repair and reconfiguration without complete system shutdown.
Solution Approach 2:
The system incorporates dynamic reconfiguration capabilities through programmable control that allows hydraulic pathways to be dynamically routed and reassigned. The control system can dynamically switch between different hydraulic circuits and reassign actuators to different functions based on operational needs and failure conditions, transforming a static hard-plumbed system into a dynamically adaptable one.
2Reliability
If redundant control systems are implemented, then system reliability improves, but device complexity increases and internal hydraulic redundancy is not built into existing systems
Solution Approach 1:
The control pod design incorporates universal interfaces and standardized hydraulic circuits that can serve multiple functions. The same hydraulic infrastructure supports both primary and redundant operations, allowing the system to maintain reliability through redundancy while avoiding the complexity of completely separate redundant systems. The control architecture can dynamically assign functions to available circuits, making the system multi-functional rather than requiring dedicated circuits for each function.
3Loss of time
If hydraulic elements fail in traditional systems, then downtime increases and costly repairs are required, but the system lacks the capability for rapid isolation and reconfiguration
Solution Approach 1:
The system is pre-configured with isolated hydraulic circuits and standby pathways before failures occur. Isolation valves and reconfiguration protocols are prepared in advance, allowing rapid response to failures without requiring complex on-site modifications. The control system maintains ready-to-use alternative pathways that can be activated immediately upon failure detection, minimizing downtime and simplifying repair procedures.
4Adaptability or versatility
If spare capacity is built into the system, then adaptability and repairability improve, but device complexity and initial system cost increase
Solution Approach 1:
The system merges spare capacity with operational circuits through shared hydraulic infrastructure. Instead of completely separate standby systems, the design integrates reserve pathways and reconfigurable circuits that can serve both active and backup functions. This consolidation allows the system to maintain adaptability and repairability while reducing the overall complexity compared to fully redundant separate systems.
Data Source
AI summary
Blowout preventer (BOP) systems and methods for providing additional redundancy and reliability are provided. A BOP system for providing additional redundancy can include a first set of components including a BOP control pod with a primary regulator and a secondary regulator, where the primary regulator and the secondary regulator are arranged in a parallel configuration; a hydraulic supply line in communication with the BOP control pod; a pod select valve in communication with the primary regulator and the secondary regulator; and a bypassable hydraulic regulator in communication with the pod select valve; and a second set of components, the bypassable hydraulic regulator disposed between the pod select valve and the second set of components, where a hydraulic regulator bypass line bypasses the bypassable hydraulic regulator between the pod select valve and the second set of components.