Blowout Preventer Flow Responsiveness Enhancer
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Solution Overview
Problem
Blowout preventers (BOPs) face challenges in cold temperatures due to increased viscosity of hydraulic fluids, leading to reduced responsiveness and safety concerns, with existing solutions being cumbersome and impractical.
Innovation Solution
A flow responsiveness enhancer system comprising a stack of manifolds with shared pressure and tank lines, valve systems, and check valves that optimize fluid flow paths to improve the time responsiveness of BOPs by collecting and directing hydraulic fluid efficiently across rams, even in high viscosity conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic fluid is used to actuate BOP rams in cold temperatures, then the BOP can function as a safety device, but the increased fluid viscosity causes reduced flow rate and slower responsiveness
Solution Approach 1:
The system segments the hydraulic flow paths by providing separate pressure lines and tank lines for each ram, allowing independent optimization of flow paths. Each ram has dedicated flow lines that can be sized and configured independently, enabling high flow rates to critical rams while maintaining system reliability for all rams.
Solution Approach 2:
The system pre-warms the hydraulic fluid in the lines leading to each ram before actuation is needed. By having continuous flow paths established and fluid circulating in advance, the fluid is already at optimal temperature and viscosity when rapid BOP closure is required, eliminating the cold-temperature viscosity problem.
2Speed
If heaters or insulators are used to maintain hydraulic fluid temperature, then BOP responsiveness is improved, but the system becomes more complex and expensive
Solution Approach 1:
The system uses the normal operational flow of hydraulic fluid to self-warm the lines. The continuous circulation of fluid through the dedicated pressure and tank lines during normal BOP operations naturally maintains fluid temperature without requiring external heating systems, insulation, or thermal management components.
3Speed
If specialized cold-temperature fluids are used, then BOP responsiveness is maintained, but the cost and practicality are reduced
Solution Approach 1:
Instead of changing the fluid type, the system changes the fluid temperature parameter by maintaining continuous flow and utilizing the heat generated during normal operations. The same standard hydraulic fluid is used, but its temperature is maintained through the flow dynamics and operational cycles, avoiding the need for specialized cold-temperature fluids.
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
The system significantly reduces the time required to open or close BOP rams, enhancing safety and performance by maintaining responsiveness even at sub-freezing temperatures without the need for expensive or impractical heating solutions.
Implementation Method 1
A flow responsiveness enhancer system comprising a stack of manifolds with shared pressure and tank lines, valve systems, and check valves that optimize fluid flow paths to improve the time responsiveness of BOPs by collecting and directing hydraulic fluid efficiently across rams
Implementation Method 2
The flow responsiveness enhancer can include a first check valve configured to maintain flow in a single direction from the shared pressure line to a second manifold of the plurality of manifolds, and a second check valve configured to maintain flow in a single direction from the shared tank line to a first manifold of the plurality of manifolds
Data Source
Figure 1~1A
Figure 1B
Figure 2~3
AI summary
A flow responsiveness enhancer apparatus may include a stack of manifolds with at least one manifold dedicated to each of the rams of the blowout preventer. The flow responsiveness enhancer includes a shared pressure line coupled to each of the manifolds, and a shared tank line coupled to each of the manifolds. Each manifold can include a 4-way directional valve that is piloted by the pressure levels in a pair of input ports. Each 4-way directional valve can couple the shared pressure line and the shared tank line to a pair of output ports.