BOP Closing Unit Pressure Sensing for Accumulator-Free Hydraulics
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Solution Overview
Problem
Drilling rigs face challenges with large hydraulic accumulators required for BOP systems, which occupy valuable space and are costly, especially in offshore contexts, due to increasing energy demands and regulatory constraints, necessitating a more efficient and space-effective power solution.
Innovation Solution
A hybrid electric closing unit with a pressure sensing system that manages the start-stop operation of primary pumps and maintains predetermined static pressure, using a battery-powered system to reduce dependency on hydraulic accumulators, incorporating a tank, primary pumps, valves, and pressure transducers to regulate hydraulic fluid pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If large hydraulic accumulators are used to meet increasing BOP energy demands, then the energy storage capacity is improved, but the space occupied and system cost increase significantly
Solution Approach 1:
The patent replaces the traditional mechanical hydraulic accumulator system with an electric motor-driven pump system. The electric motor (36) drives the pump (20) to pressurize hydraulic fluid, eliminating the need for large physical accumulators. This substitution of mechanical energy storage with electrical energy storage and conversion resolves the contradiction by providing equivalent energy delivery capability without the bulky accumulator vessels.
Solution Approach 2:
The patent changes the energy storage parameter from hydraulic pressure in accumulators to electrical energy in motor/controller systems. By using an electric motor with variable frequency drive, the system can store and deliver energy electrically, then convert it to hydraulic pressure on-demand. This parameter change allows the same energy function to be achieved with significantly reduced physical volume.
2Reliability
If large hydraulic accumulators are installed to meet BOP shear requirements, then the system reliability is improved, but the transportation and installation difficulty increases
Solution Approach 1:
The patent replaces heavy mechanical accumulators with lighter electric motor and pump components. The motor (36) and pump (20) assembly is significantly more compact and easier to transport than equivalent-capacity hydraulic accumulators. This substitution maintains system reliability through electronic control while dramatically improving ease of transportation and installation.
Solution Approach 2:
The patent segments the energy storage and delivery function into separate components: an electric motor (36) for energy storage, a pump (20) for energy conversion, and a control system for energy management. This segmentation allows each component to be optimized independently and transported separately, then assembled on-site, resolving the transportation and installation difficulties associated with monolithic accumulator systems.
3Volume of stationary object
If battery-powered pumping systems are used to replace accumulator systems, then the space efficiency is improved, but the system complexity increases
Solution Approach 1:
The patent uses the electric motor (36) to perform multiple functions: it can drive the pump (20) to pressurize hydraulic fluid for BOP operation, and it can also power electrical components such as the pressure transducer (32) and control electronics. This multi-functionality reduces overall system complexity by consolidating power sources, even though the motor-control-pump assembly is more complex than simple accumulators.
Solution Approach 2:
The patent incorporates a pressure transducer (32) that provides feedback to the motor controller (24), creating a closed-loop control system. The transducer monitors hydraulic pressure and signals the controller to start or stop the motor (36) to maintain predetermined static pressure. This feedback mechanism automates pressure regulation, reducing the need for complex manual control systems and safety valves, thereby managing overall system complexity.
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 solution reduces the need for large accumulators by efficiently managing hydraulic energy through a battery-powered system, optimizing space and cost, while ensuring reliable operation of BOP systems even in power loss scenarios.
Implementation Method 1
a first pressure transducer disposed between the at least one primary pump and at least one valve of the plurality of valves, wherein the at least one primary pump, the pressure transducer, and the at least one valve of the plurality of valves are hydraulically connected with the tank, wherein the first pressure transducer manages a start-stop operation of the at least one primary pump
Implementation Method 2
at least one primary pump configured to pump hydraulic fluid from the usable volume of the tank
Data Source
AI summary
A control system includes a closing unit including a tank including a usable volume of the control system, at least one primary pump configured to pump hydraulic fluid from the usable volume of the tank, a plurality of valves, and a first pressure transducer disposed between the at least one primary pump and at least one valve of the plurality of valves. The at least one primary pump, the pressure transducer, and the at least one valve of the plurality of valves are hydraulically connected with the tank. The first pressure transducer manages a start-stop operation of the at least one primary pump. Hydraulic fluid within the control system has a predetermined static pressure. The at least one pump is powered by an electric energy source.