Subsea BOP Safety Valve Proof Testing via Manifold Pressure
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Solution Overview
Problem
Subsea BOP systems face challenges in testing the integrity of hydraulic safety valves without retrieving them from the sea floor, which is impractical and difficult, and existing solutions require additional high-pressure hydraulic cycles or opening and closing cycles, potentially degrading the system.
Innovation Solution
A BOP safety system that uses back pressure and a reduced number of sensors to perform proof testing, including pressurizing a manifold, detecting pressure increases, and allowing fluid flow between the BOP bonnet and manifold to test valve integrity without applying hydraulic closing pressure, thereby avoiding system degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional testing methods are used to test BOP safety valves, then valve integrity can be verified, but additional high-pressure hydraulic cycles and opening/closing cycles are required, causing system degradation and wear
Solution Approach 1:
The invention extracts the testing function from the traditional high-pressure hydraulic cycling process. By using a separate test pump to apply test pressure directly to the valve bonnet while the BOP remains in its operational position, the system verifies valve integrity without requiring full operational cycles that cause wear to the BOP seals and hydraulic components.
Solution Approach 2:
The invention introduces an intermediary testing mechanism that uses a test pump and test pressure application system separate from the main BOP hydraulic system. This intermediary approach allows valve testing through pressure application to the bonnet without engaging the main hydraulic closing mechanism, thereby avoiding wear on the primary BOP components while still verifying valve functionality.
2Loss of time
If BOP systems remain subsea for extended periods, then operational efficiency is improved, but the ability to test and verify valve functionality without retrieval becomes difficult
Solution Approach 1:
The invention creates a multi-functional testing system that can verify valve integrity through pressure testing without requiring physical retrieval of the BOP. The test pump and pressure application mechanism provide universal testing capability that works whether the BOP is on the sea floor or during retrieval, eliminating the need to choose between extended subsea deployment and accessible testing.
Solution Approach 2:
The BOP system performs self-testing through the integrated test pump and pressure application mechanism. The system can verify its own valve integrity without external intervention or retrieval, allowing extended subsea deployment while maintaining the ability to test functionality. The test manifest and pressure gauges provide self-diagnostic capability that operates independently of physical access.
3Reliability
If redundant control systems are implemented to improve safety, then safety integrity level is increased, but system complexity and the number of components requiring testing increase
Solution Approach 1:
The invention segments the testing process by applying test pressure to each valve bonnet independently through the test pump system. Rather than requiring comprehensive testing of all hydraulic circuits and components, the segmentation approach allows each safety valve to be tested individually through pressure application to its bonnet, verifying functionality without requiring complex integration testing of the entire redundant control system.
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
Enables effective testing of BOP safety valves subsea during pressure testing, reducing the need for additional diagnostic equipment and minimizing wear on the BOP system, while maintaining safety and reliability standards.
Implementation Method 1
a first sensor operable to detect the flow from the BOP to the manifold
Implementation Method 2
the dump valve is operable to allow flow from the BOP to the manifold
Data Source
AI summary
A blowout preventer (BOP) safety system for testing the integrity of safety valves at the sea floor is disclosed. The system includes a BOP stack including a BOP, the BOP comprising a BOP shear ram and a first hydraulic circuit, the first hydraulic circuit in fluid communication with the BOP shear ram and having an open side and a close side. The system further includes a manifold, wherein the manifold is disposed proximate to and in fluid communication with a dump valve, a first sensor, and a supply valve and a first safety valve disposed between and in fluid communication with the manifold and the BOP on the close side, wherein the dump valve is operable to allow flow from the BOP to the manifold through the safety valve, and wherein the first sensor is operable to detect the flow from the BOP to the manifold.