BOP Seal Assembly Segmentation for High-Pressure Leakage
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Solution Overview
Problem
Existing blowout preventer (BOP) systems face challenges in effectively sealing tubulars during high-pressure and high-temperature conditions, leading to potential leakage and environmental hazards in oilfield operations.
Innovation Solution
A seal assembly for BOPs is introduced, comprising a seal plate with seal grooves, a seal carrier with carrier lips, and elastomeric or metal seals, which are positionable in sealing engagement with the BOP housing and components, providing a self-aligning and secure seal through fasteners and door assemblies, enabling effective sealing of channels and tubulars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sealing methods are used in BOP systems, then the structure remains simple, but sealing reliability deteriorates under high-pressure and high-temperature conditions
Solution Approach 1:
The seal assembly is divided into multiple functional components: seal plate with grooves, seal carrier with lips, and elastomeric or metal seals. This segmentation allows each component to be optimized for its specific function while collectively providing reliable sealing under high-pressure and high-temperature conditions.
Solution Approach 2:
The seal carrier is disposed about the perimeter of the seal plate, with carrier lips positioned in seal grooves on the seal plate. The seals are nested within seal receptacles on the carrier. This nested configuration creates multiple sealing interfaces that enhance reliability without requiring a completely new system architecture.
2Ease of manufacture
If simple seal structures are used, then ease of manufacture is improved, but sealing effectiveness under high pressure deteriorates
Solution Approach 1:
The seal plate is pre-formed with seal grooves, and the seal carrier is pre-equipped with carrier lips and seal receptacles. This preliminary preparation of sealing surfaces and structures simplifies the final assembly process while ensuring that all sealing components are properly positioned and configured for effective sealing under high pressure.
Solution Approach 2:
The seal assembly combines different materials including elastomeric materials for flexible sealing, metal materials for structural strength, and potentially rubber materials for additional sealing capability. This composite material approach allows the seal to withstand high-pressure and high-temperature conditions while maintaining manufacturability of individual components.
3Reliability
If multiple seal components are assembled, then sealing reliability is improved, but assembly complexity increases
Solution Approach 1:
The seal carrier integrates multiple functions into a single component: it provides structural support, holds the seals in receptacles, and positions the carrier lips in the seal grooves on the plate. This merging of functions reduces the number of separate assembly steps compared to having entirely separate components for each function.
Solution Approach 2:
The seal carrier acts as an intermediary component between the seal plate and the seals. It pre-positions the seals in receptacles and provides carrier lips that engage with the plate's seal grooves, thereby mediating the assembly process and ensuring proper alignment and engagement of all sealing surfaces.
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 seal assembly effectively prevents leakage by ensuring a reliable sealing engagement between the BOP housing, door assembly, and tubulars, even under high-pressure conditions, enhancing safety and environmental protection in oilfield operations.
Implementation Method 1
The seal carrier and the seal include a rubber material and/or a metal material
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A seal assembly 223 for a blowout preventer of a wellsite is provided. The blowout preventer includes a housing and at least one component 225 operatively connectable to the housing. The housing has a bore and a channel therethrough. A tubular is positionable through the bore and engageable therein. The seal assembly 223 includes a seal plate 352, a seal carrier 354, and at least one seal 356. The seal plate 352 is operatively connectable between the housing and the at least one component of the blowout preventer, and has at least one seal groove 353 extending therein. The seal carrier 354 is disposable about a perimeter of the seal plate 352, has at least one carrier lip disposable in a seal groove(s) 353, and has at least one seal receptacle. The seal 356 is receivably positionable in the seal receptacle, and in sealing engagement with one of the housing, the component, and combinations thereof.