BOP Single-Piece Replaceable Insert for Ram Cavity Wear
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Solution Overview
Problem
The prolonged and costly process of repairing and refurbishing blowout preventers (BOPs) due to wear, which involves extensive machining, welding, and heat treatment, poses challenges in maintaining performance and preventing crack development, and requires a more efficient and cost-effective solution.
Innovation Solution
A single replaceable insert is designed for the ram cavity of BOPs, which can be easily mounted at the upper intersection of the throughbore and ram cavity, eliminating the need for side and bottom inserts, and made from non-metallic materials like fluoroelastomer, allowing for quick replacement and sealing without the need for extensive refurbishment processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If extensive machining, welding, and heat treatment processes are used to refurbish the BOP body, then the BOP can be restored to operative condition, but the process takes approximately 45 days and carries high risk of crack development
Solution Approach 1:
The BOP body is divided into a permanent outer shell and a replaceable inner insert component. The insert contains the sealing surfaces and ram contact areas, allowing it to be independently replaced without refurbishing the entire BOP body. This segmentation enables quick replacement of worn components while preserving the durable outer structure.
Solution Approach 2:
The insert is designed as a consumable component that can be easily replaced when worn. Instead of investing extensive time and resources in refurbishing the entire BOP body, the worn insert is removed and replaced with a new or refurbished insert, significantly reducing downtime and refurbishment costs.
2Reliability
If the entire BOP body is refurbished through prolonged machining and welding processes, then sealing performance can be restored, but there is high chance of crack development affecting performance
Solution Approach 1:
The insert is designed as a separate, replaceable component that contains all sealing surfaces and ram contact areas. When the insert becomes worn or damaged, it can be removed and replaced without subjecting the BOP body to extensive machining and welding that could create cracks. The permanent outer shell remains intact and undamaged.
Solution Approach 2:
The problematic sealing components are extracted from the BOP body as a separate insert assembly. This allows the sealing function to be maintained by replacing the insert rather than refurbishing the entire body, eliminating the need for prolonged welding and heat treatment that could induce cracks in the BOP shell.
3Reliability
If multiple inserts (side inserts and bottom inserts) are used in the ram cavity, then sealing can be achieved, but the complexity of repair increases and more parts need to be replaced
Solution Approach 1:
Multiple separate sealing components (side inserts, bottom inserts, and top insert) are merged into a single integrated insert assembly. This unified design maintains comprehensive sealing coverage around the ram while reducing the number of individual parts that need to be managed, installed, and maintained. The single insert assembly can be replaced as one unit, simplifying repair operations.
Data Source
AI summary
A replaceable seat seal is used to form a replaceable portion of the ram cavity in a BOP that allows the upper central portion of the ram cavity to be replaced when wear occurs. A method is provided to produce a BOP that with a replaceable portion of the ram cavity. The single piece insert, also referred to as a single insert, utilizes only the single insert to repair the BOP as compared to another design that comprised a top insert, bottom insert, and two side inserts. The top insert of the prior art is comparable in construction and mounting position to the single insert.