BOP Test Spool With Segmented Plug For Wellhead-Independent Integrity Verification
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Solution Overview
Problem
Existing blow-out preventer (BOP) testing procedures are hindered by obsolete or damaged equipment, leading to incomplete integrity tests, which compromise safety during drilling operations, especially in cases of damaged tubing hanger seals, corroded spools, and obsolete wellheads, resulting in 'drilling under risk' scenarios.
Innovation Solution
A BOP test spool system with a test plug and loading shoulder design that allows for complete pressure testing of BOPs independently of the wellhead, enabling secure sealing and testing without requiring reliable wellhead connections, using a test plug with a tapered outer shape that automatically centers within the spool and is secured by lock-down screws, facilitating easy insertion and removal without additional tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If regular BOP testing procedures are used, then BOP integrity can be verified, but the test cannot be completed due to damaged tubing hanger seals and corroded spools that leak pressure
Solution Approach 1:
The patent introduces a test spool as an intermediary component between the wellhead and BOP stack. This test spool includes a sealed test chamber with a test plug that creates an isolated testing environment, allowing pressure testing to be performed without being affected by leaks in the damaged tubing hanger seals or spools. The intermediary test spool effectively mediates between the faulty wellhead components and the BOP stack, enabling reliable integrity verification.
2Reliability
If wellhead connections are required for BOP testing, then testing can be performed through the wellhead, but obsolete or damaged wellhead equipment prevents complete testing
Solution Approach 1:
The patent segments the BOP testing function from the wellhead by introducing a self-contained test spool assembly. The test spool includes a test chamber, test plug, and pressure testing components as separate modular units that can be attached to the BOP stack independently of the wellhead. This segmentation allows complete BOP testing to be performed without relying on the condition or compatibility of obsolete wellhead equipment.
3Productivity
If partial BOP testing is conducted due to equipment limitations, then some testing can be performed, but the risk of BOP failure during drilling cannot be fully excluded
Solution Approach 1:
The test spool acts as an intermediary that enables complete BOP testing by providing a sealed test environment isolated from wellhead leaks. The test chamber can be pressurized to full test pressure without pressure loss from damaged seals, allowing all BOP components to be thoroughly tested. This eliminates the need for partial testing and ensures complete safety verification before drilling operations.
4Productivity
If drilling continues under risk without complete BOP testing, then operations can proceed, but safety compensation measures and dispensations are required
Solution Approach 1:
The test spool enables preliminary complete BOP testing to be performed before drilling operations begin. By providing a reliable sealed testing environment, the system allows all BOP components to be fully verified for integrity prior to drilling. This preliminary action eliminates the need to drill under risk and ensures that full safety measures are in place before operations commence.
Data Source
AI summary
The present invention relates to a blow-out preventer BOP test spool system, comprising a test spool to be mounted between a well head and a blow-out preventer; the test spool having an inner cylindrical hole extending in vertical direction of the test spool; the inner cylindrical hole in vertical direction comprising an upper section and a lower section, wherein the lower section comprises a smaller inner diameter than the inner diameter of the upper section; and a test plug, insertable into the inner cylindrical hole of the test spool, the test plug having a cylindrical outer shape with an outer diameter that is smaller than the inner diameter of the upper section and is larger than the inner diameter of the lower section, such that the plug can abut a loading shoulder between the upper and lower section and the plug is not able to move further down within the test spool. The invention also relates to a corresponding method for testing a blow-out preventer.