Forged BOP Internal Cavity Profile for Workover Rig Sealing
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Solution Overview
Problem
Existing BOPs for lower working pressure (LWP) workover rigs face challenges in manufacturing due to the complexity and difficulty of forging smaller components, leading to structural flaws and reduced longevity, maintenance needs, and incompatibility with standard components.
Innovation Solution
A forged Ram BOP with a machined internal cavity profile featuring a flat upper sealing surface, raised landing surface, mud slots, and side entry ram access, designed for easy machining and interchangeability with standard components, enhancing operational life and reducing maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If casting is used to manufacture BOPs for LWP workover rigs, then manufacturing complexity is reduced, but structural strength and longevity are compromised due to flaws and weak areas
Solution Approach 1:
The BOP body is divided into a forged outer shell and a machined internal cavity assembly. The internal cavity is separated as a distinct component that can be precision-machined independently and then integrated into the forged body, allowing each part to be optimized for its specific manufacturing process
Solution Approach 2:
The invention merges forging and machining processes by creating a hybrid component where the outer shell is forged for strength while the internal cavity is machined for precision. This combination allows the BOP to achieve both structural integrity and manufacturing feasibility
2Strength
If forging is used to manufacture BOPs, then structural strength and longevity are improved, but manufacturing complexity increases due to tooling and manufacturing difficulty for smaller components
Solution Approach 1:
The manufacturing process is segmented into two distinct phases: forging the outer shell and separately machining the internal cavity. This segmentation allows the complex machining operations to be performed on a pre-formed forged body, reducing overall manufacturing complexity
Solution Approach 2:
The forged body is created first as a preliminary structure that provides the necessary strength and form. Subsequently, the internal cavity is machined into this pre-formed structure, allowing precision work to be done on an already-strengthened component rather than attempting to forge the entire complex geometry
3Strength
If traditional forged BOP design is used, then structural integrity is maintained, but maintenance accessibility and operational life are reduced due to lack of side entry access
Solution Approach 1:
The BOP design is segmented to include a removable internal cavity assembly that can be accessed through a side entry opening. This allows the internal components to be separated from the main forged body for maintenance purposes
Solution Approach 2:
The internal cavity and its components are designed to be extractable through the side entry access point. This extraction capability allows maintenance personnel to remove and replace internal components without compromising the integrity of the main forged BOP body
4Device complexity
If standard ram access design is used, then structural simplicity is maintained, but component replacement time and maintenance complexity increase
Solution Approach 1:
The BOP design incorporates dynamic accessibility through the side entry access point, which can be opened or closed as needed. This dynamic feature allows quick access to internal components for maintenance while maintaining structural integrity during operation
Solution Approach 2:
The side entry access point serves as an intermediary mechanism that provides access to internal components without requiring complete disassembly of the BOP. This mediator structure enables efficient maintenance while preserving the overall structural design
Data Source
AI summary
A machined internal cavity for a forged block of a workover BOP. The ram internal cavity has a bore along an inner cavity wall into which a ram guide is insertable. The ram cavity has a flat upper sealing surface that is engageable with a seal on a ram and a raised landing surface to guide the ram to engage the seal with the flat upper sealing surface. Mud slots are machined on the lower surface of the machined internal cavity profile. The ram has a side entry access point into which the rams are installed or accessed within the machined internal cavity.