Hybrid Electric Pressure Control System for BOP Power Management
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Solution Overview
Problem
Drilling rigs face challenges with large hydraulic accumulators required for blowout preventer (BOP) systems, which occupy valuable space and are costly, especially in offshore and land-based settings where space and transportation are limited, and API regulations further complicate the issue.
Innovation Solution
The implementation of a power management system that includes a capacitor management system with supercapacitors and a stored electrical system to support the pressure control equipment, replacing traditional hydraulic accumulators with a hybrid electric pressure control system that uses electric motors and programmable logic controllers to manage power effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic accumulators are used to power BOP systems in emergency situations, then reliable power delivery is achieved, but space occupation and cost increase significantly
Solution Approach 1:
The patent replaces the traditional hydraulic accumulator system with an electric motor-driven pump system. The electric motor converts electrical energy directly into mechanical energy to drive the pump, eliminating the need for large hydraulic accumulators while maintaining the ability to deliver power quickly during emergency situations. This substitution of mechanical energy storage with electrical energy conversion resolves the space reliability contradiction.
Solution Approach 2:
The patent changes the energy storage parameter from hydraulic energy (requiring large volume accumulators) to electrical energy (requiring compact battery or capacitor systems). By changing the physical state and storage mechanism of energy, the system achieves smaller footprint while maintaining emergency power delivery capability, thus resolving the space occupation issue.
2Reliability
If hydraulic accumulators are used to meet API regulations and BOP shear requirements, then system reliability is improved, but transportation and space issues worsen
Solution Approach 1:
The patent replaces the hydraulic accumulator system with an electric motor and pump system that can be more easily transported and installed. The electric motor-driven configuration allows for modular assembly and reduced transportation requirements, making it more suitable for remote drilling locations while still meeting BOP shear requirements through controlled hydraulic pressure delivery.
Solution Approach 2:
The patent implements a dynamic control system that adjusts pump operation based on real-time pressure and flow requirements. The system can rapidly adjust hydraulic pressure and flow rate to meet varying BOP shear requirements, providing flexibility and adaptability that reduces the need for oversized accumulators and improves ease of manufacture and transportation.
3Area of stationary object
If electric motors are used to power pumps directly, then space efficiency is improved, but power delivery speed may be reduced
Solution Approach 1:
The patent incorporates energy storage devices (batteries or capacitors) that are charged in advance during normal operation. When emergency situations arise, the stored energy is immediately available to power the electric motor, ensuring rapid power delivery without waiting for external power sources or hydraulic charge-up. This preliminary energy storage resolves the speed contradiction.
Solution Approach 2:
The patent creates a hybrid system combining electric motors, energy storage devices, and hydraulic pumps into an integrated unit. This composite system leverages the fast response of electrical energy conversion combined with the high power density of hydraulic systems, achieving both space efficiency and rapid power delivery capability simultaneously.
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
This solution reduces the dependency on hydraulic accumulators, optimizing space and cost by providing efficient, on-demand power for BOP systems, supporting both normal operations and emergency power needs through electric power management.
Implementation Method 1
a capacitor management system with supercapacitors
Implementation Method 2
at least one pump including an electric motor configured to power the pump
Implementation Method 3
hydraulic power unit including: a fluid reservoir, and at least one pump
Data Source
AI summary
A system includes a pressure control equipment and a hydraulic power unit including a fluid reservoir, and at least one pump including an electric motor configured to power the pump. The at least one pump of the hydraulic power unit is in direct fluidic communication with the pressure control equipment.