Hydraulic Manifold Control Assembly for BOP Systems
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Solution Overview
Problem
Conventional surface blowout preventer (BOP) and diverter control systems are bulky, costly, and complex, with harsh environmental conditions necessitating hazardous area-rated components, which increases costs and complexity, while also requiring custom-designed piping and tubing that complicates installation and maintenance.
Innovation Solution
A compact hydraulic manifold control assembly featuring intrinsically safe I/O modules, self-contained solenoid rack modules, integrated manifold assemblies, and a digital automatic diverter sequence, which reduces bulkiness, enhances maintenance accessibility, and simplifies installation by eliminating unnecessary components and custom piping, using intrinsically safe electrical components and flexible sealing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hazardous area-rated components and custom-designed piping systems are used, then safety and reliability are improved, but system complexity, cost, and installation time increase significantly
Solution Approach 1:
The control system is divided into modular functional units (flow control valves, solenoid valves, manifolds, tubing assemblies) that can be independently configured and assembled. This segmentation allows the system to maintain safety through standardized hazardous area-rated components while reducing overall complexity by eliminating custom-integration requirements.
Solution Approach 2:
The system employs universal connection standards and standardized tubing assemblies that can be used across different BOP control applications. This universality eliminates the need for custom-designed piping systems for each project, reducing installation complexity and time while maintaining safety through proven standardized components.
2Reliability
If custom-designed piping and tubing runs are installed for each project, then system integrity and safety are ensured, but installation cost and time are significantly increased
Solution Approach 1:
Tubing assemblies are pre-configured and pre-assembled with connections already established before arrival at the installation site. This preliminary action eliminates the need for time-consuming on-site piping fabrication and welding, significantly reducing installation time while maintaining system integrity through factory-controlled assembly procedures.
Solution Approach 2:
The system uses standardized, replaceable tubing assemblies rather than permanent custom-welded piping. These standardized components can be quickly installed and replaced if needed, reducing installation time and cost while maintaining safety through standardized design and testing protocols.
3Object-affected harmful factors
If flameproof equipment and hardened components are used, then protection against hazardous environment is improved, but system bulk and cost increase
Solution Approach 1:
The system replaces heavy mechanical flameproof enclosures with intrinsically safe electrical designs that eliminate the need for bulky explosion-proof housing. Intrinsically safe components are designed to operate at energy levels too low to cause ignition, allowing compact enclosures while maintaining protection in hazardous environments.
Solution Approach 2:
The electrical components are designed with intrinsically safe parameters (limited voltage, current, and energy) that inherently prevent ignition of hazardous atmospheres. This parameter change allows the use of compact, lightweight enclosures instead of heavy flameproof equipment, reducing system bulk while maintaining safety.
4Strength
If flow control valves are permanently attached to function plates or skid frame, then structural integrity is maintained, but maintenance accessibility and ease of repair are reduced
Solution Approach 1:
The flow control valves are segmented from the skid frame structure and mounted on removable function plates. This segmentation allows the valves to remain securely attached during operation (maintaining structural integrity) while enabling easy removal of the entire function plate assembly for maintenance, improving accessibility without compromising strength.
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 solution results in a more cost-effective, robust, and maintainable control system with reduced installation time, improved reliability, and enhanced safety for hazardous environments, by eliminating bulky components and simplifying the piping system design.
Implementation Method 1
a solenoid rack module comprising a solenoid, a valve, and a compressed air line, wherein said solenoid is operable to open or close said valve in response to receiving a signal
Implementation Method 2
a first regulator attached to said first manifold, wherein said first regulator attached to said first manifold is operable to regulate a first available internal pressure of said hydraulic fluid within said first manifold
Implementation Method 3
said flow control valve is operable to receive and redirect said hydraulic fluid from said manifold to a location exterior to said hydraulic manifold control assembly
Data Source
AI summary
A Hydraulic Manifold Control Assembly for use in connection with surface blowout preventers and diverter control systems. Said Hydraulic Manifold Control Assembly incorporates design elements and methods which reduce overall envelope dimensions, improving maintenance accessibility, thereby reducing overall installation and manufacturing time and ultimately contributing to a more robust, cost effective end-product. Said design elements and methods include: the use of intrinsically safe I/O modules and components; the employment of a removable valve assembly rack installation method; the use of a removable face plate for identification of flow control valves; the implementation of a digital automatic diverter sequence; the use of integrated manifold assemblies; and the integration of a wide-range function count.