Hydraulically-Actuated Device Reliability Testing Without Full Actuation
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Solution Overview
Problem
Existing methods for testing the reliability of hydraulically-actuated devices, such as blowout preventers, require full actuation and are time- and cost-intensive, making it difficult to assess their reliability without disrupting operations.
Innovation Solution
A system and method that allow for testing of hydraulically-actuated devices without full actuation, by moving the piston to a maximum position and varying pressures within the chambers to simulate actuation, thereby reducing the probability of failure on demand.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If full actuation testing is performed on hydraulically-actuated devices, then reliability assessment accuracy is improved, but testing time and operational disruption increase
Solution Approach 1:
The patent applies partial action by performing pressure differential testing on the piston without requiring full actuation through the entire stroke. The piston is moved to a test position and pressure differentials are applied and held, rather than requiring complete movement from first to second position. This partial testing approach maintains reliability assessment capability while significantly reducing testing time and operational disruption.
Solution Approach 2:
The patent implements preliminary action by performing pressure differential tests at intermediate positions before full actuation is required. By testing the piston at various positions along its stroke rather than only at end positions, reliability is assessed preliminarily throughout operation, reducing the need for time-consuming full actuation tests and enabling earlier detection of potential failures.
2Reliability
If full actuation testing is performed on hydraulically-actuated devices, then reliability assessment accuracy is improved, but operational disruption and cost increase
Solution Approach 1:
The patent applies partial action by performing pressure differential testing on the piston without requiring full actuation through the entire stroke. The piston is moved to a test position and pressure differentials are applied and held, rather than requiring complete movement from first to second position. This partial testing approach maintains reliability assessment capability while significantly reducing testing time and operational disruption.
3Reliability
If safety systems are integrated with existing BOP, then system availability is improved, but fault transfer risk increases
Solution Approach 1:
The patent applies segmentation by dividing the pressure control system into separate, independent channels. The first pressure source and second pressure source operate independently to control the piston in different directions, with dedicated control circuits and monitoring systems. This segmentation isolates faults within individual channels, preventing fault transfer between systems while maintaining high system availability through redundant independent pathways.
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 proposed solution enables efficient and cost-effective testing of hydraulically-actuated devices, reducing the probability of failure on demand and increasing the availability, reliability, and fault-tolerance of blowout prevention systems.
Implementation Method 1
the piston is movable relative to the housing to a maximum first position in response to pressure within the second chamber being greater than pressure within the first chamber and to a maximum second position in response to pressure within the first chamber being greater than pressure within the second chamber
Implementation Method 2
a hydraulic pressure source configured to vary pressure within at least one of the first chamber and the second chamber
Data Source
AI summary
This disclosure includes methods for testing hydraulically-actuated devices and related systems. Some hydraulically-actuated devices have a housing defining an interior volume and a piston disposed within the interior volume and dividing the interior volume into a first chamber and a second chamber, where the piston is movable relative to the housing between a maximum first position and a maximum second position in response to pressure differentials between the first and second chambers. Some methods include: (1) moving the piston to the first position by varying pressure within at least one of the first and second chambers such that pressure within the second chamber is higher than pressure within the first chamber; and (2) while the piston remains in the first position: (a) reducing pressure within the second chamber and/or increasing pressure within the first chamber; and (b) increasing pressure within the second chamber and/or decreasing pressure within the first chamber.