Interlocking Dual V-Shaped Shear Ram for BOP Seal Integrity
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Solution Overview
Problem
BOP stacks are bulky and expensive to install and maintain, requiring heavy lifting equipment and frequent maintenance due to issues like stuck cut pipe or wireline blocking the seal or shearing function, which limits economic reworking of wells.
Innovation Solution
An interlocking dual v-shaped shear ram assembly with angled shoulders and wear pads that prevent rotation and bending, enhancing shearing capabilities and seal performance by engaging upper and lower rams in a manner that prevents rotation and deformation, using packer material with inserts to increase pressure and improve sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional shear rams are used for cutting pipe and wireline, then the BOP can perform sealing and cutting functions, but the cut pipe or wireline may become stuck within the BOP shear rams blocking the BOP from forming a complete seal or shearing function, requiring frequent maintenance
Solution Approach 1:
The shear ram is divided into multiple functional segments including upper and lower rams with distinct V-shaped cutting surfaces, interlocking shoulders for positioning, and separate wear pads for protective function. This segmentation allows each component to perform its specific function optimally while reducing interference during operation.
Solution Approach 2:
Different regions of the shear ram components have different properties: the cutting surfaces have specific V-shapes for shearing, the shoulders have flat planar engagement surfaces for interlocking, and wear pads provide protective material. This local differentiation of properties ensures optimal performance in each zone while preventing operational issues.
2Adaptability or versatility
If BOP stacks are designed with standard shear rams, then they can cut pipe and wireline, but the BOP stacks become bulky and heavy requiring heavy lifting equipment for installation and removal
Solution Approach 1:
The upper and lower rams are positioned within ram cavities in a nested arrangement, with the rams fitting closely within the available space. This nested configuration allows the BOP to maintain cutting functionality while reducing overall bulk and weight compared to traditional designs.
3Reliability
If BOP stacks are designed with standard shear rams, then they can seal the wellbore, but maintenance costs are high which severely limits the wells that can be economically reworked
Solution Approach 1:
The wear pads are designed as replaceable components that can be discarded after use and recovered for replacement. This allows the main ram structure to be retained and reused, significantly reducing maintenance costs compared to replacing entire shear ram assemblies.
4Device complexity
If shear rams are designed without interlocking features, then the structure is simpler, but the rams may rotate or bend within the ram cavity causing jams after cutting
Solution Approach 1:
The interlocking shoulders feature asymmetric flat planar engagement surfaces with specific angles on the upper and lower rams. This asymmetric design creates a mechanical interlock that prevents rotation and bending of the rams within the cavity, ensuring reliable cutting performance without excessive complexity.
Data Source
AI summary
The present invention provides a dual interlocking v-shaped shear ram assembly comprising an upper ram and lower ram, each defining a v-shaped cutting surface. A plurality of angled surfaces on the upper ram and lower ram engage to form an interlocking connection that prevents rotation of either the upper ram or lower ram in the ram cavity and seals the wellbore. The upper ram has a surface along 90% to 100% of the length thereof that conforms to the surface of the corresponding ram cavity.