Mechanical Backup Activation for Wellbore Fluid Control
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Solution Overview
Problem
Blowout preventers may fail to activate and contain uncontrolled fluid flow from a wellbore, compromising safety due to system failures, such as hydraulic activation system failures.
Innovation Solution
A mechanical activation system is introduced, comprising an activation shaft, a rotatable drive shaft, a drive loop, and a pneumatic motor, which engages threaded profiles to translate and rotate the shafts, enabling the pipe ram blocks to close around the drill pipe and prevent fluid flow, acting as a contingency when the primary hydraulic system fails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a primary hydraulic activation system is used to close pipe ram blocks, then the ease of operation is improved, but the reliability deteriorates due to potential system failures
Solution Approach 1:
The patent implements a mechanical backup activation system with springs pre-loaded to automatically close the pipe ram blocks if hydraulic pressure is lost. This beforehand cushioning ensures that the critical function of wellbore closure is maintained even when the primary hydraulic system fails, directly addressing the reliability concern while preserving ease of operation under normal conditions.
Solution Approach 2:
The patent changes the activation parameter from purely hydraulic pressure to a mechanical spring-force-based system as a backup. By having two different activation mechanisms with different operating principles, the system ensures that if one parameter (hydraulic pressure) becomes unavailable, the other parameter (mechanical spring force) can still achieve the desired closure action, thereby improving reliability.
2Reliability
If a mechanical activation system with multiple components is added as backup, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The patent segments the activation system into distinct functional modules: the primary hydraulic activation system and the secondary mechanical activation system with springs and linkages. This segmentation allows each subsystem to be independently designed, analyzed, and maintained, making the overall complex system more manageable while ensuring that failure of one segment does not compromise the other.
Solution Approach 2:
The patent introduces intermediate mechanical components (springs, linkages, and mechanical shafts) that serve as a mediator between the stored mechanical energy and the pipe ram blocks. These intermediary elements translate the spring force into the necessary closing motion, providing a reliable backup mechanism without requiring direct complex integration with the hydraulic system.
3Power
If threaded profiles are used to engage the drive shaft and activation shaft, then the mechanical advantage is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent uses homogeneous threaded profiles on both the drive shaft and activation shaft, ensuring consistent engagement geometry. By standardizing the thread design and material properties, the system achieves reliable mechanical advantage while reducing the variability introduced by non-uniform manufacturing, thereby balancing power transmission effectiveness with manufacturing feasibility.
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 mechanical activation system effectively prevents uncontrolled fluid flow by ensuring the pipe ram blocks can close around the drill pipe, even if the primary hydraulic system fails, thereby maintaining wellbore safety and controlling fluid flow.
Implementation Method 1
The drive shaft has a threaded exterior profile by which the drive loop engages the drive shaft to rotate the drive shaft. The threaded exterior profile of the drive shaft also engages a threaded interior profile of the activation shaft that causes the activation shaft to translate as the drive shaft rotates.
Implementation Method 2
a pneumatic motor that is operable to activate the drive loop
Implementation Method 3
Blowout preventers are designed to seal around a pipe during wellbore control situations in order to contain the pressure of the formation fluid within the wellbore and therefore avoid uncontrolled flow of the formation fluid from the wellbore.
Data Source
AI summary
A fluid management system for controlling fluid flow at a wellbore includes a closing element formed complementary to a drill pipe disposed within the wellbore and an activation system. The activation system is configured to move the closing element into an activated position against the drill pipe to close the wellbore around the drill pipe for preventing fluid from flowing out of the wellbore. The activation system includes an activation shaft coupled to the closing element and a rotatable drive shaft configured to cause translation of the activation shaft to push the closing element into the activated position against the drill pipe.