Modular Backup Hydraulic Supply for BOP Component Bypass
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Solution Overview
Problem
Subsea drilling operations face challenges with blowouts, where existing BOP systems require redundant control units for safety, leading to costly downtime and revenue loss due to the inability to efficiently retrieve and maintain large, non-retrievable components.
Innovation Solution
A modular fluid supply apparatus with primary and secondary fluid flow routes, including an intervention shuttle valve and modular removable block, allows for safe bypass of faulty components, enabling continued operation and easy maintenance by deploying a remotely operated vehicle (ROV) to connect hydraulic supply to BOP functions, providing operational redundancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dual redundancy control units (blue pod and yellow pod) are installed to prevent loss of control, then safety and reliability are improved, but device complexity and cost increase
Solution Approach 1:
The control system is divided into modular functional blocks (flow control components, valves, actuators) that can be independently replaced. This segmentation allows maintenance of individual components without affecting the entire redundant system, reducing the complexity burden of having dual redundancy units.
Solution Approach 2:
The patent enables rapid replacement of failed flow control components with pre-positioned backup components. Instead of retrieving entire control units, individual faulty components are discarded and replaced, recovering system operation quickly while maintaining the redundancy architecture.
2Reliability
If large non-retrievable control units are used for redundancy, then safety redundancy is improved, but ease of repair and operational redundancy deteriorate
Solution Approach 1:
The control units are segmented into retrievable modular components. Each flow control component is designed as a separate replaceable module that can be independently retrieved, repaired, or replaced by ROV, eliminating the need to retrieve entire large control units.
Solution Approach 2:
The system transitions from static non-retrievable control units to dynamic retrievable modular components. The modular components can be dynamically deployed, retrieved, and replaced based on operational needs and failure conditions, enabling both safety and operational redundancy.
3Reliability
If stopping drilling operations to replace failed components is required, then reliability is maintained, but productivity and time efficiency worsen
Solution Approach 1:
The system enables self-service maintenance through ROV-based component replacement. Failed flow control components can be replaced underwater without requiring surface intervention or cessation of drilling operations, allowing the well to continue producing while maintenance is performed.
Solution Approach 2:
The modular replaceable component design allows continuous drilling operations to proceed while failed components are replaced underwater. The useful action of drilling and production continues uninterrupted, with only the specific faulty component being replaced, maintaining both reliability and productivity.
4Ease of repair
If modular removable blocks with stab type connections are used, then ease of repair and maintenance speed improve, but device complexity increases
Solution Approach 1:
Multiple connection functions (mechanical attachment, fluid sealing, electrical connectivity) are merged into integrated stab type connections. This consolidation simplifies the overall connection system despite the modular architecture, as single connection actions establish multiple functional links simultaneously.
Solution Approach 2:
The stab type connections utilize hydraulic sealing mechanisms that automatically establish fluid-tight seals upon engagement. This hydraulic sealing approach simplifies the connection system by using pressure-activated sealing rather than complex mechanical sealing arrangements, improving ease of repair while controlling complexity.
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 downtime and increases safety by allowing independent control of BOP functions, facilitating fast maintenance and replacement, while being cost-effective and compatible with existing systems, thus preventing unplanned stack retrievals and maintaining safe operation during component downtime.
Implementation Method 1
an intervention shuttle valve having a primary inlet and a secondary inlet
Implementation Method 2
The hose connects to the intervention shuttle valve and the modular removable block of secondary flow control components via a stab type connection
Data Source
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AI summary
A system and method to allow backup or alternate fluid flow routes around malfunctioning components using removable, modular component sets. In one exemplary embodiment, an ROV (106) establishes a backup hydraulic flow to a BOP (22) function by attaching one end of a hose to a modular valve block (18, 77) and the other end to an intervention shuttle valve (16), thus circumventing and isolating malfunctioning components. A compound intervention shuttle valve (16) is provided that comprises first (100) and second (600) primary inlets, first (101) and second secondary inlets (601), and an outlet (50). A modular valve block is provided that comprises a directional control valve (40, 42), a pilot valve (41, 43), a manifold pressure regulator (45), a pilot pressure regulator (46), stab type hydraulic connections and an electrical wet-make connection (410).