Modular BOP Control System Segmentation for Rig Time Reduction
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Solution Overview
Problem
Legacy drilling systems require labor-intensive redesign and reconfiguration of control manifolds for each jack-up specification or stack change, consuming valuable rig time and resources due to non-modularized and non-customizable designs, especially in managing pressure kicks and fluid control during offshore drilling operations.
Innovation Solution
A modular BOP control system with segregated functional modules for blowout preventers, diverter, and ram BOPs, featuring standardized interconnections for electrical and hydraulic lines, allowing for easy swapping and customization, and a compact skid design that reduces cabling and piping needs at the wellsite.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If legacy drilling systems use non-modularized control manifolds, then system reliability is maintained through fixed design, but labor-intensive redesign and reconfiguration is required for each jack-up specification or stack change
Solution Approach 1:
The control manifold system is divided into separate modular units, each capable of being independently configured and connected. This segmentation allows different modules to be assembled in various configurations to match specific jack-up specifications without redesigning the entire system, thus reducing rig time while maintaining reliability.
Solution Approach 2:
The modular control manifold design creates universal interfaces and standardized connection points that can accommodate multiple jack-up specifications and stack configurations. This universality enables a single set of modular components to serve multiple functions and applications, eliminating the need for custom redesign for each specification.
2Productivity
If non-modularized control systems are used, then system stability is maintained, but valuable rig time is consumed due to labor-intensive redesign
Solution Approach 1:
The control system transitions from a static, fixed design to a dynamic, reconfigurable modular architecture. This allows the system to adapt its configuration based on specific operational requirements while maintaining standardized connection protocols, thereby improving rig-up efficiency without introducing excessive complexity.
3Ease of repair
If standardized interconnections are implemented in modular system, then ease of repair and customization is improved, but initial system complexity increases
Solution Approach 1:
By segmenting the control system into modular units with standardized interfaces, the patent enables individual modules to be easily removed, repaired, or replaced without affecting the entire system. The standardized interconnections simplify the repair process while the modular architecture manages complexity through clear separation of functions.
Data Source
Figure 1A~1B
Figure 2
Figure 3A
AI summary
Disclosed here is a system and method for modular BOP control. The modular BOP control unit system of one embodiment includes a skid (36) having a plurality of module pockets configured to receive a group of modular control units, one dedicated to the annular BOP, one dedicated to the diverter and one dedicated to the ram BOPs. The modular units can include: a main control unit module (38) including a choke valve switch, a kill valve switch, a pressure gauge for air supply pressure to the BOP control unit system, a pressure gauge for BOP annular pressure, and an annular BOP regulator, a diverter valve module (42) including a set of pressure gauges, a regulator, and a diverter panel; and a BOP valve module (40) including a second set of pressure gauges, a set of ram control valves, and a BOP manifold regulator.