Pressure Control Equipment Stack Test System
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Solution Overview
Problem
Mineral extraction systems face challenges in efficiently testing the structural integrity of pressure control equipment (PCE) stacks, which can lead to undesirable fluid leaks due to irregularities in the stack's geometry, necessitating a reliable method to detect and address such issues.
Innovation Solution
A test system is developed to automatically test the PCE stack by directing fluid into it and monitoring pressure over time, using a control system with sensors and actuators to identify any structural irregularities causing fluid leaks, and providing notifications for maintenance or inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual testing methods are used to inspect PCE stack structural integrity, then testing can be performed with simple equipment, but testing efficiency is low and fluid leaks may occur due to undetected irregularities
Solution Approach 1:
The PCE stack performs self-testing by using its own internal geometry and fluid pathways to detect irregularities. The system autonomously monitors pressure changes during fluid direction operations to identify structural issues without requiring external inspection equipment or personnel intervention.
Solution Approach 2:
The system implements continuous pressure monitoring that provides real-time feedback on the structural integrity of the PCE stack. Pressure sensors detect changes in pressure differential across the stack, and this feedback is used to automatically identify irregularities such as holes, openings, or worn seal elements, enabling timely maintenance actions.
2Reliability
If automated testing with fluid direction and pressure monitoring is implemented, then structural irregularities can be reliably detected, but system complexity increases
Solution Approach 1:
The PCE stack is designed to serve multiple functions: it performs both its primary pressure control function and self-testing functions using the same structural components. The geometry of the stack itself is utilized for testing, eliminating the need for separate dedicated testing equipment and reducing overall system complexity.
Solution Approach 2:
Fluid acts as an intermediary medium to transmit information about structural integrity. By directing fluid through the PCE stack and monitoring pressure changes, the system uses the fluid's behavior as a mediator to detect irregularities such as holes, openings, or seal wear without requiring direct physical inspection of these hidden features.
3Measurement precision
If pressure monitoring over time is conducted to detect fluid leaks, then accurate detection of structural issues is achieved, but testing time increases
Solution Approach 1:
The system employs periodic pressure monitoring at strategically selected time intervals during the testing process. Rather than continuous monitoring, pressure is measured at key phases of fluid direction operations, which maintains measurement precision for detecting structural irregularities while significantly reducing the total testing time required.
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 system effectively detects and reports structural issues in the PCE stack, ensuring the equipment's integrity and preventing fluid leaks, thereby enhancing the reliability and safety of mineral extraction operations.
Implementation Method 1
monitoring pressure over time, using a control system with sensors and actuators to identify any structural irregularities causing fluid leaks
Data Source
AI summary
A test system for a pressure control equipment (PCE) stack includes a pump for directing fluid into the PCE stack, a drive for operating the pump to control fluid flow into the PCE stack, and a controller communicatively coupled to the drive and a sensor that transmits sensor data indicative of pressure within the PCE stack. The controller instructs the drive to cause the pump to direct fluid into the PCE stack until the sensor data indicates that the pressure within the PCE stack has reached a threshold pressure, blocks fluid flow into and out of the PCE stack upon receiving sensor data indicating the pressure within the PCE stack has reached the threshold pressure, monitors the pressure within the PCE stack over a time interval, and determines a condition of the PCE stack based on a change in the pressure within the PCE stack during the time interval.