Pilot Pressure Regulator Piston for Fluid Hammer Reduction
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Solution Overview
Problem
Hydraulic shock or fluid hammer occurs in drilling systems due to sudden changes in fluid flow, leading to equipment degradation and failures in downstream components like solenoid valves and BOP rams, as existing pressure regulators cause sudden reductions in flow that result in vibrations.
Innovation Solution
A pressure regulator system with a movable regulator piston controlled by pilot pressure, where a controller monitors the state of the function and adjusts hydraulic pressure to gradually move the piston from an open to a closed position, reducing fluid hammer by smoothing the flow transition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the control piston moves quickly to a closed position to stop fluid flow, then the response time is improved, but fluid hammer and vibrations occur causing equipment degradation
Solution Approach 1:
The system performs preliminary action by gradually reducing flow before complete closure. The control piston moves to an intermediate position first to partially close the supply port, allowing flow to be reduced gradually before the operator piston closes the outlet port, preventing sudden flow cessation and fluid hammer
Solution Approach 2:
The system uses dynamic control where the control piston position is adjusted based on the state of the operator piston. The control piston moves to different positions (fully open, partially closed, fully closed) at different stages of the operator piston's movement, creating a dynamic flow control strategy that prevents fluid hammer while maintaining response speed
2Object-affected harmful factors
If the control piston moves slowly to reduce flow gradually, then fluid hammer is reduced, but the response time increases
Solution Approach 1:
The system implements periodic action through a multi-stage closing process. The control piston performs sequential movements: first moving to an intermediate position to partially close the supply port, then moving to the fully closed position after the operator piston has moved. This staged approach reduces fluid hammer while maintaining acceptable response time
3Device complexity
If the regulator uses a simple on/off control mechanism, then the device complexity is reduced, but equipment failures occur due to fluid hammer vibrations
Solution Approach 1:
The system uses feedback by monitoring the state of the operator piston and adjusting the control piston position accordingly. The control piston's position is determined based on feedback from the operator piston's movement stage, creating a control mechanism that prevents fluid hammer and improves equipment reliability without excessive 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
The solution effectively reduces hydraulic shock by gradually closing the fluid path, preventing sudden stops and oscillations, thereby minimizing equipment damage and extending the lifespan of drilling system components.
Implementation Method 1
a regulator piston that moves between an open and a closed position based on a change in hydraulic pressure applied to the regulator piston via a pilot port
Implementation Method 2
The regulator piston is in an open position when the hollow portion at least partially aligns with the input and output ports so that fluid flows between the input and output ports
Data Source
AI summary
A pressure regulator for a BOP stack includes a housing having an input port, an output port, and a pilot port and a regulator piston axially movable through the housing between an open position and a closed position. The regulator piston has an internal passage formed through its first axial end. When the regulator piston is in the open position, the internal passage is in fluid communication with the input and output ports. When the regulator piston is in the closed position, the internal passage is in fluid communication with the output port and fluidly isolated from the input port. A space with regulator fluid is also provided within the housing adjacent a second axial end of the regulator piston, opposite the first axial end, wherein the space is fluidly isolated from the input port and the output port in both the open position and the closed position.