Sacrificial Wellhead Adapter for BOP Testing
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Solution Overview
Problem
Current methods for testing blowout preventers, including the shear ram, require tripping the drill pipe to the surface, which is time-consuming and costly, and pose a risk of damaging the existing wellhead component during testing.
Innovation Solution
A sacrificial wellhead adapter with a top locking mechanism and bottom locking mechanism allows for testing of blowout preventers without pulling the drill pipe out of the hole, using a test plug with an activated load shoulder and elastomeric seals to protect the wellhead component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the drill pipe is tripped to the surface for BOP testing, then the BOP can be tested according to regulatory requirements, but the operation time increases significantly (at least eight hours of rig time)
Solution Approach 1:
The system divides the testing apparatus into separable components: a test plug that can be run on the drill string, a sacrificial adapter that interfaces with the wellhead, and a load ring mechanism. This segmentation allows the test plug to be deployed and retrieved without tripping the entire drill string, enabling testing while the drill string remains in the hole.
Solution Approach 2:
The sacrificial adapter serves as an intermediary component between the wellhead and the test plug. It provides the necessary interface and load-bearing capability, allowing the test plug to be activated and tested without requiring the drill string to be removed. The adapter absorbs the mechanical loads and provides sealing, enabling the test to proceed with the drill string in place.
2Reliability
If the drill pipe is tripped to the surface for BOP testing, then the BOP can be tested, but the operation costs increase due to extended rig time
Solution Approach 1:
By segmenting the testing system into a removable test plug and a permanent sacrificial adapter, the invention enables testing operations without tripping the drill string. The test plug can be deployed and retrieved independently, maintaining drilling continuity and avoiding the productivity loss associated with tripping operations.
Solution Approach 2:
The sacrificial adapter with its load ring mechanism provides self-contained load-bearing and sealing capabilities. The system is designed to be activated externally through the drill string, allowing the test plug to perform its function independently without requiring the drill string to be removed or reconfigured.
3Ease of operation
If the bowl protector is retrieved for testing, then the test apparatus can be installed, but the risk of damaging the existing wellhead component increases
Solution Approach 1:
The sacrificial adapter is designed as a disposable component that protects the permanent wellhead. It is installed once, allows multiple testing operations, and is then discarded. This eliminates the risk of damaging the expensive, permanent wellhead component during testing operations, as the sacrificial adapter absorbs any potential damage.
Solution Approach 2:
The sacrificial adapter acts as a protective intermediary between the test apparatus and the permanent wellhead component. It provides a sacrificial interface that can be damaged or worn during testing without affecting the integrity of the permanent wellhead, thereby eliminating the damage risk while maintaining ease of operation.
4Object-affected harmful factors
If the sacrificial adapter is used for testing, then the wellhead component is protected from damage, but an additional component must be installed
Solution Approach 1:
The sacrificial adapter is a simple, disposable component that replaces complex protection schemes. Instead of designing complex protective mechanisms for the permanent wellhead, the invention uses a simple sacrificial adapter that can be installed once and discarded after use, reducing overall system complexity while providing robust protection.
Solution Approach 2:
The sacrificial adapter extracts the protective function from the permanent wellhead assembly. By separating the protection function into a dedicated sacrificial component, the permanent wellhead remains simple and unchanged, while the adapter provides all necessary protection and interface functions.
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 operation time and costs by eliminating the need to trip the drill pipe and safeguards the existing wellhead equipment from damage during periodic testing, saving at least eight hours of rig time and enabling testing while the drill string is still suspended.
Implementation Method 1
a sealing profile for receiving an elastomeric seal
Implementation Method 2
a plurality of lock down screws configured to be activated as a load ring
Data Source
AI summary
An apparatus or a well tool for testing a blowout preventer (BOP) on a surface wellhead. The apparatus includes a sacrificial wellhead adapter, a top locking mechanism adapted to lock the adapter to a BOP riser, and a bottom locking mechanism adapted to lock the adapter to a permanent tubing or casing spool of the surface wellhead. The apparatus further includes a plurality of lock down screws configured to be activated as a load ring. The sacrificial wellhead adapter further comprises a first profile for accommodating a test plug load ring, and a sealing profile for a test plug. The apparatus further includes a test plug with an activated load shoulder. The test plug is activated externally by energizing the lock down screws. The apparatus further includes a load ring configured to lock the test plug in place.