Subsea Hose Replacement Tool for BOP Maintenance
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Solution Overview
Problem
The frequent disconnection of blowout preventers (BOPs) from offshore wells due to faulty hydraulic hoses results in significant financial losses, as multiple pulls are necessary to fix or replace these hoses, leading to prolonged downtime and increased costs.
Innovation Solution
A subsea apparatus and method using an electromechanical tool with wrench heads and swivel fittings to replace faulty hoses directly at the seafloor, allowing for decoupling and recoupling of hoses without pulling the BOP, utilizing a powering unit to rotate the wrench heads and swivel fittings for secure connection and disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If BOP is pulled from well to replace faulty hoses on offshore vessel, then hose replacement can be performed, but downtime and financial losses increase
Solution Approach 1:
The hose assembly is segmented into modular components (hose, swivel fitting, connector) that can be independently replaced. The electromechanical tool allows individual hose replacement without affecting other components, enabling quick substitution of only the faulty segment while maintaining the rest of the system.
Solution Approach 2:
An electromechanical tool with wrench heads and swivel fittings acts as an intermediary device between the BOP and the replacement hose. This tool enables subsea hose replacement operations without requiring BOP retrieval, serving as a mediator that facilitates repairs in situ.
2Reliability
If multiple BOP pulls are performed to fix faulty hoses, then all hose connections can be inspected, but productivity decreases
Solution Approach 1:
The system performs preliminary inspection and replacement actions subsea before the BOP needs to be pulled. By addressing hose issues in situ during normal operations, the system prevents the need for multiple production interruptions, maintaining both reliability and productivity.
Solution Approach 2:
The BOP system performs self-maintenance through subsea hose replacement capabilities. The electromechanical tool enables the system to service its own hydraulic connections without external intervention requiring BOP retrieval, allowing continuous operation and maintaining drilling productivity.
3Loss of time
If subsea hose replacement is implemented, then BOP downtime is reduced, but device complexity increases
Solution Approach 1:
The electromechanical tool is designed as a universal device that can handle multiple hose sizes, configurations, and connection types through interchangeable wrench heads. This multi-functionality consolidates what would otherwise require multiple specialized tools, managing complexity while enabling comprehensive subsea hose replacement capability.
Solution Approach 2:
The tool incorporates dynamic elements including rotatable wrench heads and flexible positioning mechanisms that adapt to different hose orientations and connection points. This dynamic design allows a single apparatus to handle various hose replacement scenarios without requiring multiple fixed-configuration tools.
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 approach reduces the number of BOP pulls required to address faulty hoses, thereby minimizing downtime and financial losses by enabling efficient subsea hose replacement, facilitating quicker maintenance and reducing the need for repeated BOP disconnections.
Implementation Method 1
a powering unit coupled to the second wrench head, wherein the powering unit is configured to cause the second wrench head to rotate with respect to the first wrench head, wherein the rotation of the second wrench head causes the swivel fitting to rotate with respect to the hose fitting
Implementation Method 2
rotating, with the second wrench head of the electromechanical tool, the second swivel fitting with respect to the hose fitting, wherein the second swivel fitting is rotated until the second hose is securely coupled to the hose fitting
Data Source
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AI summary
Systems and methods for replacing a hose coupled to a BOP located subsea are provided. Embodiments include coupling an electromechanical tool to a hose fitting coupled to the BOP, and rotating, with the electromechanical tool, a first swivel fitting with respect to the hose fitting until a first hose is decoupled from the hose fitting. Some embodiments may also include coupling, with the electromechanical tool, a second swivel fitting to the hose fitting to couple a second hose to the hose fitting. The second swivel fitting may be rotated with respect to the hose fitting until the second hose is securely coupled to the hose fitting.