Variable Displacement Hydrostatic Test System for Blowout Preventers
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Solution Overview
Problem
Current hydrostatic test systems for blowout preventers (BOPs) are inefficient due to their fixed displacement design, requiring high horsepower, being manually operated, and lacking displacement resolution and automation, which leads to unreliable pressure control and leak detection, especially at higher pressures.
Innovation Solution
A fully variable displacement hydrostatic test system driven by an electric, air, or internal combustion motor, equipped with precision electronic transducers and a computer processor to optimize displacement based on pressure and flow feedback, allowing for precise control and automated testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a fixed displacement hydrostatic test system is used, then the system can perform pressure testing, but it requires high horsepower and lacks displacement resolution
Solution Approach 1:
The patent applies variable displacement technology to the intensifying pump, allowing the displacement to be dynamically adjusted during operation. This enables the pump to provide fine displacement resolution at high pressures while maintaining efficient power utilization, resolving the contradiction between measurement precision and power requirements
Solution Approach 2:
The system changes the displacement parameter of the intensifying pump based on operating conditions. By varying the displacement according to pressure and flow feedback, the system achieves both high precision control and optimized power consumption across different test phases
2Extent of automation
If a fixed displacement hydrostatic test system is used, then the system structure is simple, but it lacks automation and requires manual operation
Solution Approach 1:
The patent implements feedback control systems that automatically adjust pump displacement based on pressure and flow measurements. This automation capability allows the system to maintain optimal performance without manual intervention, resolving the contradiction between automation extent and device complexity
Solution Approach 2:
The system replaces manual mechanical control with electronic control systems and automated feedback loops. This substitution enables automation of the testing process while managing complexity through integrated control architecture
3Reliability
If a fixed displacement hydrostatic test system is used, then the system can operate at high pressure, but it lacks reliable leak detection capability
Solution Approach 1:
The variable displacement pump provides dynamic adjustment capability that enables precise pressure control during leak detection phases. The system can slow down displacement changes to detect small pressure variations that indicate leaks, improving both reliability and measurement precision simultaneously
4Reliability
If a fixed displacement hydrostatic test system is used, then the system can perform testing, but it has poor controllability and repeatability
Solution Approach 1:
The automated feedback control system continuously monitors test parameters and adjusts pump displacement to maintain precise control. This ensures repeatable test results and improves controllability by eliminating manual operation variables
Solution Approach 2:
The variable displacement capability allows the system to dynamically adjust operating parameters for optimal controllability at different test phases, improving both ease of operation and test repeatability
Data Source
AI summary
A method and apparatus for testing blowout preventers for leaks involves maintaining a constant pressure in the portion of the blowout preventer to be tested. A sensor is connected to a controller for maintaining a constant pressure within the blowout preventer. Any amount of fluid introduced into or removed from the blowout preventer in order to maintain constant pressure is measured and is an indication of the leak rate in the blowout preventer. Additionally vibration instrumentation may be used to detect the location and amplitude of vibrations emitted by the test fluid passing from a high pressure regime to the low pressure regime across a leak path.