Wellsite Charging Unit Pressure Maintenance
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Solution Overview
Problem
Existing wellsite activation systems for blowout preventers face challenges in maintaining consistent pressure during interruptions or variations in operation, which can lead to inadequate activation of blowout preventers, particularly when power is cut off or fluid pressure drops below predetermined levels.
Innovation Solution
An activation system comprising a pump unit, a pressure circuit with an unloader valve, and an accumulator bank, along with a charging unit that includes a charging accumulator and a pressure reducing valve, ensures continuous pressurization of the accumulator bank by selectively receiving and storing fluid under pressure, maintaining the activation pressure of the blowout preventer even during power outages or pressure fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple pump system is used to activate blowout preventers, then the device complexity is reduced, but the reliability of maintaining activation pressure during power interruptions deteriorates
Solution Approach 1:
The charging pump and charging accumulator are configured to pre-charge the accumulator bank to a pressure higher than the activation pressure requirement. This preliminary action ensures that even if the main pump fails or power is interrupted, sufficient pressure remains in the accumulator bank to activate the blowout preventer. The system proactively builds excess pressure reserve before emergencies occur.
Solution Approach 2:
The charging accumulator acts as a cushion or buffer that stores additional pressurized fluid independently of the main pump system. This beforehand cushioning provides a pressure reserve that compensates for potential pump failures or power interruptions, ensuring continuous availability of activation pressure without requiring complex redundant pump systems.
2Reliability
If the pump continuously supplies fluid to maintain pressure, then the activation pressure is maintained, but the energy consumption increases during normal operation
Solution Approach 1:
The unloader valve is configured to periodically release excess fluid from the pump when the accumulator bank reaches its maximum charge pressure. This periodic action allows the pump to operate in cycles rather than continuously, maintaining pressure reliability while reducing overall energy consumption. The pump runs intermittently to recharge the accumulator rather than operating constantly.
Solution Approach 2:
The charging accumulator serves itself by automatically receiving and storing excess fluid from the pump when pressure conditions are favorable, without requiring continuous active control or additional energy input. Once charged, it autonomously maintains the pressure reserve, reducing the need for continuous pump operation and associated energy consumption.
3Reliability
If the accumulator bank is charged to high pressure continuously, then the activation pressure is ensured, but the risk of overpressurization and safety hazards increases
Solution Approach 1:
The unloader valve is pressure-sensitive and automatically responds to the pressure level in the accumulator bank. When the pressure reaches a predetermined maximum level, the valve opens to release excess fluid, providing negative feedback control. This automatic feedback mechanism prevents overpressurization while ensuring the accumulator is charged to sufficient levels for reliable blowout preventer activation.
Solution Approach 2:
The unloader valve acts as an intermediary safety device between the pump and the accumulator bank. It mediates the pressure flow by allowing fluid to pass through under normal conditions but blocking or redirecting excess pressure when limits are approached, thus protecting the system from overpressurization while maintaining activation pressure availability.
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 maintains the necessary pressure for activating blowout preventers, ensuring they can function reliably even when power is interrupted or fluid pressure drops, thereby preventing blowouts and ensuring safe wellsite operations.
Implementation Method 1
a pump unit, a pressure circuit with an unloader valve to selectively permit the fluid to pass from the pump unit to the wellsite component, and an accumulator bank operatively connectable to the pressure circuit to store at least a portion of the fluid under pressure
Implementation Method 2
a pressure reducing valve operatively connectable to the charging circuit to selectively pass the fluid from the charging accumulator to the accumulator bank whereby an activation pressure of the fluid provided to the wellsite component is maintained
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A charging unit, system and method are provided. The system includes an activation unit and a charging unit. The activation unit includes a pump unit, a pressure circuit with an unloader valve to selectively permit fluid to pass from the pump unit to the wellsite component, and an accumulator bank operatively connectable to the pressure circuit to store the fluid under pressure for passage to the wellsite component whereby the wellsite component is selectively activated. The charging unit includes a charging circuit operatively connectable to the pressure circuit to selectively receive the fluid from the pump unit, a charging accumulator operatively connectable to the charging circuit to store the fluid under pressure, and a pressure reducing valve operatively connectable to the charging circuit to selectively pass the fluid from the charging accumulator to the accumulator bank whereby an activation pressure of the fluid provided to the wellsite component is maintained.