Automated bop control and test system

Abstract

A method and apparatus for testing a blowout preventer which includes a plurality of safety devices and an assembly of fluid control valves that are remotely actuatable to an open and closed position for controlling flow of drilling fluids into a well includes a hydraulic power unit control station for remotely and selectively actuating one or more safety devices and fluid control valves to a test orientation. A hydrostatic test system supplies fluid under first and second test pressure and documents any pressure loss due to fluid leaks within a closed system.

Claims

1. A method of conducting a pressure test for a blowout preventer which includes a plurality of safety devices operated by hydraulic pressure and for an assembly of fluid control valves and conduits for directing pressurized drilling fluid into or out of a wellbore, the fluid control valves being remotely actuated to an open or closed position comprising; a) determining a test plan for testing isolated portions of the blowout preventer and fluid control valves and conduits, b) causing pressurized fluid from a hydraulic power unit to align one or more of the safety devices within the blowout preventer and the fluid control valves according to the test plan, and c) applying a first fluid test pressure to the blowout preventer and to the assembly of fluid control valves and conduits via a hydraulic test system.

2. The method of claim 1 including the step of applying a second fluid test pressure to the blowout preventer and assembly of fluid control valve and conduits.

3. The method of claim 2 including the step of selecting one or more different safety devices according to the test plan and selecting one or more different fluid control valves to close and causing pressurized fluid to operate the one or more safety devices and to close the one or more different fluid control valves according to the test plan.

4. The method of claim 1 wherein the hydraulic power unit supplies pressurized fluid to the blowout preventer for operating the safety devices in the event of an emergency and also provides pressurized fluid for remotely controlling the fluid control valves to an open or closed position, during a test procedure.

5. The method of claim 4 further compressing the step of providing a hydraulic power unit remote control station for controlling the hydraulic power unit.

6. The method of claim 5 further comprising sensing the condition of the fluid control valves and sending information about the condition to the hydraulic unit remote control station.

7. The method of claim 1 further comprising the step of providing a hydraulic power unit local control station.

8. Apparatus for testing a blowout preventer having a plurality of safety devices and an assembly of fluid control valves and conduits for directing drilling fluid into a well comprising; a) a hydraulic power unit for operating one or more of the safety devices in the blowout preventer in the event of an emergency, b) a hydrostatic test system for pressurizing one or more safety devices and the assembly of fluid control valves to a first test pressure, c) the fluid control valves adapted to be remotely controlled to an on and off state, and a hydraulic power unit control station coupled to the hydraulic power control unit to remotely and to selectively control the safety devices in the blowout preventer and the state of the fluid control valves during a test cycle.

9. Apparatus for testing a blowout preventer as claimed in claim 8 further including a communications link between the hydraulic power unit and the hydraulic power unit control station for selectively actuating the safety devices and closing the valves to an off condition in accordance with a test plan.

10. Apparatus as claimed in claim 8 wherein the hydrostatic test system is also controlled by the hydraulic power unit control station.

11. Apparatus as claimed in claim 8 wherein the hydrostatic test system is adapted to supply fluid under a first test pressure and a second test pressure to the blowout preventer.

12. The apparatus of claim 8 wherein the blowout preventer is in fluid communication with the assembly of fluid valves and conduits.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic view of a conventional blowout preventer showing various safety control devices and pressure controlling valves.

(2) FIG. 2 is a schematic showing of a conventional testing arrangement for a blowout preventer.

(3) FIG. 3 is a schematic showing of an automated control and testing system for a blowout preventer according to an embodiment of the invention

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(4) As shown in FIG. 1, a typical blowout preventer assembly 40 includes a plurality of valves 1-32 for controlling the pressurized drilling fluid in a safe and controlled manner.

(5) BOP assembly 40 also includes a number of sealing and shearing devices 34, 35 and 36 that are hydraulically actuated to provide various means of sealing around the drill string or shearing it off completely.

(6) In this example, the BOP includes an annular sealing device 34, pipe rams 35 and blind rams 36.

(7) A typically testing arrangement is shown in FIG. 2. The blowout preventer assembly 40 is connected to a hydraulic power unit 50 utilized to actuate the safety devices 34, 35, and 36 in the event of an emergency. Hydraulic power unit 50 may be controlled by a local control station 60 or a remote control station 70 via a control cable 80 or a wireless control.

(8) The safety devices and external valves are connected to a portable hydraulic test system 90 which generates testing fluid under various pressures for testing the integrity of the various valves and safety devices as described above.

(9) As an example, the chart below illustrates a typically sequence of tests involving the various valves and safety devices. The valves are aligned and set by hand.

(10) TABLE-US-00001 Test Low Test High Test Number Test Against Pressure & Times Pressure & Times Test 1 V1, V2, V8 Pipe Rams, Low: 250 psi, High: 5000 psi, V20, V22, V24, V25 5 minutes 10 minute Test 2 V7, V(, Pipe Rams, Low: 250 psi, High: 5000 psi, V19, V21, V23, V25 5 minutes 10 minute Test 3 Topdrive Hydraulic Low: 250 psi, High: 5000 psi, Valve, Pipe Rams, 5 minutes 10 minute V10, V13 Test 4 Lower Topdrive Low: 250 psi, High: 5000 psi, Manual Valve, Pipe 5 minutes 10 minute Rams, V11, V12 Test 5 Lower Topdrive Low: 250 psi, High: 3500 psi, Manual Valve, 5 minutes 10 minute ANNULAR PREVENTER, V11, V12 Test 6 V14, Blind Rams, V19, Low: 250 psi, High: 5000 psi, V21, V23 5 minutes 10 minute Test 7 Casing, V14 Blind Low: 250 psi, High: 1500 psi, Rams, V19, V21, V23, 5 minutes 30 minute V15, V18 Test 8 Cup Type Tester, V14, Low: 250 psi, High: 5000 psi, Pipe Rams, V19, V21, 5 minutes 10 minute V23, V15, V18 Test 9 Cup Type Tester, V14, Low: 250 psi, High: 5000 psi, Pipe Rams, V19, V21, 5 minutes 10 minute V23, V16, V17

(11) Referring to FIG. 3 of an embodiment of the invention will be described.

(12) A schematic of a rig setup utilizing the new and unique features of the current invention is depicted in FIG. 3. BOP assembly internal sealing and shearing devices 34-36, BOP 40 assembly external automated valves 1-32 shown schematically at 41, and hydraulic power unit 50 are in control fluid communication via control fluid conduit 45. Control fluid conduit 45 is made up of multiple discrete fluid control circuits. Hydraulic power unit 50 may include local control station 60. Hydraulic power unit 50 and hydrostatic test system 90 are also in signal communication with remote control station 70 via signal cable 80. Hydrostatic test system 90 is in intensifying fluid communication with BOP assembly internal sealing and shearing devices 34-36 via intensifying fluid conduit 100. A suitable hydrostatic test system is disclosed in U.S. patent application Ser. No. 14/932,727 filed Nov. 4, 2015, the entire contents of which is incorporated herein by reference thereto. BOP assembly external automated valves 1-32 are in intensifying fluid communication with hydrostatic test system 90 via conduit 101. During a test utilizing the new and unique features of the current invention, BOP assembly internal sealing and shearing devices 34-36 and BOP assembly external automated valves 1-32 are aligned according to the test plan by providing the proper control signals from remote control station 70 via signal cable 80. For Example: test 1 of the test plan depicted in the chart requires closing the pipe rams of BOP Assembly as well as BOP assembly external automated valves numbers 1, 2, 8, 20, 22, 24, and 25. A suitable computer program within remote control station 70 would enable the specific solenoid valve of hydraulic power unit 50, via signal cable 80, directing hydraulic control fluid, via control fluid conduit 45 to close the Pipe Rams of BOP assembly 40. Additionally the suitable computer program within remote control station 70 would enable the specific solenoid valves of hydraulic power unit 50, via signal cable 80, directing intensified hydraulic control fluid, via control fluid conduits 45 and 46 to close BOP assembly external automated valves numbers 1, 2, 8, 20, 22, 24, and 25. Subsequent to remote control station 70 confirming proper alignment of BOP assembly internal sealing and shearing devices 34-36 and BOP assembly external automated valves 1-32 via signal cable 80, remote control station 70 will initiate the hydrostatic pressure test of BOP assembly internal sealing and shearing devices 34-36, and selected BOP assembly external automated valves 1-32 via signal cable 80. High pressure intensifying fluid from hydrostatic test system 90 will intensify the internal pressure of BOP assembly internal sealing and shearing devices 34-36 and BOP assembly external valves 1-32 according to the specific alignment schedule of the test plan via intensifying conduits 100 and 101.

(13) Subsequent to a successful pressure test, intensifying fluid is relieved from BOP assembly internal sealing and shearing devices 34-36 and BOP assembly external valves 1-32 via hydrostatic test system 90 and intensifying fluid conduits 100 and 101. BOP assembly internal sealing and shearing devices 34-36 and BOP assembly external valves 1-32 will be aligned for the next test according to the test plan by providing the proper control signals from remote control station 70 via signal cable 80 to hydraulic power unit 50 and hydrostatic test system 90 so the next subsequent test can be initiated. This process is repeated for each test of the test plan.

(14) Utilizing the new and unique features of the current invention provides for fully automatic, integrated, BOP assembly operation and testing thereby significantly increasing safety, while dramatically reducing cost. The principles, preferred embodiment, and mode of operation of the present invention have been described in the foregoing specification. This invention is not to be construed as limited to the particular forms disclosed, since these are regarded as illustrative rather than restrictive. Moreover, variations and changes may be made by those skilled in the art without departing from the spirit of the invention. For example an electrical control system could be used for electrically controlling valve 1-32 to an open or closed position with the use of solenoid controlled valves.

(15) Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations may be made herein without departing from the spirit and scope of the invention as defined by the appended claims.