Patent Publication Number: US-2018031440-A1

Title: Bop test apparatus

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a nonprovisional application that claims priority from U.S. provisional application No. 62/366,762, filed Jul. 26, 2016. 
    
    
     TECHNICAL FIELD/FIELD OF THE DISCLOSURE 
     The present disclosure relates to oilfield test equipment. 
     BACKGROUND OF THE DISCLOSURE 
     On a drilling rig, many pieces of equipment are subjected to high pressures. Routine testing may be required before and during use of the equipment to ensure the device is functioning properly. Typically, either pneumatic, electric, or diesel power sources may be utilized. Because it uses a compressible medium, pneumatic testing may not be suitable for all pieces of equipment and pressures. Hydraulic testing may require multiple pieces of equipment, including for example multiple pumps and data collection devices, to be assembled and configured for each test. 
     For example, a blowout preventer (BOP) is a piece of safety equipment located at the surface which must be able to resist high pressures in the wellbore without failure. The BOP includes one or more valves and other fittings to regain control of a wellbore that has encountered a loss of control of formation fluids, such as a kick. Regular testing of the BOP and its associated components, including, for example and without limitation, choke manifolds, kelly valves, drill-string safety valves, etc., may be required by law or other regulating authority. 
     SUMMARY 
     A BOP test apparatus is disclosed. The BOP test apparatus includes an outer frame, a hydraulic pump, the hydraulic pump powered by an electric motor, and a charger pump, the charger pump powered by a second electric motor. The BOP test apparatus also includes a regulator, the regulator positioned to regulate the pressure of a fluid pumped by the hydraulic pump and a valve, the valve positioned to open or close fluid flow from the hydraulic pump to an outlet. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present disclosure is best understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion. 
         FIG. 1  is a perspective view of a BOP test apparatus consistent with at least one embodiment of the present disclosure. 
         FIG. 2  is an elevation view of the BOP test apparatus of  FIG. 1 . 
         FIG. 3  is an elevation view of the side of the BOP test apparatus of  FIG. 1 . 
         FIG. 4  is a schematic view of the BOP test apparatus of  FIG. 1 . 
         FIG. 5  is a schematic view of a BOP test apparatus consistent with at least one embodiment of the present disclosure attached to a BOP and choke. 
         FIG. 6  is a schematic view of a BOP test apparatus consistent with at least one embodiment of the present disclosure attached to a BOP. 
         FIG. 7  is a partially transparent view of a BOP test apparatus consistent with at least one embodiment of the present disclosure. 
         FIG. 8  is a partially transparent end view of the BOP test apparatus of  FIG. 7 . 
         FIG. 9  is a partially transparent top view of the BOP test apparatus of  FIG. 7 . 
         FIG. 10  is a schematic view of the BOP test apparatus of  FIG. 7 . 
     
    
    
     DETAILED DESCRIPTION 
     It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. 
       FIGS. 1-3  depict BOP test apparatus  100 . BOP test apparatus  100  may include outer frame  101 . In some embodiments, outer frame  101  may include one or more lift points  103  for coupling to, for example and without limitation, one or more hoisting lines for movement of BOP test apparatus  100 . In some embodiments, outer frame  101  may include one or more forklift pockets  105  to, for example and without limitation, allow a forklift to lift BOP test apparatus  100 . In some embodiments, outer frame  101  may be fluid tight at the bottom to, for example, contain any spills within BOP test apparatus  100 . 
     In some embodiments, BOP test apparatus  100  may include outer walls  107 . Outer walls  107  may, for example and without limitation, isolate the internal components of BOP test apparatus  100  from the surrounding environment. Outer walls  107  may, in some embodiments, include one or more access doors, control panels, or other features as discussed herein below and otherwise. 
     In some embodiments, as depicted in  FIG. 3  and discussed further herein below with respect to  FIG. 4 , BOP test apparatus  100  may include hydraulic ports  109 . Hydraulic ports  109  may couple to one or more hydraulic lines for supplying fluid to BOP test apparatus  100  and for hydraulic lines for routing pressurized fluid from BOP test apparatus  100 . 
     In some embodiments, as depicted in  FIG. 2 , BOP test apparatus  100  may include control panel  111 . Control panel  111  may include controls for controlling the operation of BOP test apparatus  100 . For example and without limitation, control panel  111  may include regulator  113 . Regulator  113  may be used to preselect a regulated pressure for an output of BOP test apparatus  100 . In some embodiments, regulator  113  may be calibrated. In some embodiments, BOP test apparatus  100  may include valve  115 . Valve  115  may be fluidly coupled to allow selective fluid flow at the preselected pressure through one or more hydraulic ports  109 . In some embodiments, valve  115  may include block body  117 . In some embodiments, valve  115  may be an isolation valve. In some embodiments, control panel  111  may include one or more gauges for measuring and/or displaying output pressure of BOP test apparatus  100 . In some embodiments, for example and without limitation, analog gauge  119  may display an output pressure to an operator. In some embodiments, digital gauge  121  may measure output pressure of BOP test apparatus  100 . 
     In some embodiments, BOP test apparatus  100  may include one or more storage compartments. For example, BOP test apparatus  100  may include high pressure hose storage compartment  129 . In some embodiments, BOP test apparatus  100  may include hydraulic wrench assembly  131 . Hydraulic wrench assembly  131  may include one or more hydraulic wrenches and associated hardware. In some embodiments, BOP test apparatus  100  may include storage for mobile hydraulic pressure unit  133 . Mobile hydraulic pressure unit  133  may, as understood in the art, allow hydraulic pressure to be stored and utilized at a location away from BOP test apparatus  100 . In some embodiments, mobile hydraulic pressure unit  133  may be charged or powered by BOP test apparatus  100 . In some embodiments, mobile hydraulic pressure unit  133  may be used to power hydraulic wrench assembly  131 . 
     In some embodiments, as depicted in  FIG. 4 , BOP test apparatus  100  may include hydraulic pump  135 . In some embodiments, hydraulic pump  135  may be, for example and without limitation, a triplex positive displacement pump as understood in the art. In some embodiments, hydraulic pump  135  may be powered by an electric or fossil fuel motor. Although described herein as a hydraulic pump, one having ordinary skill in the art with the benefit of this disclosure will understand that a pneumatic pump may be utilized without deviating from the scope of this disclosure. In some embodiments, hydraulic pump  135  may be driven by electric motor  136 . Electric motor  136  may be run from power input  138 . In some embodiments, BOP test apparatus  100  may include charger pump  137 . Charger pump  137  may, for example and without limitation, be utilized to prime hydraulic pump  135 . In some embodiments, charger pump  137  may be powered electrically by a second electric motor and apart from hydraulic pump  135 . In some embodiments, where charger pump  137  is a manual type, charger pump  137  may be powered by electric motor  136 . Hydraulic pump  135  may be used to pump fluid from one or more inlets  141  to a low pressure outlet  142 ′. In some embodiments, valve  115  may be coupled between hydraulic pump  135  and high pressure outlet  143 . In some embodiments, hydraulic pump  135  may be operated continuously, and valve  115  may divert fluid to an outlet  142  when fluid is not routed to outlet  143 . In some embodiments, one or more filters  144  may be included in BOP test apparatus  100 . In some embodiments, regulator  113  may be positioned to regulate the output pressure of hydraulic pump  135  as previously described. In some embodiments, one or more pressure relief valves  145  may be positioned to, for example and without limitation, provide relief for overpressure situations. 
     In some embodiments, one or more of hydraulic pump  135 , charger pump  137 , and valve  115  may be controlled by control system  147 . Control system  147  may receive inputs from control panel  111  and one or more sensors in BOP test apparatus  100 . In some embodiments, control system  147  may include computer readable memory storage media to record pressures measured by digital gauge  121 . In some embodiments, pressures may be recorded by an analog chart recorder. In some embodiments, control system  147  may include a telemetry system to, for example and without limitation, allow pressure readings to be transmitted to a remote site. The telemetry system may transmit information over a wired or wireless connection, including, for example and without limitation, Wi-Fi, cellular, or satellite communication links. In some embodiments, BOP test apparatus  100  may include one or more auxiliary test outlets  159  positioned to allow connection of additional pressure sensor equipment to BOP test apparatus  100  including, for example and without limitation, a control system for a drilling rig on which BOP test apparatus  100  is positioned. 
     In some embodiments, BOP test apparatus  100  may include one or more power electronics components, including transformer  149 . Transformer  149  may transform supplied electric power to a different voltage for use with other equipment. In some embodiments, one or more 110V 60 Hz outlets  161  may be powered by transformer  149 . 
     In some embodiments, as depicted in  FIG. 5 , BOP test apparatus  100  may be positioned in a wellsite. BOP test apparatus  100  may be transported utilizing one or more of lift points  103  or forklift pockets  105  as previously discussed. 
     Inlet  141  of BOP test apparatus  100  may be coupled to one or more fluid supplies, including, for example and without limitation, fluid tank  151  or any fluid reservoir. In some embodiments, high pressure outlet  143  may be coupled to test hose  153 . Test hose  153  may be coupled to one or more components of BOP  20  during testing operations as described herein below. In some embodiments, clean low pressure outlet  142 ′ may return fluid from BOP test apparatus  100  to fluid tank  151 . In some embodiments, dirty low pressure outlet  146  may dump fluid to a sump, cellar, or, as depicted in  FIG. 5 , disposal tank  148   
     For example and without limitation, a BOP testing cycle may include testing the components of BOP  20  sequentially. BOP  20 , as depicted in  FIG. 6 , may include one or more valves including ram blowout preventer  22  and annular blowout preventer  24 . BOP  20  may be coupled to choke  26  between the components of BOP  20 . In some embodiments, the testing cycle may include coupling side port entry sub  155  to BOP  20 . Test plug  157  may be positioned within BOP  20  to, for example and without limitation, isolate wellbore  15  below BOP  20  from the interior of BOP  20 . Test plug  157  may be coupled to test joint  160  to, for example and without limitation, position it within BOP  20 . 
     Test hose  153  may be coupled to side port entry sub  155  of BOP  20 . Pressurized fluid from BOP test apparatus  100  may be introduced into BOP  20 , while the components of BOP  20 , including, for example and without limitation, ram blowout preventer  22 , annular blowout preventer  24 , and choke  26  depicted in  FIG. 5 . Valves to be tested may be actuated sequentially. Digital gauge  121  as previously described may record pressure readings during the test procedure to, for example and without limitation, record and ensure proper pressure testing of the components of BOP  20 . In some embodiments, pressure testing may be recorded with an external recording device such as an analog chart recorder. 
     In some embodiments, as depicted in  FIGS. 7-10 , BOP test apparatus  200  may omit hydraulic wrench assembly  131  and thereby be made more compact. In such an embodiment, BOP test apparatus  200  may be designed to remain on the rig floor of a drilling rig. In such an embodiment, BOP test apparatus  200  may be transported with the drilling rig on a rig skid such that BOP test apparatus  200  does not need to be rigged up and down each time the rig is assembled and disassembled. 
     In some embodiments, BOP test apparatus  200  may include outer frame  201 . In some embodiments, outer frame  201  may include one or more lift points  203  for coupling to, for example and without limitation, one or more hoisting lines for movement of BOP test apparatus  200 . In some embodiments, outer frame  201  may include one or more forklift pockets  205  to, for example and without limitation, allow a forklift to lift BOP test apparatus  200 . In some embodiments, outer frame  201  may be fluid tight at the bottom to, for example, contain any spills within BOP test apparatus  200 . 
     In some embodiments, BOP test apparatus  200  may include outer walls  207  (two of which are depicted as transparent for clarity in  FIG. 7 ). Outer walls  207  may, for example and without limitation, isolate the internal components of BOP test apparatus  200  from the surrounding environment. Outer walls  207  may, in some embodiments, include one or more access doors, control panels, or other features as discussed herein below and otherwise. In other embodiments, outer walls  207  may be removable or omitted from BOP test apparatus  200 . 
     In some embodiments, as depicted in  FIGS. 7 and 8  and discussed further herein below with respect to  FIG. 10 , BOP test apparatus  200  may include hydraulic ports  209 . Hydraulic ports  209  may couple to one or more hydraulic lines for supplying fluid to BOP test apparatus  200  and hydraulic lines for routing pressurized fluid from BOP test apparatus  200 . 
     In some embodiments, BOP test apparatus  200  may include control panel  211 . Control panel  211  may include controls for controlling the operation of BOP test apparatus  200 . For example and without limitation, with reference to the schematic view shown in  FIG. 10 , control panel  211  may include regulator  213 . Regulator  213  may be used to preselect a regulated pressure for an output of BOP test apparatus  200 . In some embodiments, regulator  213  may be calibrated. In some embodiments, BOP test apparatus  200  may include valve  215 . Valve  215  may be fluidly coupled to allow selective fluid flow at the preselected pressure through one or more hydraulic ports  209 . In some embodiments, valve  215  may be an isolation valve. In some embodiments, control panel  211  may include one or more gauges for measuring and/or displaying output pressure of BOP test apparatus  200 . In some embodiments, for example and without limitation, analog gauge  219  may display an output pressure to an operator. In some embodiments, digital gauge  221  may measure output pressure of BOP test apparatus  200 . 
     In some embodiments, BOP test apparatus  200  may include hydraulic pump  235 . In some embodiments, hydraulic pump  235  may be, for example and without limitation, a triplex positive displacement pump as understood in the art. In some embodiments, hydraulic pump  235  may be powered by an electric or fossil fuel motor. Although described herein as a hydraulic pump, one having ordinary skill in the art with the benefit of this disclosure will understand that a pneumatic pump may be utilized without deviating from the scope of this disclosure. In some embodiments, hydraulic pump  235  may be driven by electric motor  236  as shown in  FIGS. 7-9 . Electric motor  236  may, in some embodiments, couple to hydraulic pump  235  by belt  238 . In some embodiments, BOP test apparatus  200  may include charger pump  237 . Charger pump  237  may, for example and without limitation, be utilized to prime hydraulic pump  235 . In some embodiments, charger pump  237  may be powered electrically by a second electric motor and apart from hydraulic pump  235 . In some embodiments, charger pump  237  may be powered by electric motor  236 . Hydraulic pump  235  may be used to pump fluid from one or more inlets  241  to a low pressure outlet  242 . In some embodiments, valve  215  may be coupled between hydraulic pump  235  and outlet  243 . In some embodiments, hydraulic pump  235  may be operated continuously, and valve  215  or bypass valve  248  may divert fluid to an outlet  242 ′ when fluid is not routed to outlet  243 . In some embodiments, one or more filters  244  may be included in BOP test apparatus  200 . In some embodiments, regulator  213  may be positioned to regulate the output pressure of hydraulic pump  235  as previously described. In some embodiments, one or more pressure relief valves  245  may be positioned to, for example and without limitation, provide relief for overpressure situations. In some embodiments, one or more needle valves  247  or ball valves  249  may be positioned to divert fluid to a dirty low pressure outlet  246 , which may be used to dump fluid to a sump, cellar, or disposal tank as discussed above. Needle valve  247  may also be used to discharge pressure within BOP test apparatus  200  such as, for example and without limitation, for repair if washout occurs. In some embodiments, bleed valve  251  may be positioned to, for example and without limitation, bleed fluid pressure from BOP test apparatus  200 . 
     The foregoing outlines features of several embodiments so that a person of ordinary skill in the art may better understand the aspects of the present disclosure. Such features may be replaced by any one of numerous equivalent alternatives, only some of which are disclosed herein. One of ordinary skill in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. One of ordinary skill in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.