CROSS REFERENCE TO RELATED APPLICATIONThis application claims priority to provisional application 62/093,200, filed Dec. 17, 2014.
FIELD OF THE DISCLOSUREThis application concerns oil and gas well drilling blowout preventers, and in particular to a mounting arrangement for solenoid valves and hydraulic valves.
BACKGROUNDOffshore drilling operations require a blowout preventer connected with the drilling riser to control well pressure. A typical subsea blowout preventer (“BOP”) has many components, such as one or more annular blowout preventers, several pipe rams, connectors for connecting to wellhead equipment, and a quick release connector for releasing an upper portion of the BOP and the drilling riser from a lower portion in the event of an emergency. Most of these components, also referred as functions, are hydraulically actuated.
The BOP has a control system, also referral to as a multiplex or MUX pod layout, to control these various functions by supplying hydraulic fluid pressure to perform the particular function. The control system has hydraulic valves, called SPM (sub plate manifold) valves, that supply hydraulic fluid pressure to the various BOP components. The control system has solenoid valves, that when receiving on electrical signal, send a hydraulic pilot signal to one of the hydraulic valves.
In typical applications, the cap portions of the hydraulic valves may require threading to a valve body, which can cause cross threading and galling. In addition, there can be overlapping external tubing runs that connect to each individual pilot line, making some hydraulic valves difficult to access. Some prior art arrangements require removal or repositioning of the external tubing to access the hydraulic valve of interest tor purposes of replacing or repairing the valve. Fittings of external tubing typically have a limited lime they can be removed and fitted, and they may leak if tightened incorrectly.
SUMMARYA blowout preventer control system includes a valve block having a hydraulic valve face. An electrically actuated solenoid valve secures to the valve block. A hydraulic valve cavity extends into the valve block from the hydraulic valve face. A hydraulic valve fit, at least partially within the hydraulic valve cavity. A hydraulic valve cap secures to the hydraulic valve face, covering the hydraulic valve cavity. The cap has a piston chamber that sealingly receives the piston. A solenoid valve pilot passage in communication with the solenoid valve has a valve block portion in the valve block that extends to the hydraulic valve face. The pilot passage has a cap portion within a side wall of the cap that sealingly joins the valve block portion of the pilot passage and leads to the piston chamber. A hydraulic pilot signal from the solenoid valve to the hydraulic valve moves the hydraulic valve when the solenoid valve is electrically actuated.
The valve block may also have a solenoid valve face. A solenoid valve cavity extends into the valve block from the solenoid valve face. The solenoid valve is mounted in the solenoid valve cavity. The valve block portion of the pilot passage has an inner end that joins the solenoid valve cavity. A solenoid valve supply passage may extend within the valve block to the solenoid valve cavity.
A hydraulic valve supply passage extends within the valve block to the hydraulic valve cavity. A hydraulic valve outlet passage extends within the valve block hydraulic valve cavity. Movement of the hydraulic valve in one direction selectively opens the hydraulic valve supply passage to the hydraulic valve outlet passage.
The valve blink may have a plurality of solenoid valve cavities, each extending into the valve block from the solenoid valve face. The valve block may have a plurality of hydraulic valve cavities, each extending into the valve block from the hydraulic valve face. Each of the caps of the hydraulic valves may he secured by a plurality of fasteners to the hydraulic valve face.
In one embodiment, the solenoid valve cavities are located side-by-side along a length of the valve block. The solenoid valve supply passage extends lengthwise within the valve block. The hydraulic valve cavities are located side-by-side along a length of the valve block. The hydraulic valve supply passage extends lengthwise within the valve block. The hydraulic valve supply passage may be parallel with the solenoid valve supply passage.
The valve block has a back on an opposite side from the hydraulic valve face. In the example shown, each of the hydraulic valve outlet passages extends from one of the hydraulic valve cavities to the back.
In one embodiment, the valve block has two ends facing in opposite direction. The solenoid valve supply passage has an inlet at one of the ends. The hydraulic valve supply passage has an inlet at one of the ends.
BRIEF DESCRIPTION OF THE DRAWINGSSo that the manner in which the features, advantages and objects of the disclosure, as well as others which will become apparent, are attained and can be understood in more detail, more particular description of the disclosure briefly summarized above may be had by reference to the embodiment thereof which is illustrated in the appended drawings, which drawings form a part of this specification. It is to be noted, however, that the drawings illustrate only a preferred embodiment of the disclosure and is therefore not to be considered limiting of its scope as the disclosure may admit to other equally effective embodiments.
FIG. 1 is a schematic front view of an upper portion of a blowout preventer control system in accordance with this disclosure.
FIG. 2 is perspective view of one of the control modules of the control system ofFIG. 1.
FIG. 3 is a sectional view of the control module ofFIG. 2 taken along the line3-3 ofFIG. 2.
DETAILED DESCRIPTION OF THE DISCLOSUREThe methods and systems of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown, the methods and systems of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout.
FIG. 1 schematically illustrates an upper part of acontrol system11 for a subsea blowout preventer (not shown). The subsea blowout preventer (“BOP”) has many components, such as one or more annular blowout preventers, several pipe rams, connectors for connecting to wellhead equipment, and a quick release connector for releasing an upper portion of the BOP and a riser from a lower portion in the event of an emergency. Most of these components, also referred as functions, are hydraulically actuated.Control system11, also referred to as a multiplex or MUX pod layout, is mounted to the BOP and controls these various functions by supplying hydraulic fluid pressure to perform the particular function.
Control system11 includes a supporting frame13, which may be of various configurations.Several control modules15 mount to frame13. In this example.FIG. 1 shows only fourcontrol modules15, and normally there would be at least four times that amount.Control modules15 may be mourned to frame13 one above the other in one or more vertical columns, andFIG. 1 shows two vertical columns.
Eachcontrol module15 has a number ofhydraulic valves17, commonly called SPM (sub plate mounted) valves. Eachhydraulic valve17 controls hydraulic fluid flow to one of the components of the blowout preventer to perform one of the functions. Eachcontrol module15 has a number ofsolenoid valves19, each of which controls one of thehydraulic valves17.Solenoid valves19 are electrically actuated and deliver hydraulic pilot signals to thehydraulic valves17.FIG. 1 shows sixhydraulic valves17 and sixsolenoid valves19 in eachcontrol module15, but that number can vary. Eachcontrol module15 has asolenoid valve housing21 that encloses all of thesolenoid valves19.Housing21 normally contains an electrical insulation dielectric liquid that is pressure compensated to equal the hydrostatic pressure of sea water. Eachhousing21 may have aremovable cover plate23 to provide access tosolenoid valves19 whencontrol system11 is retrieved for maintenance.FIG. 1 shows one of thecover plates23 broken out to illustrate thesolenoid valves19 therein.FIG. 3 shows thecover plate23 removed.
Control system11 has two subsea electronics modules (SEM)25, each mounted to areceptacle27 that may be connected to frame13. Each SEM25 has electronic circuitry to send signals to thevarious solenoid valves19. SEMs25 are redundant with each other. Further, typically all of thecontrol modules15 are redundant with anothercontrol module15.
Referring toFIG. 1, eachcontrol module15 has a manifold orvalve block29, which may be a solid single piece of a steel alloy.Valve block29 has ahydraulic valve face31, which in this example, is flat and located in a single plane that extends the length ofvalve block29.Valve block29 also has asolenoid valve face33, which in this example, is flat and located in a single plane that extends the length ofvalve block29.Solenoid valve face33 is shown as the upper horizontal side ofvalve block29.Hydraulic valve face31 is shown as the vertical front ofvalve block29, in a plane perpendicular to the plane ofsolenoid valve face33.Valve block29 has two oppositely facing ends34.
Eachhydraulic valve17 has aseparate cap35 with aflange37 and acylindrical portion39 extending outward fromflange37. Fasteners41 extend through eachflange37 to secure hydraulic valve caps35 side-by-side tohydraulic valve face31. Eachsolenoid valve19 has aseparate cover43 that secures with fasteners tosolenoid valve face33.
Referring toFIG. 3,valve block29 also has a back45, which may be in a single vertical plane parallel tohydraulic valve face31. Also,valve block29 may have a flat bottom47 that is in a single horizontal plane parallel withsolenoid valve face33.
Solenoid valve face33 has a row of solenoid valve cavities49 (one shown inFIG. 3), the row extending along the length ofvalve block29. Eachsolenoid valve cavity49 extends intovalve block29 from and normal tosolenoid valve face33.Solenoid valve cavities49 may be identical. One of thesolenoid valves19 secures within each of thesolenoid valve cavities49.FIG. 3 shows one of thesolenoid valves19 schematically, illustrating that a lower portion fits withinsolenoid valve cavity49 while an upper portion protrudes a short distance abovesolenoid valve face33.Solenoid valve19 may be secured insolenoid valve cavity49 by various manners, such as by threads.Solenoid valves19 may be identical, each having an electrical solenoid portion that when energized by an electrical signal shifts a valve portion from a closed position to an open position.
A solenoidvalve supply passage51 extends lengthwise throughvalve block29, intersecting the lower end of each of thesolenoid valve cavities49. Solenoidvalve supply passage51 joins each of thesolenoid valve cavities49 together. Solenoidvalve supply passage51 has an inlet53 (FIG. 2) on one of the valve block ends34 for supplying hydraulic fluid pressure to eachsolenoid valve cavity49.
Hydraulic valve face31 has a row of hydraulic valve cavities55 (one shown inFIG. 3), the row extending along the length ofvalve block29. Each hydraulic valve cavity55 extends intovalve block29 normal tohydraulic valve face31. The axis of each hydraulic valve cavity55 is perpendicular to the axis of eachsolenoid valve cavity49 and intersects the axis of one of thesolenoid valve cavities49. Hydraulic valve cavities55 may be identical. One of thehydraulic valves17 secures into each of the hydraulic valve cavities55. Art inner portion ofhydraulic valve17 fits within hydraulic valve cavity55 and an outer portion protrudes forward fromhydraulic valve face31.Hydraulic valves17 may have a variety of configurations and may be identical.
A hydraulic valve supply passage57 extends lengthwise throughvalve block29, intersecting a lower side of each of the hydraulic valve cavities55. Hydraulic valve supply passage57 joins each of the hydraulic valve cavities55 together. Hydraulic valve supply passage57 has an inlet58 (FIG. 2) on one of the valve block ends34 for supplying hydraulic fluid pressure to each hydraulic valve cavity55. Hydraulicvalve supply inlet58 may be on the same valve block end34 as solenoid valvesupply passage inlet53, as shown, or alternately on an opposite end34. Hydraulic valve supply passage57 is parallel to solenoidvalve supply passage51 in this embodiment.
A separate hydraulicvalve millet passage59 extends from each hydraulic valve cavity55 to valve block back45. Hydraulicvalve outlet passages59 are parallel with each other and generally perpendicular to hydraulic valve supply passage57. A hydraulic line (not shown) connects each hydraulicvalve outlet passage59 to a component of the BOP to perform a function. When one of thesolenoid valves19 hydraulically signals one of thehydraulic valves17, thehydraulic valve17 will move to an open position, providing hydraulic fluid from hydraulic valve supply passage57 to one of the hydraulicvalve outlet passages59. In an alternate embodiment, whensolenoid valve19 is de-energized, fluid pressure at the component BOP function may exit from hydraulicvalve outlet passage59 through a vent port (not shown) located onvalve block29.
Aseparate pilot passage61 extends from eachsolenoid valve cavity49 to one of the hydraulic valve cavities55. Eachpilot passage61 has an inner or valve block portion61athat extends fromsolenoid valve cavity49 tohydraulic valve face31. Eachpilot passage61 has an outer orcap portion61bthat mates with pilot passage inner portion61aand extends within a side wall ofhydraulic valve cap35. In this embodiment, the side wall of eachhydraulic valve cap35 has a ridge63 (shown also inFIG. 2) that joins and extends along an upper side thecylindrical portion39 ofcap35 parallel with an axis of thecylindrical portion39. Pilot passageouter portion61bextends withinridge63 coaxial with pi lot passage inner portion61a. A seal (not shown) seals the junction of pilot passage inner portion61aandouter portion61b.Pilot passage61 has a connectingportion61cthat joins the outer end of pilot passageouter portion61band extends down to apiston chamber65 formed in thecylindrical portion39 ofcap35. Pilotpassage connecting portion61cis formed by drilling a bole perpendicular to the drilled hole that forms pilot passageouter portion61b.After drilling connectingportion61c,a machinist will install aplug66 to block the entry portion of the drilled hole forming connectingportion61c.When one of thesolenoid valves19 is electrically actuated, a hydraulic signal flows from solenoidvalve supply passage51 throughpilot passage61 topiston chamber65. Optionally, a vent passage (not shown) may extend throughvalve block29 to allow pressure to escape from the hydraulicvalve pilot passage61 when one of thesolenoid valves19 is de-energized.
In this embodiment,hydraulic valve17 includes astationary cage67 located in hydraulic valve cavity55. Anouter annulus seal69seals cage67 to the cylindrical inner wall surface of hydraulic valve cavity55.,Cage67 has a plurality of apertures orports71 formed therein that register with hydraulic valve supply passage57.Cage67 has a rearward end that abuts and seals against aback end seat73 that surrounds the entrance of hydraulicvalve outlet passage59.Cage67 has an opposite end that abuts and seals against aforward end seat75.
Amovable spool77 is located incage67 and is scaled by aninner annulus seal78.Spool77 strokes relative tocage67 between the closed position shown and an open position. In the closed position, which is shown, a forward end ofspool77 seals againstforward cad seat75. The closed position blocks flow of hydraulic fluid from hydraulic valve supply passage57 into the interior ofspool77. In the open position,spool77 abuts and seals againstback end seat73. Hydraulic fluid flows from hydraulic valve supply passage57 throughcage ports71, intospool77 and outhydraulic valve outlet59.
Astem79 connects to spool77 to movespool77.Stem79 extends forward fromspool77 intocap piston chamber65.Stem77 has apiston81 on its forward end withincap piston chamber65. One or more concentric coil springs83 (two shown)surround stent79 andurge spool77 toward the closed position. Aspring housing85 surrounds a part ofspring83 and hasthreads86 that secure to threads in hydraulic valve cavity55.Spring housing85 also secures a spring rearwardretainer87 againstforward seat75. A spring forwardretainer89 secures to stem79 for movement therewith.Stem79 will slide relative to springrearward retainer87 andforward seat75. When solenoidvalve19 is de-energized,spring83 returnshydraulic valve17 to the normal position.
In operation, an operator on the drilling rig sends a signal to one of the control pods25, which in response, sends an electrical signal to one of thesolenoid valve19. Thesolenoid valve19 shifts, opening solenoidvalve supply passage51 topilot passage61. Hydraulic fluid flows from solenoidvalve supply passage51 throughpilot passage61 topiston chamber65.Piston81 moves stem79 andspool77 from (he closed position shown inFIG. 3 to an open position, withspool77 abuttingback end peat73. Hydraulic fluid from hydraulic valve supply passage57 then flows throughcage ports71 into the interior ofspool77 and outoutlet passage59. The hydraulic fluid flows to a component of the BOP to perform a function.
If a vent passage arrangement (not shown) is used, whensolenoid valve19 is de-energized,pilot passage61 opens to the vent passage (not shown). Hydraulic fluid would then flow throughpiston chamber65 throughpilot passage61 and out the vent passage.Spring83 moves stem79 andspool77 from the open position to the closed position, withspool77 abuttingfront end seat75. Hydraulic fluid pressure then travels fromhydraulic outlet59 to the hydraulic valve vent passage (not shown), releasing pressure from a component of the BOP.
The internal passages of valve module disclosed in one of the embodiments eliminate the need for external tubing to provide pilot pressure to the hydraulic valves. Some embodiments of the disclosure include a bolt-on installation method for the hydraulic valve caps, which will make the assembly easier than prior art types that require rotation of a cap to secure threads. The face mounted cap eliminates the problem of cross threading and galling caused by mis-threading the assembly during makeup of the assembly. The embodiments described and shown herein eliminate or reduce the need for an operator to remove components from the system to access the hydraulic valves. For example, the design of the present disclosure can improve access by eliminating the tubing in front of the hydraulic valves and the fittings. The resulting clear access to the hydraulic valves will make it easier to detect leaks, conduct maintenance and repairs, and/or replace valves. The embodiments of the disclosure will also eliminate the need to re-tighten fittings that may otherwise result in leaks. In addition, the overall reduction in the number of components in the system leads to an increase in reliability, which is advantageous.
It is to be understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation.1. A blowout preventer control system, comprising:
- a valve block having a hydraulic valve face;
- an electrically actuated solenoid valve secured to the valve block;
- a hydraulic valve cavity extending into the valve block from the hydraulic valve face;
- a hydraulic valve at least partially within the hydraulic valve cavity;
- a hydraulic valve cap secured to the hydraulic valve face covering the valve cavity; and
- a solenoid valve pilot passage in communication with the solenoid valve and having a valve block portion in the valve block that extends to the hydraulic valve face, the pilot passage having a cap portion within a side wall of the cap that sealingly joins the valve block portion of the pilot passage and leads to the hydraulic valve to communicate a hydraulic pilot signal from the solenoid valve to move the hydraulic valve when the solenoid valve is electrically actuated.