Kinetic Pressure Control has developed the 18 ¾" 15000 psi blowout stopper (KBOS) system for applications on all subsea well activities. The 18 ¾" 15000 psi systems builds upon the successful development of the 5-1/8" 15000 psi KBOS system for surface BOP applications[5]. The system can be configured within the existing subsea BOP, by replacing a casing shear ram or blind shear ram, or can be configured as a shut-in device below the BOP. The KBOS system provides a significant improvement over existing shear ram technology, providing the ability to shear/seal any items in the wellbore, which reduces the likelihood of a blowout, resulting in an improved risk profile. The KBOS is a proprietary design which uses a pyro-technical, electrically initiated process the actuate the shearing process. The system has been designed and tested to actuate and shear/seal in milliseconds, under full wellbore flowing conditions and meets NACE/ISO sour service requirements without exemptions. The control system includes real-time monitoring and function testing capabilities, and requires minimal in-service maintenance, as the working components are isolated from the wellbore fluids. A computational predictive model has been developed, with a test regime conducted to validate the model results. A full qualification program, with 3rd party certification, has been completed to industry standards. Shearing tests have been conducted for a large range of tubulars which have been challenging to shear with existing technology. These include: 9 ½" drill collars, combinations of large OD casing and inner strings, high strength drill pipe and tool joints, wireline, and production tubing. A subsea test of the system was successfully performed in 2019 to shear large OD casing and inner string. The KBOS system utilizes technology from other industries (ballistics, military, automotive) to provide improved shearing and sealing capabilities for all well activities (drilling, completion, intervention). The improved shearing/sealing capacity and reduced time enable a reduced likelihood of a blowout and improved risk profile
A proprietary design using a pyro-mechanical, electrically initiated, kinetic energy enabled shearing action has safely and reliably delivered on the promise of "Shear Anything" and seal successfully. The kinetic blowout stopper (K-BOS) will shear anything in the well above the bit thus eliminating non-shearables from the oil & gas lexicon. Further a superior clean fish with minimal deformation is produced by the kinetic shearing action. The K-BOS will shut-in full flow and pressure blowouts in milliseconds with its simple protected hermetically sealed construction for unparalleled post–shearing sealing performance and dramatically reduce extremely deadly and damaging flammable and/or toxic gas releases. With unrivalled confidence and reliability with best-in-industry control system monitoring and function testing and actuation techniques, the K-BOS requires virtually zero maintenance because of its simple construction where the working components are not wetted by wellbore fluids until actuation, meaning lower costs and reduced NPT and downtime. Like the automotive air bag, the K-BOS is self-contained and meets US and International deregulation requirements regarding safety and logistics of pyrotechnic devices. Starting with ballistic modeling technology developed for the military, the models were adapted to the K-BOS application and predicted the outcomes of shearing tests with different common tubulars including traditional "unshearables." A testing regime has been conducted to validate the models, demonstrate repeatability of the results, and demonstrate that a post shear seal could be achieved. More than 30 test serials with the K-BOS 4-1/16″ prototype including empty well-bore tests, shear tests ranging from 5/16″ wireline to 3-1/2″ Drill Collar with a 1″ Wall Thickness. All tests to date have sheared the target tubular without failure. Multiple materials and configurations have been tested. In all the shearing tests, the K-BOS successfully sheared the target while achieving all safety objectives. The shear test program has validated the models and has also provided validation data allowing for adjustments to the modeling technology for this specific application and resulting in a high level of accuracy and precision in design and shear performance expectations. The shear testing also showed that the K-BOS can shear without damaging the seals and provides an adequate sealing surface after shearing. The K-BOS has successfully met technical readiness level 5 (API 17N scale) and is ready to move on to in the field scale shear and seal testing. These results and the continuation to continuing development further the prospects of ensuring the K-BOS achieves its mission to strengthen the industry's social license to operate.
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