Emergency Plugging and Killing of Blowout Preventer Failure
Year: 2025
Type: article
Abstract: The blowout preventer (BOP) is the most important and the last line of safety defense in drilling engineering. Once a blowout occurs and the BOP fails, engineers will lose control of the entire wellbore pressure, and combustible fluids in the formation will continuously sprayed out, which can easily cause huge losses of life and property. At present, reliable and highly recognized emergency measures for BOP failure are lacking. Therefore, we propose a plugging method after the failure of the BOP that can maintain good control within the secondary well control. Numerical and experimental results indicate that using a small-to-medium displacement (1–2 m3/min) during the early stage of plugging and applying multiple plugging and killing cycles significantly improves plugging stability and killing efficiency. PEEK (polyether ether ketone) was selected as the bridging material for field plugging tests on full-scale blowout preventers, verifying its sealing effectiveness at pressures up to 80 MPa. Subsequently, the CFD–DEM was used to simulate the well killing process after plugging. This study mainly focused on the transportation of particles in a pipeline and the analysis of the process of well killing after plugging. The research results indicate that PEEK demonstrates sufficient pressure-bearing capacity under real blowout conditions. Also reveal that PEEK’s exceptional wear resistance and impact strength help maintain sealing stability during repeated particle–wall collisions, effectively reducing secondary erosion and prolonging the operational lifespan of temporary plugging structures. After undergoing six high-pressure tests of 70 MPa and two high-pressure tests of 80 MPa within 25 min, it remained intact. Both cylindrical and spherical particles can smoothly pass through the storage tank and double-bend pipeline at different displacements. Considering the retention effect of the plugging material, it is recommended to use 1–2 m3/min of pumping the plugging material at medium and small displacements in the early stage of plugging. During the process of plugging and killing, it is recommended to use alternating plugging and killing across multiple operations to prevent further blowouts to achieve the best plugging and killing effect.
Source: Processes
DOI: 10.3390/pr13123959
Authors: Xuliang Zhang, Zhi Zhang, Qingfeng Li, Haitao Wang, Hangbo Cui, Hua Wang, Fumin Gao
Language: English
Subfield: Ocean Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $2,896
OpenAlex ID: W4417114584