DL Safe-Set Rig-Repack Washpipe Cartridge 5000 Psi

Revolutionary one-piece quick change design

The core of the Blak-Jak system is an integrated "self-contained unit" (cartridge) design. This innovative configuration pre-integrates the flushing tube, seals, bearings, and related components into a single, quick-change module. The game-changing aspect lies in relocating the most complex and time-consuming seal replacement and cartridge maintenance operations from hazardous high-altitude top drive positions to safer, more accessible rig floor environments (repackaged on the rig floor, not at the swivel).

Advanced materials science and manufacturing technology

To ensure reliability in extreme conditions, the Blak-Jak system follows the highest standards in material selection and manufacturing processes.

Washpipe: To meet the growing demand for high-pressure drilling, the 7500 PSI version of the washpipe is specifically manufactured using "high-strength alloy steel" (HSAS). The standard 5000 PSI version also employs high-grade alloy steel compliant with API specifications, such as AISI 4130 chromium-molybdenum steel, which is extensively used in high-pressure components of oil and gas systems.

Enclosures and other metal components: To achieve a lightweight design, the system's external enclosures and other non-core pressure-bearing components draw on the successful experience of other products in the Blak-Jak series. These components may be manufactured using high-strength aviation-grade aluminum alloy and undergo anodizing treatment. This approach ensures structural strength while significantly reducing overall weight and providing excellent corrosion resistance.

Manufacturing standards: All components are designed, manufactured and tested in accordance with NOV's rigorous internal quality control system and comply with relevant American Petroleum Institute (API) specifications, such as API 8C standards, to ensure global versatility, reliability and seamless integration with other equipment.

Humanized and safety engineering design

Every detail of the Blak-Jak system reflects a deep concern for the safety and convenience of field operators.

Non-hammering installation: This is the core safety feature of the system. By using a special "spanner bar" to tighten the nuts, the entire installation process has controllable torque and smooth operation, completely eliminating the huge safety risks caused by hammering operations.

Lightweight Design: The system achieves 25% lighter overall weight compared to traditional OEM designs and competing products. This seemingly simple parameter improvement creates a virtuous cycle of safety and efficiency. The reduced weight ensures easier and safer handling during high-altitude hoisting and positioning, significantly lowering the risk of component falls and operator muscle strain. Simultaneously, the simplified operation directly shortens installation time, providing physical assurance for achieving the "15-minute rapid replacement" goal.

Convenient assembly/disassembly: The system achieves simplified disassembly and assembly during ground preparation. Its design enables complete unit pre-tightening through a single fastening action, eliminating the need for external power sources like hydraulic or pneumatic systems. This streamlined process ensures maintenance work is both straightforward and efficient.

Significant reduction in non-production time (NPT): A leap from hours to minutes

In the drilling industry, time is money. Non-productive Time (NPT) serves as a critical negative indicator for measuring operational efficiency and project profitability. The Blak-JAK system revolutionizes downtime management through its innovative quick-change design, slashing downtime caused by blowout pipe maintenance from 2-4 hours in traditional methods to under 15 minutes.

We can build a simple cost model to quantify this value. Take a typical offshore rig, for example, where the daily rate is typically between $300,000 and $500,000, which means downtime costs of up to $12,500 to $21,000 per hour.

Cost saving per change:

Traditional replacement time (average): 3 hours

Blak-Jak replacement time: 0.25 hours

Time saved: hours

Direct cost savings:

Establish a new benchmark for drilling platform safety: eliminate risks from the source

The Blak-Jak system sets a new safety benchmark for RIGS by eliminating two types of high-risk operations through its "hammerless" and "ground maintenance" design.

Eliminating Hammer-Related Injuries: The hammer is widely recognized as one of the most hazardous tools on drilling platforms. By implementing mechanical fastening through wrench rods, the Blak-Jak system completely eliminates "object strike" accidents caused by hammer operations – incidents that account for a significant proportion of occupational injury statistics in the industry. This not only safeguards the physical health of on-site personnel but also helps companies avoid costly work injury claims and reputational damage.

Reducing aerial work risks and falling object hazards: By relocating most maintenance tasks from elevated heights to drilling platform ground, this system delivers one of its most significant safety contributions. It dramatically cuts personnel exposure to hazardous high-altitude environments, thereby significantly lowering the probability of falls from height – the industry's deadliest accident type--. Additionally, its lightweight design (25% lighter than competitors) further reduces risks of falling objects during aerial hoisting and equipment replacement operations, ensuring safety for both personnel below and surrounding facilities.

Optimizing Total Cost of Ownership (TCO): Going beyond initial purchase

Smart decision makers focus on total cost of ownership (TCO) over the life cycle, rather than just the initial purchase price. The Blak-Jak system demonstrates strong economy in terms of TCO.

Extended service life: The precision design of the system and controllable and uniform installation torque ensure that the seal runs in the best working condition, avoid premature wear or damage caused by improper installation, thus effectively extending the service life of the seal and reducing the consumption frequency of spare parts.

Reduce maintenance labor costs: Maintenance work is simplified, and most of them can be completed by a single person on the ground, which means less personnel input and shorter working hours, directly saving valuable human resources and related costs.

Optimizing inventory management: The "standby unit" model enables drilling platforms to maintain operational continuity by maintaining only a limited number of complete spare assemblies, eliminating the need for stockpiling large quantities of scattered components like seals, bearings, and flushing pipes required in traditional systems. This approach not only reduces capital tied up in inventory but also streamlines complex inventory control and logistics operations.

Table 1: Maintenance performance comparison matrix of flushing system

Industry leader: Benchmark analysis against major fast change system competitors

Table 2: Comparison of competitive features of quick-change flushing tube system

Typical application scenarios

High/ultra-high pressure drilling (High-Pressure Drilling): The system offers two pressure class options of 5000 PSI and 7500 PSI, which can fully meet the current demand for high-pressure drilling in deep water, deep and shale gas fields, and leaves a technical reserve for future exploration into higher pressure environments.

Offshore Platforms: Offshore platforms are highly sensitive to NPT and operate in more complex environments. The Blak-Jak system offers extremely short maintenance time, lightweight design and enhanced corrosion resistance, making it an ideal choice for maximizing the economic efficiency and safety of offshore operations.

Managed Pressure Drilling (MPD): This technique requires precise wellbore pressure control and demands the highest sealing integrity from the circulation system. The Blak-Jak system's reliable sealing performance and exceptional operational stability ensure accurate bottomhole pressure maintenance during MPD operations, effectively preventing complex issues such as kicks and blowouts.

Extreme Temperature Environments (Extreme Temperature Environments): By selecting optional high temperature resistant seals, the system is capable of drilling in high temperature and high pressure (HTHP) Wells or polar cold regions, ensuring reliable sealing performance over a wide range of temperatures.

Technical specifications list

For the convenience of technology selection and comparison, the following are the key technical parameters of theMISSION BLAK-JAK 5000 PSI system.

Table 3: Mission Black-Jak 5000 PSI System Technical Specifications

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