US20080264646A1 - Modular Actuator for Subsea Valves and Equipment, and Methods of Using Same - Google Patents
Modular Actuator for Subsea Valves and Equipment, and Methods of Using Same Download PDFInfo
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- US20080264646A1 US20080264646A1 US11/721,871 US72187105A US2008264646A1 US 20080264646 A1 US20080264646 A1 US 20080264646A1 US 72187105 A US72187105 A US 72187105A US 2008264646 A1 US2008264646 A1 US 2008264646A1
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Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/02—Surface sealing or packing
- E21B33/03—Well heads; Setting-up thereof
- E21B33/035—Well heads; Setting-up thereof specially adapted for underwater installations
- E21B33/0355—Control systems, e.g. hydraulic, pneumatic, electric, acoustic, for submerged well heads
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/02—Surface sealing or packing
- E21B33/03—Well heads; Setting-up thereof
- E21B33/035—Well heads; Setting-up thereof specially adapted for underwater installations
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B34/00—Valve arrangements for boreholes or wells
- E21B34/02—Valve arrangements for boreholes or wells in well heads
- E21B34/04—Valve arrangements for boreholes or wells in well heads in underwater well heads
Definitions
- the present invention is generally directed to the field of actuators, and more particularly to a modular actuator for subsea valves and equipment, and various methods of using same.
- the present invention is directed to a system for controlling an actuator for a downhole safety valve in a subsea Christmas tree.
- the production from a subsea well is controlled by a number of valves that are assembled into a Christmas tree.
- the actuation of the valves is normally dependent upon hydraulic fluid to operate hydraulic actuators for the valves and is therefore entirely dependent upon an external source for the supply of pressurized hydraulic fluid.
- Hydraulic power is normally supplied through an umbilical running from a station located on a vessel on the surface or, less common, from a land based station.
- the actuators are controlled by pilot valves housed in a control module located at or near the subsea installation, the pilot valves directing the supply of hydraulic fluid to each actuator, as dictated by the need for operation.
- the pilot valves may be operated by electric means and such a system is therefore called an electro-hydraulic system.
- actuators and valves for subsea wells are dictated by stringent demands on the standard and function for these valves, because of the dangers of uncontrolled release of hydrocarbons.
- a typical demand is that these valves must be failsafe closed, meaning that they must close upon loss of power or control.
- the only practical means today in subsea environments is to use springs that are held in the compressed state by the hydraulic pressure, keeping the valve open, and will be released in the event of loss of hydraulic pressure, thus closing the valve.
- the spring force needed to close a valve is dependent upon both well pressure and ambient pressure, with larger ambient pressure demanding larger springs.
- a connection between the well and a monitoring and control station must be established.
- This station can either be located in a floating vessel near the subsea installations or in a land station a long distance away.
- Communication between the control station and the subsea installation is normally provided by installing an umbilical between the two points.
- the umbilical contains lines for the supply of hydraulic fluid to the various actuators in or by the well, electric lines for the supply of electric power and signals to various monitoring and control devices and lines for signals to pass to and from the well.
- This umbilical is a very complicated and expensive item, costing several thousand dollars per meter.
- EP Patent Application No. 1209294 discloses an electro-hydraulic control unit with a piston/cylinder arrangement with the piston dividing the cylinder into two chambers, a fluid connection between the two chambers and a valve to configure the fluid flow such that pressureized hydraulic fluid only may flow in one direction, but not in both directions.
- U.S. Pat. No. 6,269,874 discloses an electro-hydraulic surface controlled subsurface safety valve actuator that comprises an electrically actuated pressure pump and a dump valve that is normally open so that if power fails, the pressure is released and the safety valve closes.
- the present invention is directed to an apparatus for solving, or at least reducing the effects of, some or all of the aforementioned problems.
- the present invention is directed to a modular actuator for subsea valves and equipment, and various methods of using same.
- the actuator comprises a hydraulic actuator, at least one housing and a self-contained hydraulic supply system positioned within the at least one housing.
- the actuator comprises a hydraulic actuator, at least one housing and a plurality of components positioned within the at least one housing, the components comprising a self-contained hydraulic supply system and a control system to control delivery of a high pressure hydraulic fluid produced by the self-contained hydraulic supply system.
- the actuator comprises a hydraulic actuator, at least one housing and a self-contained hydraulic supply system positioned within the at least one housing, the self-contained hydraulic supply system comprising a pump driven by an electrical motor, at least one fluid reservoir and a control/vent valve.
- the actuator comprises a hydraulic actuator, at least one housing and a self-contained hydraulic supply system positioned within the at least one housing, the self-contained hydraulic supply system comprising a pump driven by an electrical motor, at least one fluid reservoir and a control/vent valve.
- the actuator further comprises a control system positioned within the at least one housing to control delivery of a high pressure hydraulic fluid produced by the self-contained hydraulic supply system and a self-contained source of electrical power positioned within the at least one housing, wherein the self-contained source of electrical power is the primary source of electrical power for the modular actuator.
- FIG. 1 is a schematic depiction of one illustrative embodiment of the present invention employed in connection with a subsea valve;
- FIG. 2 is another schematic depiction of an alternative embodiment of the present invention employed in connection with a subsea equipment item
- FIGS. 3 a - 3 f describe various aspects of a modular actuator in accordance with one illustrative embodiment of the present invention
- FIG. 4 is a schematic depiction of an illustrative modular actuator in accordance with one embodiment of the present invention.
- FIG. 5 is a depiction of yet another illustrative embodiment of a modular actuator in accordance with the present invention.
- FIG. 8 is yet another illustrative embodiment of the present invention employing an alternative valve arrangement
- fluid line is used to indicate a fluid connection between components of the system. It should be understood that in various embodiments, the fluid connection between components may comprise an actual fluid conduit such as a pipe or hose, or the components may be connected directly to each other. Any configuration which allows for fluid communication between components as described below is considered to be within the spirit and scope of the invention.
- FIGS. 1 and 2 schematically depict illustrative systems 10 employing a modular actuator 16 in accordance with various aspects of the present invention.
- the modular actuator 16 is operatively coupled to a valve actuator 15 that is operatively coupled to a subsea valve 12 positioned in a flow line or well conduit 14 .
- the valve actuator 15 may be of any type, e.g., a mechanical valve actuator, a hydraulic valve actuator, etc.
- the particular type of valve actuator disclosed herein should not be considered a limitation of the present invention.
- FIG. 1 schematically depict illustrative systems 10 employing a modular actuator 16 in accordance with various aspects of the present invention.
- the modular actuator 16 is operatively coupled to a valve actuator 15 that is operatively coupled to a subsea valve 12 positioned in a flow line or well conduit 14 .
- the valve actuator 15 may be of any type, e.g., a mechanical valve actuator, a hydraulic valve actuator, etc.
- the modular actuator 16 disclosed herein is configured so that it may be easily coupled and decoupled from the subsea equipment, e.g., the valve actuator 15 , to which it is attached by a variety of techniques, e.g., by use of an ROV (remotely operated vehicle), a diver, etc., and retrieved to the surface as necessary for repairs.
- ROV remotely operated vehicle
- FIGS. 3 a - 3 f depict one illustrative embodiment of the modular actuator 16 in accordance with the present invention.
- the modular actuator 16 comprises a hydraulic actuator and one or more housing portions that are adapted to contain various components of the modular actuator 16 , including a self-contained hydraulic supply system.
- the modular actuator 16 comprises a linear override tool 16 A and housings 16 B, 16 C, 16 D for housing various electrical and hydraulic components, including hydraulic fluid, associated with the modular actuator 16 .
- the illustrative embodiment depicted herein comprises three separate housings 16 B, 16 C, 16 D, those skilled in the art, with the benefit of the present disclosure, will understand that the modular actuator 16 may comprise one or more housings to house the various components of the system described herein. Thus, the present invention should not be considered as limited to the illustrative embodiments depicted herein.
- an interface device 17 may be provided between the modular actuator 16 and the valve actuator 15 .
- the interface device 17 may comprise a spool having a first flange 17 A, a second flange 17 B and a travel indicator 17 C.
- the first flange 17 A is adapted to be coupled to the valve actuator 15 .
- the interface device 17 may be coupled to the valve actuator 15 at the time the subsea system is placed into service. Thereafter, the modular actuator 16 may be operatively coupled to the flange 17 B when desired or needed, as will be described more fully below.
- the shaft 16 G when the modular actuator 16 is activated or stroked, the shaft 16 G will extend into the bore of the interface device 17 thereby insuring that the modular actuator 16 remains in place irrespective of whether the valve actuator 15 is positioned horizontally, vertically, or at any other angle. Additional operational aspects of the modular actuator 16 will be described more fully below.
- the solenoid valve 16 S When the solenoid valve 16 S is de-energized, e.g., in an emergency situation, the solenoid valve 16 S returns (due to its spring return) to its closed position, as depicted in FIG. 3 f . With the solenoid valve 16 S in the closed position, the high pressure hydraulic fluid in the chamber 16 T is free to return to the accumulator 16 K, and the shaft 16 G is free to travel to the left in FIG. 3 f , as indicated by the arrow 16 V, until it reaches its fully retracted position.
- a force such as a spring force, may be supplied to urge the shaft 16 G to its fully retracted position. Such a force may be supplied by, for example, a return spring on a subsea safety valve.
- the modular actuator 16 comprises, in one illustrative embodiment, a fluid reservoir-accumulator 44 , a pressure intensifier 47 , a check valve 34 , a control/vent solenoid valve 40 , a battery 54 and a control system 50 .
- a plurality of hydraulic flow lines 45 , 36 , 48 and 42 are positioned within the housing 20 .
- the modular actuator 16 further comprises an illustrative electrical connection 36 that is adapted to mate with a schematically depicted electrical line 37 .
- the system within the modular actuator 16 is adapted to provide a high pressure hydraulic fluid to a component, such as the illustrative subsea valve 12 , to accomplish the desired purpose, e.g., to move a valve from a first position to a second position.
- Electrical power for the electrical components within the housing 20 may be provide by an electrical line that extends to a surface source of electrical power or it may be provided by one or more batteries that are positioned inside the housing 20 or otherwise located proximate to the modular actuator 16 .
- the batteries may be the primary source of electrical power for the electrical components within the housing 20 .
- the battery 54 (see FIG. 4 ) is positioned in the housing 20 and it is the primary source of power for the electrical components of the modular actuator 16 , e.g., the motor 31 , the control system 35 , the solenoid control/vent valve 40 , etc.
- the modular actuator 16 also has a self-contained electrical power source.
- the battery 54 (or groups thereof) may be any of a variety of commercially available batteries employed in subsea applications.
- Recharging the battery 54 may be accomplished by a substantially continuous trickle charge that is applied to the battery 54 .
- the control system 35 may be employed to monitor the stored charge in the battery 54 and when it reaches a certain minimum allowed level, the battery 54 may be recharged by temporarily coupling it to a full power electrical line.
- electrical power to the electrical components with the housing 20 may be provide by a traditional electrical power line or cable and the battery 54 , if present, may serve a traditional back-up role.
- the modular actuator may be decoupled from the subsea valve 12 or equipment 18 and taken to the surface.
- an ROV or diver may be employed to decouple the modular actuator 16 from the subsea valve 12 or equipment 18 and transport it to the surface.
- the illustrative control system 50 depicted within the modular actuator 16 is adapted to sense various conditions existing within the system contained in the modular actuator 16 and take various control actions in response thereto, as described more fully below.
- the control system 35 may take a variety of shapes and forms.
- the control system 50 comprises a programmable logic device or a microprocessor and a memory device for storing a variety of data and/or programs.
- FIG. 5 depicts yet another illustrative embodiment of the modular actuator 16 described herein.
- a hydraulic actuator 28 (having a shaft or stem 21 and an end interface 27 ) has been included in the modular actuator 16 .
- the interface 27 of the hydraulic cylinder 28 may be coupled to any of a variety of devices, e.g., a subsea valve, and actuated to open or close such a valve.
- FIG. 6 is a more detailed depiction of some of the various components of the modular actuator 16 in accordance with one illustrative embodiment of the present invention.
- an actuator 128 has a cylindrical housing 112 .
- a piston 114 is axially movable in the housing, between first and second positions.
- a stem 121 is attached to the piston 114 and extends outside the housing 112 .
- An illustrative flange or bracket 122 is provided for operatively coupling the actuator 129 to a subsea valve (not shown in FIG. 6 ).
- the actuator 129 is provided with a handle 124 that enables the actuator 129 to be transported and mounted with an ROV.
- a linear override tool 120 may also be used for manually moving the piston 114 , using an ROV tool.
- the actuator 129 depicted in FIG. 6 may be employed with a modular actuator 16 like the one schematically depicted in FIG. 4 .
- the actuator 129 depicted in FIG. 6 may also be employed with a modular actuator 16 like the one schematically depicted in FIG. 5 , wherein the actuator 129 is positioned within the housing 20 of the modular actuator 16 .
- the actuator 129 may not be provided with a separate ROV handle 124 or the linear override tool 120 .
- the piston 114 includes seals 111 to seal the piston 114 against the cylinder.
- the piston 114 defines first 113 and second 115 (see FIG. 7 ) chambers in the housing 112 .
- a fluid line 142 connects the second chamber 115 with a variable volume fluid reservoir-accumulator 144 .
- the fluid in accumulator 144 is at ambient sea pressure.
- the variable volume accumulator 144 evens out pressure surges in the return system and also provides for spare fluid capacity, as is well known in the art.
- a fluid line 145 connects the accumulator 144 with the intake side of an illustrative pressure intensifier, e.g., a pump 147 .
- the various parts of the unit are in communication with a control module 150 through cables 126 , 128 , 130 and 132 .
- the control module 150 is in communication with a remote station (not shown) via a cable 152 , to receive power and communication signals therefrom.
- valve element 202 is depicted in the closed position.
- the solenoid 138 is energized to move the two-way valve 140 to the closed position shown in FIG. 7 , against the force of the spring 129 .
- the motor 131 is operated to drive the pump 147 , thus transferring fluid from the low pressure portion of the system (comprising the second chamber 115 and the accumulator 144 ) to the first chamber 113 of the actuator 129 .
- the high pressure fluid in chamber 113 displaces the piston 114 to its second (extended) position, shown in FIG. 8 .
- valve 160 In the second position, the valve 160 allows fluid communication between the output of pump 147 and the first chamber 113 . In this position, flow line 168 is blocked. High pressure fluid from the pump 147 is introduced into the chamber 113 of the actuator 128 , thus driving the stem 121 to its extended position which opens the valve element 202 .
- valve 202 When it becomes necessary to close the valve 202 , either electively or in an emergency situation, power to the solenoid 162 is shut off, causing the three-way valve 160 to move to its first, or venting position. This opens the fluid communication path between first 113 and second 115 chambers, and blocks flow from the pump to the first chamber 113 . Since the pressure now is equalized on each side of the piston 114 , the spring 208 will force the piston 114 and stem 121 backwards to its first (retracted) position, and the valve 202 will close as fluid is transferred to chamber 115 from chamber 113 .
- the solenoid valve 160 is pressure-balanced, as will be clearly understood from FIG. 8 .
- the required biasing force of the spring 161 is very small, and thus the required holding force of the solenoid 162 may be correspondingly small.
- the modular actuator 16 may be made very small and compact. It is releasably connected to the valve 212 making it easy to replace or retrieve for repairs or maintenance.
- the hydraulic portion of the system is entirely self-contained within the housing 20 of the modular actuator 16 . Thus, no external hydraulic lines are necessary—control signals and power are transmitted through a simple and inexpensive electrical cable arrangement.
- the modular nature of the actuator 16 also makes it possible to exchange the actuator 16 with other types of actuators, such as an all-electric actuator. It is also possible to retrofit the actuator 16 onto a valve which was previously manually operated. Once the valve 212 has been fully actuated, the actuator 16 of the present invention requires very little power to hold the valve in position.
- FIGS. 9 a - 9 c Another exemplary embodiment of a modular actuator 16 in accordance with the present invention is shown schematically in FIGS. 9 a - 9 c .
- a hydraulic power unit (HPU) 380 is positioned within the housing 20 of the modular actuator 16 .
- the unit 380 includes a master cylinder 381 with a piston 382 reciprocally movable axially in the cylinder, thus dividing the cylinder into two chambers 383 and 384 .
- the two chambers 383 and 384 are interconnected through a bypass line 391 , the flow through the bypass being controlled by a bypass control valve 390 .
- the actuator that moves piston 382 may consist of an electric motor with a gearbox and transmission.
- an electric motor 385 is operatively connected to a shaft 386 by a suitable gearbox 375 , such that operation of motor 385 may precisely control the motion of piston 382 .
- Examples of a suitable motor 385 and gearbox 375 combination include a Model Number TPM 050 sold by the German company Wittenstein.
- the motor may alternatively be a linear electric motor.
- This arrangement controls the flow of fluid from master cylinder 381 to the SCSSV actuator 374 .
- a check valve 399 is mounted in line 389 , between the operation control valve 388 and the chamber 383 .
- the check valve 399 allows fluid to flow from chamber 383 to chamber 393 , but not the reverse.
- An accumulator 400 containing a supply of hydraulic fluid, is connected to the fluid line 387 via line 401 , at a point between operation control valve 388 and check valve 399 .
- the accumulator 400 provides a buffer for the high pressure hydraulic fluid, and ensures that the SCSSV will stay open under normal operating conditions.
- a pressure balanced compensator 405 is connected to a second inlet port 397 of operation control valve 388 via line 406 .
- a fluid line 408 connects compensator 405 with chamber 384 of master cylinder 381 .
- a fluid line 409 connects compensator 405 with a hydraulic coupling 411 .
- the coupling 411 allows hydraulic fluid to be supplied from an external source (not shown) so that fluid can be added to the hydraulic system.
- bypass control valve 390 is shifted to a second, or open position, as shown in FIG. 9 c . In the second position, bypass control valve 390 allows fluid to flow through the bypass line between the two chambers 383 and 384 of the master cylinder. The electric motor 385 may then be run in reverse in order to move the piston 12 back to the upper starting position.
- the operation control valve 388 may or may not be shifted to its second position and the motor 385 is energized to drive the piston 382 downward in master cylinder 381 .
- a pressure sensor 413 in line 401 monitors the pressure in the accumulator 400 , making it possible to stop the motor 385 when desired pressure is reached.
- an external source (not shown) of hydraulic fluid may be coupled to the hydraulic coupler 411 . Fluid from the external source fills the compensator 405 and first chamber 384 of master cylinder 381 . By shifting the bypass control valve 390 to its open position ( FIG. 9 c ), fluid may also flow into second chamber 383 . Bypass control valve 390 may then be moved to the closed position ( FIG. 9 b ), and piston 382 may be moved downwards to recharge the accumulator 400 , as previously described.
- the exemplary embodiment of the invention shown in FIGS. 9 a - 9 c includes a high-pressure section, including accumulator 400 , which is maintained at a pressure which is sufficient to operate the SCSSV.
- This embodiment also includes a low-pressure section, including compensator 405 , which is maintained at a second pressure which is less than the pressure required to operate the SCSSV.
- the compensator 405 may be partly filled with an inert gas such as nitrogen, which compensates for pressure differences due to operation of the SCSSV, and which also primes the system for use at various water depths.
- a standard, hydraulically actuated downhole safety-valve can be used while eliminating the need for a high-pressure hydraulic fluid supply from the surface.
- Standard downhole safety valves have a spring failsafe feature so that the valve will close when pressure is relieved in the system. The valve will therefore also close in the event of a hydraulic system failure.
- the SCSSV can quickly be closed by shifting operation control valve 388 to its second position, thus venting the high-pressure fluid from line 387 .
- the present invention is directed to a modular actuator for subsea valves and equipment, and various methods of using same.
- the actuator comprises a hydraulic actuator, at least one housing and a self-contained hydraulic supply system positioned within the at least one housing.
- the actuator comprises a hydraulic actuator, at least one housing and a plurality of components positioned within the at least one housing, the components comprising a self-contained hydraulic supply system and a control system to control delivery of a high pressure hydraulic fluid produced by the self-contained hydraulic supply system.
- the actuator comprises a hydraulic actuator, at least one housing and a self-contained hydraulic supply system positioned within the at least one housing, the self-contained hydraulic supply system comprising a pump driven by an electrical motor, at least one fluid reservoir and a control/vent valve.
- the actuator comprises a hydraulic actuator, at least one housing and a self-contained hydraulic supply system positioned within the at least one housing, the self-contained hydraulic supply system comprising a pump driven by an electrical motor, at least one fluid reservoir and a control/vent valve.
- the actuator further comprises a control system positioned within the at least one housing to control delivery of a high pressure hydraulic fluid produced by the self-contained hydraulic supply system and a self-contained source of electrical power positioned within the at least one housing, wherein the self-contained source of electrical power is the primary source of electrical power for the modular actuator.
Abstract
The present invention is directed to a modular actuator for subsea valves and equipment, and various methods of using same. In one illustrative embodiment, the actuator includes a hydraulic actuator, at least one housing and a self-contained hydraulic supply system positioned within the at least one housing.
Description
- 1. Field of the Invention
- The present invention is generally directed to the field of actuators, and more particularly to a modular actuator for subsea valves and equipment, and various methods of using same. In one illustrative example, the present invention is directed to a system for controlling an actuator for a downhole safety valve in a subsea Christmas tree.
- 2. Description of the Related Art
- The production from a subsea well is controlled by a number of valves that are assembled into a Christmas tree. The actuation of the valves is normally dependent upon hydraulic fluid to operate hydraulic actuators for the valves and is therefore entirely dependent upon an external source for the supply of pressurized hydraulic fluid. Hydraulic power is normally supplied through an umbilical running from a station located on a vessel on the surface or, less common, from a land based station. Usually the actuators are controlled by pilot valves housed in a control module located at or near the subsea installation, the pilot valves directing the supply of hydraulic fluid to each actuator, as dictated by the need for operation. The pilot valves may be operated by electric means and such a system is therefore called an electro-hydraulic system.
- The design of actuators and valves for subsea wells are dictated by stringent demands on the standard and function for these valves, because of the dangers of uncontrolled release of hydrocarbons. A typical demand is that these valves must be failsafe closed, meaning that they must close upon loss of power or control. The only practical means today in subsea environments is to use springs that are held in the compressed state by the hydraulic pressure, keeping the valve open, and will be released in the event of loss of hydraulic pressure, thus closing the valve. The spring force needed to close a valve is dependent upon both well pressure and ambient pressure, with larger ambient pressure demanding larger springs.
- For the control of subsea wells, a connection between the well and a monitoring and control station must be established. This station can either be located in a floating vessel near the subsea installations or in a land station a long distance away. Communication between the control station and the subsea installation is normally provided by installing an umbilical between the two points. The umbilical contains lines for the supply of hydraulic fluid to the various actuators in or by the well, electric lines for the supply of electric power and signals to various monitoring and control devices and lines for signals to pass to and from the well. This umbilical is a very complicated and expensive item, costing several thousand dollars per meter.
- It would therefore be very cost-saving to be able to eliminate the umbilical. Proposals have been made to use electrically operated actuators for subsea valves instead of the traditional hydraulic actuators, see for example U.S. Pat. Nos. 5,497,672 and 5,984,260. However, this entails the installation of completely new actuators, resulting that it is not possible to retrofit a hydraulic system with an electric actuator.
- EP Patent Application No. 1209294 discloses an electro-hydraulic control unit with a piston/cylinder arrangement with the piston dividing the cylinder into two chambers, a fluid connection between the two chambers and a valve to configure the fluid flow such that pressureized hydraulic fluid only may flow in one direction, but not in both directions.
- U.S. Pat. No. 6,269,874 discloses an electro-hydraulic surface controlled subsurface safety valve actuator that comprises an electrically actuated pressure pump and a dump valve that is normally open so that if power fails, the pressure is released and the safety valve closes.
- The present invention is directed to an apparatus for solving, or at least reducing the effects of, some or all of the aforementioned problems.
- The present invention is directed to a modular actuator for subsea valves and equipment, and various methods of using same. In one illustrative embodiment, the actuator comprises a hydraulic actuator, at least one housing and a self-contained hydraulic supply system positioned within the at least one housing.
- In another illustrative embodiment, the actuator comprises a hydraulic actuator, at least one housing and a plurality of components positioned within the at least one housing, the components comprising a self-contained hydraulic supply system and a control system to control delivery of a high pressure hydraulic fluid produced by the self-contained hydraulic supply system.
- In yet another illustrative embodiment, the actuator comprises a hydraulic actuator, at least one housing and a self-contained hydraulic supply system positioned within the at least one housing, the self-contained hydraulic supply system comprising a pump driven by an electrical motor, at least one fluid reservoir and a control/vent valve.
- In a further illustrative embodiment, the actuator comprises a hydraulic actuator, at least one housing and a self-contained hydraulic supply system positioned within the at least one housing, the self-contained hydraulic supply system comprising a pump driven by an electrical motor, at least one fluid reservoir and a control/vent valve. The actuator further comprises a control system positioned within the at least one housing to control delivery of a high pressure hydraulic fluid produced by the self-contained hydraulic supply system and a self-contained source of electrical power positioned within the at least one housing, wherein the self-contained source of electrical power is the primary source of electrical power for the modular actuator.
- The invention may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements, and in which:
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FIG. 1 is a schematic depiction of one illustrative embodiment of the present invention employed in connection with a subsea valve; -
FIG. 2 is another schematic depiction of an alternative embodiment of the present invention employed in connection with a subsea equipment item; -
FIGS. 3 a-3 f describe various aspects of a modular actuator in accordance with one illustrative embodiment of the present invention; -
FIG. 4 is a schematic depiction of an illustrative modular actuator in accordance with one embodiment of the present invention; -
FIG. 5 is a depiction of yet another illustrative embodiment of a modular actuator in accordance with the present invention; -
FIG. 6 is a more detailed schematic depiction of one illustrative embodiment of the present invention in a first working mode; -
FIG. 7 is a detailed schematic depiction showing one illustrative embodiment of the present invention in a fail safe mode; -
FIG. 8 is yet another illustrative embodiment of the present invention employing an alternative valve arrangement; and -
FIGS. 9 a-9 c depict an illustrative embodiment of the present invention in various operating configurations. - While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
- Illustrative embodiments of the invention are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
- The present invention will now be described with reference to the attached figures. The words and phrases used herein should be understood and interpreted to have a meaning consistent with the understanding of those words and phrases by those skilled in the relevant art. No special definition of a term or phrase, i.e., a definition that is different from the ordinary and customary meaning as understood by those skilled in the art, is intended to be implied by consistent usage of the term or phrase herein. To the extent that a term or phrase is intended to have a special meaning, i.e., a meaning other than that understood by skilled artisans, such a special definition will be expressly set forth in the specification in a definitional manner that directly and unequivocally provides the special definition for the term or phrase.
- In the following description, the term fluid line is used to indicate a fluid connection between components of the system. It should be understood that in various embodiments, the fluid connection between components may comprise an actual fluid conduit such as a pipe or hose, or the components may be connected directly to each other. Any configuration which allows for fluid communication between components as described below is considered to be within the spirit and scope of the invention.
- In the specification, terms such as “upward” or “downward” or the like may be used to refer to the direction of fluid flow between various components of the devices depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of the present application, the device and systems described herein may be positioned in any desired orientation. Thus, the reference to the direction of fluid flow should be understood to represent a relative direction of flow and not an absolute direction of flow. Similarly, the use of terms such as “above,” “below,” or other like terms to describe a spatial relationship between various components should be understood to describe a relative relationship between the components as the device described herein may be oriented in any desired position.
- Also in the following description, the terms low pressure and high pressure are used to describe various portions of the system. It should be understood that these terms are used in a relative sense. Low pressure is used to describe the fluid supply and the portions of the system in fluid communication with the fluid supply. High pressure is used to describe the fluid which is pressurized by the pump or other pressure intensifying device, and the portions of the system in fluid communication with pump output. The term high pressure is used only to indicate that this portion of the system is at a higher pressure relative to the fluid supply. The term low pressure is used only to indicate that this portion of the system is at a lower pressure than the pump output. The actual absolute or gauge pressure of the various portions of the system is irrelevant to the definition of high or low pressure.
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FIGS. 1 and 2 schematically depictillustrative systems 10 employing amodular actuator 16 in accordance with various aspects of the present invention. As depicted inFIG. 1 , themodular actuator 16 is operatively coupled to avalve actuator 15 that is operatively coupled to asubsea valve 12 positioned in a flow line orwell conduit 14. Thevalve actuator 15 may be of any type, e.g., a mechanical valve actuator, a hydraulic valve actuator, etc. Thus, the particular type of valve actuator disclosed herein should not be considered a limitation of the present invention. In the embodiment depicted inFIG. 2 , a plurality ofmodular actuators 16 are operatively coupled tovalve actuators 15 that, in turn, are operatively coupled to a item ofsubsea equipment 18, such as an illustrative Christmas tree. As will be described more fully below, in one illustrative embodiment, themodular actuator 16 of the present invention is a self-contained actuator that is adapted to actuate asubsea valve 12 or other similar type component. In the illustrative embodiment depicted inFIG. 2 , the plurality ofmodular actuators 16 are adapted to control a plurality of valves (not shown) positioned internally within the schematically depictedChristmas tree 18. - As will be described more fully below, the
modular actuator 16 described herein comprises a self-contained power supply, and it may be readily decoupled from thevalve actuator 15 and removed to the surface. Importantly, in one illustrative embodiment, themodular actuator 16 described herein comprises a self-contained hydraulic system that will be used, at least in part, to actuate thesubsea valve 12 or other like equipment. In accordance with one illustrative aspect of the present invention, since themodular actuators 16 described herein employ a self-contained hydraulic system, a supply of high pressure hydraulic fluid from a station location on a surface vessel or from a land-based station is not required. Moreover, themodular actuator 16 disclosed herein is configured so that it may be easily coupled and decoupled from the subsea equipment, e.g., thevalve actuator 15, to which it is attached by a variety of techniques, e.g., by use of an ROV (remotely operated vehicle), a diver, etc., and retrieved to the surface as necessary for repairs. -
FIGS. 3 a-3 f depict one illustrative embodiment of themodular actuator 16 in accordance with the present invention. In general, themodular actuator 16 comprises a hydraulic actuator and one or more housing portions that are adapted to contain various components of themodular actuator 16, including a self-contained hydraulic supply system. As depicted inFIGS. 3 a-3 f, themodular actuator 16 comprises alinear override tool 16A andhousings modular actuator 16. Although the illustrative embodiment depicted herein comprises threeseparate housings modular actuator 16 may comprise one or more housings to house the various components of the system described herein. Thus, the present invention should not be considered as limited to the illustrative embodiments depicted herein. - In the depicted embodiment, an
interface device 17 may be provided between themodular actuator 16 and thevalve actuator 15. Even more specifically, in the illustrative example depicted herein, theinterface device 17 may comprise a spool having afirst flange 17A, asecond flange 17B and atravel indicator 17C. Thefirst flange 17A is adapted to be coupled to thevalve actuator 15. Typically, theinterface device 17 may be coupled to thevalve actuator 15 at the time the subsea system is placed into service. Thereafter, themodular actuator 16 may be operatively coupled to theflange 17B when desired or needed, as will be described more fully below. As will be recognized by those skilled in the art after a complete reading of the present application, theinterface device 17 may take a variety of shapes and forms. For example, in one illustrative embodiment, theinterface device 17 may be designed in accordance with the teachings of a standard entitled “Design and Operation of Subsea Production Equipment Systems,” ISO/FDIS 13628-8:2000(E), pp. 39-42. In other embodiments, aseparate interface device 17 need not be provided. That is, to the extent an interface is provided, it may be provided as an integral part of either thevalve actuator 15 or themodular actuator 16. - As to more specifics, the
modular actuator 16 may comprise ahydraulic fluid reservoir 16D, anROV handle 16E, anROV handle 16F, ashaft 16G and a plurality ofseals 16H. Themodular actuator 16 is provided with arecess 161 that is adapted to be positioned around theflange 17B of theinterface device 17. A plurality ofanti-rotation devices 16J, e.g., studs or nuts, are provided to reduce or prevent rotation of themodular actuator 16 relative to theinterface device 17. -
FIGS. 3 a-3 c depict themodular actuator 16 as it is being lowered onto theflange 17B of theinterface device 17. An ROV may be used to install themodular actuator 16. As indicated previously, in one illustrative embodiment, theinterface device 17 is attached to thevalve actuator 15 as part of the initial installation process of the subsea system. Any number of valves of a particular subsea system may be provided with such aninterface device 17 such that amodular actuator 16 may be operatively coupled to such valves when needed. More specifically, in one illustrative embodiment, an ROV (remotely operated vehicle) or other like device may be employed to position themodular actuator 16 in a position where it may operate a subsea devices, such as a valve. Themodular actuator 16 may be lowered onto theflange 17B through use of an ROV that grasps ROV handle 16E.FIG. 3 c depicts themodular actuator 16 in the fully landed position. The recess 16I is sized such that themodular actuator 16 fits securely around theflange 17B. Theanti-rotation devices 16J prevent or reduce rotation of themodular actuator 16 relative to theinterface device 17 and thevalve actuator 15. When themodular actuator 16 is in a horizontal position, the weight of themodular actuator 16, along with the closeness of fit between the recess 16I and theflange 17B, tend to secure themodular actuator 16 in position. With reference toFIG. 3E , when themodular actuator 16 is activated or stroked, theshaft 16G will extend into the bore of theinterface device 17 thereby insuring that themodular actuator 16 remains in place irrespective of whether thevalve actuator 15 is positioned horizontally, vertically, or at any other angle. Additional operational aspects of themodular actuator 16 will be described more fully below. - Illustrative examples of the associated electrical and hydraulic controls that may be employed with the
modular actuator 16 are depicted inFIG. 3 f. As shown therein, the system comprises anaccumulator 16K, apump 16L, driven by anelectric motor 16M, acheck valve 16N,pressure sensors filter 16R and a solenoid valve with spring return 16S. In one illustrative embodiment, the solenoid valve 16S may be a normally closed valve, as depicted inFIG. 3 f. When the solenoid valve 16S is actuated and moved to its “open” position, thepump 16L may be activated to increase the pressure of the hydraulic fluid supplied to thechamber 16T. In turn, this causes theshaft 16G to move to the right inFIG. 3 f, as indicated by thearrow 16U. Theend 16W of theshaft 16G engages theend 15B of theshaft 15A (seeFIG. 3 e) of thevalve actuator 15 when theshaft 16G moves in the direction of thearrow 16U. Thepump 16L continues to operate until the pressure on both sides of the solenoid valve 16S is substantially equal, as determined by thepressure sensors shaft 16G is fully extended and thepump 16L may be stopped. - When the solenoid valve 16S is de-energized, e.g., in an emergency situation, the solenoid valve 16S returns (due to its spring return) to its closed position, as depicted in
FIG. 3 f. With the solenoid valve 16S in the closed position, the high pressure hydraulic fluid in thechamber 16T is free to return to theaccumulator 16K, and theshaft 16G is free to travel to the left inFIG. 3 f, as indicated by the arrow 16V, until it reaches its fully retracted position. A force, such as a spring force, may be supplied to urge theshaft 16G to its fully retracted position. Such a force may be supplied by, for example, a return spring on a subsea safety valve. A portion of theshaft 16G will remain positioned within the bore of theinterface device 17 even when the solenoid valve 16S is in its closed position (as shown inFIG. 3 f). In one embodiment, to fully retract theshaft 16G from inside the bore of theinterface device 17, an ROV is employed to grasp and pull on thehandle 16F (seeFIG. 3 e). Once theshaft 16G has been complete disengaged from the bore of theinterface device 17, themodular actuator 16 may be removed by use of an ROV that grasps thehandle 16E. An ROV may be used to open or close aneedle valve 16Y (seeFIG. 3F ), viahandle 16X (seeFIG. 3 e), to vent the system if the need arises. Atravel indicator 17C may be used to determine the movement of theshaft 15A. Thetravel indicator 17C is secured to theshaft 15A by a bolt 17D (seeFIG. 3 e). The bolt 17D is free to travel within thegroove 17E. -
FIG. 4 is a schematic depiction of the various components that may be included in one illustrative embodiment of themodular actuator 16 disclosed herein. As shown inFIG. 4 , a variety of components are positioned in a one or more housings, generally indicated by thenumber 20, associated with themodular actuator 16. The exact number of housings and the location of various components of the system described herein may vary depending upon the particular application. Of course, themodular actuator 16 will ultimately be operatively coupled to anillustrative valve actuator 15. In general, themodular actuator 16 comprises, in one illustrative embodiment, a fluid reservoir-accumulator 44, apressure intensifier 47, acheck valve 34, a control/vent solenoid valve 40, abattery 54 and acontrol system 50. A plurality ofhydraulic flow lines housing 20. Themodular actuator 16 further comprises an illustrativeelectrical connection 36 that is adapted to mate with a schematically depictedelectrical line 37. - The
pressure intensifier 47 schematically depicted inFIG. 4 may be comprised of a variety of devices. Thepressure intensifier 47 may be any device or system that employs electrical power to increase the pressure in a fluid. For example, in one embodiment, thepressure intensifier 47 may be a rotary pump driven by a schematically depictedelectric motor 31 shown inFIG. 4 . In another illustrative embodiment, thepressure intensifier 47 may also be a reciprocating pump driven by an electric motor (see, e.g.,FIGS. 9 a-9 c). In the illustrative embodiment depicted inFIG. 4 , the system within themodular actuator 16 is adapted to provide a high pressure hydraulic fluid to a component, such as the illustrativesubsea valve 12, to accomplish the desired purpose, e.g., to move a valve from a first position to a second position. - Electrical power for the electrical components within the
housing 20 may be provide by an electrical line that extends to a surface source of electrical power or it may be provided by one or more batteries that are positioned inside thehousing 20 or otherwise located proximate to themodular actuator 16. Moreover, depending upon the particular application the batteries may be the primary source of electrical power for the electrical components within thehousing 20. In one illustrative embodiment, the battery 54 (seeFIG. 4 ) is positioned in thehousing 20 and it is the primary source of power for the electrical components of themodular actuator 16, e.g., themotor 31, the control system 35, the solenoid control/vent valve 40, etc. Thus, in this embodiment, themodular actuator 16 also has a self-contained electrical power source. The battery 54 (or groups thereof) may be any of a variety of commercially available batteries employed in subsea applications. - Recharging the
battery 54 may be accomplished by a substantially continuous trickle charge that is applied to thebattery 54. Alternatively, the control system 35 may be employed to monitor the stored charge in thebattery 54 and when it reaches a certain minimum allowed level, thebattery 54 may be recharged by temporarily coupling it to a full power electrical line. In other embodiments, electrical power to the electrical components with thehousing 20 may be provide by a traditional electrical power line or cable and thebattery 54, if present, may serve a traditional back-up role. - If it is desired to replace the
battery 54 within thehousing 20 of themodular actuator 16, then the modular actuator may be decoupled from thesubsea valve 12 orequipment 18 and taken to the surface. As described previously, an ROV or diver may be employed to decouple themodular actuator 16 from thesubsea valve 12 orequipment 18 and transport it to the surface. - The
illustrative control system 50 depicted within themodular actuator 16 is adapted to sense various conditions existing within the system contained in themodular actuator 16 and take various control actions in response thereto, as described more fully below. The control system 35 may take a variety of shapes and forms. In one illustrative embodiment, thecontrol system 50 comprises a programmable logic device or a microprocessor and a memory device for storing a variety of data and/or programs. -
FIG. 5 depicts yet another illustrative embodiment of themodular actuator 16 described herein. Relative to the embodiment depicted inFIG. 4 , in the embodiment depicted inFIG. 5 , a hydraulic actuator 28 (having a shaft orstem 21 and an end interface 27) has been included in themodular actuator 16. In this illustrative embodiment theinterface 27 of thehydraulic cylinder 28 may be coupled to any of a variety of devices, e.g., a subsea valve, and actuated to open or close such a valve. -
FIG. 6 is a more detailed depiction of some of the various components of themodular actuator 16 in accordance with one illustrative embodiment of the present invention. For ease of reference many of the components shown inFIGS. 1-5 will be shown inFIGS. 6-8 with a corresponding “1” prefix. As shown therein, anactuator 128 has acylindrical housing 112. Apiston 114 is axially movable in the housing, between first and second positions. Astem 121 is attached to thepiston 114 and extends outside thehousing 112. An illustrative flange orbracket 122 is provided for operatively coupling theactuator 129 to a subsea valve (not shown inFIG. 6 ). In one illustrative embodiment, theactuator 129 is provided with ahandle 124 that enables theactuator 129 to be transported and mounted with an ROV. Alinear override tool 120 may also be used for manually moving thepiston 114, using an ROV tool. Theactuator 129 depicted inFIG. 6 may be employed with amodular actuator 16 like the one schematically depicted inFIG. 4 . Of course, theactuator 129 depicted inFIG. 6 may also be employed with amodular actuator 16 like the one schematically depicted inFIG. 5 , wherein theactuator 129 is positioned within thehousing 20 of themodular actuator 16. Of course, in that case, theactuator 129 may not be provided with a separate ROV handle 124 or thelinear override tool 120. - The
piston 114 includesseals 111 to seal thepiston 114 against the cylinder. Thepiston 114 defines first 113 and second 115 (seeFIG. 7 ) chambers in thehousing 112. Afluid line 142 connects thesecond chamber 115 with a variable volume fluid reservoir-accumulator 144. In one illustrative embodiment, the fluid inaccumulator 144 is at ambient sea pressure. Thevariable volume accumulator 144 evens out pressure surges in the return system and also provides for spare fluid capacity, as is well known in the art. Afluid line 145 connects theaccumulator 144 with the intake side of an illustrative pressure intensifier, e.g., apump 147. A stub fluid line with acoupling 143 can be incorporated into thefluid line 145, to enable fluid to be replenished and refill theaccumulator 144. Afluid line 136 connects thefirst chamber 113 with the pressure side ofpump 147. A one-way valve orcheck valve 134 is installed influid line 136, allowing fluid to flow only towardschamber 113. - An
additional fluid line 148 interconnectsfluid lines fluid line 148 there is mounted a control-vent solenoid valve 140, thevalve 140 being movable between a closed position (FIG. 7 ) preventing fluid flow throughline 148, and an open position (FIG. 8 ) allowing fluid flow throughline 148. As seen fromFIG. 8 , whenvalve 140 is in its open position fluid may flow in either direction between thefirst chamber 113 and thesecond chamber 115. Aspring 139 is arranged to bias thevalve 140 towards its open position. Asolenoid 138 may be selectively energized to move thevalve 140 to its closed position, against the biasing force of thespring 139. - The
pump 147 is operated by amotor 131. Pressure andtemperature sensors fluid lines filter unit 146 may be installed influid line 145 between the pump intake and thefluid supply 144. - The various parts of the unit are in communication with a
control module 150 throughcables control module 150 is in communication with a remote station (not shown) via acable 152, to receive power and communication signals therefrom. - In one illustrative embodiment, the
motor 131 is a brushless DC motor. Also, in one illustrative embodiment, thecontrol module 150 includes abattery 154 to provide primary power to themotor 131 and thesolenoid 138. Thebattery 154 may be trickle-charged from a local power source or from a remote location. In this instance, only a small cable would be needed to charge thebattery 154. Alternatively, primary electrical power may be supplied from a remote location and thebattery 154, if present, may merely serve as a traditional back-up source for an emergency supply of electrical power. -
FIG. 7 depicts the present invention in a fail safe mode. As shown therein, asubsea valve 212 is adapted to be operated by theactuator 129. Thevalve 212 comprises avalve element 202 connected to avalve stem 204, thevalve stem 204 extending into and through aspring housing 206. Aspring 208 is located in thespring housing 206. Thevalve stem 204 has aspring actuating flange 210 rigidly attached thereto. Thevalve stem 204 terminates in astandard interface mechanism 211. The piston stem 121 has at its end a correspondinginterface 127, allowing thevalve stem 204 to be operably connected to thepiston stem 121. - In
FIG. 7 , thevalve element 202 is depicted in the closed position. To move thevalve element 202 to its open position, thesolenoid 138 is energized to move the two-way valve 140 to the closed position shown inFIG. 7 , against the force of thespring 129. This closes the fluid path betweenchambers actuator 128. Then themotor 131 is operated to drive thepump 147, thus transferring fluid from the low pressure portion of the system (comprising thesecond chamber 115 and the accumulator 144) to thefirst chamber 113 of theactuator 129. The high pressure fluid inchamber 113 displaces thepiston 114 to its second (extended) position, shown inFIG. 8 . - Consequently, this will move the
valve stem 204, causing thevalve element 202 to move to its open position (not shown inFIG. 7 ).Pressure sensor 127 senses the pressure influid line 136, and thecontrol module 150 cuts power to themotor 131 when the pressure inline 136 is sufficient to drive thevalve stem 206 against the power of thespring 208. One-way valve 134 and two-way-valve 140 prevent high pressure fluid from exitingchamber 113, thus ensuring that thevalve element 202 is held in its open position. In moving thevalve element 202 to its open position, thespring 208 is compressed thereby creating a bias return force in thespring 208 that will tend to move thevalve element 202 to its closed position. - When it becomes necessary to close the
valve 202, either electively or in an emergency situation, power to thesolenoid 138 is shut off, causing the two-way valve 140 to move to its open position shown inFIG. 8 as a result of the biasing force provided by thespring 139. This opens the fluid communication path between first 113 and second 115 chambers, and blocks or shuts off flow from thepump 147 to thefirst chamber 113. Since the pressure now is equalized on each side of thepiston 114, thespring 208 will force thepiston 114 and stem 116 backwards to its first (retracted) position, and thevalve 202 will close as fluid is transferred tochamber 115 fromchamber 113. -
FIG. 8 shows a system similar in many respects to the system ofFIG. 6 . However, inFIG. 8 , aflow line 167 extends betweenchamber 113 of theactuator 129, and a first port of a three-way solenoid valve 160. A second port ofvalve 160 is connected to flowline 136, which is in turn connected to the output ofpump 147. A third port ofvalve 160 is connected to flowline 168, which is in turn connected to flowline 145. Thevalve 160 is biased towards a first, or venting position (not shown) by aspring 161. Asolenoid 162 is selectively operable to movevalve 160 to a second position, as shown inFIG. 8 . In the second position, thevalve 160 allows fluid communication between the output ofpump 147 and thefirst chamber 113. In this position,flow line 168 is blocked. High pressure fluid from thepump 147 is introduced into thechamber 113 of theactuator 128, thus driving thestem 121 to its extended position which opens thevalve element 202. - When it becomes necessary to close the
valve 202, either electively or in an emergency situation, power to thesolenoid 162 is shut off, causing the three-way valve 160 to move to its first, or venting position. This opens the fluid communication path between first 113 and second 115 chambers, and blocks flow from the pump to thefirst chamber 113. Since the pressure now is equalized on each side of thepiston 114, thespring 208 will force thepiston 114 and stem 121 backwards to its first (retracted) position, and thevalve 202 will close as fluid is transferred tochamber 115 fromchamber 113. - The
solenoid valve 160 is pressure-balanced, as will be clearly understood fromFIG. 8 . The required biasing force of thespring 161 is very small, and thus the required holding force of thesolenoid 162 may be correspondingly small. - The
modular actuator 16 according to the present invention may be made very small and compact. It is releasably connected to thevalve 212 making it easy to replace or retrieve for repairs or maintenance. The hydraulic portion of the system is entirely self-contained within thehousing 20 of themodular actuator 16. Thus, no external hydraulic lines are necessary—control signals and power are transmitted through a simple and inexpensive electrical cable arrangement. The modular nature of theactuator 16 also makes it possible to exchange theactuator 16 with other types of actuators, such as an all-electric actuator. It is also possible to retrofit theactuator 16 onto a valve which was previously manually operated. Once thevalve 212 has been fully actuated, theactuator 16 of the present invention requires very little power to hold the valve in position. - Another exemplary embodiment of a
modular actuator 16 in accordance with the present invention is shown schematically inFIGS. 9 a-9 c. A hydraulic power unit (HPU) 380 is positioned within thehousing 20 of themodular actuator 16. For convenience, theillustrative control system 50 andbattery 54 are not depicted inFIGS. 9 a-9 c. Theunit 380 includes amaster cylinder 381 with apiston 382 reciprocally movable axially in the cylinder, thus dividing the cylinder into twochambers chambers bypass line 391, the flow through the bypass being controlled by abypass control valve 390. - In the exemplary embodiment the actuator that moves
piston 382 may consist of an electric motor with a gearbox and transmission. In the exemplary embodiment, anelectric motor 385 is operatively connected to ashaft 386 by asuitable gearbox 375, such that operation ofmotor 385 may precisely control the motion ofpiston 382. Examples of asuitable motor 385 andgearbox 375 combination include a Model Number TPM 050 sold by the German company Wittenstein. The motor may alternatively be a linear electric motor. - In the well tubing there is mounted a controllable
downhole safety valve 346, known in the art as an SCSSV (Surface Controlled Subsurface Safety Valve). As is well known in the art, the SCSSV includes a hydraulic cylinder including a “slave”chamber 393. To actuate the SCSSV,chamber 393 is pressurized, pushing apiston 394 against the biasing force of aspring 395 to open thevalve 346. Afluid line 387 is connected between theslave chamber 393 with an outlet port 398 of anoperation control valve 388 positioned within thehousing 20. Afirst inlet port 396 ofoperation control valve 388 is connected tofluid line 389, which is connected tocylinder chamber 383. This arrangement controls the flow of fluid frommaster cylinder 381 to theSCSSV actuator 374. Acheck valve 399 is mounted inline 389, between theoperation control valve 388 and thechamber 383. Thecheck valve 399 allows fluid to flow fromchamber 383 tochamber 393, but not the reverse. - An
accumulator 400, containing a supply of hydraulic fluid, is connected to thefluid line 387 vialine 401, at a point betweenoperation control valve 388 andcheck valve 399. Theaccumulator 400 provides a buffer for the high pressure hydraulic fluid, and ensures that the SCSSV will stay open under normal operating conditions. - A pressure
balanced compensator 405 is connected to asecond inlet port 397 ofoperation control valve 388 vialine 406. Afluid line 408 connectscompensator 405 withchamber 384 ofmaster cylinder 381. Afluid line 409 connectscompensator 405 with ahydraulic coupling 411. Thecoupling 411 allows hydraulic fluid to be supplied from an external source (not shown) so that fluid can be added to the hydraulic system. - Referring to
FIG. 9 a, when themotor 385 is energized, thepiston 382 will move downward in themaster cylinder 381. This forces high-pressure fluid through theline 387 to theslave cylinder 393 in thedownhole valve actuator 374, with theoperation control valve 388 in a first or open position. On the downstroke, thechamber 384 ofmaster cylinder 381 is refilled fromcompensator 405.Check valve 399 andaccumulator 400 cooperate to maintain the pressure in theline 387 at a level that will hold the SCSSV valve open. Referring toFIG. 9 b, to close the SCSSV valve, theoperation control valve 388 is shifted to its second or closed position. In the second position,operation control valve 388 allows fluid to flow back up throughline 387, throughline 406 and back intocompensator 405. In other words, theslave chamber 393 of the downhole actuator is vented throughoperation control valve 388 to the low-pressure system. - The pressure differential across
piston 382 will normally force the piston back to its upper starting position when the motor is de-energized. However, under certain conditions it may be necessary to reset thepiston 382 to the upper position. To do this, bypasscontrol valve 390 is shifted to a second, or open position, as shown inFIG. 9 c. In the second position,bypass control valve 390 allows fluid to flow through the bypass line between the twochambers electric motor 385 may then be run in reverse in order to move thepiston 12 back to the upper starting position. - Referring to
FIG. 9 b, when it is desired to recharge theaccumulator 400, theoperation control valve 388 may or may not be shifted to its second position and themotor 385 is energized to drive thepiston 382 downward inmaster cylinder 381. Apressure sensor 413 inline 401 monitors the pressure in theaccumulator 400, making it possible to stop themotor 385 when desired pressure is reached. - From time to time it may become necessary to replenish the hydraulic fluid in the system, to replace fluid lost due to leaks, for example. To accomplish this, an external source (not shown) of hydraulic fluid may be coupled to the
hydraulic coupler 411. Fluid from the external source fills thecompensator 405 andfirst chamber 384 ofmaster cylinder 381. By shifting thebypass control valve 390 to its open position (FIG. 9 c), fluid may also flow intosecond chamber 383.Bypass control valve 390 may then be moved to the closed position (FIG. 9 b), andpiston 382 may be moved downwards to recharge theaccumulator 400, as previously described. - The exemplary embodiment of the invention shown in
FIGS. 9 a-9 c includes a high-pressure section, includingaccumulator 400, which is maintained at a pressure which is sufficient to operate the SCSSV. This embodiment also includes a low-pressure section, includingcompensator 405, which is maintained at a second pressure which is less than the pressure required to operate the SCSSV. Thecompensator 405 may be partly filled with an inert gas such as nitrogen, which compensates for pressure differences due to operation of the SCSSV, and which also primes the system for use at various water depths. - By utilizing the exemplary embodiment of the
modular actuator 16 shown inFIGS. 9 a-9 c, a standard, hydraulically actuated downhole safety-valve can be used while eliminating the need for a high-pressure hydraulic fluid supply from the surface. Standard downhole safety valves have a spring failsafe feature so that the valve will close when pressure is relieved in the system. The valve will therefore also close in the event of a hydraulic system failure. In an emergency the SCSSV can quickly be closed by shiftingoperation control valve 388 to its second position, thus venting the high-pressure fluid fromline 387. - The present invention is directed to a modular actuator for subsea valves and equipment, and various methods of using same. In one illustrative embodiment, the actuator comprises a hydraulic actuator, at least one housing and a self-contained hydraulic supply system positioned within the at least one housing.
- In another illustrative embodiment, the actuator comprises a hydraulic actuator, at least one housing and a plurality of components positioned within the at least one housing, the components comprising a self-contained hydraulic supply system and a control system to control delivery of a high pressure hydraulic fluid produced by the self-contained hydraulic supply system.
- In yet another illustrative embodiment, the actuator comprises a hydraulic actuator, at least one housing and a self-contained hydraulic supply system positioned within the at least one housing, the self-contained hydraulic supply system comprising a pump driven by an electrical motor, at least one fluid reservoir and a control/vent valve.
- In a further illustrative embodiment, the actuator comprises a hydraulic actuator, at least one housing and a self-contained hydraulic supply system positioned within the at least one housing, the self-contained hydraulic supply system comprising a pump driven by an electrical motor, at least one fluid reservoir and a control/vent valve. The actuator further comprises a control system positioned within the at least one housing to control delivery of a high pressure hydraulic fluid produced by the self-contained hydraulic supply system and a self-contained source of electrical power positioned within the at least one housing, wherein the self-contained source of electrical power is the primary source of electrical power for the modular actuator.
- The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. For example, the process steps set forth above may be performed in a different order. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the invention. Accordingly, the protection sought herein is as set forth in the claims below.
Claims (32)
1. A modular actuator adapted to be releasably coupled to a subsea device, comprising:
a hydraulic actuator;
at least one housing; and
a self-contained hydraulic supply system positioned within said at least one housing.
2. The modular actuator of claim 1 , wherein said subsea device comprises a valve.
3. The modular actuator of claim 1 , wherein said subsea device comprises a Christmas tree.
4. The modular actuator of claim 1 , further comprising a control system positioned within said at least one housing to control delivery of a high pressure hydraulic fluid produced by said self-contained hydraulic supply system.
5. The modular actuator of claim 1 , further comprising a self-contained source of electrical power positioned within said at least one housing, wherein said self-contained source of electrical power is the primary source of electrical power for said modular actuator.
6. The modular actuator of claim 5 , wherein said self-contained source of electrical power comprises at least one battery.
7. The modular actuator of claim 1 , wherein said self-contained hydraulic supply system comprises a pressure intensifier.
8. The modular actuator of claim 1 , wherein said self-contained hydraulic system positioned within said housing comprises a pump driven by an electrical motor.
9. The modular actuator of claim 1 , wherein said self-contained hydraulic system comprises at least one fluid reservoir and a control/vent valve.
10. The modular actuator of claim 1 , wherein said modular actuator further comprises means for releasably coupling said modular actuator to said subsea device.
11. The modular actuator of claim 2 , wherein said self-contained hydraulic supply system is adapted to supply a pressurized fluid employed in actuating said subsea valve.
12. The modular actuator of claim 3 , wherein said self-contained hydraulic supply system is adapted to supply a pressurized fluid employed in actuating a valve within said Christmas tree.
13. The modular actuator of claim 1 , wherein said modular actuator is adapted to be releasably coupled to said subsea device by an ROV.
14. A modular actuator adapted to be releasably coupled to a subsea device, comprising:
a hydraulic actuator;
at least one housing; and
a plurality of components positioned within said at least one housing, said components comprising:
a self-contained hydraulic supply system; and
a control system to control delivery of a high pressure hydraulic fluid produced by said self-contained hydraulic supply system.
15. The modular actuator of claim 14 , further comprising a self-contained source of electrical power positioned within said at least housing, wherein said self-contained source of electrical power is the primary source of electrical power for said modular actuator.
16. The modular actuator of claim 14 , wherein said self-contained source of electrical power comprises at least one battery.
17. The modular actuator of claim 14 , wherein said self-contained hydraulic supply system comprises a pressure intensifier.
18. The modular actuator of claim 14 , wherein said self-contained hydraulic system positioned within said housing comprises a pump driven by an electrical motor.
19. The modular actuator of claim 14 , wherein said self-contained hydraulic system comprises at least one fluid reservoir and a control/vent valve.
20. The modular actuator of claim 14 , wherein said modular actuator further comprises means for releasably coupling said modular actuator to said subsea device.
21. The modular actuator of claim 14 , wherein said self-contained hydraulic supply system is adapted to supply a pressurized fluid employed in actuating a subsea valve.
22. The modular actuator of claim 14 , wherein said modular actuator is adapted to be releasably coupled to said subsea device by an ROV.
23. A modular actuator adapted to be releasably coupled to a subsea device, comprising:
a hydraulic actuator;
at least one housing; and
a self-contained hydraulic supply system positioned within said at least one housing, said self-contained hydraulic supply system comprising:
a pump driven by an electrical motor;
at least one fluid reservoir; and
a control/vent valve.
24. The modular actuator of claim 23 , further comprising a control system positioned within said at least one housing to control delivery of a high pressure hydraulic fluid produced by said self-contained hydraulic supply system.
25. The modular actuator of claim 23 , further comprising a self-contained source of electrical power positioned within said at least one housing, wherein said self-contained source of electrical power is the primary source of electrical power for said modular actuator.
26. The modular actuator of claim 25 , wherein said self-contained source of electrical power comprises at least one battery.
27. The modular actuator of claim 23 , wherein said modular actuator further comprises means for releasably coupling said modular actuator to said subsea device.
28. The modular actuator of claim 23 , wherein said self-contained hydraulic supply system is adapted to supply a pressurized fluid employed in actuating a subsea valve.
29. A modular actuator adapted to be releasably coupled to a subsea device, comprising:
a hydraulic actuator;
at least one housing;
a self-contained hydraulic supply system positioned within said at least one housing, said self-contained hydraulic supply system comprising:
a pump driven by an electrical motor;
at least one fluid reservoir; and
a control/vent valve;
a control system positioned within said at least one housing to control delivery of a high pressure hydraulic fluid produced by said self-contained hydraulic supply system; and
a self-contained source of electrical power positioned within said at least one housing, wherein said self-contained source of electrical power is the primary source of electrical power for said modular actuator.
30. The modular actuator of claim 29 , wherein said self-contained source of electrical power comprises at least one battery.
31. The modular actuator of claim 29 , wherein said modular actuator further comprises means for releasably coupling said modular actuator to said subsea device.
32. The modular actuator of claim 29 , wherein said self-contained hydraulic supply system is adapted to supply a pressurized fluid employed in actuating a subsea valve.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
NO20045600A NO322680B1 (en) | 2004-12-22 | 2004-12-22 | System for controlling a valve |
NO20045600 | 2004-12-22 | ||
PCT/US2005/044997 WO2006068873A1 (en) | 2004-12-22 | 2005-12-13 | Modular actuator for subsea valves and equipment, and methods of using same |
Publications (1)
Publication Number | Publication Date |
---|---|
US20080264646A1 true US20080264646A1 (en) | 2008-10-30 |
Family
ID=35238021
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/721,871 Abandoned US20080264646A1 (en) | 2004-12-22 | 2005-12-13 | Modular Actuator for Subsea Valves and Equipment, and Methods of Using Same |
Country Status (6)
Country | Link |
---|---|
US (1) | US20080264646A1 (en) |
AU (1) | AU2005319491A1 (en) |
BR (1) | BRPI0519227A2 (en) |
GB (1) | GB2437011B (en) |
NO (1) | NO322680B1 (en) |
WO (1) | WO2006068873A1 (en) |
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Also Published As
Publication number | Publication date |
---|---|
AU2005319491A2 (en) | 2006-06-29 |
NO20045600L (en) | 2006-06-23 |
GB0713594D0 (en) | 2007-08-22 |
AU2005319491A1 (en) | 2006-06-29 |
NO20045600D0 (en) | 2004-12-22 |
WO2006068873A1 (en) | 2006-06-29 |
GB2437011B (en) | 2010-01-27 |
BRPI0519227A2 (en) | 2009-01-06 |
NO322680B1 (en) | 2006-11-27 |
GB2437011A (en) | 2007-10-10 |
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