Brushless Servo Actuator for Choke Valve with Manual Override
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Solution Overview
Problem
Existing pneumatic and hydraulic actuated systems for choke valves in managed pressure drilling face issues such as 'stick slip,' low efficiency, high maintenance requirements, and performance degradation in extreme conditions, while electric actuators are vulnerable to power loss.
Innovation Solution
A brushless servo motor-based actuator system with a linear actuator and override mechanism, providing high efficiency and manual operation capabilities, is used to control choke valves, offering improved performance and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pneumatic actuated systems are used for valve operation, then simplicity and low cost are achieved, but stick slip phenomenon occurs and operating efficiency is low (10-30%)
Solution Approach 1:
The patent replaces the pneumatic actuation system with an electric motor-driven system. The electric motor converts electrical energy to mechanical rotation, which drives the choke valve through a reduction gear and connecting mechanism. This substitution eliminates the stick-slip phenomenon inherent in pneumatic systems and improves operating efficiency from 10-30% to significantly higher levels, while maintaining ease of manufacture through standardized electric motor components.
2Ease of operation
If pneumatic actuated systems are used, then ease of operation is maintained, but performance degrades in extreme cold temperatures and high maintenance is required
Solution Approach 1:
The patent changes the operating parameters of the actuation system by using an electric motor that can operate across a wide temperature range without the performance degradation experienced by pneumatic systems in extreme cold. The electric motor's sealed construction and lack of compressible fluid eliminate temperature-sensitive performance issues, while the solid-state components require minimal maintenance compared to pneumatic seals and hoses.
3Power
If hydraulic actuated systems are used, then high power density and positional accuracy are achieved, but continuous power is required and operating cost is high
Solution Approach 1:
The patent employs periodic action by using an electric motor that operates only when valve position adjustment is needed, rather than requiring continuous power input like hydraulic systems. The motor can quickly accelerate to the required position and then idle without power consumption, eliminating the continuous energy demand of hydraulic pumps while maintaining high power density through the motor's electromagnetic design.
4Loss of energy
If electric actuators are used, then efficiency is improved, but vulnerability to power loss occurs
Solution Approach 1:
The patent applies beforehand cushioning by incorporating a manual override mechanism that allows operators to manually position the choke valve in the event of power loss. This backup capability ensures continuous operation and safety without compromising the high efficiency of the electric motor during normal powered operation, effectively cushioning against the vulnerability to power failure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves higher efficiency (75-80%) and reliability, with the ability to manually operate the valve in case of power loss, reducing maintenance needs and maintaining performance across varying conditions.
Implementation Method 1
a brushless servo motor
Implementation Method 2
a linear actuator including a rotatable screw and a nut coupled to the screw, the screw configured to be retained in place and rotatable so as to cause a linear translation of the nut with respect to the screw
Data Source
AI summary
Devices and methods for operating a linear actuator, optionally for use in controlling a choke valve as part of a managed pressure drilling operation. Such a device may include a motor, a transmission, a linear actuator and an override mechanism selectively engageable with the transmission to enable operation of the linear actuator independently of the motor.