Control Valve System for Sand Blowout and Pressure Protection

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Solution Overview

Problem

Current oil and gas recovery processes face challenges in safely and efficiently blowing out solids like sand from separation devices and managing high-pressure fluid streams to prevent equipment failure and ensure worker safety.

Innovation Solution

A control valve system comprising three valve assemblies with actuators and choke ports, allowing for controlled blowout of debris and sand while maintaining safety through fail-open and fail-closed mechanisms, and a high integrity pressure protection system that monitors and responds to over-pressurization by closing valves in a series to prevent damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separation device is used to remove solids from fluid streams, then solid removal efficiency is improved, but the device becomes full of solids over time requiring blowout operations

Engineering Contradiction:

Improvesolid removal efficiencyVSAvoidtime for blowout operations

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The valve system is divided into multiple independently controllable valve assemblies (first, second, and third valve assemblies) with separate actuators. This segmentation allows selective opening and closing of different valve sections during blowout operations, enabling efficient solids removal while maintaining system reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system performs preliminary actions by opening the second valve assembly before opening the first valve assembly during blowout operations. This sequential preliminary action ensures that the blowout path is established in a controlled manner, improving both efficiency and safety.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If high pressure fluid streams are handled in oil and gas recovery processes, then productivity is improved, but safety risks increase due to potential over pressurization

Engineering Contradiction:

Improvefluid stream handling capacityVSAvoidover pressurization risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The high integrity pressure protection system performs preliminary actions by closing the primary valve and secondary valves before pressure levels become dangerous. This advance action prevents over-pressurization while maintaining high productivity during normal operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements feedback mechanisms by monitoring pressure conditions and automatically responding by closing valves when over-pressurization is detected. This feedback loop ensures safety while allowing high-pressure fluid handling for improved productivity.

Inventive Principle:

Principle #23Feedback

3Reliability

If multiple valve assemblies are used for controlled blowout operations, then operational safety is improved, but device complexity increases

Engineering Contradiction:

Improveoperational safetyVSAvoidnumber of valve assemblies

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system divides the valve control function into multiple separate valve assemblies (first, second, and third valve assemblies), each with its own actuator. This segmentation improves operational safety by allowing independent control of different sections while managing complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple valve assemblies perform universal functions of controlling fluid flow during different operational phases (normal operation, blowout, and pressure protection). This multi-functionality justifies the increased device complexity by providing enhanced safety and operational flexibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Speed

If valves are opened while exposed to pressurized fluid, then blowout speed is improved, but risk of equipment damage increases

Engineering Contradiction:

Improveblowout speedVSAvoidequipment damage risk

Core Design Contradiction:

SpeedVSObject-affected harmful factors

Solution Approach 1:

The system performs preliminary actions by opening the second valve assembly before opening the first valve assembly during blowout operations. This sequential approach allows controlled pressure equalization and debris removal while minimizing equipment damage risk, achieving safe blowout speed.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11506006B2Control valve systems and methods for blowout of sand separation device and high integrity pressure protection

Publication Date: 2022.11.22 SAFOCO INC

AI summary

A method of blowing out debris or sand from a separation device comprises opening a second valve assembly such that the second valve assembly is not exposed to pressurized fluid from the separation device when opening. A first valve assembly is opened, wherein the first valve assembly is downstream of the separation device and upstream of the second valve assembly. Debris or sand from the separation device is blown through the first and second valve assemblies, and through a choke port of a third valve assembly. A method of closing fluid flow through a high integrity pressure protection system comprises closing a primary valve in response to detecting the over pressurization of fluid in the fluid line, and closing at least one secondary valve in response to detecting the closing of the primary valve.