Modular Pipeline Valve Station Layout With Rotatable Access Spools
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Solution Overview
Problem
The construction and maintenance of pipeline valve stations are costly and logistically challenging due to the need for on-site assembly and commissioning in remote, harsh environments, which increases expenses and delays, and existing modular solutions often require field verification and can interfere with pipeline operations.
Innovation Solution
A modular land pipeline valve control station assembly that allows pre-commissioning of control valves, instrumentation, and power supplies in a transportable module, enabling remote control from a central command center, with rotatable spools for accessing the pipeline for maintenance and bypassing, reducing on-site work and travel costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional on-site assembly and commissioning of valve stations is performed, then the pipeline can be constructed with functional valve stations, but construction costs and schedules increase due to remote location challenges and harsh environmental conditions
Solution Approach 1:
The valve station modules are pre-assembled, pre-wired, and pre-commissioned at a fabrication yard before being transported to the remote pipeline location. This preliminary action eliminates the need for costly on-site assembly and commissioning work in harsh environmental conditions, directly reducing construction costs and schedules while maintaining pipeline safety and functionality.
Solution Approach 2:
The valve station is divided into modular units that can be independently assembled, tested, and transported. This segmentation allows each module to be prepared separately in a controlled environment, improving construction efficiency and reducing the impact of remote location challenges on overall project productivity.
2Loss of time
If modular valve stations are used, then assembly time is reduced, but field verification and commissioning are still required which can interfere with pipeline operations
Solution Approach 1:
Commissioning activities including valve stroking, instrument calibration, and control system testing are completed at the fabrication yard before the module leaves the yard. This preliminary commissioning eliminates the need for post-installation commissioning that would interfere with pipeline operations, allowing the module to be immediately operational upon installation.
Solution Approach 2:
A temporary commissioning setup at the fabrication yard serves as an intermediary environment that allows complete testing and verification of the valve station module without affecting the actual pipeline operations. This intermediary commissioning phase resolves the conflict between needing to verify module functionality and maintaining pipeline operational continuity.
3Reliability
If on-site commissioning is performed in remote locations, then the valve station can be operational, but travel requirements and associated risks increase
Solution Approach 1:
The valve station module is commissioned and tested autonomously at the fabrication yard using on-site equipment and personnel, without requiring extensive travel to remote locations. This self-service commissioning approach eliminates the harmful effects of travel-related risks and costs while ensuring the valve station is fully operational before deployment.
Solution Approach 2:
All commissioning activities are performed in advance at the fabrication yard, eliminating the need for personnel to travel to remote pipeline locations for commissioning work. This preliminary action directly reduces travel risks and associated costs while ensuring the valve station is operational upon installation.
Data Source
AI summary
A system and method for a modular inland pipeline valve control station includes a control valve, a control enclosure, a flow instrument, and a piping spool connected to a pipeline. The modular inland pipeline valve station is transportable and controlled from a central control location. The modular inland pipeline valve station is constructed, assembled, tested, and commissioned with the center control center at a module yard prior to being transported and installed at the pipeline. The modules can be installed slightly offset to the pipeline with drop-out or curved rotatable spools to allow possible access to the pipeline for testing and inspection and for connecting a pig receiver, pig launcher or a bypass.