Subsea Control Module for Rapid Hydraulic Actuation
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Solution Overview
Problem
In subsea well applications, the long hydraulic control lines used for operating subsea equipment lead to slowed response times and increased costs due to the need for numerous hoses and gun drilling, and can be crimped during emergency operations, hindering the rapid closure of failsafe valves.
Innovation Solution
A control module is positioned closer to hydraulically controlled components, using electric control signals to reduce the length of hydraulic actuating fluid paths and replace multiple hydraulic lines with a single high-pressure line, allowing for rapid actuation and automatic failsafe valve closure even if the electric line is severed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If long hydraulic control lines are used to operate subsea equipment, then the equipment can be controlled from a remote module, but the response time is slowed and costs increase
Solution Approach 1:
The system divides the control function into two parts: a remote electrical control module and a local hydraulic actuation system. The electrical control signals travel through long umbilicals for remote operation, while hydraulic actuating fluid is supplied from local reservoirs near the controlled components, enabling rapid local response without compromising remote controllability.
Solution Approach 2:
The patent introduces an intermediary hydraulic reservoir and distribution system positioned between the remote electrical control module and the final hydraulic actuators. This intermediary local hydraulic system acts as a buffer that decouples the slow electrical signal transmission from the rapid hydraulic actuation, allowing remote control while maintaining fast response times.
2Adaptability or versatility
If multiple dedicated hydraulic control lines are routed to each component, then each component can be independently controlled, but the cost and complexity increase due to numerous hoses and gun drilling
Solution Approach 1:
The patent implements a universal hydraulic distribution system where a single multi-port directional control valve can route hydraulic actuating fluid to multiple different components. This single valve replaces what would otherwise require multiple separate hydraulic control lines, reducing complexity while maintaining the ability to independently control each component through electrical signaling to the valve.
Solution Approach 2:
The system merges multiple hydraulic control functions into a single hydraulic distribution point with a multi-port valve. Instead of having separate hydraulic lines for each component, all hydraulic control functions are combined at one location where a single valve can direct fluid flow to any needed component, significantly reducing the number of hydraulic lines required.
3Ease of operation
If hydraulic control lines are routed over substantial lengths, then remote control is enabled, but the control fluid flow path becomes extensive causing slowed response time
Solution Approach 1:
The system segments the control fluid pathway into two distinct parts: electrical control signals that travel long distances through umbilicals for remote operation, and hydraulic actuating fluid that travels only short distances through local reservoirs and lines near the controlled components. This segmentation allows remote control capability while maintaining short, fast fluid flow paths.
4Ease of operation
If long hydraulic control lines are used, then remote module control is achieved, but the lines can be crimped during emergency shearing operations preventing rapid valve closure
Solution Approach 1:
The patent extracts the hydraulic fluid supply function from the vulnerable long control lines and places it in local reservoirs positioned near the controlled components. This extraction removes the critical hydraulic supply path from the danger zone where crimping can occur, ensuring that even if long control lines are damaged during emergency shearing, the local hydraulic system remains intact and can still actuate failsafe valves rapidly.
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
This solution significantly reduces response times, decreases costs by minimizing the number of hydraulic lines, and ensures failsafe valves can close rapidly during emergencies without fluid flow through crimped lines.
Implementation Method 1
Components of the subsea equipment are controlled via electrohydraulic controls located in a module above the subsea test tree
Implementation Method 2
A control module is positioned closer to hydraulically controlled components, using electric control signals to reduce the length of hydraulic actuating fluid paths
Data Source
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AI summary
A technique facilitates control over flow of hydraulic actuating fluid used to perform a plurality of actuating functions in a subsea well application. A control module (60) is employed for controlling a plurality of hydraulically controlled components (56) and is located along a subsea test tree (36) at a position relatively close to the hydraulically controlled components (56). The control module (60), in turn, is controlled electronically via an electric line (66) which provides electric control signals corresponding to desired control instructions regarding the hydraulically controlled components (56). By moving the control module (60) closer to the hydraulically controlled components (56) response time is greatly reduced.