Integrated Subsea Function Block With HIP Internal Flow Channels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current subsea equipment manufacturing processes, particularly those involving forging and machining, face challenges in producing complex structures due to difficulties in tool access, leading to larger-than-needed components, increased costs, and prolonged manufacturing, assembly, and transportation times, exacerbated by the need for strict international standards and high-capacity logistics.
Innovation Solution
The integration of valve blocks, hydraulic components, fluid transport channels, and other functions into a single metallic body using the hot isostatic pressing (HIP) powder metallurgy process, allowing for complex geometries and reduced component count, thereby simplifying manufacturing and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional forging and machining processes are used to manufacture subsea equipment, then the equipment can withstand subsea environmental severity, but the equipment becomes extremely large and heavy (weighing up to hundreds of tons)
Solution Approach 1:
The patent combines multiple separate subsea equipment components (separators, pumps, valves, manifolds) into a single integrated metallic block. This merging reduces the overall weight and volume while maintaining the reliability and robustness required for subsea environmental conditions through careful material selection and integrated design
Solution Approach 2:
The metallic block performs multiple functions simultaneously - fluid separation, pumping, valve control, and manifold distribution - all within a single component. This multi-functionality eliminates the need for multiple separate heavy components while maintaining system reliability through integrated design
2Reliability
If conservative design standards are applied to ensure high reliability in subsea environments, then the equipment becomes robust, but the metallic structures become extremely large
Solution Approach 1:
By merging multiple functional components into one integrated metallic block, the patent reduces the total volume occupied by separate components while maintaining conservative design standards for reliability. The integrated design eliminates gaps and interfaces between separate components, optimizing space utilization
Solution Approach 2:
The patent utilizes complex three-dimensional internal geometries and curved cavities within the metallic block that cannot be achieved by traditional forging. This allows optimal arrangement of functional elements in 3D space, reducing overall volume while maintaining reliability requirements
3Ease of manufacture
If traditional forging and machining processes are used, then manufacturing is feasible with standard tools, but complex structures such as overlapping curved cavities cannot be manufactured
Solution Approach 1:
The patent employs additive manufacturing which fundamentally changes the manufacturing parameters and processes. Instead of subtractive machining from solid blocks, the technology builds complex geometries layer by layer, enabling the creation of overlapping curved cavities and intricate internal structures that are impossible with traditional forging and machining
Solution Approach 2:
The patent replaces traditional mechanical manufacturing processes (forging, machining with lathes and milling cutters) with additive manufacturing technology. This substitution enables direct fabrication of complex geometries without requiring multiple tool access operations, tipping of blocks, or post-machining operations
4Ease of operation
If multiple separate components are used in subsea systems, then manufacturing and assembly are straightforward, but significant time and resources are consumed during manufacturing, assembling and testing stages
Solution Approach 1:
By integrating multiple components into a single metallic block, the patent dramatically reduces the number of manufacturing, assembly, and testing operations required. The integrated design eliminates the need for assembling multiple separate components and reduces testing complexity, thereby reducing time and resource consumption despite the complexity of the final structure
5Device complexity
If multiple separate components are used, then component management is simplified, but heavy and large equipment requires very high capacity transportation
Solution Approach 1:
The patent merges multiple separate heavy components into a single integrated metallic block. While this increases the complexity of the individual component, it optimizes transportation by consolidating what would have been multiple heavy items into one unit, potentially improving logistics efficiency through better utilization of transportation capacity
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 approach results in reduced weight, fewer components, shorter manufacturing times, lower costs, and increased reliability by enabling the production of complex parts with internal curves within a single component, addressing the inefficiencies of traditional methods.
Implementation Method 1
said metallic body is produced by the powder metallurgy process of hot isostatic pressing
Data Source
AI summary
An integrated function metallic block is capable of integrating into a single metal block the functions of valve blocks, block of hydraulic components of the pumping system, channels for transporting produced and separated fluids, flanges for choke connections and sensors, connection fittings and other components capable of being manufactured mutually within a single metallic block. The integrated function block is composed of complex geometry circuits having curves, slants and connections with other channels occurring within the block mass, and is preferably manufactured through the powder metallurgy process of hot isostatic pressing to obtain complex geometries having the lowest possible weight.