Subsea Multi-Valve Electric Actuator Without Hydraulic Supply
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Solution Overview
Problem
Existing hydrocarbon production manifold systems require remote operation via ROVs or hydraulic supplies, which are cumbersome and inefficient, especially for subsea operations.
Innovation Solution
A rotary-linear actuator system with a drive gear and valve actuator controller that allows for remote operation of multiple valves without hydraulic supply, featuring a drive gear that shifts between different valve operating shafts and includes sensors for precise control and override mechanisms for manual operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If hydraulic operated valves are used for remote operation, then valve control capability is achieved, but hydraulic supply infrastructure and control modules are required
Solution Approach 1:
The patent replaces the hydraulic mechanical system with an electrical system. The electric actuator uses an electric motor to drive a rotary mechanism that operates the valve, eliminating the need for hydraulic supply lines, hydraulic power units, and associated control modules. This substitution of hydraulic mechanics with electrical actuation directly resolves the contradiction by maintaining remote operation capability while removing complex hydraulic infrastructure.
Solution Approach 2:
The electric actuator is designed as a universal device that can operate multiple different valves through a single unit. The actuator includes a rotary mechanism with multiple positions that can engage with different valve stems, allowing one actuator to control multiple valves. This multi-functionality eliminates the need for separate actuators for each valve, reducing overall system complexity while maintaining full remote operation capability.
2Ease of operation
If ROV operation is used for valve control, then valve operation is achieved, but continuous ROV presence and manual intervention are required
Solution Approach 1:
The electric actuator is equipped with sensors that automatically detect valve position and system status, and a controller that autonomously controls the actuation sequence. The system can automatically position the rotary mechanism to engage the correct valve stem and execute the opening or closing operation without requiring continuous ROV presence or manual intervention. This automation transforms the system from requiring external ROV operation to self-service automatic operation, eliminating time loss associated with ROV intervention.
Solution Approach 2:
The actuator includes position sensors and controllers that provide feedback on the actuation process. The sensors detect the position of the rotary mechanism and the status of the valve, and the controller uses this feedback to automatically adjust and complete the operation. This closed-loop feedback system enables autonomous operation without continuous ROV monitoring or intervention, resolving the time loss issue by allowing unattended automatic valve control.
3Measurement precision
If multiple valves are operated individually, then each valve can be controlled precisely, but operation time and complexity increase
Solution Approach 1:
The electric actuator is designed as a universal multi-functional device that can operate multiple different valves through a single unit. The rotary mechanism includes multiple predetermined positions, each corresponding to a different valve stem. By rotating to the appropriate position, the single actuator can engage and operate any of the multiple valves in the system. This eliminates the need for multiple separate actuators and enables rapid switching between valves, significantly increasing operation speed and productivity while maintaining precise control through the sensor-feedback system.
Data Source
AI summary
The present invention relates to a subsea manifold valve actuator, with a rotary actuator rotating a drive gear and a linear actuator shifting the drive gear linearly between different positions in mesh with different driven gears, each operating a valve of a subsea manifold for oil and gas. A valve actuator controller is connected to the rotary actuator and the linear actuator. Furthermore methods for operating and installing the subsea manifold valve actuator are disclosed.