Subsea Separator Vessel Integrating Valves into Machined Blocks
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Solution Overview
Problem
Current subsea separation stations are cumbersome, costly, and difficult to install due to their large size, weight, and complex structure, which includes numerous tubes and valves, leading to issues like hydrate formation and increased manufacturing and operational expenses.
Innovation Solution
A subsea separator vessel design that integrates valves into a single machined block on the top, reducing the need for a separate manifold and internal tubes, thus minimizing the overall structure's size and weight while maintaining functionality through a compact, enclosed volume for gravitational separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional manifold structure with multiple tubes and valves is used, then the separation function is achieved, but the structure becomes heavy and complex, increasing manufacturing and installation costs
Solution Approach 1:
The patent merges the manifold structure with the separator vessel by integrating valve bodies directly into the vessel walls. The first valve body is formed as an integral part of the first wall, the second valve body as an integral part of the second wall, eliminating the need for separate manifold connections and reducing structural complexity while maintaining separation functionality
Solution Approach 2:
The separator vessel walls serve multiple functions: they contain the separation chamber, provide structural support, and integrate the valve bodies directly into them. This multi-functionality reduces the number of separate components needed, simplifying the overall structure while achieving both separation and control functions
2Adaptability or versatility
If multiple tubes are used for fluid routing, then operational flexibility is achieved, but the number of dead legs increases, leading to hydrate formation and higher insulation requirements
Solution Approach 1:
The inlet and outlet conduits are integrated directly into the separator vessel walls, eliminating separate external tube connections. This merging reduces dead legs where fluid stagnation could occur, minimizing hydrate formation risks while maintaining operational flexibility through the integrated valve system
Solution Approach 2:
The patent extracts the valve bodies from separate manifold components and integrates them directly into the vessel walls. This removes the need for external tube connections and reduces the number of potential dead legs, eliminating hydrate formation risks in external conduits while preserving operational control flexibility
3Reliability
If a large separator vessel with multiple nozzles is used, then adequate separation is achieved, but the footprint and foundation requirements increase, making installation more costly
Solution Approach 1:
The patent merges the valve bodies with the separator vessel walls, integrating control functions directly into the separation chamber structure. This eliminates the need for external manifold assemblies and reduces the overall footprint while maintaining adequate separation efficiency through the integrated design
Solution Approach 2:
The separator vessel walls serve multiple functions: containing the separation chamber, providing structural support, and housing the valve bodies directly within them. This multi-functionality consolidates the overall structure, reducing the footprint and foundation requirements while maintaining separation efficiency
4Adaptability or versatility
If numerous valves and tubes are assembled with welds, then operational control is achieved, but manufacturing and installation time increase
Solution Approach 1:
The patent merges the valve bodies with the separator vessel walls through integral formation, eliminating the need for separate assembly and welding operations. This integration maintains operational control through the valve mechanisms while dramatically reducing manufacturing and installation time by eliminating multiple assembly steps
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 design significantly reduces manufacturing, installation, and operational costs by simplifying the structure, minimizing dead legs, and preventing hydrate formation, while allowing for a lighter and more efficient subsea separation process.
Implementation Method 1
a gravitational separation system such as that shown in FIG. 1 is generally used. In this figure it is noted that said separation system (10) comprises a horizontal vessel (01), of sufficient proportions to provide residence time, so as to permit separation of the phases of gas (03) and liquid (04) of the multi-phase fluid (02) by gravity
Data Source
AI summary
A subsea separator vessels includes single machined blocks integrated into a hull so as to combine all the valves used in the process of separating the multiphase fluid in the interior of the blocks. The separator vessels have by-pass valves in their blocks, if necessary to interrupt the separation process. The blocks function as a structure for the separating vessels, thereby replacing all of the metal structure necessary to support the tubes and valves of a conventional manifold, thus reducing the total area occupied by the separation station in the seabed.