Universal Thermal Actuation for Hybrid Pressure Protection Valves
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Solution Overview
Problem
Current High Integrity Pressure Protection Systems (HIPPS) are inefficient and unreliable in blocking or releasing overpressure fluids, especially in critical services like pipelines and subsea applications, due to high costs, material wastage, and failure to address critical operational torque and force issues, leading to potential accidents like the Deepwater Horizon incident.
Innovation Solution
A universal thermal actuation subsystem based on thermodynamics, integrating normal open and normal closed valves with thermal actuators, providing redundancy and fast response times without external power, capable of operating in extreme conditions and reducing system complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional HIPPS uses two overpressure rating shut off valves, two actuators and pressure transmitters with feedback control system, then overpressure protection is achieved, but the system has high cost, acts only at components level, and requires high pressure rating components that waste materials and capacity in normal pressure conditions
Solution Approach 1:
The patent combines multiple pressure protection functions (blocking and releasing) into a single integrated valve design. The valve incorporates both a blocking element and a releasing element in one body, eliminating the need for separate shut-off valves and actuators. This merging reduces component count, simplifies the system architecture, and eliminates the redundancy of having multiple pressure-sensing and actuation systems while maintaining high integrity pressure protection.
Solution Approach 2:
The single valve design performs multiple functions: it can block overpressure fluids, release overpressure fluids, and respond to pressure conditions. The valve body and actuation mechanism are designed to handle both blocking and releasing operations, making the component universal and multi-functional rather than requiring specialized components for each function.
2Reliability
If conventional HIPPS uses high pressure rating valves constructed under overpressure class at least two or three time in overpressure fluid zone, then overpressure protection is provided, but materials and capacity are wasted in normal pressure conditions
Solution Approach 1:
The valve is designed with local pressure containment features rather than requiring the entire valve body to be constructed for high pressure ratings. The blocking and releasing elements are positioned to contain pressure locally where needed, allowing the majority of the valve body to be constructed from standard pressure-rated materials. This reduces material usage and cost while maintaining the necessary pressure protection capability.
3Productivity
If partial stroke test method is used for validation, then some testing is performed, but critical points like closed positions where operation torque and forces would increase dramatically are not addressed and valve and actuation could fail
Solution Approach 1:
The valve design incorporates features that allow it to self-validate its pressure protection function during normal operation or simple testing. The blocking and releasing elements are designed to automatically respond to pressure conditions, and the single valve configuration allows for more comprehensive testing of the full stroke and critical positions without requiring complex external testing equipment or procedures.
4Reliability
If conventional releasing subsystem uses plug axial pressure surge relief valves with main three functions sensing, tracking and releasing, then pressure surge protection is provided, but the system has lower reliabilities at both component levels as well at system levels
Solution Approach 1:
The patent integrates the sensing, tracking, and releasing functions into a single valve mechanism rather than using separate components for each function. The valve body incorporates pressure sensing features, the actuation mechanism provides tracking response, and the blocking/releasing elements perform the releasing function. This merging into one integrated component simplifies the subsystem architecture and improves reliability by reducing the number of potential failure points.
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
The solution enhances system reliability, reduces execution time, and increases the lifespan of pressure protection systems, ensuring high integrity and safety by integrating thermal actuators with normal open and closed valves, achieving reliable fluid control and reducing operational costs.
Implementation Method 1
The thermal actuator is based on thermodynamics (ideal gas law with three basic elements pressure, volume and temperature (heat))
Implementation Method 2
a thermal system (pressure sources, volume vessel and heat source)
Data Source
AI summary
This invention relates to an universal thermal actuation imbedded in Hybrid High Integrity Pressure Protection System (H-HIPPS) for critical services in pipelines, refiners, power plants and subsea, the hybrid system includes a quick isolation subsystem between an overpressure zone and a normal pressure zone and a quick releasing subsystem between the overpressure zone and a lower pressure zone with quadruple redundancies, more particularly, the universal thermal actuation subsystem based on thermodynamics has a thermal system (pressure sources, volume vessel like air return reservoir and heat source) and a control chamber and shutter valves, the isolation subsystem system controlled by the actuation system has one normal open valve, the releasing subsystem system controlled by the actuation system has one normal closed valve, the actuation systems can be used for both linear and rotary actuation applications anywhere either remote locations or subsea.