Automated Wellhead Valve Actuation for Remote Manual Stem Operation
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Solution Overview
Problem
Manual operation of wellhead valves requires significant physical effort and increases the risk of operator injury, particularly when valves are stuck or overtightened, leading to potential improper or incomplete maintenance during integrity testing and greasing procedures.
Innovation Solution
An automatic valve actuation system comprising a motor-driven actuation device with extendable arms and a stem adapter that can be operatively coupled to a valve stem, allowing for remote and automated operation of manual wellhead valves, adjustable to fit various sizes and orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual valve actuation is used, then valve operation can be performed with simple equipment, but operator physical effort and injury risk increase significantly
Solution Approach 1:
The patent replaces manual mechanical actuation with an automated actuation device that uses a motor to rotate the valve stem. The device includes a mounting bracket that attaches to the valve body and a motor assembly that automatically rotates the stem through the required number of revolutions, eliminating the need for operators to manually turn handwheels or operate valves requiring significant physical effort.
Solution Approach 2:
The actuation device is designed to autonomously perform the valve actuation task without continuous human intervention. Once positioned and activated, the motor-driven system automatically completes the rotation cycle, counts revolutions, and stops when the valve reaches its target position, allowing the system to serve itself rather than requiring constant operator input.
2Device complexity
If manual valve actuation is used, then equipment cost is reduced, but operator safety and proper maintenance completion deteriorate
Solution Approach 1:
The actuation device incorporates a revolution counting mechanism that provides feedback on the number of rotations completed. This feedback system ensures the valve is actuated through the precise number of revolutions required, preventing under- or over-actuation. The system can detect when the valve has reached its target position and automatically stops, ensuring reliable and complete maintenance operations.
Solution Approach 2:
By replacing manual actuation with an automated motor-driven system, the patent eliminates human error and variability in valve operation. The automated system consistently performs the actuation with the correct force and rotation count, ensuring that maintenance tasks are completed reliably regardless of operator condition or valve resistance.
3Reliability
If automated actuation device is used, then operator safety and maintenance reliability improve, but device complexity and initial cost increase
Solution Approach 1:
The actuation device is divided into separate functional modules: a mounting bracket assembly for attachment to the valve, a motor assembly for providing rotational force, a transmission mechanism for transferring motion to the valve stem, and a revolution counting system. This segmentation allows each component to be optimized independently and facilitates easier maintenance and replacement of individual parts without replacing the entire system.
Solution Approach 2:
The actuation device is designed with universal mounting capabilities that can accommodate different valve sizes and configurations. The mounting bracket system can be adjusted to fit various valve bodies, and the motor assembly can be configured to provide the appropriate torque and rotation count for different valve types, making the system versatile across multiple applications.
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 system reduces physical effort and risk of injury for operators by enabling safe and efficient automatic opening and closing of manual wellhead valves, ensuring proper maintenance and integrity testing without manual exertion.
Implementation Method 1
an actuation device, one or more arms operatively coupled to and extending from the actuation device
Data Source
AI summary
An automatic valve actuation system includes an actuation device, one or more arms operatively coupled to and extending from the actuation device, and a stem adapter attached to a distal end of the one or more arms to operatively couple the one or more arms to a valve stem of a manually-operable valve. Operation of the actuation device rotates the one or more arms and correspondingly rotates the valve stem to open or close the manually-operable valve.