The present invention relates generally to the field of subsea drilling, processing and production equipment, and more particularly to an improved subsea actuation system for such equipment.
In subsea oil and gas exploration, the drilling system or wellhead may be located many thousands of feet below the sea surface. Specialized equipment is therefore used to drill, produce and process oil and gas on the sea floor, such as subsea trees, processing systems, separators, high integrity pipeline protection systems, drills, manifolds, tie-in systems and production and distribution systems. Such equipment is commonly controlled by a number of types of valves, including blow-out preventers to stop the unintended discharge of hydrocarbons into the sea.
With existing systems, such valves are typically operated hydraulically by providing pressurized hydraulic fluid from a surface vessel down to the wellhead. Large hydraulic power lines from vessels or rigs on the ocean surface feed the ocean floor drilling, production and processing equipment, and the many subsystems having valves and actuators. However, such lines are expensive to install and maintain and in some cases may not be feasible, such as at depths over 10,000 feet or under the arctic circle ice caps.
Accordingly, it would be desirable to provide an actuator that would not require such an umbilical connection from the surface and that would still operate with the desired force and functionality.
With parenthetical reference to corresponding parts, portions or surfaces of the disclosed embodiment, merely for the purposes of illustration and not by way of limitation, the present invention provides a subsea drilling, production or processing actuation system comprising a variable speed electric motor (10) adapted to be supplied with a current, a reversible hydraulic pump (8, 28) driven by the motor, a hydraulic piston assembly (92, 101, 111, 121, 131) connected to the pump and comprising a first chamber (2), a second chamber (3) and a piston (4) separating the first and second chambers and configured to actuate a valve (91) in a subsea system, a fluid reservoir (14) connected to the pump and the hydraulic piston assembly, the pump, hydraulic piston assembly and reservoir connected in a substantially closed hydraulic system, and a pressure compensator (13, 65) configured to normalize pressure differences between outside the hydraulic system and inside the hydraulic system.
The subsea system may further comprise a failsafe mechanism (98). The fail-safe mechanism may comprise a spring element (36) biasing the piston in a first direction. The fail-safe mechanism may comprise a fail-safe valve (35) between the first chamber and the second chamber or between the second chamber and the reservoir and the fail-safe valve may be arranged to open in the event of a power failure allowing equalization of fluid pressure in the first and second chamber on each side of the piston. The fail-safe mechanism may comprise a two-stage actuator.
The subsea system may further comprise a filter between the pump and the hydraulic piston assembly.
The electric motor may comprise a brushless DC motor, or may be selected from a group consisting of a stepper motor, brush motor and induction motor. The hydraulic pump may be selected from a group consisting of a fixed displacement pump, a variable displacement pump, a two-port pump, and a three-port pump. The pump may comprise a two-port pump (8) or a three-port pump (28). The piston may comprise a first surface area exposed to the first chamber and a second surface area exposed to the second chamber. The first surface area (4c) may be substantially equal to the second surface area (4b). The first surface area (4a) may be substantially different from the second surface area (4b).
The hydraulic piston assembly may comprise a cylinder (1) having an first end wall (1b) with the piston disposed in the cylinder for sealed sliding movement therealong, and a first actuator rod (5) connected to the piston for movement therewith and having a portion sealingly penetrating the first end wall. The cylinder may have a second end wall (1a) and the hydraulic piston assembly may comprise a second actuator rod (5a) connected to the piston for movement therewith and having a portion sealingly penetrating the second end wall.
The valve may comprise a stop valve in a subsea blow-out preventor, and the stop valve may comprise a shearing ram. The valve may comprise a control valve in a subsea production or processing system.
The pressure compensator may comprise a membrane (15) in the fluid reservoir (13). The pressure compensator may comprise a piston (67) in a cylindrical housing (66).
The valve may be in an assembly selected from a group consisting of a subsea blow-out preventer, a subsea production tree or wellhead system, a subsea processing or separation system, a subsea tie-in system, a subsea chock, a subsea flow module or a subsea distribution system. The subsea system may further comprise blocking valves operatively arranged to selectively isolate the pump from the first and second chambers. The subsea system may further comprise a position sensor (40) configured to sense the position of the piston. The subsea system may further comprise a pressure sensor (41, 42) configured to sense pressure in the first or second chamber.
At the outset, it should be clearly understood that like reference numerals are intended to identify the same structural elements, portions or surfaces consistently throughout the several drawing figures, as such elements, portions or surfaces may be further described or explained by the entire written specification, of which this detailed description is an integral part. Unless otherwise indicated, the drawings are intended to be read (e.g., cross-hatching, arrangement of parts, proportion, degree, etc.) together with the specification, and are to be considered a portion of the entire written description of this invention. As used in the following description, the terms “horizontal”, “vertical”, “left”, “right”, “up” and “down”, as well as adjectival and adverbial derivatives thereof (e.g., “horizontally”, “rightwardly”, “upwardly”, etc.), simply refer to the orientation of the illustrated structure as the particular drawing figure faces the reader. Similarly, the terms “inwardly” and “outwardly” generally refer to the orientation of a surface relative to its axis of elongation, or axis of rotation, as appropriate.
Referring now to the drawings, and more particularly to
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Piston 4 will extend or move to the right when bidirectional motor 10 is rotated in a first direction, thereby rotating bidirectional pump 8 (namely driven gear 55) in first direction 46 and drawing fluid through port 8b from line 7 and chamber 3. Pilot operated check valve 11 is opened by the pressure built up in line 20 due to the output of pump 8 into line 6, which allows additional drawing of fluid from line 12 and reservoir 14. Bidirectional pump 8 also outputs fluid through port 8a into line 6, closing check valve 9 and thereby isolating line 6 from reservoir 14. The fluid in line 6 flows into chamber 2 of assembly 101, thereby creating a differential pressure on piston 4 and causing it to extend rod 5 to the right.
Piston 4 will retract rod 5 or move to the left when bidirectional motor 10 is rotated in the other direction, thereby rotating bidirectional pump 8 in direction 45 and drawing fluid through port 8a from line 6 and chamber 2. Pilot operated check valve 9 is opened by the pressure built up in line 19 due to the output of pump 8 into line 7, which allows additional fluid from line 6 to flow into system pressure compensated reservoir 14. Bidirectional pump 8 also outputs fluid from port 8b into line 7, closing check valve 11 and thereby isolating line 7 from reservoir 14. The fluid in line 7 flows into chamber 3 of assembly 101, thereby creating a differential pressure on piston 4 and causing it to retract rod 5.
The function of this anti-cavitation configuration is to address the volumetric differences between opposed chambers 2 and 3. For example, when piston 4 moves leftwardly within cylinder 1, the volume of fluid removed from collapsing left chamber 2 will be greater than the volume of fluid supplied to expanding right chamber 3.
Controller 95 controls the current to motor 10 at the appropriate magnitude and direction. The position of rod 5 is monitored via position transducer 40, and the position signals are then fed back to motor controller 95. In addition or alternatively, the pressure in lines 6 and 7 to chambers 2 and 3 are monitored with pressure transducers 41 and 42, respectively, and the pressure signals are fed back to motor controller 95. Variable speed bidirectional motor 10 and pump 8 control the speed and force of piston 4, and in turn rod 5, by changing the flow and pressure acting on piston 4. This is accomplished by looking at the feedback of position transducer 40 and/or pressure transducers 41 and 42 and then closing the control loop by adjusting the motor 10 speed and direction accordingly. While position sensor 40 is shown as a magnetostrictive linear position sensor, other position sensor may be used. For example, an LVDT position sensor may be used as an alternative.
Another embodiment 110 is shown in
Piston 4 will move to extend rod 5 when bidirectional motor 10 is rotated in a first direction, thereby rotating bidirectional pump 8 in first direction 45 and drawing fluid through port 8b from line 7 and chamber 3. Bidirectional pump 8 also outputs fluid into line 6 and tank 14. Since chamber 2 is always connected to tank 14, springs 36 force piston 4 to the right to extend rod 5.
Piston 4 will move left to retract rod 5 when bidirectional motor 10 is rotated the other direction, thereby rotating bidirectional pump 8 in other direction 46 and drawing fluid through port 8a from line 6. Bidirectional pump 8 also outputs fluid into line 7 and chamber 3. Since chamber 2 is always connected to reservoir 14, the differential piston force between the pressure from chamber 3 and springs 36 causes piston 4 to move to the left and retract rod 5.
Again, variable speed bidirectional motor 10 and pump 8 control the speed and force of piston 4 by changing the flow and pressure acting on piston 4 using feedback from position transducer 40 and/or pressure transducers 41 and 42 and then closing the control loop by adjusting the speed and direction of motor 10 accordingly.
When valve 35 is de-energized, such as in an emergency power loss, the spring of solenoid valve 35 will return it to an open position. In this state, chamber 3 is connected through line 21 to chamber 2 and to reservoir 14, thereby equalizing pressure in chambers 2 and 3. Since the fluid pressure is now equalized on each side of piston 4, springs 36 will extend rod 5, and valve 91 will close as fluid is transferred from chamber 3. Thus, regardless of pump 8 output, springs 36 will extend rod 5 and close valve 91. If desired, the system could be similarly arranged to provide a failsafe in the piston retracted position.
Another embodiment 120 is shown in
Piston 4 will move right to extend rod 5b and retract rod 5a when motor 10 is rotated in a first direction, thereby rotating bidirectional pump 8 in first direction 45 and drawing fluid through port 8b from line 7 and chamber 3. Pump 8 also outputs fluid into line 6 and chamber 2, creating a differential pressure on piston 4 and causing it to extend rod 5b and retract rod 5a.
Piston 4 will move to the left to retract rod 5b and extend rod 5a when bidirectional motor 10 is rotated the other direction, thereby rotating bidirectional pump 8 in direction 46 and drawing fluid through port 8a from line 6 and chamber 2. Bidirectional pump 8 also outputs fluid into line 7 and chamber 3, creating a differential pressure on piston 4 and causing it to retract rod 5b and extend rod 5a.
Again, variable speed bidirectional motor 10 and pump 8 control the speed and force of piston 4 by changing the flow and pressure acting on piston 4 using feedback from position transducer 40 and/or pressure transducers 41 and 42 and then closing the control loop by adjusting the motor 10 speed and direction accordingly.
Another embodiment 130 is shown in
Piston 4 will move right to extend rod 5 when bidirectional motor 10 is rotated in a first direction, thereby rotating bidirectional pump 28 in first direction 45 and drawing fluid through port 28b from line 7 and chamber 3 and through port 28c from line 18 and reservoir 14. Bidirectional pump 28 also outputs fluid from port 28a into line 6, closing check valve 9 and thereby isolating line 6 from reservoir 14. The fluid in line 6 flows into chamber 2, creating a differential pressure on piston 4 and causing it to extend rod 5.
Piston 4 will move left to retract rod 5 when bidirectional motor 10 is rotated the other direction, thereby rotating bidirectional pump 28 in the other direction 46 and drawing fluid through port 28a from line 6 and chamber 2. Bidirectional pump 28 outputs fluid from port 28c into lines 18 and 12 and reservoir 14 and also outputs fluid from port 28b into line 7, closing check valve 11 and thereby isolating line 7 from reservoir 14. The fluid in line 7 flows into chamber 3, creating a differential pressure on piston 4 and causing it to retract rod 5.
Again, variable speed bidirectional motor 10 and pump 8 control the speed and force of piston 4 by changing the flow 47 or 48 and pressure acting on piston 4 using feedback from position transducer 40 and/or pressure transducers 41 and 42 and then closing the control loop by adjusting the motor 10 speed and direction accordingly.
Check valves 9 and 11 will open to compensate for system fluid changes caused by actuator leakage to the outside environment or system fluid volume changes due to significant thermal changes. Although not shown, a filter unit may be installed in the fluid lines between pump 8 and chambers 2 and 3.
Actuation system 100 provides a number of benefits. Unexpectedly, system 100 provides actuating forces that are high enough to meet the rigorous demands of a subsea environment and subsea systems that require stringent standards and levels of functionality because of the dangers of an uncontrolled release of oil and gas. System 100 allows for variable speed actuation and full control of the location of the actuator within its range of motion. System 100 operates independently of a hydraulic system linked to the ocean surface and is a closed system with self-contained hydraulic supply and return porting and limited fluid contamination and leakage concerns. Power is not required when the system is not in use, which improves efficiency. System 100 also allows for fail safe features which have minimal impact on cost, weight or reliability.
The present invention contemplates that many changes and modifications may be made. Therefore, while an embodiment of the improved subsea actuation system has been shown and described, and a number of alternatives discussed, persons skilled in this art will readily appreciate that various additional changes and modifications may be made without departing from the spirit of the invention, as defined and differentiated by the following claims.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/US12/27852 | 3/6/2012 | WO | 00 | 8/28/2013 |
Number | Date | Country | |
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61449740 | Mar 2011 | US |