Keywords: Actuation Design Subsea valves

Oil & Gas / OffshOre

Advances in Automated Subsea Valves

Significant steps in the global subsea oil and gas industry have pioneered new engineering techniques in both exploration and extraction. As the industry has moved into ultra deep water applications, this has presented a range of technical challenges with regards to the design and performance criteria for critical equipment, such as valve and actuation systems. Here, Pieter Kok reviews these technical challenges and the key considerations during the design process and testing procedure in order to provide a fully verified solution for specific applications. wear characteristics of the equipment, and hyperbaric testing to demonstrate the performance limits of the valve and actuator assembly. However, both operators and manufacturers understand that the limited accessibility of installed equipment and the uniquely harsh environment of the deep ocean require design and materials to outperform any scenario that can be conceived.

Factors affecting design and performance

Valve and actuator designs have had to evolve to cope with the challenges of operating in ultra deep water, and the subsequent hydrostatic pressure caused by the total height of the seawater column. Hydrostatic pressure produced by the weight of the seawater submits submerged equipment to pressure equal in all directions which impacts on the valve operating torques and self-seal capabilities. Where the internal pressure of the valve is atmospheric, for example, then the valve shell and sealing components may face high differential pressure. To overcome challenges of

Fasani slab gate valve which includes an integrated linear actuator operations in deeper waters, however, are far from ideal and the immense depths involved in ultra deep water projects in particular significantly restrict the repair of valves and actuators. Whilst this equipment can be retrieved by ROV, it is not the preferred solution. In these applications, valves and actuators are designed and test to operate automatically throughout their expected lifecycle, which can be between 20 and 50 years, without repair.

By Pieter Kok, Tyco Valves & Controls

roven performance is key for valve and actuator components used in subsea applications. As subsea well and pipeline equipment keeps pace with industry developments which enable seabed processing and extraction operations, so too must valve and actuator manufacturers continue to innovate and provide highly reliable, maintenance-free solutions. This approach requires high level engineered products that offer proven performance through an extensive test program including hyperbaric testing to simulate the severe conditions present at ultra deep water depths of 3000 metres. Ultra-deep water applications require the most robust and reliable equipment. For subsea projects in shallow coastal waters, asset operators can use experienced dive teams to reach damaged or faulty valve and actuator components. Maintenance
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Design standards, but not standard designs

The main standards involved in the design of subsea valves are ISO 13628 4 / API 17D: Subsea wellhead and tree equipment, and ISO 14723 / API 6D SS: Subsea Pipeline Valves. As product reliability becomes ever more important, API 17D has become the reference standard. These standards introduced life cycle endurance testing intended to evaluate the long term

Tyco Valves & Controls FCT hyperbaric chamber for simulated testing in ultra deep water projects
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Oil & Gas / OffshOre offer many challenges to engineers. Water pressures, corrosion, temperature fluctuation and variances in the viscosity of the liquid flowing through the pipeline must all be considered as par t of the overall valve and actuation system design. Specific criteria relating to special material selection, optimised torque profile and online diagnostic capability can all contribute to more effective and efficient design for ultra deep water valve equipment. Hydraulic actuator design in ultra deep water Considerations for fail safe hydraulic actuator design have the same requirements across both shallow and ultra deep water applications. For instance, the materials typically selected are protected with specific painting systems to prevent seawater corrosion. Fur thermore, both mechanism housing and spring car tridge are pressure compensated by a closed or open circuit, to allow the use of the reduced structure not becoming overstressed by the external pressure at depths of 3,000 metres. The most significant change however to fail-safe actuators for ultra deep water is in the design philosophy of the ROV override mechanism. Overriding the ROV system enables direct operation using low resisting torque which avoids compression of the spring. During the ROV stroke, the actuator spring is not compressed preventing this critical component being overstressed, and reducing the risk of mechanical fatigue. This design includes a functionality in the valve actuator coupling system allowing to perform the actuator/valve diagnosis by uncoupling the spring actuated clutch via an ROV operated tool from the valve stem adaptor without removing the actuator. Therefore the actuator can be stroked without moving the valve, thus allowing functional check of the actuator itself. After the diagnostic test actuator will automatically return to the normal position when the first operation is carried out.

operating in such extreme environments, a number of considerations need to be made in the overall design and construction of valve and actuation equipment and given the performance requirements of ultra deep water applications, a long design life based on high efficiency is key. Significant temperature changes pose a risk for valve and pipeline integrity. With deep seawater generally no more than 2C, this can be at great contrast to the temperature flow within the pipeline liquids upstream of the field can be 80C and above for high temperature wells. Despite dramatic advances in subsea engineering capabilities, the pressures and temperatures in ultra deep water operation create an environment that is highly conducive to leakage due to the immense depth and excessive temperatures involved. For actuators
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specifically, ensuring that no piping and fittings are connected to pressurised sections will dramatically reduce the risk of leakage.

Addressing design considerations up front

End user or OEM specifications can differ by region which creates a challenge when designing valve and actuation equipment to meet with these necessary approvals. Complying with such standards requires a number of considerations to be made in the design process. Since requirements and specifications are changed in relation to the water depth and operational environment, a new approach to design and development is needed to deliver a valve and actuation package which meets the specific project requirements. Depths of more than 1,000 metres

Maintaining a commitment to testing

In todays business environment it is
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Oil & Gas / OffshOre designs to suit the pressure, temperature, and medium passing through the valve its corrosiveness and state. Actuators are selected for the appropriate working conditions. From approved designs, forged valve components are received in the workshop, where the in-house team undertake manufacture, welding and assembly of the valve and actuation system. This is then tested individually and as a complete package. As a global valve and control expert designing valves and actuators for the subsea oil and gas industry, rather than a subsea company manufacturing valves, Tyco can apply insight and industry knowledge to comply with the requirements for any specific application or project. The pace of development and change within the subsea oil and gas extraction industry continues to present many challenges and opportunities. Valve and actuation product manufacturers have a responsibility to ensure the maximum safety for people and the environment. Only by working collaboratively with a strong focus on testing and measurement can the industry succeed in recovering oil and gas from ultra-deep water it really is a case of no compromises.

Functional testing for subsea valves using a hyperbaric chamber essential that continuous investments are made, particularly in research, development and product testing. There can be no compromises when it comes to testing for ultra-deep water operation. Although many of the design requirements for valves and actuators operating in the rigorous subsea environment are common, there are specific needs for assemblies working in the deepest locations. Testing and quality control minimises the risk of failure or fault and products undergo a stringent course of test procedures including hydrostatic shell testing, vacuum tests, stepwise seat tests, seat relief test, jam test, hyperbaric chamber testing and sand slurry tests. Extended lifecycle testing further exposes the components to temperature extremes, whilst at the same time dynamically cycling the products under
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About the author

Pieter Kok is Global Market Manager Upstream, Oil & Gas at Tyco Flow Control. After studying as a mechanical engineer he joined Anderson Greenwood in 1983 as a product specialist for safety relief valve and instrumentation products. Anderson Greenwood became par t of Keystone in 1987 and he continued his role as product manager. Since Keystone joined Tyco Flow Control in 1989 he has held several positions in international sales and marketing for the Anderson Greenwood brand. Prior to his current role, he held several positions as sales and product manager for Tyco Engineered Products responsible for the different Tyco Valves & Controls products in international markets.

various pressure conditions to check seal integrity and component mechanics. Though design standards require 200 dynamic cycles for an automated hydraulic valve, some oil and gas operators and subsea product suppliers have introduced a stringent requirement based on six times the number of operating cycles to ensure there are no concerns regarding the robustness or performance of a valve and actuation system.

The Tyco approach to the subsea industry

Through its FCT ball valve, Fasani slab gate valve and Biffi actuator brands, Tyco continues to invest in its engineering resources in subsea. Because there is no such thing as a standard well or valve every control package is custom-built. This approach ensures that at the specification stage, the design team adapt proven

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