U.S. patent application number 14/838179 was filed with the patent office on 2015-12-24 for gate valve rotary actuator.
This patent application is currently assigned to CAMERON INTERNATIONAL CORPORATION. The applicant listed for this patent is Cameron International Corporation. Invention is credited to Loc Gia Hoang.
Application Number | 20150369001 14/838179 |
Document ID | / |
Family ID | 40156589 |
Filed Date | 2015-12-24 |
United States Patent
Application |
20150369001 |
Kind Code |
A1 |
Hoang; Loc Gia |
December 24, 2015 |
Gate Valve Rotary Actuator
Abstract
A subsea system includes a subsea manifold comprising a
plurality of well connections, the subsea manifold configured to be
in fluid communication with a plurality of wells through the
plurality of well connections and a plurality of valves, each
corresponding to one of the plurality of well connections, to
control fluid flow through the corresponding well connections. The
subsea system further includes a valve actuator comprising a
transmission and a motor, the valve actuator coupled to at least
one of the plurality of valves to move the valve between an open
position and a closed position and a remote controller configured
to communicate with and control the valve actuator.
Inventors: |
Hoang; Loc Gia; (Houston,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Cameron International Corporation |
Houston |
TX |
US |
|
|
Assignee: |
CAMERON INTERNATIONAL
CORPORATION
Houston
TX
|
Family ID: |
40156589 |
Appl. No.: |
14/838179 |
Filed: |
August 27, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12663414 |
Dec 7, 2009 |
9145979 |
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PCT/US2008/066311 |
Jun 9, 2008 |
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14838179 |
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60934251 |
Jun 12, 2007 |
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Current U.S.
Class: |
166/250.01 ;
166/373; 166/66.4; 166/75.11 |
Current CPC
Class: |
F16K 31/04 20130101;
E21B 34/04 20130101; F16K 3/0254 20130101; F16K 31/508 20130101;
F16K 31/445 20130101; F16K 31/047 20130101; E21B 34/00
20130101 |
International
Class: |
E21B 34/00 20060101
E21B034/00; F16K 3/02 20060101 F16K003/02; E21B 34/04 20060101
E21B034/04; F16K 31/04 20060101 F16K031/04 |
Claims
1. A subsea system, comprising: a subsea manifold comprising a
plurality of well connections, the subsea manifold configured to be
in fluid communication with a plurality of wells through the
plurality of well connections; a plurality of valves, each
corresponding to one of the plurality of well connections, to
control fluid flow through the corresponding well connections; a
valve actuator comprising a transmission and a motor, the valve
actuator coupled to at least one of the plurality of valves to move
the valve between an open position and a closed position; and a
remote controller configured to communicate with and control the
valve actuator.
2. The subsea system of claim 1, wherein: the subsea manifold
further comprises a pipeline connection; and the subsea manifold is
configured to direct fluid flow from the plurality of well
connections to the pipeline connection.
3. The subsea system of claim 2, wherein the pipeline connection is
configured to be in fluid communication with a pipeline or a
production riser.
4. The subsea system of claim 1, wherein the at least one of the
plurality of valves comprises a valve body with a closure member
configured to move between the open position and the closed
position within the valve body.
5. The subsea system of claim 4, wherein the valve actuator
comprises: a housing fixably coupled to the valve body; a sleeve
having a first end rotatably coupled to the housing and a second
end projecting out of the housing; a valve stem partially disposed
within the sleeve and extending into the valve body; a screw member
coupled to the valve stem and the sleeve so that rotation of the
sleeve causes translation of the valve stem; the transmission
coupled to the housing and engaged with the sleeve; and the motor
coupled to the transmission so that operation of the motor causes
rotation of the sleeve.
6. The subsea system of claim 4, further comprising a position
sensor configured to measure the position of the closure member
with respect to the valve body.
7. The subsea system of claim 6, wherein the remote controller is
configured to communicate with the position sensor and receive the
measured position of the closure member with respect to the valve
body from the position sensor.
8. The subsea system of claim 7, wherein the remote controller is
configured to control the valve actuator based upon the measured
position of the closure member with respect to the valve body
received from the position sensor.
9. The subsea system of claim 1, wherein the motor comprises at
least one of a hydraulic motor, an electric motor, and a pneumatic
motor.
10. The subsea system of claim 9, wherein the motor comprises an
electric motor, and wherein the remote controller is configured to
send an electric signal to the electric motor to control the valve
actuator.
11. The subsea system of claim 1, wherein the remote controller
comprises a user interface.
12. The subsea system of claim 1, further comprising a clutch
mechanism configured to selectively de-couple the valve actuator
from the at least one of the plurality of valves.
13. A method for controlling fluid flow through a subsea well, the
method comprising: receiving a control signal from a remote
controller at a valve actuator; moving a valve between an open
position and a closed position with the valve actuator based upon
the received control signal, the valve actuator comprising a
transmission and a motor; and selectively controlling fluid flow
through the subsea well based upon the position of the valve.
14. The method of claim 13, wherein the selectively controlling
fluid flow through the subsea well comprises selectively producing
fluid through a subsea manifold comprising a well connection in
fluid communication with the subsea well, a pipeline connection,
and the valve.
15. The method of claim 13, wherein the valve comprises a valve
body and a closure member such that the moving the valve between
the open position and the closed position comprises moving the
closure member within the valve body between the open position and
the closed position.
16. The method of claim 15, wherein the valve actuator comprises: a
housing fixably coupled to the valve body; a sleeve having a first
end rotatably coupled to the housing and a second end projecting
out of the housing; a valve stem partially disposed within the
sleeve and extending into the valve body; a screw member coupled to
the valve stem and the sleeve so that rotation of the sleeve causes
translation of the valve stem; the transmission coupled to the
housing and engaged with the sleeve; and the motor coupled to the
transmission so that operation of the motor causes rotation of the
sleeve.
17. The method of claim 15, further comprising measuring a position
of the closure member with respect to the valve body with a
position sensor.
18. The method of claim 17, further comprising receiving the
measured position of the closure member with respect to the valve
body from the position sensor at the remote controller.
19. The method of claim 13, wherein the remote controller comprises
a user interface.
20. A system for use with a subsea well, comprising: a valve
comprising a valve body with a closure member configured to move
between an open position and a closed position within the valve
body to selectively control fluid flow through the subsea well; a
valve actuator coupled to the valve and configured to move the
valve between the open position and the closed position, the valve
actuator comprising: a housing fixably coupled to the valve body; a
sleeve having a first end rotatably coupled to the housing and a
second end projecting out of the housing; a valve stem partially
disposed within the sleeve and extending into the valve body; a
screw member coupled to the valve stem and the sleeve so that
rotation of the sleeve causes translation of the valve stem; a
transmission coupled to the housing and engaged with the sleeve;
and a motor coupled to the transmission so that operation of the
motor causes rotation of the sleeve; and a remote controller
configured to communicate with and control the valve actuator.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND
[0003] This section is intended to introduce the reader to various
aspects of art that may be related to various aspects of the
present invention, which are described and/or claimed below. This
discussion is believed to be helpful in providing the reader with
background information to facilitate a better understanding of
various aspects of the present invention. Accordingly, it should be
understood that the following statements are to be read in this
light, and not as admissions of prior art.
[0004] The present invention relates generally to valve actuators.
More specifically, the present invention, in accordance with
certain embodiments, relates to actuators for subsea or surface
high-pressure, large diameter gate valves. As one example, the
present invention relates to a combination of a rotary actuator and
a high-efficiency mechanical device that converts the rotary motion
to linear motion so as to actuate a gate valve.
[0005] Increasing performance demands for subsea hydrocarbon
production systems have led to a demand for high-performance
control systems to operate subsea pressure control equipment, such
as valves and chokes. Traditionally, pressure control equipment
rely on hydraulic actuators for operation. Hydraulic actuators
receive pressurized hydraulic fluid from a direct hydraulic control
system or an electrohydraulic control system, for example. Direct
hydraulic control systems provide pressurized hydraulic fluid
directly from the control panel to the subsea valve actuators.
Electrohydraulic control systems utilize electrical signals
transmitted to an electrically actuated valve manifold that
controls the flow of hydraulic fluid to the hydraulic actuators of
the pressure control equipment.
[0006] The performance of both direct hydraulic and
electrohydraulic control systems is affected by a number of
factors, including the water depth in which the components operate,
the distance from the facility controlling the operation, and a
variety of other constraints. Thus, as water depth and field size
increases, the limits of hydraulic control systems, whether
hydraulic or electrohydraulic, become an increasing issue. Further,
even when the use of a hydraulic control system is technically
feasible, the cost of the system may preclude its use in a smaller
or marginal field.
[0007] In order to provide an alternative to hydraulic control
systems, full electrical control systems, including fully electric
actuators, have been developed. Instead of relying on pressurized
hydraulic fluid to actuate the pressure control components,
electrical actuators are supplied with an electric current. The
reliance on electric current can allow for improved response times,
especially over long distances and/or in deep water.
[0008] Thus, there remains a need to develop methods and apparatus
for allowing operation of subsea actuators that overcome some of
the foregoing difficulties while providing more advantageous
overall results.
SUMMARY OF THE PREFERRED EMBODIMENTS
[0009] Certain exemplary embodiments of the present invention are
directed toward methods and apparatus for actuating a gate valve
using a rotary motor. As one example, a valve actuator comprises a
screw member coupled to a valve stem and a sleeve such that
rotation of the sleeve causes translation of the valve stem. The
sleeve has a first end that is rotatably coupled to a housing that
is fixably coupled to a valve body and a second end that projects
out of the housing. The valve stem is partially disposed within the
sleeve and extends into the valve body. A transmission is coupled
to the housing and engaged with the sleeve. A motor is coupled to
the transmission so that operation of the motor causes rotation of
the sleeve.
[0010] Thus, the present invention comprises a combination of
features and advantages that enable it to overcome various problems
of prior devices. The various characteristics described above, as
well as other features, will be readily apparent to those skilled
in the art upon reading the following detailed description of
certain exemplary embodiments of the invention, and by referring to
the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] For a more detailed description of exemplary embodiments of
the present invention, reference will now be made to the
accompanying drawings, wherein:
[0012] FIG. 1 is a partial sectional view of a valve assembly
comprising a balance stem and constructed in accordance with
embodiments of the invention;
[0013] FIG. 2 is a partial sectional view of a valve assembly
comprising a self-locking transmission constructed in accordance
with embodiments of the invention;
[0014] FIG. 3 is a partial sectional view of a valve assembly
comprising a clutch constructed in accordance with embodiments of
the invention;
[0015] FIG. 4 is a partial sectional view of a valve assembly
comprising a wrap spring clutch constructed in accordance with
embodiments of the invention; and
[0016] FIG. 5 is a schematic view of a manifold including valves
constructed in accordance with embodiments of the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Referring now to FIG. 1, an exemplary valve system 10 is
illustrated. Such valve systems are employed to control fluid flow
among various oilfield components. As one example, valve system 10
can be employed to control flow with respect to a Christmas tree, a
production manifold assembly, a fluid processing assembly, a blow
out preventer, to name but a few pieces of equipment. The
illustrated valve system 10 comprises valve body 12, closure
assembly 14, and actuator system 16. Closure assembly 14 is shown
in an open position on the left half 18 of FIG. 1 and in a closed
position on the right half 20 of FIG. 1. The two halves of FIG. 1
are also shown ninety degrees opposed. Valve body 12 comprises body
22 held together by cavity closures 25 and having bore 24 extending
therethrough. Coupled to one end of body 22 is stem cover 26.
Stationary housing 28 is coupled to the opposite end of body 22.
Closure assembly 14 comprises closure member 34 and valve seat 32,
both of which are disposed within valve cavity 30 in body 22.
Balance stem 36 and actuator stem 38 are coupled to opposite ends
of closure member 34 and extend through body 22.
[0018] Actuator system 16 is coupled to stationary housing 28 and
comprises threaded stem 40, coupling 42, rotating sleeve 44,
bearings 46, threaded member 48, transmission 50, motor 52, and
stem housing 54. Threaded stem 40 is connected to actuator stem 38
by coupling 42. Threaded stem 40 is engaged with threaded member
48, which is rotationally fixed (i.e., does not rotate) relative to
rotating sleeve 44. Threaded member 48 may be a power screw or
other mechanism that translates rotational motion into linear
motion, such as a ball screw, roller screw, or other such devices
that are known in the art. Bearings 46 are retained by stationary
housing 28 and allow rotation of sleeve 44 relative to the
stationary housing and valve body 12. Transmission 50 operatively
couples motor 52 to rotating sleeve 44. Stem housing 54 is fixably
coupled to rotating sleeve 44.
[0019] Valve 10 is actuated, i.e., moved between its open position
and its closed position, by axially translating stem 38 so as to
shift the position of closure member 34. Stem 38 is axially
translated by actuation of rotating sleeve 44 and rotating threaded
member 48. The rotation of threaded member 48 causes axial
translation of threaded stem 40, which translates in unison with
stem 38, closure member 34, and balance stem 36. Valve 10 may also
be actuated by applying torque to stem housing 54, independent of
the motor 52 and transmission 50 or in conjunction therewith. As
one example, the stem housing may be actuated by a remotely
operated vehicle if the motor were to fail or needed additional
assistance, for instance.
[0020] In an automated mode, sleeve 44 is rotated by activating
motor 52 so as to provide rotational energy to transmission 50.
Transmission 50 transfers rotational energy from motor 52 to sleeve
44 so that the activation of the motor results in rotation of the
sleeve. In certain embodiments, transmission 50 is designed to
minimize the torque or speed requirements of motor 52. Motor 52 may
be a hydraulic, electric, pneumatic, or any other rotating
motor.
[0021] Valve system 10 includes one or more position sensors 55,
such as Hall-effect sensors or the like, to detect the position of
the closure member 34 with respect to the bore 24. These position
sensors 55 communicate with an automated controller or with a user
interface located at a remote position, for example. Additionally,
the valve system 10 is in communication with control circuitry that
allows for the control of the valve 10 from a remote location. In
fact, by controlling current to the motor, the position of the
closure member can be manipulated remotely.
[0022] Balance stem 36 has the same diameter as stem 38 so that
pressure forces are balanced across closure member 14. When the
pressure forces acting on closure member 14 are not balanced, the
differential pressure generates an axial force on stem 38, which
may affect the operation of actuator system 16. In certain
embodiments, valve 10 may not include balance stem 36 so as to take
advantage of the pressure imbalance.
[0023] Referring now to FIG. 2, valve system 100 is similar to
valve system 10 but does not include a balance stem 36. Valve
system 100 comprises valve body 102, closure assembly 104, and
actuator system 106. Closure assembly 104 is shown in an open
position on the left half 108 of FIG. 2 and in a closed position on
the right half 110 of FIG. 2. The two halves of FIG. 2 are also
shown ninety degrees opposed. Valve body 102 comprises body 112
having bore 114 extending therethrough. Coupled to one end of body
112 is stationary housing 118. Closure assembly 104 comprises
closure member 124 and valve seat 122, both of which are disposed
within valve cavity 120 in body 112.
[0024] Actuator system 106 is coupled to stationary housing 118 and
comprises threaded stem 130, coupling 132, rotating sleeve 134,
bearings 136, threaded member 138, transmission 140, motor 142, and
stem housing 144. Threaded stem 130 is connected to actuator stem
128 by coupling 132. Threaded stem 130 is engaged with threaded
member 138, which is rotationally fixed relative to rotating sleeve
134. Bearings 136 are retained by stationary housing 118 and allow
rotation of sleeve 134 relative to the stationary housing and valve
body 102. Transmission 140 operatively couples motor 142 to
rotating sleeve 134. Stem housing 144 is fixably coupled to
rotating sleeve 134.
[0025] As discussed above in reference to valve system 10 of FIG.
1, balance stem 36 serves to eliminate a pressure imbalance across
closure member 124. Valve system 100 does not use a balance stem so
as to take advantage of this pressure imbalance so as to bias
closure member 124 to the closed position. In order to counteract
the biasing force, transmission 140 is a self-locking transmission
that will not rotate unless motor 142 also rotates.
[0026] Because of the biasing force, motor 142 is designed to
generate sufficient power to overcome the pressure differential
across closure member 124 while moving the closure member to the
closed position. Conversely, actuator system 106 requires very
little, if any, power output from motor 142 to move closure member
124 to the open position. The low power requirement allows valve
100 to be opened by actuator system 106 being operated by a system
providing limited power, such as may be provided by a remotely
operated vehicle in an emergency situation.
[0027] FIG. 3 shows valve system 100 further comprising a clutch
mechanism 150 that is coupled to transmission 140. Clutch mechanism
150 operates to selectively de-couple motor 142 and transmission
140 from rotating sleeve 134. For example, clutch mechanism 150
would operate in a default engaged mode where motor 142 and
transmission 140 are engaged with rotating sleeve 134. To close
valve 100, such as in an emergency mode, clutch mechanism 150 would
activate so that sleeve 134 would be free to rotate in response to
the rotation of threaded member 138 as threaded stem 130 moves
axially in response to the pressure acting on closure member 124
and stem 128.
[0028] FIG. 4 shows valve system 100 further comprising wrap spring
clutch 160 that is coupled to rotating sleeve 134 and stationary
housing 118. Wrap spring clutch 160 allows rotating sleeve 134 to
rotate in one direction relative to stationary housing 118 but
prevents rotation in the opposite direction while the wrap spring
clutch is engaged. For example, wrap spring clutch 160 could be
arranged such that rotating sleeve 134 can rotate as closure member
124 is moved to the open position. Wrap spring clutch 160 would
prevent rotating sleeve 134 from rotating in the opposite
direction, effectively preventing closure member 124 from moving
away from the open position. Once wrap spring clutch 160 is
released, rotating sleeve 134 can freely rotate, thus allowing the
pressure acting on stem 128 to move the closure member 124 to the
closed position. Wrap spring clutch 150 could be remotely released
or could be designed to release in the event of loss of control so
that valve system 100 would be a fail-safe close valve.
[0029] FIG. 5 is a schematic illustration of a subsea manifold 200
including a plurality of satellite well connections 205 and a pair
of pipeline connections 210. Subsea manifold 200 receives produced
fluids through well connections 205 from multi-well templates or
satellite wells in order to control, commingle and divert the flow
to pipeline, or a production riser, through pipeline connections
210. A plurality of valve assemblies 215 controls the flow through
manifold 200 in order to isolate single wells, or groups of wells,
as needed for testing, maintenance, or other production
reasons.
[0030] As each valve assembly 215 has at least one operator 220,
providing rotary actuators, as described above, greatly reduces the
complexity of the components needed to operate manifold 200. The
minimum torque and speed requirements of the motors needed to
operate the actuators described herein allow for the use of
substantially less hydraulic or electric power than is required in
conventional systems. For example, a 6.375'' diameter--15,000 psi
gate valve could be operated with a 0.5 horsepower rotary actuator
that, in combination with the actuators described herein, can fully
open or close the valve within one minute. This rotary actuator
could be an electric, hydraulic, or pneumatic actuator, depending
on the requirements of the system in which the valve is used.
[0031] While exemplary embodiments of this invention have been
shown and described, modifications thereof can be made by one
skilled in the art without departing from the scope or teaching of
this invention. Again, the embodiments described herein are
exemplary only and are not limiting. Many variations and
modifications of the system and apparatus are possible and are
within the scope of the invention. For example, the relative
dimensions of various parts, the materials from which the various
parts are made, and other parameters can be varied, so long as the
override apparatus retain the advantages discussed herein. Further,
the actuators described herein may be suitable for being
retrofitted onto existing valves to replace conventional hydraulic,
or other types of, actuators, and therefore may be constructed
independently of the valve components. Accordingly, the scope of
protection is not limited to the embodiments described herein, but
is only limited by the claims that follow, the scope of which shall
include all equivalents of the subject matter of the claims.
* * * * *