A Novel Subsea Actuator to Electrify Small-Bore Valve

Orth, Alexandre; Hendrix, Gottfried; Kubacki, Markus; Silva, Pedro Joao Duarte da; Negri, Juliano Victor De

doi:10.4043/31083-ms

Cited by 8 publications

(1 citation statement)

References 6 publications

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“…Tian [27] proposed a high-dynamic-speed control strategy for subsea electrical actuators, which remarkably improved the system's dynamics. Alexandre [28] presented the development and qualification of a novel subsea electric actuator for rotary small-bore valves, which included a field-proven spring and the electric drive and controls. Liu [29] developed a redundant control system of an all-electric actuator and proposed a two-layer synchronous control strategy of an integrated condition detection module.…”

Section: Introductionmentioning

confidence: 99%

An All-Electric Gate Valve Actuator for Subsea Production Control Systems, Part A: Prototype and Test

Wang

Wen

Liu

et al. 2023

JMSE

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To bridge the gap that exists in the key equipment of the new subsea production control system, the all-electric subsea gate valve actuator, and exploit subsea oil and gas resources with high reliability and safety while saving energy, this paper proposes a novel concept prototype of an all-electric subsea gate valve actuator which has the key functions of a redundant drive, failsafe closing, auxiliary override, position indication, and low-power position holding. It satisfied the electrically-driven requirements of the subsea gate valves and achieved Safety Integrity Level 3. The prototype was developed and tested successfully. The all-electric subsea gate valve actuator is suitable for controlling subsea gate valves with various sizes and rated working pressures to minimize the power consumption for the purpose of keeping the valves open and safely closing them in the event of the electrical failure. An override and position-indicating mechanism is equipped for emergency operation and the visual indication of the status of subsea gate valves.

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Section: Introductionmentioning

confidence: 99%

An All-Electric Gate Valve Actuator for Subsea Production Control Systems, Part A: Prototype and Test

Wang

Wen

Liu

et al. 2023

JMSE

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The Digital Twin: Optimizing the System Design from the First Draft to the Cloud

Kubacki

Silva

Neto

2022

Day 1 Mon, May 02, 2022

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In order to realize the benefits of the digitalization and automation of production and processing systems, users first need to increase the level of integration, controllability and monitoring capabilities of each component applied. Therefore, digital twins turn out to be a highly important asset not only for designing greenfield applications, but also for improving brownfield machines. Up to now, digital twins were barely implemented to their full potential throughout the design, integration, and operation phases of production and processing equipment. Based on the experiences gained during the development of a subsea valve actuator, this paper highlights the importance of the digital twin to speed up the engineering and qualification of an innovative mechatronic system, reducing not only the time to market, but also increasing quality and allowing a fast reaction to the experience of the users. As a perspective, the paper shows how an accurate digital twin is a key to successful integration of a new component into complex machines. This includes the entire product lifecycle, from the conceptual work of a system and its virtual commissioning up to remote cloud-based monitoring systems. This paper finishes with an overview of some of the challenges which need to be resolved by the cooperation among different players in order to allow a wide and deep application of Digital Twin in the energy sector industry.

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Enabling All-Electric Subsea Control Systems without Compromising Safety - A Case Study Comparing Functional Safety Systems Using Springs or Batteries

Orth

Neto

Hendrix

2022

Day 4 Thu, May 05, 2022

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The electrification of subsea control and production systems is essential to achieve the low carbon emission and high productivity targets that the offshore industry is facing now. But how to electrify these controls without compromising safety? This paper provides a comparison of the design strategies using mechanical springs or electric batteries to implement safety functions in control systems, considering as a case study the development of the new subsea electric actuator for small-bore valves SVA R2 from Bosch Rexroth. Traditionally, to control process valves with safety functions, hydraulic actuators have been applied with field-proven springs to bring the valve to a specific position (open or closed, depending on the application) in case of a safety-related failure such as a loss of power supply. However, the first electric subsea actuators developed with fail-safe springs turned out to be too large, heavy, inefficient, and costly due to their complex electro-mechanic system for broad adoption by the subsea industry. Thus, new electric subsea actuators [2] were developed using electric batteries to reduce overall size, but this added new risks: now the safety control has to detect a dangerous situation by itself and actively drive the system to the safe position. But, at the OTC 2021, a new electric subsea actuator for small bore valves was presented which achieves Safety Integrity Level SIL 3 using field-proven springs as compact as a hydraulic actuator (OTC-31083-MS) [17]. Following the functional safety methodology acc. to the IEC 61508, IEC 61511 and ISO 13849, this work provides a comparison between a control architecture with mechanical springs and another with electric batteries, considering the whole product life cycle (design, manufacture, installation, commissioning, and operation). An evaluation of the failure modes and failure mechanisms of existing subsea equipment, from field data available in the OREDA@Cloud, gives a proper assessment of the risks associated with implementing the new functional safety architecture. Costs of engineering, production and operation are taken into account to find out the most technical and economically feasible solution. This case study is a reference for the design and qualification of new subsea electric actuators with functional safety requirements using mechanical springs or electric batteries. It provides technical guidelines and risk assessment for designers and users of subsea control systems such as machine builders, EPCI companies, operators, service providers or certification bodies. If electrification is a prerequisite for a low carbon future, safety is a prerequisite for the adoption of all-electric control systems. This paper shows how to electrify subsea production and process systems by using mechanical springs or electric batteries without compromising safety.

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A Novel Subsea Actuator to Electrify Small-Bore Valve

Cited by 8 publications

References 6 publications

An All-Electric Gate Valve Actuator for Subsea Production Control Systems, Part A: Prototype and Test

An All-Electric Gate Valve Actuator for Subsea Production Control Systems, Part A: Prototype and Test

The Digital Twin: Optimizing the System Design from the First Draft to the Cloud

Enabling All-Electric Subsea Control Systems without Compromising Safety - A Case Study Comparing Functional Safety Systems Using Springs or Batteries

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