Systems and methods for actuating hydraulically-actuated devices

Abstract

This disclosure includes systems and methods for actuating hydraulically-actuated devices.

Claims

1. A system comprising: one or more valve assemblies, each having: a conduit defining an inlet configured to be in fluid communication with a pressure source configured to provide a hydraulic fluid, an outlet configured to be in fluid communication with a respective hydraulically-actuated device, and a vent configured to be in fluid communication with a reservoir and/or a subsea environment; and a first and a second valves in fluid communication with the conduit wherein: the first valve is movable between a first valve first position in which the first valve permits fluid communication from the inlet to the second valve and a first valve second position in which the first valve prevents fluid communication from the inlet to the second valve; and the second valve is movable between a second valve first position in which the hydraulic fluid that flows through the second valve from the first valve is directed to the outlet and a second valve second position in which the hydraulic fluid that flows through the second valve from the first valve is directed to the vent.

2. The system of claim 1, where, for at least one of the valve assembl(ies), the second valve comprises an electrically-actuated valve.

3. The system of claim 2, where, for at least one of the valve assembl(ies), the second valve comprises a three-way valve.

4. The system of claim 1, where: for at least one of the valve assembl(ies), the respective hydraulically-actuated device comprises a respective blowout preventer of a blowout preventer stack; the system comprises one or more sensors configured to detect at least one of: loss of fluid and/or electrical communication between the blowout preventer stack and an above-sea control station; and disconnection of a lower marine riser package from the blowout preventer stack.

5. The system of claim 4, where the sensor(s) comprise a proximity sensor configured to capture data indicative of disconnection of the lower marine riser package from the blowout preventer stack, a pressure sensor configured to capture data indicative of loss of fluid communication between the blowout preventer stack and the above-sea control station, a voltage sensor configured to capture data indicative of loss of electrical communication between the blowout preventer stack and the above-sea control station, or a combination thereof.

6. The system of claim 5, where at least one of the sensor(s) is configured to capture data indicative of at least one of: temperature, pressure, and flow rate of hydraulic fluid within the system.

7. The system of claim 1, wherein at least one of the valve assembl(ies) is configured to detect a fault in the system without a need for the system to actuate the hydraulically-actuated device.

8. The system of claim 1, further comprising a processor configured to actuate at least one of the valve assembl(ies) between: a first state in which the first valve is in the first valve first position and the second valve is in the second valve first position; and a second state in which the first valve is in the first valve first position and the second valve is in the second valve second position.

9. The system of claim 1, further comprising one or more sensors configured to capture data indicative of at least one of: temperature, pressure, and flow rate of hydraulic fluid within the system.

10. The system of claim 9, wherein the processor is further configured to actuate at least one of the valve assembly/assemblies based, at least in part, on data captured by the one or more sensors.

11. A method for detecting a fault in a system configured to actuate a hydraulically-actuated device, the method comprising: actuating a first valve of a valve assembly in the system, the valve assembly including a conduit defining an inlet in fluid communication with a pressure source configured to provide a hydraulic fluid, an outlet in fluid communication with the hydraulically-actuated device, and a vent in fluid communication with a reservoir and/or a subsea environment, the first valve being actuated to an open position configured to direct the hydraulic fluid from the inlet to a second valve of the valve assembly; actuating the second valve to a position configured to direct the hydraulic fluid to the vent; supplying the hydraulic fluid from the pressure source through the first valve and the second valve; capturing data indicative of an actual system parameter; comparing the actual system parameter with a corresponding expected system parameter; detecting the fault when a condition is met; and actuating the first valve to a closed position configured to prevent fluid communication between the inlet and the second valve.

12. The method of claim 11, wherein the fault is detected without a need for the system to actuate the hydraulically-actuated device.

13. The method of claim 11, wherein the hydraulically-actuated device is a blowout preventer.

14. The method of claim 11, wherein the condition is selected from: (a) a difference between the actual system parameter and the corresponding expected system parameter exceeding a threshold; (b) a time rate of change of the actual system parameter below or above a threshold; and (c) the actual system parameter below or above the corresponding expected system parameter.

15. The method of claim 11, wherein the system further comprises at least three sensors configured to capture the data, the condition being a majority of the sensors capturing data that indicate the fault.

16. The method of claim 11, wherein the actual system parameter is pressure and/or flow rate of the hydraulic fluid.

17. The method of claim 16, wherein the fault is associated with the pressure source when the actual system parameter is below the corresponding expected system parameter.

18. The method of claim 16, wherein the fault is a leak associated with the valve assembly when the actual system parameter is a difference between a first flow rate of the hydraulic fluid at an upstream location in the system and a second flow rate of the hydraulic fluid at a downstream location in the system, the difference exceeding the corresponding expected system parameter.

19. The method of claim 18, wherein the upstream location is the inlet and the downstream location is the vent.

20. The method of claim 11, wherein the fault is associated with the first valve when the actual system parameter indicates that the first valve is not in the open position, and the corresponding expected system parameter indicates that the first valve is in the open position.

21. The method of claim 11, further comprising actuating the hydraulically-actuated device when the fault is detected.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers.

(2) FIG. 1 is a schematic of a first embodiment of the present systems.

(3) FIG. 2 depicts an embodiment of the present methods for assessing the reliability of component(s) associated with actuation of a hydraulically-actuated device.

(4) FIG. 3 is a schematic of a second embodiment of the present systems.

(5) FIG. 4 depicts an embodiment of the present methods for actuating a hydraulically-actuated device.

DETAILED DESCRIPTION

(6) Referring now to the drawings, FIG. 1 shows a first embodiment 10 of the present systems. System 10 can include a control unit 14, one or more valve assemblies 18 (e.g., one valve assembly, as shown), a hydraulically-actuated device 22, and a pressure source 26. As will be described in more detail below, system 10 can be configured to actuate hydraulically-actuated device 22, facilitate testing of component(s) (e.g., pressure source 26, valve assembly 18, and/or the like) associated with actuation of the hydraulically-actuated device, and/or the like. Hydraulically-actuated device 22 can be a BOP 30, such as, for example, a ram- or annular-type BOP. BOP 30 can be included in a BOP stack 34. In other embodiments, a hydraulically-actuated device (e.g., 22) can be any suitable device, such as, for example, an accumulator, test valve, failsafe valve, kill and/or choke line and/or valve, riser joint, hydraulic connector, and/or the like.

(7) Pressure source 26 can be configured to provide fluid to hydraulically-actuated device 22 to actuate the hydraulically-actuated device. For example, some hydraulically-actuated devices (e.g., 22) may require fluid at a flow rate of between 3 gallons per minute (gpm) and 130 gpm and a pressure of between 500 pounds per square inch gauge (psig) and 5,000 psig for effective and/or desirable operation, and a pressure source (e.g., 26) configured to actuate such a hydraulically-actuated device can be configured to output fluid at these flow rates and pressures. Pressure source 26 can comprise any suitable pressure source, such as, for example, a pump, accumulator, hydraulic power unit, subsea environment (e.g., 38), and/or the like. By way of example, a pressure source (e.g., 26) can include one or more pumps (e.g., piston, diaphragm, centrifugal, vane, gear, gerotor, screw, and/or the like pump(s)), which may be disposed subsea. Such pump(s) can be driven by electrical motors (e.g., using power supplied by one or more batteries 70, one or more auxiliary lines, and/or the like). The present systems (e.g., 10) can be used with any suitable hydraulic fluid, such as, for example, an oil-based fluid, sea water, desalinated water, treated water, water-glycol, and/or the like.

(8) Valve assembly 18 can include a conduit 42 defining an inlet 46 in fluid communication with pressure source 26 and an outlet 50 in fluid communication with hydraulically-actuated device 22 such that, for example, fluid pressurized by the pressure source can be used to actuate the hydraulically-actuated device via the conduit. Conduit 42 can include a vent 54, which can be in fluid communication with a fluid reservoir 58, such as, for example, an accumulator. In other embodiments, a vent (e.g., 54) can be in fluid communication with a subsea environment (e.g., 38). Conduit 42 can be rigid and/or flexible.

(9) Valve assembly 18 can include one or more valves, such as a first valve 62 and/or a second valve 66, each in fluid communication with conduit 42. First valve 62 can be movable between a first (e.g., open) position, in which the first valve permits fluid communication from inlet 46 to outlet 50, and a second (e.g., closed) position, in which the first valve prevents fluid communication from the inlet to the outlet.

(10) Second valve 66 can be configured to selectively direct fluid flowing within conduit 42 to outlet 50 or vent 54. For example, second valve 66 can be movable between a first (e.g., “outlet”) position, in which fluid that flows through the second valve is directed to outlet 50, and a second (e.g., “vent”) position, in which fluid that flows through the second valve is directed to vent 54. To illustrate, when second valve 66 is in the first position, the second valve can direct fluid to hydraulically-actuated device 22, to, for example, actuate the hydraulically-actuated device, and, when the second valve is in the second position, the second valve can direct fluid to vent 54, to, for example, facilitate testing of system 10 component(s) without fully actuating the hydraulically-actuated device. In some embodiments, a second valve (e.g., 66) can be movable to a third (e.g., closed) position, in which fluid communication through the second valve is prevented.

(11) Valve(s) 62 and/or 66 can be electrically-actuated; for example, the valve(s) can comprise solenoid valves. An electrically-actuated valve may offer certain advantages over a hydraulically-actuated valve. To illustrate, an electrically-actuated valve may be more reliable (e.g., via not requiring a pilot pressure signal, requiring fewer hydraulic conduits and/or connections to operate, and/or the like), have a quicker response time, be more easily monitored (e.g., via monitoring current, voltage, and/or the like supplied to the valve), and/or the like than a hydraulically-actuated valve. Nevertheless, in some embodiments, valve(s) (e.g., 62 and/or 66) can be hydraulically-actuated. Valve(s) (e.g., 62, 66, and/or the like) of the present valve assemblies (e.g., 18) can comprise any suitable valve, such as, for example, a spool valve, check valve (e.g., ball check valve, swing check valve, and/or the like), ball valve (e.g., full-bore ball valve, reduced-bore ball valve, and/or the like), and/or the like, and can comprise any suitable configuration, such as, for example, two-port two-way (2P2W), 2P3W, 2P4W, 3P4W, and/or the like.

(12) Valve assembly 18 can be actuated between a first (e.g., “actuating”) state, in which valve 62 is in the first position and valve 66 is in the first position, and a second (e.g., “testing”) state, in which valve 62 is in the first position and valve 66 is in the second position. When valve assembly 18 is in the first state, fluid from pressure source 26 can be directed to hydraulically-actuated device 22 to, for example, actuate the hydraulically-actuated device, and, when the valve assembly is in the second state, fluid from the pressure source can be directed to vent 54 to, for example, facilitate testing of system 10 component(s) without fully actuating the hydraulically-actuated device.

(13) System 10 can include one or more batteries 70 configured to supply power to system component(s), such as pressure source 26, valve assembly 18, control unit 14, and/or the like. One or more batteries 70 can comprise any suitable battery, such as, for example, a lithium-ion battery, nickel-metal hydride battery, nickel-cadmium battery, lead-acid battery, and/or the like. One or more batteries 70 can be rechargeable using, for example, power supplied via one or more auxiliary lines.

(14) System 10 can include one or more sensors 74 configured to capture data indicative of system 10 parameters such as, for example, a pressure, flow rate, temperature, and/or the like of fluid within the system (e.g., within pressure source 26, hydraulically-actuated device 22, fluid reservoir 58, conduit 42, and/or the like), the position of valve(s) (e.g., 62, 66, and/or the like), the dimension(s) (e.g., size, thickness, and/or the like) of an object (e.g., pipe) disposed within BOP 30, a position, velocity, and/or acceleration of a component (e.g., ram) of the BOP, a charge level, discharge rate, and/or the like of a battery 70, a speed of a motor and/or a pump (e.g., of pressure source 26), a torque output by the motor, a voltage and/or current supplied to the motor, and/or the like. Data captured by sensor(s) 74 can be transmitted to processor 78 (described in more detail below), an above-sea control station, and/or the like. Some systems (e.g., 10) can include a memory configured to store at least a portion of data captured by sensor(s) (e.g., 74).

(15) Sensor(s) 74 can comprise any suitable sensor such as, for example, a pressure sensor (e.g., a piezoelectric pressure sensor, strain gauge, and/or the like), flow sensor (e.g., a turbine, ultrasonic, Coriolis, and/or the like flow sensor, a flow sensor configured to determine or approximate a flow rate based, at least in part, on data indicative of pressure, and/or the like), temperature sensor (e.g., a thermocouple, resistance temperature detector, and/or the like), position sensor (e.g., a Hall effect sensor, potentiometer, and/or the like), voltage sensor, current sensor, acoustic sensor (e.g., a piezoelectric acoustic sensor, ultrasonic vibration sensor, microphone, and/or the like), and/or the like.

(16) System 10 can be configured to facilitate testing of system components without fully actuating hydraulically-actuated device 22. For example, FIG. 2 depicts an embodiment 86 of the present methods. Method 86 can be implemented, in part or in whole, by a processor (e.g., 78). At step 90, a first valve (e.g., 62) of a valve assembly (e.g., 18) can be moved to an open position while a second valve (e.g., 66) of the valve assembly is in a position configured to direct fluid to a vent (e.g., 54) (e.g., after step 90, the valve assembly is in the second state). At step 94, fluid from a pressure source (e.g., 26) can be supplied through the first and second valves and thereby be directed to the vent. By directing fluid from the pressure source to the vent, system (e.g., 10) components, such as the pressure source, first valve, and/or the like, can be actuated without fully actuating the hydraulically-actuated device.

(17) At step 98, data indicative of one or more actual system parameters can be captured (e.g., using sensor(s) 74). Such actual system parameter(s) can include any suitable parameter, such as, for example, any one or more of those described above with respect to sensor(s) 74. At step 102, the actual system parameter(s) can be compared to corresponding expected system parameter(s). Such expected system parameter(s) can include, for example, known, minimum, maximum, calculated, commanded, and/or historical value(s). At step 106, fault(s) can be detected. For example, a fault can be detected if difference(s) between the actual and expected system parameter(s) exceed a threshold (e.g., the actual and expected system parameter(s) differ by 1, 5, 10, 15, 20% or more), a time rate of change of an actual system parameter (which may itself be a system parameter) is below or exceeds a threshold, an actual system parameter is below a minimum value or exceeds a maximum value, and/or the like. Further, a fault may be detected if, for example, a majority of (e.g., two out of three) sensor(s) 74 participating in a voting scheme capture data that indicates a fault. Faults detected at step 106 can be communicated to an above-sea control station, stored in a memory, and/or the like. At least a portion of steps 94, 98, 102, and/or 106 can be performed concurrently.

(18) To illustrate, if the captured data indicates that the first valve is not in the open position (e.g., data captured by valve position sensor(s) 74, fluid flow rate and/or pressure sensor(s) 74 that are upstream and/or downstream of the first valve, and/or the like) when the first valve is expected to be in the open position, a fault associated with the first valve may be detected. To further illustrate, if the captured data indicates that a pressure and/or flow rate of fluid provided by the pressure source (e.g., data captured by fluid pressure and/or flow rate sensor(s) 74 and/or the like) is below a commanded, minimum, and/or historical value, a fault associated with the pressure source may be detected. To yet further illustrate, if the captured data indicates that a difference between a flow rate of fluid at a first location within the system (e.g., at inlet 46 of conduit 42) and a flow rate of fluid at a second location within the system (e.g., at vent 54) (e.g., data captured by fluid pressure and/or flow rate sensor(s) 74 and/or the like) exceeds a maximum value, a fault (e.g., leak) associated with the valve assembly may be detected.

(19) At step 110, the first valve can be moved to a closed position. Steps 90-110 can be repeated any suitable number of times, and such repetition can occur at any suitable interval (e.g., 2, 4, 6, 8, 10, 12, or more hours, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more days, and/or the like). In these ways and others, method 86 and similar methods can provide for testing of component(s) (e.g., pressure source 26, first valve 62, second valve 66, and/or the like) that are associated with actuation of a hydraulically-actuated device (e.g., 22), without requiring full actuation of the hydraulically-actuated device. Such testing can be used to reduce a PFD of the component(s).

(20) System 10 can include a processor 78, which can form part of a control unit 14. As shown, processor 78 and/or control unit 14 can be located subsea (e.g., coupled to other component(s) of system 10), and can be disposed within an atmospheric pressure vessel 82. Processor 78 can be configured to communicate with an above-sea control station to, for example, send and/or receive data, commands, signals, and/or the like. In some embodiments, a processor (e.g., 78) and/or control unit (e.g., 14) can be located above-sea (e.g., on an above-sea control station). As used herein, “processor” encompasses a programmable logic controller.

(21) Processor 78 can be configured to actuate valve assembly 18. For example, processor 78 can be configured to move first valve 62 and/or second valve 66 to the first position, the second position, or any position between the first and second positions. More particularly, processor 78 can be configured to actuate valve assembly 18 based, at least in part, on data captured by sensor(s) 74. For example, processor 78 can adjust the position of first valve 62 and/or second valve 66 until the position of the first and/or second valves, a fluid flow rate and/or pressure within system 10, a position of a component (e.g., a ram) of hydraulically-actuated device 22, and/or the like, as indicated in data captured by sensor(s) 74, meets a commanded or threshold value. For further example, processor 78 can actuate valve assembly 18 to actuate BOP 30 if data captured by sensor(s) 74 indicates a loss of fluid and/or electrical communication between BOP stack 34 and an above-sea control station, disconnection of a lower marine riser package from the BOP stack, and/or the like (described in more detail below with respect to system 114). In some embodiments, a processor (e.g., 78) can be configured to control additional component(s) of a system (e.g., 10), such as, for example, a pressure source (e.g., 26) (e.g., a pump and/or motor thereof), and/or the like.

(22) FIG. 3 shows a second embodiment 114 of the present systems. In this embodiment, components that are similar in structure and/or function to those discussed above may be labeled with the same reference numerals and a suffix “a.” While system 114 is depicted without a second valve 66, other embodiments that are otherwise similar to system 114 can include such a second valve (e.g., and can be capable of performing function(s) described above for system 10).

(23) Hydraulically-actuated device 22a of system 114 can comprise a BOP 30a, and the system can be configured to function as a safety and/or back-up blowout prevention system. For example, processor 78a can be configured to actuate valve assembly 18a and/or pressure source 26a to actuate BOP 30a to close the wellbore in response to a command received from an above-sea control station (e.g., via a dedicated communication channel, acoustic interface, and/or the like), a signal from a traditional autoshear, deadman, and/or the like system, and/or the like.

(24) For further example, processor 78a can be configured to actuate valve assembly 18a and/or pressure source 26a based, at least in part, on data captured by sensor(s) 74a. To illustrate, system 114 can include sensor(s) 74a configured to detect disconnection of a lower marine riser package 118 from BOP stack 34a, such as, for example, proximity sensor(s) (e.g., electromagnetic-, light-, or sound-based proximity sensor(s)), and processor 78a can be configured to actuate BOP 30a to close the wellbore based, at least in part, on data captured by the sensor(s). To further illustrate, system 114 can include one or more relays 122 and/or sensor(s) 74a configured to detect a loss of fluid and/or electrical communication between BOP stack 34a and an above-sea control station, and processor 78a can be configured to actuate BOP 30a to close the wellbore, based at least in part, on data captured by the sensor(s). The use of sensor(s) 74a and/or relay(s) 122 to detect disconnection of lower marine riser package 118 from BOP stack 34a and/or loss of fluid and/or electrical communication between the BOP stack and an above-sea control station can facilitate redundancy (e.g., two, three, or more sensors can be configured to capture data indicative of the same event), scalability (e.g., sensor(s) can be added and/or removed), and/or the like, thereby increasing fault-tolerance, reliability, and/or the like.

(25) For yet further example, FIG. 4 depicts an embodiment 126 of the present methods, which can be implemented, in part or in whole, by a processor (e.g., 78a). At step 134, data indicative of one or more actual system (e.g., 114) parameters can be captured (e.g., using sensors 74a). Such actual system parameter(s) can include any suitable parameter, such as, for example, any one or more of those described above with respect to sensor(s) 74. At steps 138 and 142, in a same or similar fashion to as described above for method 86, the actual system parameter(s) can be compared to corresponding expected system parameter(s) to detect fault(s). At step 146, if fault(s) are detected, depending on the nature of the fault(s), a valve assembly (e.g., 18a) and/or a pressure source (e.g., 26a) can be actuated in order to actuate a BOP (e.g., 30a) to close the wellbore.

(26) In a system (e.g., 114) having a plurality of valve assemblies (e.g., 18a), after a first one of the valve assemblies is actuated to actuate its respective BOP (e.g., 30a), a second one of the valve assemblies can be actuated to actuate its respective hydraulically-actuated device. For example, the second one of the valve assemblies can be actuated after a predetermined period of time elapses from actuation of the first one of the valve assemblies.

(27) The present systems (e.g., 10, 114) can include any suitable number of valve assembl(ies) (e.g., 18, 18a, and/or the like) (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more valve assemblies), each in fluid communication with any suitable number of pressure source(s) (e.g., 26, 26a, and/or the like) (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more pressure sources) and any suitable number of hydraulically-actuated device(s) (e.g., 22, 22a, and/or the like) (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more hydraulically-actuated devices).

(28) The above specification and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. As such, the various illustrative embodiments of the methods and systems are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and embodiments other than the one shown may include some or all of the features of the depicted embodiment. For example, elements may be omitted or combined as a unitary structure, and/or connections may be substituted. Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and/or functions, and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments.

(29) The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” or “step for,” respectively.