Development of Large Bore High Pressure Subsea HIPPS Valves
Transcript of Development of Large Bore High Pressure Subsea HIPPS Valves
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Development of Large Bore High Pressure Subsea HIPPS Valves
Chris Williamson Engineering Director BEL Valves
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Overview
• What is a High Integrity Pressure Protection System (HIPPS)
• Drivers for using Subsea HIPPS
• The HIPPS valve as a key project technology enabler
• Technology Stretch
• Design Parameters
• The Qualification Journey
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What HIPPS Does
• Exploits the difference
between
-Shut-in Pressure
-Flow Pressure
• Permits the downstream
flowline to be de-rated to a
lower level of pressure
• Protecting it, sensing over
pressure and shutting down
the overall system quickly
P2
P1
Final Element
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Generic Subsea HIPPS Schematic
P1 P2
Logic
PT PT PT
PT PT PT PT PT
Final Elements
Logic Solver
Sensors
By-pass
Valves Chemical Injection
Test Valve
PT PT Gate Valve
A HIPPS Final Element
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Drivers for Implementing Subsea HIPPS
• Fully pressure rated flow-lines not feasible
– manufacturing / installation limitations
• Use HIPPS to provide required risk reduction
• Commercial drivers define HIPPS Integrity level
• Safety is managed by flow-line fortification not by HIPPS
Additional riskreduction required
Target mitigated risk
Initial design
Existing mechanical protection e.g tree valve, ESDV
Final design
Ris
k
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Technology Stretch
XHP Subsea
Valve Supply
Typical Manifold
Subsea Valve
Supply
Pressure (PSI)
No
min
al S
ize (
In)
HIPPS experience
HIPPS
Future
15,000 20,000 10,000 5,000
2
8
14
20
HP Subsea
Valve Supply
Oseberg A
Shah Deniz II
Rhum
Jura
Bardolino Penguins
Juno
Kingfisher
Devenick
Shearwater
Erskine
Mallard
Zakum Gas
Jade
Mobile Bay
Kashagan
Shah Deniz
Gulfaks
Tweedsmiur
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• SIL 3 Capable (3rd party TUV Certification required)
• Valve must close on demand
• Valve must close in time required
• Valve leakage shall be minimised
• Integrity maintained over 30+ years field life
• Through conduit gate valve choice for Subsea HIPPS
• Horizontal or vertical Installation
Valve / Actuator Criteria
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Large Bore HIPPS Valve Parameters
• Through Conduit Gate Valve
• Weight 18 Tonnes
• 10” (254mm) Full Bore
• Height 3.4m
• Shut In pressure 990 Bar
• Fail-Safe-Close
• Closure Time <15 seconds
• Water depth 660m
• Early life gas flow 163m3/s
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Materials
9
• F22 forged body & Bonnet
• Fully clad alloy 625
• Alloy 718 trim
• HVOF Tungsten Carbide hard facing
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Testing Summary
• Extended PR2 (600 cycles)
• Hyperbaric (660m)
• Open compensator testing
• Primary Qualification Scope
• Closure time testing
• SIL Certification
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Extended API 6A PR2 Pressure Temperature Cycling
TEMP
100oC Max
Room
-29oCMin
TIME
450 Ambient Cycles
75 Cycles at Max Temp
75 Cycles at Min Temp
Apply Pressure
Hold Pressure For 1 Hr
Hold Pressure For 1 Hr
Release Pressure
Apply Pressure Release
Pressure Hold Pressure For 1 Hr
Hold Pressure For 1 Hr
Apply Pressure
Release Pressure
Strip Valve and Inspect
• Extended from 200 to 600 cycles
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System Closure Time Testing
• Aim, to confirm as a system required closure times could be met
– Conducted in Hyperbaric chamber to mimic the affect of hydrostatic head
• Testing confirmed 15s closure time target achievable
Actuator
Valve
PT
N2
Test HPU
LV
DT
Simulated tubing and coupler restrictions
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• Minimise hydraulic fluid swept volume
• Use of variable orifice damper
• 250mm diameter piston
• 21L swept volume to exhaust in <15 seconds, against seabed pressure
• Open & Closed Pressure Compensation
Valve Closure (Dynamic Balance)
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Valve Closure (coupled analysis)
• Accelerate / Decelerate 1.5T gate and drive train
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Status as of End of February 2015
• Valve/Actuator Qualification including PR2 - completed
• System closure time testing (inc QEV) - completed
• SIL Certification Final Report Pending
• Production valves
in manufacture
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Thank You
This presentation must not be used or reproduced without written permission from BEL Valves Ltd