Development of Large Bore High Pressure Subsea HIPPS Valves

Chris Williamson Engineering Director BEL Valves

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

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

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

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

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

• 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

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

Materials

9

• F22 forged body & Bonnet

• Fully clad alloy 625

• Alloy 718 trim

• HVOF Tungsten Carbide hard facing

Testing Summary

• Extended PR2 (600 cycles)

• Hyperbaric (660m)

• Open compensator testing

• Primary Qualification Scope

• Closure time testing

• SIL Certification

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

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

• 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)

Valve Closure (coupled analysis)

• Accelerate / Decelerate 1.5T gate and drive train

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

Thank You

Chris.Williamson@belvalves.com

This presentation must not be used or reproduced without written permission from BEL Valves Ltd