4. SUBSEA COMPLETION EQUIPMENT
4.1 SpoolTree Assembly
4.1.5 Injection Valve Block Assembly
The injection valve block assembly is a single block containing one 5”-10,000 psi and one 2-1/16”-10,000 psi hydraulically actuated gate valves. They function as the injection wing valve and annulus crossover valve designated as IWV and XOV, respectively on the tree panels. The valves use the standard Cameron FLS cavity design and incorporate CM actuators that provide “fail closed” capabilities. The springs used to augment stem-assisted closing of the valve are designed to be sufficient for water depths to 3,280'. All actuator spring chambers have been filled with HW525 control fluid and plumbed to a transfer barrier accumulator. ROV interface and manual override requirements are listed in Section 6.
The block allows for mounting the injection pressure sensor and the ¾”
chemical injection valve.
The 5” IWV on the injection valve block as well as the 5” IMV on the spool body are designated underwater safety valves (USV). See TC-002120-01 Operation and Maintenance Manual.
For Design and Operation Parameters of the 5” and 2” Valves and Actuators – See SK-144073-59 and SK-144073-60.
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Description: INJECTION WING VALVE BLOCK ASSEMBLY Part No.: 2054403-14-02
P/N Revision: C01
Drawing No.: SK-097609-13
ITEM QTY. PART NO. DESCRIPTION
0 1 2148860-59 17D PRODUCT DOCUMENTATION PACKAGE, 0 1 2148860-60 17D PRODUCT DOCUMENTATION PACKAGE, 0 1 610470-65 PRODUCT DOCUMENTATION PACKAGE FOR 1 1 2054404-14-02 INJECTION WING VALVE BLOCK ASSY:
2 1 2096051-06 ASSY, 5-1/8 10,000 CM ACTUATOR VE 3 1 2013400-54 NAMEPLATE FOR SUBSEA GATE VALVE, 4 6 705786 SCR # 4 X 0.250 18-8 DR RND HD TYPE U 5 20 713837 GREASE, 0 TO 350 DEGREES (1 #CAN) 6 1 2096105-11 ASSY, 2-1/16 5,000 & 10,000 CM
7 1 2013400-56-01 NAMEPLATE FOR GATE VALVES, API 6A
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4.1.6 “CM” Actuators (Injection/Annulus)
Subsea actuators are designed to provide ‘fail closed’ operation of the relevant gate valve and are controlled by hydraulic supply. For ease of assembly, handling, and maintenance, actuators are designed as separate units that can be detached from their respective valve assembly without having to fully dismantle the actuator, break the valve bonnet/body connection, or disturb the stem
packing.
Note: 1. Actuators may only be assembled to their respective valve assembly after installation of the gate, stem, and bonnet.
2. Prior to installation of the actuator assembly, piston stroke is set by an adjusting ring installed on the valve (external to the bonnet).
Two ports are provided in the actuator cylinder for OPEN and CLOSE hydraulic connectors. The ports also facilitate venting of air from the system and enable flushing to the required cleanliness standard. All units are flushed to NAS 1638 Class 6 cleanliness standard prior to delivery.
Note: When actuators are cycled (OPEN/CLOSE), volumetric changes take place in the spring chamber (the volume in the spring chamber reduces on the opening stroke, and increases on the closing stroke). These changes are compensated for by the inclusion of a transfer barrier accumulator in the hydraulic circuit.
The actuator assemblies fitted to the valve blocks are all single acting compact actuators of the rising stem type, with linear override and position indicator.
They provide overall control of respective gate valves. Connection to the gate valve is by means of an internally threaded lock ring engaging a corresponding thread on the outer diameter of the bonnet with the actuator rising stem being threaded onto the valve stem.
Contained within the spring housing is the spring and the spring plate. They are held in the housing by the retainer ring which is secured to the spring housing by a lock ring. An o-ring provides sealing between the retainer ring and spring housing preventing ingress of seawater into the spring housing. The piston is fitted through the cylinder (which is seated in the main bore of the spring
housing) and carries the rising stem. Sealing between the rising stem and piston is by means of three seal rings, while sealing between piston and cylinder is by means of the piston seal assembly. A scraper ring is also fitted into a groove in the piston and is used to prevent ingress of debris into the actuator internals.
Note: The scraper ring prevents debris reaching the seals, thus preventing damage to the seals.
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Fitted at the outboard end of the actuator is a stem housing. The stem housing is retained by a clamp ring, which is bolted to the retainer ring. Also at the
outboard end is an indicator assembly. Housed within the stem housing and fitted to the outboard end of the rising stem is an indicator inner ring, which is secured in position by a set screw. Installed around the outside of the stem housing an indicator ring is secured by four set screws (fitted through the indicator outer ring and stem housing), to the indicator inner ring.
The indicator assembly provides a positive indication of valve position and is controlled by the piston stroke. The length of piston stroke is adjustable by means of an adjusting ring installed on the bonnet of the gate valve.
Note: The piston stroke is correctly set during manufacturing.
In the event of a control systems failure, the actuator can be overridden by means of a special hydraulic tool being installed onto the stem housing at the front end of the actuator, attached by ROV. The hydraulic tool is then used to exert a force on the end of the rising stem, compressing the spring and opening the valve. If required the valve may be locked in the open position by leaving the tool in place with the hydraulic pressure locked in.
Linear ROV override of the injection and annulus valves is accommodated by a bayonet style interface.
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Description: 5” CM ACTUATOR ASSEMBLY Part No.: 2096051-06
P/N Revision: B01
Drawing No.: SK-096783-06
ITEM QTY. PART NO. DESCRIPTION
1 1 2096058-07 SPRING HOUSING 2 2 2096059-01 LOCKRING
3 1 2096060-01 RETAINER RING
4 1 2096061-11 PISTON (JIC HYDRAULIC PORTS) 5 1 2096062-01-01 CLAMP RING
6 1 2096063-01-01 CYLINDER 7 1 2096064-01 SPRING PLATE
8 1 2054158-27 STEM HOUSING W/LINEAR OVERRIDE 9 1 2062995-04 RISING STEM ASSY. 5.1/8" 10,000 10 1 2054160-01 INDICATER RING - INNER
11 1 2054161-01 INDICATOR RING - OUTER 12 1 2096066-01 SPLIT RETAINING RING
13 1 2027135-16 SPRING COMPRESSION 5" 25 1 2734300-37-01 PISTON SEAL RING, HALLITE 53, 220MM 26 1 702645-45-81 O-RG .275W X 14.475ID 90D NITRILE 28 3 501133-04-05 PLUG, TUBING-HEX 3/8 TUBE SST
29 1 2013400-32 NAMEPLATE F/GV ACTUATORS, ALT:255124-05 30 4 702525-10 SCR # 4 X 0.188 STL DR RND HD TYPE U 32 2 042000-02-23 BACK-UP RING, SIZE 223 1.647 ID X 33 2 200226 PIN, DOWEL- .250 DIA X 1.000 LG 34 1 2205671-01 CONTROL LINE ADAPTOR, JIC 37 DEG 35 1 702645-38-21 O-RG .210W X 12.975ID 90D NITRILE 36 1 2096067-01 END PLATE, SPRING HOUSING 37 1 2730878 PLUG, MALE HEAD N0.8 JIC 37 DEG, 38 1 M584842 PLUG,PIPE,SOCKET HD,1/4,
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Description: 2” CM ACTUATOR ASSEMBLY Part No.: 2096105-11
P/N Revision: B01
Drawing No.: SK-096799-09
ITEM QTY. PART NO. DESCRIPTION
1 1 2096107-03 SPRING HOUSING
2 2 2054178-04 LOCKRING 2 1/16"-10K 'CM' ACTUATOR 3 1 2096108-01 RETAINER RING
4 1 2054180-05 PISTON-LINEAR OVERRIDE.
5 1 2096416-03 CYLINDER.
6 1 2054182-01 SPRING PLATE
7 1 2054199-08 RISING STEM ASSY. 2.1/16" 5K & 10K 8 1 2054184-01 INDICATOR RING - INNER
9 1 2054161-01 INDICATOR RING - OUTER 10 1 2054185-01 SPLIT RETAINING RING 11 1 2027135-17 SPRING - COMPRESSION
22 1 2714169 PISTON SEAL ASSY.115MM NOM OD ALPHA 23 1 702645-36-91 O-RG .210W X 07.975ID 90D NITRILE
24 1 2205671-03 CONTROL LINE ADAPTOR, 9/16"-18UNF 25 4 501133-04-05 PLUG, TUBING-HEX 3/8 TUBE SST
26 1 2013400-32 NAMEPLATE F/GV ACTUATORS, ALT:255124-05 27 2 042000-01-17 BACK-UP RING, SIZE 117 .799 ID X
28 2 200226 PIN, DOWEL- .250 DIA X 1.000 LG 29 1 2096011-02 SPRING HOUSING END PLATE 30 1 702645-36-51 O RING, SIZE AS-568-365 6.975 ID X 31 1 2054158-28 STEM HOUSING W/LINEAR OVERRIDE 32 1 191882-05 BUSH GUIDE
33 1 2748500-01 O-RING, SIZE AS-568-906 .468 ID X
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4.1.7 “FLS” Gate Valves (Injection/Annulus)
The valves that control the injection and annulus flow are Cameron’s FLS model gate valves. The valve design features are described below to give a detailed picture of these components that are critically important in subsea trees.
The FLS model is the latest refinement of the Cameron “F”-Series of valves which have been supplied for production and drilling service since 1958.
Metal to Metal Sealing
Sealing at gate to seat and seat to body is metal to metal. Seal surfaces on both sides of the seats and gate are lapped to a mirror finish and are verified to be flat within less than 4 helium light bands to ensure gas tight sealing. Lubricant is used to limit wear, friction, and intrusion of contaminants into the valve cavity, not as an aid to sealing. One-piece floating seats and a floating slab gate
provide reliable performance through simplicity of operation and a minimum of sealing interfaces. Cavity clearances are carefully controlled to limit the amount of float needed, and modified acme threads at the gate-to-stem connection provide sufficient freedom of movement in all directions to effect a positive downstream seal.
Improved Seat Seal Design
In addition to the lapped metal to metal seal between the seats and valve body, the “FLS” gate valve incorporates two V-type lip seals on the body sealing face of each seat. These OD and ID seals are each constructed of a pressure
energized non-elastomeric lip seal that is spring loaded by an Elgiloy finger spring. Material of the lip seal is carbon filled PEEK or virgin PTFE, depending on the service and application.
The OD and ID lip seals perform several functions in the “FLS” valve:
Contaminants and debris are excluded from the metal sealing surfaces of the seat and body between the two seals. The spring loaded feature of the seals maintains contact between the gate and seats, wiping the seal surfaces and protecting them from damage due to sand or other contaminants. Body cavity clearance is effectively reduced to zero, while the downstream sealing function of the slab gate design is retained. Sealing integrity is enhanced at very low differential pressures, where low bearing stresses limit the effectiveness of the metal-to-metal seal.
The “FLS” seat and seal design was first developed for drilling service, to eliminate damage and erosion of the body seal faces caused by sand, abrasives, and heavy drilling mud.
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Bi-Directional Sealing
The “FLS” is a truly symmetric bi-directional design, without a “preferred direction” of operation in this configuration. The seal diameters and bearing areas of the “FLS” seats are designed to prevent trapping of pressure inside the valve cavity, so that the valve can be used with a failsafe actuator with
well-pressure-assisted closing without a lower stem or internal porting. Testing has been performed to verify that no pressure locking or starvation occurs with the “FLS” in this application.
Stem Packing
Stem seal is a non-elastomeric lip seal. This pressure energized seal is
constructed of filled PTFE, and is spring energized with Elgiloy finger springs.
Sealant injection is neither required nor recommended for the stem seal.
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Description: 5” FLS GATE VALVE SUB-ASSEMBLY Part No.: 2096075-05-04
P/N Revision: A02
Drawing No.: SK-096791-01
ITEM QTY. PART NO. DESCRIPTION
1 1 2096073-04-01 BONNET, 5-1/8"-10K ACTUATED VALVE.
2 1 2054087-05-01 STEM: 5-1/8"-10K ACTUATED VALVE 3 1 2054104-03-01 GATE - 5-1/8" 10K ACTUATED VALVE 4 2 140413-01-71-03 SEAT, 5.1/8" 10000 "FLS" GV
5 2 2147124-07-03 OD FACE SEAL, 6.648 ID, SPLIT RING 11 1 2054478-01-01 ADJUSTING RING - 5-1/8" 10,000 12 2 718300 SEAL RING, 2.75 ID X 3.25 OD X 9MM 18 1 2136596-01 ASSY, PRESSURE RELIEF CHECK VALVE.
19 1 2136606-01 GREASE FILLER ASSEMBLY. 25 1 631486-04 REVERSE PRESSURE SUPPORT RING,
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Description: 2” FLS GATE VALVE SUB-ASSEMBLY Part No.: 2096165-11-02
P/N Revision: A02
Drawing No.: SK-096118-11
ITEM QTY. PART NO. DESCRIPTION
1 1 2054085-03-04 BONNET, 2-1/16" 10K ACTUATED VALVE 2 1 2096166-03-01 STEM, 2.1/16" 10K ACTUATED VALVE 3 1 2054112-02-01 GATE, 2-1/16 2,000 - 10,000 CM 4 2 2054117-01-01 SEAT WITH TFL PREP, 2-1/16 2,000 - 5 2 140146-03-01-03 OD FACE SEAL 2.790 ID X 3.063 OD PSL3 6 2 140398-02-01-03 ID FACE SEAL 2.260 ID X 2.525
7 1 2054121-01-01 GLAND, 2-1/16" 10K ACTUATED VALVE 8 8 219066-11-06-11 STUD, DBL ENDED 1.125- 8UN -2A X
18 1 2136596-01 ASSY, PRESSURE RELIEF CHECK VALVE.
19 1 2734297-03 FITTING, INJECTION .750-16UNF WITH 20 1 221034-03 CHECK VLV ASSY (get from Leeds) 21 1 M526742 SCR 0.750-16 X 0.375 HOL HEX SET STL 22 2 005930-14 PIPE PLUG HEX HD 1/4"NPT --ST/STL-- 23 1 702645-34-41 0-RG .210W X 03.850ID 90D NITRILE 24 1 700338 PIN, ROLL .250 X 2.000 SST
25 1 631486-01 REVERSE PRESSURE SUPPORT RING,
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4.1.8 ¾” Hydraulically Operated Gate Valve
The Annulus Wing Valve (AWV) is a subsea hydraulically operated ¾” gate valve, rated 10,000 psi working pressure. This valve has been designed and hyperbarically tested to operate at seawater depths to 5,000 ft. The valve has an ROV override of multi-turn (6 turns open to close) operation, and also features positive indication of open and closed positions via an indicator connected to the actuator piston.
See ¾” Hydraulically Operated Gate Valve Drawing SK-118590-02.
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4.1.9 ½” 15,000 psi Needle Valves
These valves are used to isolate the SCM, SV1, SV2, and GT lines. These valves require 270 degree of rotation and are manually operated using an ROV.
A visual position indication of the valve is provided by a pointer located on the end effector in the ROV bucket. ROV interface and manual override
requirements are listed in Section 6.
See Isolation Needle Valve Drawing SK-098369-01.
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