Innovative Subsea Valve Actuation: Balancing High Torque and Energy Efficiency with All-Electric Technology

The transition toward All-Electric Subsea (AES) installations is an ongoing trend in subsea production and processing, driven by the potential for installation and operational cost reduction, fast system response, reduction of umbilical cables’ diameter, high level of operational flexibility, environment-friendly design, and the ability to achieve longer step-out distances cost-effectively. However, the electric actuation of multiturn control valves typically demands a considerable high electric power. To address this challenge, an innovative all-electric multiturn actuator was developed, optimized for low-power operation and high torque demands of up to 2,700 Nm in compliance with API 17H Class 4 interfaces. The system was designed to be capable of operation via existing Subsea Electronic Modules (SEMs) by operating strictly within their power limitations, enabling cost-effective electrification of high-torque production valves without additional subsea electrical infrastructure. The modular electro-mechanical design uses proven industrial components, ensuring high efficiency, scalability, and compliance with industry standards. The system embedded controller and sensors enable advanced condition monitoring, predictive maintenance, and high availability. This paper outlines the development of this innovative all-electric multiturn actuator particularly designed to operate rotary valves of subsea trees and manifolds. The main achievements, demonstrated through simulation and testing, are (1) a cost-effective modular design using industrial components, (2) an environmentally friendly setup, (3) lower power consumption and high efficiency, and (4) high availability and condition monitoring. This actuator helps close the gap to accomplish the All-Electric Subsea (AES) approach, enabling the electrification of high-torque production valves without requiring additional subsea electrical infrastructure, operating within the power limitations of existing Subsea Electronic Modules (SEMs). This capability not only has potential to accelerate the AES approach but also increases the system reliability, availability and significantly reducing capital and operational costs.