Flow Control Valves: Common Problems and Solutions in Energy

Flow control system efficiency is central to operational sustainability across multiple energy markets. When operating optimally, these systems improve productivity, lower operating costs, increase reliability, reduce emissions and enhance safety. However, outdated systems and equipment — which continuously bear extreme demands — present a major challenge. To ensure safe and smooth operations, aging control systems within the oil and gas industry need preemptive maintenance monitoring to support peak performance.

Thankfully, advancing technologies offer significantly improved methods to solve engineering problems, leading to more accurate and efficient processes. Let’s explore the critical nature of control systems in addressing energy market challenges and enhancing system performance — and how technological advancements can help.

The Impacts of Aging Systems and Infrastructure

Oil and gas leaks or release from aging flow control systems can have disastrous consequences, including worker injuries, safety hazards, pollution, environmental damage, danger to surrounding communities — and ultimately, a major blow to a company’s bottom line. In addition, the energy market faces increased scrutiny from regulators and the public concerning environmental impact and safety risks. Even if your outdated system doesn’t result in a catastrophe, you could still face the pressures and fines of increased regulation.

Let’s unpack some of the problems posed by aging technology:

• Unresponsive BOP Control Systems: Due to outdated designs, aging systems lack the latest safety features. As one example, unreliable blowout preventer (BOP) control systems may not be able to handle sudden changes in extreme pressure environments. This increases the risk of failure and exacerbates the safety risks of uncontrolled flow during drilling.
• Reduced Performance: As with safety features, obsolete flow control systems lack the latest high-performance components. Not only does this reduce efficiency, but systems are also more likely to suffer breakdowns — both critically detrimental to your bottom line.
• Lack of Spares: The inaccessibility to spares for outdated machinery parts further prolongs downtime during repairs. This affects productivity and significantly impacts profitability.
• High Energy Consumption: Outdated technology leans heavily on energy consumption; higher energy outputs for lower performance ultimately means increased operational costs down the line.

Enhancing Flow Control Systems for Improved Efficiency

Despite the problems posed by aging systems, technological advancements can offer noteworthy flow control improvements in the energy market. Let’s take a look at simple maintenance strategies to enhance your system and maximize efficiency.

Seal Replacement

While seal maintenance is crucial, complete seal replacement on aging flow control components can be costly. But service providers that leverage new technologies can offer re-lapping services as an alternative solution. This provides a precise and consistent solution to recondition tungsten carbide seals, removing surface irregularities and imperfections. It extends the seal lifespan and effectively restores full functionality to prevent leakage in a cost-effective way.

Customized Conversions

Reverse-flow hydraulic locking failure in blowout preventer circuits can be a critical problem in aging systems. Considering the immense pressure the systems are under, consequences can be severe if control fluid pressure prevents component movement.

Energy companies can solve this issue with cutting-edge directional flow control advancements by integrating newer check and shuttle control valve designs that accommodate unique flow rates and shuttling pressures. The check valves permit free oil flow in one direction and block oil flow in the opposite direction, eliminating reverse flow. In new shuttle valve designs with the shuttle as the only moving component, the shuttle shifts back and forth to allow fluid to pass from a given inlet to the outlet while blocking the opposite inlet.

Together, these control valve options facilitate the smooth functioning of the BOP and solve hydraulic locking, allowing drill ships to resume operations safely and efficiently.

Smart Valves

Since the margin between function and failure is minuscule in the energy market, there is a growing need for automation and precision. Valves, therefore, require accurate controls behind them to complete an effective design.

With modern technology, smart valves offer improved accuracy and significantly more data transferred between the control point and control center. Since systems can communicate data continuously and immediately, operators gain a real-time view to manage quality control components.

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Optimizing Regulator Performance and Deck Testing Efficiency

Accurate prediction of oil or gas production requires effective well testing. But testing processes are easily hindered by vibrating unstable regulators, causing fittings to loosen from excessive shaking. As a result, deck testing becomes resource-intensive — involving extra labor hours, equipment operation, and finances.

There are several alternative solutions to improve deck testing efficiency and regulator performance. These solutions provide reliable and smooth hydraulic pressure during testing — while also reducing testing time.

Advanced Regulator Features to Improve Performance

Advanced regulators that feature guided hydraulic damping technology significantly reduce dynamic oscillation. Some other features key to improved regulator performance during well testing include:

• Bolted plunger guides for accurate guidance
• Dynamic plunger T-seals to prevent spiral wound O-ring failures
• Improved set point resolution to lower deadband

Reducing Debris Levels

Control fluid contamination or buildup of solids are also common issues that significantly reduce system performance. Besides hindering efficiency, this can lead to unnecessary downtime in various oil and gas operations.

Control valves with dual direction seal-in dependability and high debris tolerance will ease system component wear and tear, improving overall service life and decreasing ownership costs.

Upgrading for Energy Savings and Long-Term Reliability

As the scale of projects in the energy market has increased, so too have demands and pressure on equipment. To maintain safe operations, optimize productivity, and reduce operational costs, it’s essential that infrastructure maintains prime working condition, even as it ages.

Relapping seals, implementing upgraded check or shuttle valves and leveraging smart valve technology are all effective solutions to improving efficiency, enhancing safety, and reducing downtime in aging systems. In addition, expert insights and advanced engineering developments allow flow control suppliers to offer customized solutions — specific to unique control system designs.

You don’t have to risk major losses due to aging infrastructure. With specialist field engineers and well-established manufacturing teams leveraging new technologies, energy companies can work cleaner, safer and more cost-effectively.

Colleen Uriarte is the marketing manager for Gilmore and has worked with Gilmore’s technical authorities for over a decade to provide quality product content for the company.