This document discusses the development of a smart emergency shutdown system (Smart ESD) for surface safety valves. The Smart ESD aims to enable remote monitoring and control of safety valves to improve safety, reduce costs, and predict failures through condition monitoring. It consists of a controller unit, pump unit, sensors and connectivity unit. Field testing was conducted to analyze the system's performance under different conditions. The Smart ESD is intended to be retrofitted on existing valves and provide autonomous valve control, failure prediction and reduced operating expenses through remote monitoring and diagnostics.

1. Digital Oilfields
May 18, 2022
Towards an Autonomous
Surface Safety Valve
Hossam Gharib, Ph.D., P.Eng.
Senior Product Engineer
Surface Safety Systems
Stream-Flo Industries Ltd.

2. Agenda
1. Surface Safety Valve (SSV)
2. Problem Definition
3. Smart Emergency Shutdown System (Smart ESD)
4. System Testing
5. Predicting Failures through Condition Monitoring
6. Field Implementation
7. Conclusion
Towards an Autonomous Surface Safety Valve 2

3. Stream-Flo Group of Companies
Towards an Autonomous Surface Safety Valve 3
Basic self-contained
hydraulic SSV
Electro-hydraulic
Control Panels
Electro-hydraulic
SSV
❑ Electro-hydraulic powered systems
❑ Pneumatic-hydraulic powered
systems
❑ Data logging
❑ Local and remote process control
❑ Data communication
❑ Condition monitoring
Data logging, process
control, and
communication
Safety Systems Division

4. Surface Safety Valve (SSV)
Towards an Autonomous Surface Safety Valve 4
Surface Safety
Valve
Hydraulic Control
Circuit

5. Problem Definition
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❑ Time saving
❑ Equipment life improvement
❑ Failure prediction
Condition
Monitoring
Safety
❑ Roadway incidents
❑ Personnel not fully equipped/aware of the problem
❑ Personnel required to be on site during hazardous operations
❑ Inspection
❑ Partial/full stroke testing
❑ Multiple site visits
❑ Manual pressure adjustment
Operating
Cost

6. Visual Inspections
Real-time Condition
Monitoring
Failure Prediction
Delayed ESD
Response
Replace Solenoid
Valve
Towards a Smart ESD
Towards an Autonomous Surface Safety Valve 6

7. Elements of the Smart ESD System
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Controller Unit
Pump Unit
Sensor and Connectivity Unit
Control Elements
Sensing Elements

8. Controller
(Edge Processing Unit)
Electro-Hydraulic
Power Unit
Handheld
Interface
Electric Power
LTE
VPN
LTE
Actuator
Gate
Valve
Modbus RTU
WiFi
Cloud
LTE
SSV
Remote
Control Panel
PLC / DCS
Architecture of the Smart ESD System
Towards an Autonomous Surface Safety Valve 8

9. Class 1
Division 2
Class 1
Division 1
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Smart ESD Test Unit
Controller
Unit
Pump
Unit
Sensor and
Connectivity
Unit
Control
Element
Sensing
Element
Sensing
Element
Sensing
Element

10. Higher actuator pressure
during opening
Low-pressure vs. high-
pressure response time-delay
Towards an Autonomous Surface Safety Valve 10
Time-based Opening Response

11. First 2 seconds of closing
SOV response
BTC
response
Towards an Autonomous Surface Safety Valve 11
Time-based Closing Response

12. SOV response
Time to settle
Signal pressure signature
indicative of control circuit health
Towards an Autonomous Surface Safety Valve 12
Time-based Partial Stroke Response

13. BTC
BTO
Hysteresis
Closing time saturates due to
hydraulic circuit back pressure
Increased hysteresis indicates an
increase in friction
Towards an Autonomous Surface Safety Valve 13
Signature and Effect of Line Pressure

14. Predicting Failures with Condition Monitoring
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Data Logging
Reference Baseline
Physics-based
Models
Data-Based Models
(Model Bias)
Logic and
Evaluation
Condition
Prediction
Predicting Failure to ESD
Condition
Time
Failure
(Healthy System)
Critical health events

15. Field Implementation - Retrofit
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Position
Sensors
Pump Unit
Sensor and
connectivity unit
Solenoid Valve
(Control Element)
Level Sensor
Pressure Sensor

16. Conclusion
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Smart
ESD
Remote
Control
Edge
Computing
Failure
Prediction
Condition
Monitoring
Diagnostic
Tests
Lower
Opex
Improved
Safety
Easy
Retrofits