Atlas 21 in Production

Pilot production of the first Atlas SSCV has begun at Total Valve Systems in Broken Arrow, Oklahoma. The first customer is a leading manufacturer of electric submersible pumps and the Atlas 21 will be used to provide back-pressure to validate pump performance. It replaces a valve with a conventional multiple-orifice disc trim and offers over 40% higher capacity along with greatly increased accuracy.

The control valve is a key element of horizontal pump test benches, moving on a track to accommodate pumps that can be as much as 40′ long. Pump companies are expanding their product lines to include high-volume pumps used in skid-mounted systems to rapidly transfer produced water from oil and gas production. The Atlas 21 (130 Cv) will greatly increase the range of pumps to be tested on this customer’s bench, up to 70,000 bpd at less than 300 psi discharge pressure.

The product line includes the Atlas 15 (70 Cv), derived from the field trial valves, and the Atlas 32 (300 Cv) that will large scale applications in  refineries and chemical plants plus replace ball and plug valves to test pumps in the range of 100,000 bpd at 100 psi. Replacing complex, multi-valve back-pressure manifolds, or multiple test benches, the Atlas 15 and Atlas 32 together will allow the full product line of any ESP company to be tested on a single test system.

Preliminary product information can be found on the “How it Works” page

5000 PSI – Low Noise – Fine Control

Ongoing field trials have validated the HBGV performance for several months. The newest installation in the test facility of a major pump manufacturer has been well-accepted as the HBGV outperforms the back pressure control valve it replaced. Daily use has subjected the valve to pressures up to 3600 psi.

We have been stalking “bigger game”, and today we bagged it: 5000 psid and over 400 gpm. The HBGV was conceived to precisely control choked flow, and it did that. With the valve throttled below 10% open, SPL measured just above 80.

So where do you find a 5000 psi flow test facility? You create one, with the help of a company in the business of servicing hydraulic fracturing skids. We adapted the 5000 RTJ flanges to 1502 hammer union fittings required in the 15ksi world. Next, the HBGV was connected to a manifold in front of the angle-pattern chokes in place for pump testing:hp-test-plumbingThe green intake pipe in the picture originated at the output of a piston pump driven by diesel motor supplying 1200 HP.

Up to this time VSI has only offered field trial valves, and now we’re ready for a RFQ. Please contact us with your severe service control valve problem/application to find out why the HBGV would be a cost effective solution.

ASME SmartBrief Featured HBGV

Back at the beginning, prior to the official launch of VSI, we were recognized in the press for our pursuit of a better way to control choked flow. i2E in Oklahoma provided the tools to get VSI launched, and this feature in the business pages of the two major newspapers helped. When ASME picked up the story, our plans were given a big boost. SmartBrief 2014

With two valves in field trial and manufacturing preparations in work, we are comfortable with how the follow-up to the story in the December 21, 2014 Tulsa World is unfolding.141221 – VSI

First Delivery for Field Trial

VSI delivered the first Helical Bevel Gear-drive Valve, the HBGV, on Thursday, February 18, 2016. The valve will be installed as a pump back pressure regulator on an injection skid manufactured by Global Production Systems, GPS, in Shawnee, Ok.

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GPS is a leader in injection systems design and manufacturing that include instrumentation and control systems permitting the multi-stage centrifugal pumps to operate most efficiently.

While this marked a significant milestone for VSI in the development of the HBGV, the near future looks bright as we actively seek other field trial applications for a 5,000 psi rated choked flow control valve with a flow coefficient up to 60.

We have two API 6A compliant valves and one Class 1500 RF flanged valve in production, ready soon to drop in and replace problem-plagued 2″ conventional control valves. The electronic actuation system is capable of 1% accuracy with 20:1 rangeability. HBGV SN160201 Assembled

Flow Lab Tests Complete – Performance Confirmed

IMG_20160128_111431559The final round of lab testing wrapped up this week. Flow test data gathered at the Radford Company valve test facility confirmed predictions of CFD simulations made prior to the launch of VSI. Maximum Flow Coefficient was measured to be 75 in turbulent flow. The HBGV1 was confirmed to have negligible pressure recovery in the valve and an effective CsubV of nearly 60 in full choked flow as pressure recovered far downstream.

Flow Testing the HBGV

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Flow testing of the HBGV began at Total Valve Systems in Broken Arrow, OK. The 2″ control valve was confirmed to have a flow coefficient above 60 Cv, the primary performance specification. Lobo Engineering PLC is processing the 136,000 data points to establish the inherent characteristic and choked flow performance ratings.

 

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Assembly of the First HBGV

DSCF2769The first of five pre-production severe service control valves is prepared for flow testing and field trials. From the 3-D printed patterns for the internals to the rigorous CNC machining of the Body and Hub, the manufacturing process was complex. Eight contractors were coordinated by VSI to produce the valve in three months.

This video records the moment the HBGV came to life: Control Valve Actuates

HBGV1 Technical Brief Released – First RFQ!

VSI is actively setting up the field trial locations for the first valves. Two submersible pump companies have expressed their intent to wring out the HBGV in their pump testing laboratories, and several other applications are being pursued in Casper, Wyoming and Baton Rouge, Louisiana. Customers need a Tech Brief: Tech Brief – HBGV1

Last week, with the first valves in production and parts still on order, VSI received a request for quote to replace a Masoneilan 18400 LincolnLog (Trademark) control valve in water injection service, dropping 500 psi to 3 psi. The end user is considering our offer, subject to the approval of substituting electric actuation for pneumatic.

Traditional industrial control systems rely on pneumatic controls and actuation, primarily for enabling a spring-over-diaphragm actuator to open or close a valve when the pneumatic system fails. “So 20th Century”; with a simple battery backup system, the HBGV will open, close, or go to a specific position on loss of signal. No pneumatics. No springs. No positioner. No actuator change if fail-closed valve needs to now fail-open.  No problem.

SLS Patterns for the Helical Bevel Gear Parts

Ranging from difficult to impossible to machine, the four key components that comprise the patented helical bevel gear-drive must be cast. For the 5 field trial valves, the patterns were scaled up from the digital model to allow shrinkage of the molten metal part and printed in wax. The patterns were produced by American Precision Prototyping, LLC with the selective laser sintering process at a fraction of the cost of traditional molded pattern tooling.

Alpha Investment Casting received the patterns and entered them into production, leapfrogging the steps of setting up permanent tooling in the injection press and molding a few patterns. VSI benefits from quick delivery of parts that meet production part specifications.Patterns and Calipers

Electric Actuator Selected for Field Trials

The first five HBGVs are in production and the search for a multi-turn actuator lead us to the Indelac LA7B-12MVQ-MT. For the rigorous field tests expected this fall, we specified an actuator that was robust, fast, accurate and easy to commission. The selected actuator is a multi-turn device, 115 VAC powered with 4-20 mA input, 2000 lb-in output and continuous duty cycle. Applied to the HBGV, the actuator can respond to a command for a 5% change in restriction in less than 7 seconds.2 inch API 5000 - Indelac - Discharge - White