safety driven performance 2013
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Lloyd’s Register Energy - Drilling
Integrating ModuSpec and WEST Engineering Servicesto advance excellence in drilling safety, integrity and performance
Safety Driven Performance 2013Alan TurnerSystems & Controls Technical Specialist
October 2013
Lloyd’s Register Energy - Drilling
Agenda
• Introduction• Fiber Bragg Gratings Explained• Examples of Asset Integrity Monitoring in the Nuclear
and Wind Energy Sectors• Discussion of a Riser Tensioner Monitoring System
Installed on the Discovery Luanda• Discussion of an Instrumented BOP at the West Tech
Lloyd’s Register Energy - Drilling
Introduction• Fiber Optic Sensors have been widely utilized in
Structural Health Monitoring (SHM) for more than 10 years now.
•Main applications include:• Civil Structures• Trains• Marine – LNG Ships, Composite Hulls• Energy – Wind, Nuclear, Hydroelectric, Oil and
Gas.• Aerospace• Geotechnical
Lloyd’s Register Energy - Drilling
Fiber Bragg Gratings ExplainedA Fiber Bragg Grating is a periodic change of the refractive index in the core region of an optical fiber.
Lloyd’s Register Energy - Drilling
Fiber Bragg Gratings ExplainedEach grating sensor is at a different fiber location and allocated a separate central wavelength and spectral operating window band.
Lloyd’s Register Energy - Drilling
Advantages of Fiber Bragg Gratings• Immunity to electromagnetic interference (EMI) and electrical discharge
(lightning).• Passive operation, intrinsically safe.• Water and corrosion resistant.• Excellent resolution and range.• Rugged, small size and light weight.• Small size allows for insitu measurements.• Multiple sensors per channel.• Absolute measurement.• Low signal loss, sensors may be interrogated for many kilometers.• Signal conditioning equipment has a much smaller foot print.
Lloyd’s Register Energy - Drilling
Micron Optic Sensor Types
os3110 Metallic Weldable Strain Gage
os3200 Non-Metallic Flexible Strain Gage
os3155 Metallic Weldable Strain Gage
os1100 Single FBG in polyimide coated fiber
os4100 Temperature Compensation Gage
os4200 Single Ended Calibrated Temperature Gage
os4310 Double Ended Calibrated Temperature Gage
os4350 Double Ended Calibrated Temperature Gage
os7100 Accelerometer
Lloyd’s Register Energy - Drilling
Micron Optic Interrogators and Controller
• 4 channels with a spectral width of 1510 to 1590 nm. Available from 1410 to 1590 nm• 1 hz to 2 khz scanning frequency• Wavelength repeatability 1 pm@1khz, 0.05 pm with 1,000 averages• Power consumption 25 watts, 50 watts max• Operating temperature 0 to 50 degrees C• Available from 1 to 16 channels
• 1.4 GHz Pentium, 512 MB DDR, a 32 GB Solid State HD and Windows XP operating system• Peripheral interfaces include USB, Ethernet, RS232/422/485 and a user configurable digital
I/O• Provides power management through wake-on-LAN and wake-on-clock functions. Small foot
print, mounts directly on the interrogator
Lloyd’s Register Energy - Drilling
Examples of Asset Integrity Monitoring Pipeline Monitoring Williams North West Pipeline
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Examples of Asset Integrity Monitoring3.5 MW Clipper Liberty Wind Turbine
Lloyd’s Register Energy - Drilling
Installation of Robert E Ginna Nuclear Plant
NEMA 4 Enclosure with splice tray.
Instrumented Tendon
Os3600 surface mount concrete strain gage and instrumented rebar, located on containment structure just below roof line
Roof penetration to instrumentation rack located in room below the roof.
Lloyd’s Register Energy - Drilling
Installation of Robert E Ginna Nuclear Plant
• A fiber optic strain gage was applied to a currently exposed hoop direction rebar.
• A fiber optic concrete strain gage was installed 6” (15 cm) below the rebar excavation in the hoop direction.
• These gages are monitored in the same DAS as the tendon monitoring system
Rebar and Concrete Strain Monitoring
Lloyd’s Register Energy - Drilling
Installation at Robert E Ginna Nuclear Plant
Shim and tendon with sensors installed for a total of 20 instrumented tendons.
Lloyd’s Register Energy - Drilling
Installation of Robert E Ginna Nuclear Plant
Rebar and Concrete Monitoring Pre/During/Post Integrated Leak Rate Test
Rebar Strain Concrete Strain
Containment Press
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Discussion of A Riser Tensioner Monitoring System Installed on the Discovery Luanda
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Overview• Meet API 16Q requirements for a more accurate
determination of the reduction factor.• Need to measure full system load, current system
measurements based on hydraulic pressure.• Long term• Reliable• Intrinsically safe operation.• Quick implementation and ease of installation.• Provides for remote monitoring and maintenance capability.
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1 2 3
6 5 46
Top View of Tensioner Layout Under Drill Floor
Functional Description of The Riser Tensioners
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Protection wrapping of sensor locations for transportation to the DSL.
Surface preparations and sensor installation.
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• Sensor locations after tensioner installation on the DSL.
• Each tensioner has 3 os3155s 120 degrees apart in the axial direction.
• Each tensioner has 1 os3200 in the hoop direction to measure pressure.
Lloyd’s Register Energy - Drilling
• Acquisition rate is 10 Hz• X Axis represents approximately 2.41 minutes of data• Y Axis = Strain• Waveforms confirm a swell period of ~ 12.5 seconds
correlating to ships weather
Lloyd’s Register Energy - Drilling
Conclusion/Discussion• Sensors were installed in the Bosch Rexroth facility in Uden
Netherlands in September 2012.• System was commissioned in May 2013.• Sensors were damaged during transport and installation.• Sensor protection not robust enough.• Despite damage, enough survived to acquire loads on each
tensioner.• Redundancy in built-in system installation allows for sensor
recovery.• Real time calculations and display are within 5% of modeled
loads.
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Overview• LRDIS has instrumented a BOP on site.• We are able to detect the pressure inside the BOP bonnet from a hoop
oriented strain sensor.• Also detect dimensional changes in the bonnet due from an axial mounted
strain sensor.• Allows us to infer correctly, pressure and operation –
• The position of the RAMS,• Fluid flow• Solenoid operation• Regulator operation• Choke and Kill Lines• Fail-safe Valves• Pre-charge on Subsea Accumulators• Etc.
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Software Has Been Developed to Replay Data for BOP Operational Demonstration
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Hoop gage responds During cylinderpressurization.
Axial gage responds after rams engage.
• Acquisition rate is 100 Hz• X Axis = Time• Y Axis = Strain
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Expanded plot reveals a signature related to a clicking sound, from the bonnet, heard before rams engaged. More testing and analysis to determine source of signal response. This response appears to respond to the MPLs.
• Acquisition rate is 1000 Hz• Waveforms could confirm bad bearing, MLPs,
etc.?• Possible to count the threads in the piston rod?
Lloyd’s Register Energy - Drilling
Ideal System• Independent of the OEM equipment• Never needs calibration• Doesn’t require local power• Today subsea engineers rely on:
• Gallon count• Pressure feedback• Solenoid diagnostics
• Tells us strain, temperature, and pressure
Lloyd’s Register Energy - Drilling
Conclusion/Discussion• Sensors were installed in the West Tech facility on a Hydril
Pipe Ram.• Testing revealed pressure and mechanical elongation of the
bonnet.• Operational information of the BOP was realized.• Software has been developed to replay data acquired
during operation to demonstrate operation of the BOP.• More testing needed to baseline the BOP.• This includes installing more sensors on valves, solenoids,
accumulators and hydraulic lines.
Lloyd’s Register Energy - Drilling
Conclusion/Discussion• Future integration of the monitoring systems, with
asset management systems currently deployed or in development. These are:
• LRED BOP RiskWatcher and RiskSpectrum software for real time BOP risk assessment.
• LRED RIGSIGHT software for asset integrity monitoring and Integrated Operations Management (IOM).
Lloyd’s Register Energy - Drilling
Acknowledgments• Williams (End customer)
• Durham Geo Slope Indicator (DGSI)• Tel: 800-837-0864, email: dge-solutions@durhamgeo.com, web:
www.durhamgeo.com• Micron Optics, Inc• Tel: 404-325-0005, email: info@micronoptics.com, web:
www.micronoptics.com• University Of Minnesota
• Jeff Marr Tel (612) 624-4427, email: marrx003@umn.edu • Sandia National Laboratories
• Jonathan White Tel (505) 284-5400, email: jonwhit@sandia.gov • Transocean
• Aaron Barr Tel (713-232-7959), email: aaron.barr@deepwater.com • WEST Drilling Equipment Center
• (T) 281 375 5515
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