Intelligent BOP RAM Actuation Sensor Systems

Transcription

1 Intelligent BOP RAM Actuatin Sensr Systems Emad Andarawis GE Glbal Research Ultra-Deepwater Drilling, Cmpletins and Interventins (includes GEOR & ESR) TAC Meeting January 20, 2016 Greater Frt Bend Ecnmic Develpment Cuncil Bardrm, Sugar Land, TX 1 Cpyright 2016 General Electric rpsea.rg

2 Team, Wrking Grup and Dmain Experts Darryl Fett (Prject Champin Ttal) Jse Piedras, Herve De_Nauris (Ttal) Brian Tarr (Shell) Lenard Childers (BP) Greg Myers, Anthny Spinler, Bb Judge (GE Hydril) Greg Gillette (GE Research) Bill Head (RPSEA) Bill Fincham (NETL) Prject Team: Cheng-P Chen, Ed Nieters, Yuri Pltnikv, Esmaeil Heidari, Ganesh Krishnamrthy, Chris Wlfe, Steven Klpman, Gautam Naik, Dayu Huang, Jay Unnikrishnan, Glen Kste (GE Glbal 2 Research)

3 Prgram verview Objective: Develp a nvel aut-cmpensated sensr system fr accurately detecting the presence f drill cllars, tl jints and ther un-shearable bjects in the vicinity f BOP rams. Phase 1: Develp sensr, signal cnditining and errr-crrectin cncepts Evaluating integratin f sensr with the BOP Phase 2: Detailed Sensr System Design Prttype cnstructin Prttype test Deliverables (Test Reprts): Prttype sensing system functinal testing in simulated envirnment Sensr mechanical testing 33 mnth perid f perfrmance 3

4 Financials Cst Share current spend: $217,928 Tech Transfer current spend: $52,620 4

5 Envisined Sensing System 5 Envisined Aut-cmpensated sensing system capable f accurately perfrming the measurement in the presence f cnfunding nise.

6 Sensing apprach & dwn-selectin at end f phase 1 X-ray least prmising detectin technlgy fr envirnment EM nt affected by drilling mud characteristics, but suffers signal lsses due t steel in BOP bdy Errr in pipe psitin can be crrected in 3-cil system Drilling mud highly attenuative t ultrasund signals Acceptable signal detectable Multiple circumferentially placed transducers capable f lcalizing and detecting pipe diameter Ttal sensing system pwer cnsumptin f <10 watts expected reductin f 2-5x pssible with duty-cycle cntrl System cmbining 5 UT and 3-cil EM sensrs prvides rbust signal detectin and errr crrectin 6

7 Summary f task 7 findings Defined number f sensrs and placement Defined specificatins fr sensrs Defined requirements fr signal cnditining and prcessing electrnics Defined mechanical integratin design EM: Electrnics and prcessing Number f cils: 3 Data Acquisitin requirements UT: Cnfiguratin f cils: 1 xmit, 2 receive Placement f cils: 8 inches Excitatin wavefrm: Multi frequency UT: 16bit/1MSPS EM: 16bit 100KSPS Prcessing algrithm design UT: Cmbined ring-dwn tracking filter, crrelatin based algrithm Number f sensrs: 8 circumferential Frequency f excitatin: lw Measurement methdlgy Pulse-ech fr jint/diameter measurement Mechanical System Cnfiguratin EM: Abslute signal pipe diameter; Differential signal jint detectin Pitch-Catch fr speed f sund Riser spl piece abve BOP Excitatin wavefrm Cmbined single pulse, and cded pulse train 2 thick peek insert 1.5 PEEK pckets fr UT and cututs fr EM sensrs 7

8 EM Measurement System 3-cil system Detectin algrithm Meas. cil 1 Input Amp. 3 signals prcessing Drive cil Exciter Data Acquisitin Multi-frequency demdulatin Meas. cil 2 Input Amp. Lw sensitivity t axial shift 8 Jint detected by first and secnd receive sensrs

9 EM system Data acquisitin and prcessing platfrm Tl Jint Labratry testing rig with a real pipe jint in the 19 spl bdy 9 High sensitivity t diameter; lw sensitivity t axial psitin Pipe t wall & back

10 EM system 10

11 UT Sensr Diameter and psitin sensing apprach Time f flight measurement distance frm sensr t target Finding a circle tangential t ther circles/arcs Minimum 3 sensrs required fr exact determinatin f psitin and diameter Schematic f pipe crss-sectin with 3 UT sensrs. The string psitin is estimated based n the arcs, the radii f which are calculated using time-f-flight data frm UT sensrs Demnstratin f algrithm in MATLAB fr different cases Black circle: Outer steel pipe Blue circles: Circles with radii calculated frm time f flight data frm sensrs Red circle: Calculated psitin and dimensin f string 11

12 UT system under test 19 diameter tank 3.5 diameter target 16.5 PPG OBM Inches Inches Detected signal frm target

13 UT pipe diameter detectin algrithm 8 sensrs prvide ~100% sensr cverage fr jint detectin in presence f limited range and UT angular spread Actual versus predicted Drill pipe vs. jint 13 8 circumferentially placed sensrs sufficient t detect presence f tl jints in lw SNR scenaris

14 UT Sensing Prttype Test

15 Electrnics Design and Build Excitatin and acquisitin cntrl functinal. EM pulser and receiver bard built and tested. Multi-channel pulser evaluatin cmplete. 1-channel receiver bard testing cmplete, Enhanced perfrmance, multi-channel receiver bard fabricatin in prgress 15

16 Scpe Extensin Prpsal: Test Rig-Ready Prttype Milestnes Develp user interface that cmbines acquisitin cntrl, data analysis and display frm all sensrs. Rig-ready Electrnics-- frm factr and rbust packaging Interface t WITS system develpment and test Integratin testing and reprt ut 16 Deliverables Reprt summarizing rig-ready user interface, electrnics and WITS interface develpment. Integratin test results and rig test readiness evaluatin reprt.

17 Fiber Sensing Thughts Fiber Sensing Discussin 17

18 Fiber Optic Technlgy Fr Subsea Cnditin Mnitring Fiber Optic Sensing GE is brad and deep in fiber ptic sensing with cmmercial cnditin mnitring prducts and research in subsea sensing systems Fiber reliability is severely impacted by the FBG 1 writing prcess and the cmbinatin f water and strain -> GE has slutins t bth Remaining Technlgy Gaps fr a BOP Mnitring On an internal prgram GE has develped an FBG strain sensing cable ptimized fr strain transfer, manufacturability, and subsea durability GE test fr RPSEA f fiber ptic acustic telemetry Example fiber ptic prduct frm GE fr Generatrs The FBG strain sensing cable cre has been built and tested n the reel but nt yet in peratin GRC life testing f fibers under strain in water 2 Strain measuring subsea cable cre 18 1 FBG=Fiber Bragg Grating 2 Kaustubh Nagarkar, Victr Ostrverkhv, Mahadevan Balasubramaniam, Slawmir Rubinsztajn, Glen Kste, et al. " Optical fiber reliability in subsea mnitring ", Prc. SPIE 9491, Sensrs fr Extreme Harsh Envirnments II, 94910H (May 13, 2015).

19 Fiber Technlgy Fr BOP Cnditin Mnitring Prpsal: Validate Technical Viability Underwater Milestnes Fiber package and deplyment adaptatin fr BOP-specific applicatin In-water testing including repeated ram clsures Mnitr peratr stress and acustics Develp crrelatins with MPL wear Data analysis and reprt ut Deliverables Reprt summarizing test results with emphasis n sensr system perfrmance and reliability and its capability t detect any changes in the BOP cnditin ver the testing perid 19

20 Questins? "This presentatin was prepared with the supprt f RPSEA under Award N Hwever, any pinins, findings, cnclusins r ther recmmendatins expressed herein are thse f the authr(s) and d nt necessarily reflect the views f RPSEA." 20

21 Cntacts Principal Investigatr: Emad Andarawis GE Glbal Research Prject Manager: Bill Fincham NETL Technical Crdinatr: Bill Head RPSEA