Remotely Operated Seabed Geotechnical Drilling and Sampling Technology. Performance and Benefits of an Automated System.

Transcription

1 Remotely Operated Seabed Geotechnical Drilling and Sampling Technology Performance and Benefits of an Automated System. Allan Spencer, Cellula Robotics UK Ltd. HYDROGRAPHY, GEOPHYSICS & GEOTECHNICS Thursday 17 March 2016

2 Presentation Structure Context Purpose What are Seabed drills (SBD) and their applications? What are the pros and cons of the SBD method over surface methods? End-Rod vs Wireline The CRD100 SBD description and overview Why is automation important for this application and what issues does it seek to address? Implementation How is automation implemented on the CRD 100 system: NASREM Architecture principle and application to Seabed drilling Example of an automated SBD routine (Get_Tool_From_Carousel) Further Developments Higher Levels of Automation Implementation Task execution time prediction modelling Summary & Conclusions 2

3 Context What are Seabed drills (SBD) and their applications? What are the pros and cons of the SBD method over surface methods? End-Rod vs Wireline The CRD100 SBD description and overview 3

4 Geotechnics Exploration Evaluating resources Site investigation Characterising soil properties Site modification Installing pins/pilings, caissons & foundations 4

5 Exploration - Sampling Seafloor Massive Sulphides Manganese Nodules Methane Gas Hydrates 5

6 Site Investigation FPSO suction anchor CPT Wind farm foundations Core Sample Oil & gas platform jacket 6

7 Site Modification Pipeline pins Grouted micro piles Anchor templates 7

8 Offshore Geotechnical Drilling Moored barge DP vessel Jack-up barge 8

9 Geotechnical Seabed Drill Examples 9

10 SBD vs Surface Methods Pros Efficiency Access to vessels Drill string length vs water depth Weather tolerance Sample & Data Quality Mud line detection Bore hole depth control Drill bit stability Subsea capping of soft sediments Health, Safety & the Environment Rod / tool handling Shallow gas Drilling mud Cons Efficiency Mobilisation to vessels can be complicated and expensive Hole re-entry unproven Core diameters can be limited Sample & Data Quality Core samples cannot be recovered until EOH (end of hole) Health, Safety & the Environment Drilling mud limited capacity 10

11 SBD Vs Surface Methods Surface vessel Drill ship vs VOO Umbilical vs drill pipe 3000 m Seafloor Drill vs Re-entry/guide frame 11

12 End-Rod vs Wire line END ROD METHOD Top Drive and Spindle Drill Pipe Foot Clamps BHA Pre-assembled with core barrel 12

13 End-Rod vs Wire line WIRE LINE METHOD Top Drive and Spindle Wire line core barrel Drill Pipe Foot Clamps BHA Pre-assembled with wire line core barrel 13

14 CRD 100 Offshore Spread A-Frame Umbilical winch Spares Sample storage Seafloor Drill Workshop Control van Geotechnical laboratory 14

15 CRD 100 Subsea Module Lift point Lifting Lugs Thrusters Mud Storage Bladder CPU Can Expansion UPS Can Valve Pack Tool Arms Aft Legs Forward Legs Carousel Drill Head Feed Motor 15

16 Purpose Why is automation important for this application and what issues does it seek to address? 16

17 Purpose Drivers for automating the SBD system: o Reduction in errors due to the human interaction flawed decision-making based on incomplete data o Optimise execution time of repetitive tasks o Relieve operator fatigue and avoid distraction o Improve process efficiency and allow a credible option to surface methods in terms of sample quality Considerations: o Risk of operator complacency o Mistrust of the control system 17

18 Implementation How is automation implemented on the CRD 100 system: NASREM Architecture principle and application to Seabed drilling. 18

19 NASREM SPDM Application o Special Purpose Dextrous Manipulator (SPDM). o Utilises ground-based telerobotic control developed from the NASREM architecture. Image: o Completed construction tasks on the international space station. 19

20 OPERATOR INTERFACE NASREM Standard Reference Model SENSORY PROCESSING DETECT, INTEGRATE WORLD MODELING MODEL,EVALUATE TASK DECOMPOSITION PLAN, EXECUTE GOAL G 6 M 6 H 6 SERVICE MISSION G 5 M 5 H 5 SERVICE BAY MAPS OBJECT LISTS STATE VARIABLES EVALUATION FCNS. G 4 G 3 M 4 M 3 H 4 H 3 TASK E-MOVE PROGRAM FILES G 2 M 2 H 2 PRIMITIVE G 1 M 1 H 1 COORDINATE TRANSFORM SERVO SENSE ACTION 20

21 CRD 100 Major Software Components 21

22 CRD 100 NASREM Architecture SURFACE SUBSEA SERVER SUBSEA SM (LEVEL-4) SM (LEVEL-3) SM (LEVEL-2) SM (LEVEL-1) SENSE PLAN WM (LEVEL-4) WM (LEVEL-3) WM (LEVEL-2) WM (LEVEL-1) TASK (LEVEL-4) TASK (LEVEL-3) TASK (LEVEL-2) TASK (LEVEL-1) ACTION L4 L3 L2 L1 DRILLGUI Pilot GUI Co-Pilot GUI CRD 100 NASREM 4-Level Hierarchical Control Structure Mode Auto Manual Diagnostic Cmd Level L4-L3 L2 L1 Cmd issuer Pilot/Co-Pilot GUI Pilot/Co-Pilot Joystick Pilot/Co-Pilot GUI CHAIR Level Commands Pilot Co-Pilot Actions on the JS JS Level-6 Ground Level-5 Level-4 Level-3 Level-2 Level-1 Actions on Drill Strings Actions on Individual Drill Tools Actions on Multiple Drill Components Actions on Individual Drill Components Actions on I/O Board 22

23 Implementation How is automation implemented on the CRD 100 system: Example of an automated SBD routine (Get_Tool_From_Carousel) 23

24 CRD 100 Automation Example 24

25 CRD 100 Automation Example Preconditions are satisfied? (Level-4) YES L3 TASK BREAKDOWN YES Postconditions are satisfied? (Level-4) YES Next Higher Level Command NO Is there any condition that is not met In subtasks? YES Auto Abort Manual Mode System State Pre-condition Post-condition Tool is in carousel True False Upper gripper open True False Lower gripper open True False Upper arm holds a tool False True Lower arm holds a tool False True Carousel stopped True True Tool is in carousel True False Upper gripper open True False 25

26 CRD 100 Task Time Prediction Time Taken for Each Activity 21m Boring with continuous core sampling and casing in upper 7.5m: 0 to -7.5m BML: 5 x conventional core barrels (146mm OD) to -7.5m BML: 5 x casing string (114mm OD) T Coring Casing Laying Wireline Sampling Trip Out Rod Trip Out Casing With automation & wire line: 6.7 hrs With end rod: 17.3 hours. Wire line method is 4.4 times faster. -7.5m to -21m BML: Wireline core sampling: 92mm OD x 74mm ID inner tubes + 89mm OD drill rods. Rods & casings tripped out at EOH Coring advance rate assumed at 2mm/sec. If boring was 64.5m: wire line would be 6.7 times faster 26

27 Summary & Conclusions The remote control of seabed drilling and sampling operations is generally heavily reliant on human intervention and interaction via the surface control console/interface The drilling and sampling process is characterised by a number of repetitive tasks which can increase the potential for catastrophic human errors as a result of operator fatigue and distraction. Automation of these tasks can reduce the likelihood of these errors and also increase process efficiencies through an overall reduction in operating time. The NASA Standard Reference Model NASREM has been applied to the design of the control system architecture for the CRD 100 drilling and sampling machine. The latest built CRD 100 (2015) features automation capability to the NASREM level-4 task level. Level-5 task verbs have been coded, bench tested and now require testing on a CRD 100 platform 27

28 Summary & Conclusions A task execution time prediction model has been developed and partially validated against actual task executions durations measured during recent CRD 100 trials. This task time prediction model has value both for the system developer and operator in overall performance prediction and improvement activities and in specific drilling and sampling mission planning. The application of the wire line process to seabed drilling and sampling machines has greatly improved process efficiency and can be 4-5 times faster than the alternative surface based method. 28

29 References Jackson, E., Buchan, K., Eddy, D. and Springle, G., Ground-Based Control of the SPDM Manipulator. Proceedings of the International Conference on Intelligent Teleoperation Greensboro, NC. Lumia, R., Fiala, J. and Wavering, A., The NASREM Robot Control System Standard. Robotics and Computer-Integrated Manufacturing, 6 (4), pp Yetginer, A. G. and Tjelta, T. I., Seabed Drilling vs Surface Drilling A Comparison. In: S. GOURVENEC and D. WHITE, eds. Frontiers in Offshore Geotechnics II, London: Taylor Francis. 29

30 Thank-you! For further information: Cellula Robotics UK Ltd. Brathens Eco-Business Park Hill of Brathens Glassel Aberdeenshire AB31 4BW Tel E: W: 30 Copyright 2016 Cellula Robotics Ltd.