Intelligent BOP RAM Actuation Sensor Systems

Transcription

1 Intelligent BOP RAM Actuation Sensor Systems Emad Andarawis GE Global Research Ultra-Deepwater Drilling, Completions and Interventions TAC meeting January 29, 2014 Greater Fort Bend Economic Development Council Boardroom, Sugar Land, TX 1 rpsea.org

2 Working Group / Domain Experts o Leonard Childers (BP) o Herve De_Naurois (Total) o Greg Gillette (GE Hydril) 2

3 Program Overview o Phase 1 Develop sensing system for detecting drill collars, tool joints and other unshearable objects in vicinity of BOP rams Develop sensor error correction scheme for reliable detection Develop sensor integration concept o Phase 2 Design and construct and test prototype o Start Date Oct-2013 / POP 33-months 3

4 Program Overview o Phase 1 Develop sensing system for detecting drill collars, tool joints and other un-shearable objects in vicinity of BOP rams Develop sensor error correction scheme for reliable detection Develop sensor integration concept o Phase 2 Design and construct and test prototype o Start Date Oct-2013 / POP 33-months 4

5 Program Schedule, Milestones and Deliverables 5

6 Task 5 Develop BOP Ram Sensing and Interface Concept o 5.1 Perform sensor evaluation for diameter, thickness, and location measurement o 5.2 Characterize drilling fluids o 5.3 Develop sensor signal conditioning and processing concepts o 5.4 Evaluate sensing system error sources o 5.5 Evaluate multi-sensor data correlation o 5.6 Perform sensor system operational reliability and risk assessment 6

7 Task 5 Develop BOP Ram Sensing and Interface Concept o 5.1 Perform sensor evaluation for diameter, thickness, and location measurement o 5.2 Characterize drilling fluids o 5.3 Develop sensor signal conditioning and processing concepts o 5.4 Evaluate sensing system error sources o 5.5 Evaluate multi-sensor data correlation o 5.6 Perform sensor system operational reliability and risk assessment 7

8 Task 6 Develop Sensor Integration Concept o 6.1 Evaluate mechanical integration of sensor with BOP o 6.2 Evaluate software integration of sensor with BOP o 6.3 Phase 1 report 8

9 Phase 2 o Task 7 Detailed Sensor System Design 7.1 Define sensor configuration and design sensor electronics 7.2 Design signal conditioning and sensor data processing algorithms and software 7.3 Develop mechanical integration design o Task 8 Prototype Construction 8.1 Build sensor prototype 8.2 Develop software for integration with sensor prototype 8.3 Evaluate sensing system manufacturability o Task 9 Sensor System Prototype Test 9.1 Design and build test bed 9.2 Perform sensor system functional testing in simulated environment 9.3 Perform mechanical and endurance testing 9

10 Financials Year 1 Cumulative Baseline/Actual Comparison $1,600,000 $1,400,000 $1,200,000 $1,000,000 $800,000 $600,000 Project Cost Baseline Actual $400,000 $200,000 Tech Transfer current spend: $6,166 $ Through Jan 24th 10

11 Envisioned BOP Sensing System 11 Envisioned Auto-compensated sensing system capable of accurately performing the measurement in the presence of confounding noise.

12 Program Approach o Sensing System Evaluate applicable sensing technologies including: Ultrasound Electromagnetic, RF, Capacitive Xray Multi-sensor data correlation / auto-compensation approach Homogeneous sensors Heterogeneous sensors o Prototype Functional testing in lab-scale test bed Functional validation in BOP emulating test bed Endurance testing in simulated vibe, pressure and temperature environment 12

13 Sensor Selection 13

14 Sensor Evaluation testbed o Initial-subscale sensor evaluation testbeds for sensor down selection Sub scale/fullscale geometries Critical performance parameters First sensor down-selection based on Attenuation/coupling through drilling fluid Signal/noise versus distance Achievable measurement resolution/fidelity 14

15 Sensor Evaluation Electromagnetic o Critical Parameters Wetted versus unwetted. Field shaping Frequency Distance Losses in magnetic materials / Distance of sensor from casing Power 15

16 Sensor Evaluation Electromagnetic Casing Drilling fluid Drill string EM sensor under test Tool joint 16

17 Sensor Evaluation Electromagnetic Complex impedance versus pipe diameter Impedance Time 17 Baseline (no drill pipe) Smaller diameter pipe Larger diameter drill pipe (tool joint)

18 Sensor Evaluation -- Ultrasound o Critical parameters Mechanical Coupling Wetted versus unwetted Frequency Ring-down Distance Placement Drilling fluid Target UT sensor under test Variable distance between sensor and target 18

19 Sensor Evaluation X-ray o Critical Parameters Energy level Wetted versus unwetted Field shaping Distance/attenuation Integration time Transmission vs. backscatter X-ray test setup 19 Image Quality Indicator

20 Sensor Evaluation X-ray Drilling mud 20 Drilling mud + 1 layer of casing Drilling mud + 2 layer of casing

21 Sensor Evaluation X-ray 21 X-ray attenuation evaluation through oil & water based mud for wetted and unwetted sensors

22 Next Steps next 6 months o o o o o Complete initial sensor down-selection Sensor technology Wetted versus unwetted sensors Water versus oil based drilling mud Finalize requirements and sensing goals Measurement speed Drill pipe/tool joint geometries Build Rev 2 characterization test bed Complete second-level characterization Presence of cuttings, drill pipe motion Down-select approach Sensor technology Placement Frequency range / energy level Rev-2 Characterization testbed. 22

23 Questions? "This presentation was prepared with the support of RPSEA under Award No However, any opinions, findings, conclusions or other recommendations expressed herein are those of the author(s) and do not necessarily reflect the views of RPSEA." 23

24 Contacts PI: Emad Andarawis GE Global Research RPSEA PM: Don Richardson