subsea inspection and sensings technology · pdf filesubsea inspection and sensings...
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SUBSEA INSPECTION AND SENSINGS TECHNOLOGY
CLEAR GULF JIP
David Brower [email protected]
281 464-9992
Astro Technology Inc. October 21, 2010
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CLEAR GULF JOINT INDUSTRY PROJECT
• JIP Formed in 2010 – Joint project involving NASA, Oil and Gas
companies and Astro Technology • Advances Sensing/Inspection Technology
in Deepwater Fields for Oil and Gas Exploration and Production
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CLEAR GULF JIP OVERVIEW
• Advance existing sensing technology – Measurements to mitigate structural failure
• Strain, vibration, fatigue – Flow assurance – problem identification
• Temperature, pressure, wax build-up, hydrate formation
– Leak detection – Subsea field inspections
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DEEPWATER RISERS
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SUBSEA TECHNOLOGY OVERVIEW
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CLEAR GULF JIP ADVANTAGES
• Reduce risk of hydrocarbon spillage • Improve safety • Significant cost avoidance and downtime • Assists in regulatory compliance • Improved subsea field design • Low investment cost for JIP participants • Utilize NASA facilities and expertise
– US flagship technology organization • Credible third party involvement
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EXPECTED JIP OUTCOME
• Improvement to operation methods in oil and gas projects
• Enhanced safety for offshore operations • Better environmental control and reduction
in leak potential • Industry wide job creation
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ADDITIONAL JIP NEEDS
• Cost effective methods to deploy sensors in subsea environment – Mini-Remote Operated Vehicle (ROV) – Subsea robotic manipulators and interfaces – ROV communications to topside – Additional subsea sensor types
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Offshore Projects • Bass Lite • Devils Tower • Geauxpher • Troika • Pluto • BP Ocean Clipper / Ocean Confidence • Mardi Gras • Holstein • Thunder Horse • Brass LNG – Engineering phase
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TRIDENT SUBSEA MONITORING SYSTEMS
INSTRUMENTATION METHODS
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Monitoring Systems
• Deepest monitoring system – 7500 ft • Longest monitoring system– 60 miles @
7000 ft depth • Coldest – cryogenic LNG and LN2 • Hot – interior of solid rocket motor
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Vision for Offshore Monitoring Technology
• Monitoring Systems as a vital input to long term Riser and Pipeline Integrity Management
• Smart Field Technology supporting Flow Assurance of pipeline systems
• Innovative methods implementation
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SCOPE OF WORK
• Temperature, pressure, strain monitoring • Mitigate structural failure • Low cost – ease of use inspection system • Flow assurance • Hydrate and wax detection • Slugging – sloshing monitoring • Leak detection • Subsea field real time monitoring
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SOW - Visual Inspection of Subsea Deepwater Pipelines
• Preliminary study to visually inspect pipeline at depths up to 10,000 feet.
• React to anomalies reported through fiber optic monitoring system.
• Visual data will be analyzed and displayed along with strain, pressure and temperature data.
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First use of fiber optic sensors on a subsea pipeline to monitor pressure, strain and vibration in external casing pipe bundle during fabrication. Astro Technology was used in this new application.
Bullwinkle Platform
Troika - Gulf of Mexico
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FIBER-OPTIC SENSORS FOR DEEPWATER DRILLING
OCEAN CLIPPER
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OCEAN CLIPPER VIV DATA
Fiber-optic Sensor Data
-30
-20
-10
0
10
20
time (~6 minutes)
mic
rost
rain
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FIBER-OPTIC SENSORS FOR DEEPWATER DRILLING
• Measurement of strain & vortex induced vibration (VIV)
• Tool for service life evaluation & time-to-inspection • Concern for structural integrity of drilling risers • Fiber-optic sensors for deepwater drilling
operations – Depths up to 12,500 feet – currently 7500 feet
• Fatigue assessment • Real-time monitoring of strain and vibration • Riser management tool to
– Increase service life – Detect damage
Show Riser Manager Current Tank
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Bass Lite Real Time Monitoring
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Ruggedization and Reliability Efforts
Ruggedization task developed for pipelines/risers Sensors, connectors, cabling, deployment methods
7500-ft deep instrumented systems
9-month deployment in deepwater followed by
topside inspection and verification testing
Laboratory testing demonstrated sensor and hardware usage up to 12,500-feet depths
RESULTS: Successfully demonstrated
ruggedness and reliability
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Deployment from Ocean Confidence
Moonpool access to the riser flange
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Observations Following Nine-month Deployment
– The fiber-optic sensors were fully functional
following 9-months of subsea service – The sensors were able to accurately measure
dynamic strains in the joint – The Fiberglas/epoxy case used to protect
sensors maintained integrity and showed no evidence of degradation
– Subsea connector - fiber-optics in excellent condition
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Post Deployment Riser Observations
Removal of buoyancy modules to inspect sensors and protective Fiberglas/epoxy wrap
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Excellent Fiberglas/epoxy condition
Intact rugged optical cable
Post Deployment Riser Observations
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Strain Readings for New Iberia Test #1 - Pick up at Flange
-500.00
-400.00
-300.00
-200.00
-100.00
0.00
100.00
200.00
300.00
400.00
1 75 149
223
297
371
445
519
593
667
741
815
889
963
1037
1111
1185
1259
1333
1407
1481
1555
1629
1703
1777
1851
1925
1999
2073
2147
2221
2295
Time
Mic
rost
rain Strain 1
Strain 2Strain 3Strain 4
Data collected when one end of the joint was lifted with a crane
Post Deployment Riser Testing
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Riser Monitoring System
• Offshore Cable Installation
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Riser Monitoring System
• Topside Equipment Rack Installation
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SCR Monitoring System
• Offshore Installation
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Riser Monitoring System
• Sensor Station Installation
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Riser Monitoring System
• SCR Cable Manufacture
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Riser Monitoring System
• Hull Conduit Cable Installation
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Riser Monitoring System
• Kit Equipment Manufacture
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Riser Monitoring System
• Kit Equipment Manufacture
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Riser Monitoring System
• Offshore Fiber and Electrical Hookup
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Riser Monitoring System
• Offshore Cable Installation
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Riser Monitoring System
• Offshore Installation
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Riser Monitoring System
• Offshore Cable Installation
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Riser Monitoring System
• Offshore Installation
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Riser Monitoring System
• Deepwater Installation
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Riser Monitoring System
• Deepwater Installation
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Riser Monitoring System
• Deepwater Installation
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Deepwater Data – Steady State
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Deepwater Data – Chain Jacks Moving Platform
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Proprietary and Confidential
Property of Astro Technology Inc.
Reproduction without permission is prohibited
Deepwater Data – Flushing Pig Passage
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Riser Monitoring System
• Clamshell Qualification Testing
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Riser Monitoring System
• Sensor Station Installation
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LNG SENSOR LAYOUT
LNG
Multi Product
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LNG SENSOR LAYOUT
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SENSOR LAYOUT
FOBA location
PLET strain monitoring locations
Bulkhead PLET
STRUCTURAL MONITORING
BULKHEAD MONITORING
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Cabling, Splicing and Connectors
FOBA Examples
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Cabling, Splicing and Connectors PLET Instrumentation
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Subscale Test Summary
• Ambient temperature • One million cycles • One hertz • ~1100 microstrain • No degradation in
adhesive/bonding observed
CYCLIC TEST
Fatigue Cycling Ambient Temperature
1538.4
1538.6
1538.8
1539
1539.2
1539.4
1539.6
1539.8
1540
1540.2
1540.4
0 00 10 00 20 00 30 00 40 00 50 00 60 00 70 00 80 00 90 00 100 00
Wav
elen
gth
(nm
)
Series1
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Subscale Test Summary
• LN2 temperature – -192 deg C
• 50,000 cycles • ~1100 microstrain • One hertz • No degradation in
adhesive/bonding observed
CYCLIC TEST
Cryogenic Fatigue Test Compression
1534
1535
1536
1537
1538
1539
1540
1541
0 1000 2000 3000 4000 5000
Time (s)
Wav
elen
gth
(nm
)Series1
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Subscale Test Summary CRYOGENIC LEAK TEST
Fast response time
Detect leak in 2 seconds
Identify location of leak in ~ 2 minutes
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Hydrate Blockage • Advanced method developed to scan pipeline
and detect blockage – Relative amount – Location – ROV deployable
• Subscale demonstration
– Successfully demonstrated blockage in 8 inch pipelines
– Transducers in development for deepwater application
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Software – Process Monitoring • Fully utilize existing measurements
– Hundreds of isolated measurements – Advanced Monitoring places data in context (as
opposed to raw data) – Holistic view of available measurements
• Provides Smart Notifications
– Early leak detection – Identify leak location – Reduction of unplanned shutdowns due to false
alarms – Abnormal situation management
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Deepwater Monitoring Software Connect to live systems Web accessible configuration and results
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Monitoring from Remote Locations • Remote display of real-time data • Secure & encrypted data transmission • Getting the right data to the right people to
make the right decisions
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Remote Access to Pipeline Data
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Software Benefits Trident Subsea Systems
• Meet regulatory reporting requirements • Flow assurance of oil and gas transport
pipelines • Structural characterization • Visualize data from remote locations • Reduce alarms by consolidating relevant
information • Improved design and operations • Improved safety and environmental criteria