Instrumentation of Top Drives for Prevention of Dropped Objects on Drill
Floors
Chris Tolleson
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The Lloyd’s Register Group at a glance
• Offices in 250 locations worldwide delivering services in
228 countries and territories
• 9,000 employees of 90 nationalities
• Celebrated our 250 year anniversary in 2010
• Charitable basis - safety of life; i.e. no shareholders
• Four business divisions:
• Marine
• Energy
• Transportation
• Management Systems (LRQA)
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LR Global Technology Centre Singapore
• Created to address the challenges in the industry,
particularly energy sector
• Significant investment of S$35m over 5 years
• Current headcount of 32 employees and growing
• 5 core technology programmes:
o Risk exposure
o Next resources
o Life extension
o Uptime & Energy Efficiency
o Smart supply chain
• Research collaboration with internal and external
partners
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GTC Research Team
Expertise Areas
•
Drilling, subsea, well control
•
Asset & structural integrity
•
Hydrodynamics / CFD
•
Risk management
•
Failure analysis
•
Marine technology
•
Engineering dynamics
•
Floating offshore
•
Pipelines & risers
•
Offshore wind
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LR Global Technology Centre - Key Milestones
Sep 2012
A*Star Master Research
Agreement established
Jan 2013
First Industrial
Postgraduate Programme
candidate on board
NUS and NTU student
recruitment continues
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Feb 2013
First project agreement
signed with A*STAR
Apr 2013
Joint lab with A*STAR
Institute of High
Performance Computing
established
Oct 2013
LR Global Technology
Centre Research Lab
LR Energy Drilling Training
Centre launched
Current Focus Areas at GTC
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Subsea, Drilling & Well Control Equipment
- Radio Frequency ID tags (RFID)
- Blowout preventer (BOP) modelling
- BOP risk model
- Data mining
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Assumption on top drives
• Drops are caused by forces on top drives that exceed operational
parameters
• One could argue that dropped objects are likely to happen when the
top-drive structure is in resonance and when the vibration exceeds
certain threshold.
• On the other hand, impacts on the drill-bit are expected to cause
broad band excitation of the drilling string and top drive.
• The fact that the system is rather complex and it changes
continuously through the drilling process makes the task to obtain
the modal response of the structure complicated.
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Modal Analysis
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Operational Modal Analysis
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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.
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Fibre Optic Sensor Types
os3110 Metallic Weldable
Strain Gage
os3200 Non-Metallic Flexible
Strain Gage
os3155 Metallic Weldable Strain
Gage
os4100 Temperature
Compensation Gage
os4200 Single Ended Calibrated
Temperature Gage
os4310 Double Ended Calibrated
Temperature Gage
os4350 Double Ended Calibrated
Temperature Gage
os1100 Single FBG in polyimide
coated fiber
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os7100 Accelerometer
Fibre Optic Interrogators and Controllers

4 channels with a spectral width of 1510 to 1590 nm. Available from 1410 to 1590 nm

1hz to 2 khz scanning frequency

Wavelength repeatability 1pm@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 32GB 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
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Discussion of a Riser Tensioner
Monitoring System Installed on the
Semi-Submersible
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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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Top View of Riser Tensioner
Layout Under Drill Floor
1 2
3
6 5
4
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Functional Description of
The Riser Tensioners
Tensioners on the Semi-Submersible
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Sensor Layout for Two 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.
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Equipment Rack
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•
•
•
•
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
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Discussion
•
Sensors were installed in the Bosch Rexroth facility in Uden Netherlands in
September 2012.
•
Real time calculations and display are within 5% of modeled loads.
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Ideal System For Characterizing Top Drive Vibration and Forces
•
Independent of the OEM equipment
•
Never needs calibration
•
Doesn’t require local power
•
Intrinsically safe
•
Tells us strain, vibration, acceleration, temperature, and pressure and more…
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Conclusion
•
Drops from Top Drive JIP proposed
•
Methodology and Suitable Sensors Discussed in JIP proposal
•
Further Discussions about participation in the JIP
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Acknowledgments
•
Williams (end customer)
•
•
•
Durham Geo Slope Indicator (DGSI)
Sandia National Laboratories
•
Tel: 800-837-0864
•
Email: dge-solutions@durhamgeo.com
•
Tel: 505-284-5400
•
Web: www.durhamgeo.com
•
Email: jonwhit@sandia.gov
Micron Optics, Inc.
•
•
Jonathan White
Transocean
•
Tel: 404-325-0005
•
Email: info@micronoptics.com
•
Tel: 713-23207959
•
Web: www.micronoptics.com
•
Email: aaron.barr@deepwater.com
University of Minnesota
•
•
Jeff Marr
•
Tel: 612-624-4427
•
Email: marrx003@umn.edu
©Lloyd’s Register Global Technology Centre
•
Aaron Barr
First
name
Last name
Chris
Tolleson
Position
Systems & Controls Lead Specialist
Unit/ Department
Subsea,
Drilling & Well Control Equipment
T +44 (0)23 2345 5432 E xxxxx.xxxxx@lr.org
T: +65 6594 6960
Lloyd’s Register [Entity]
M: +65 9657 0674
71 Fenchurch Street, London EC3M 4BS
E: Chris.Tolleson@lr.org
Lloyd’s Register GTC, Global Technology Centre
1 Bukit Batok Street 22 #03-02A GRP Industrial Building
Singapore, 659592
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for a safer world
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