Reliable Power in the Offshore Drilling Industry

Transcription

1 Reliable Power in the Offshore Drilling Industry Lew Weingarth Dan Kimmel There are several types of offshore drilling rigs Platform Jackup Anchored Semisubmersible Dynamically Positioned 1

2 Platform Drilling Rig Bottom supported or anchored Semi permanent costs up to $4 Billion Daily oil production up to $30 million Multiple redundant gensets Multiple small redundant consumers Nearly constant load Data reliability issues Jackup Drilling Rig Bottom supported Costs $200-$300 million Day rate from $50K-$200K 3 5 Diesel Generators (1-4MW) Limited number of consumers Highly variable load Data reliability issues 2

3 Anchored Semisubmersible Drilling Rig Anchored in 150 3,000 meters Costs $300-$400 Million Day rate from $200K-$400K 3 5 Diesel Generators (3-7MW) Medium number of consumers Highly variable load Data reliability issues Dynamically Positioned Drilling Rig Holds station with DP Costs $500-$1,200 million Day rate from $400K-$700K 6 8 Diesel Generators (5-10MW) Hundreds of consumers 1kW 12 MW Highly variable loads Blackout risks revenue and environment Data reliability issues 3

4 Quick History of Dynamic Positioning Sedco 445 is the first DP rig 1971 to DP rigs built, 7 by sedco 1983 to DP rigs built, 5 retired Mini boom bring the worldwide DP Drilling Rig Fleet to 32 units Construction in S. Korea and Singapore increases worldwide DP Drilling Rig Fleet to 100+ units, new shipyards starting up in China, Brazil. No slowdown in sight as of 2012, launching 6-10 new DP rigs every year 3-Dec of 29 Vulnerability of DP Drilling Rigs Drive off Drift off Push off BOR < Drift off time Drive off avoidance Push off management Wellhead strength Soil strength Sea floor topography Nearby structures WSOC, FSOC Run more generators Split busses 4

5 DP Rigs Have Many Integrated Systems Generators SWBD ECR DP Control Top Drive Drawworks Driller Thrusters Mud Pump BOP Power Reliability Issues Generators Top Drive Drawworks SWBD Thrusters ECR DP Control Diesel Generator Issues Loss of fuel (human, equipment, algae) Loss of engine room (fire, flood) Loss of start air. Most vessels/rigs have dc electric starts to avoid this issue. Generator faults Human error Fuel rack Oil pressure Cooling system Mud Pump Avr glitches,failures BOP Inrush Grounding Load sharing Driller 5

6 Power Reliability Issues Generators SWBD ECR DP Control Top Drive Drawworks Thrusters Switchboard Issues AVR Protective Relays Loss of room (fire, flood) Bus faults Human error Mud Pump BOP Driller Power Reliability Issues Generators SWBD ECR DP Control Top Drive Drawworks Control Room Issues Loss of control room Loss of automation system Network errors Human error Hmi control errors Ladder Mud Pump logic writing errors Thrusters BOP Driller 6

7 Generators Top Drive Power Reliability Issues SWBD Equipment Issues Loss of equipment ECR Fault or failure Loss of control (runaway, over/under excitation) Human error DP Control Drawworks Driller Thrusters Mud Pump BOP Power Reliability Issues. Equipment issues Many large consumers Bought from multiple vendors, mostly s/n 1 Multiple missions Few to none understand power or electrical issues Power management systems must compensate in software for equipment faults Power management vendors don t understand drilling or drilling equipment Interface issues Limit power consumption, shed loads, or share reductions Under powered, cannot accommodate inrush 7

8 Power Reliability Issues. Hardware issues Unexpected faults and failures Inadequate acceptance testing Inadequate design Software typically is designed for the industrial mission, fails to compensate for every failure mode Doesn t understand the other end of an interface No allowance for knock-on effects Engineering department of owners, vendors, shipyard, Class, and Government agencies ALL lack understanding Rules and regulations are murky or conflicting Power Reliability Issues. Software issues Software is everywhere Software typically is designed for the industrial mission, fails to compensate for every failure mode Doesn t understand the other end of an interface No allowance for knock-on effects FMEAs ignore software because it s too difficult Specialized vendors producing specialized equipment Range checking seems to have been forgotten Divide by zero Tangent functions Infinite mass or zero draft 8

9 Power Reliability Issues. Noise Issues Load created noise may affect other equipment Harmonics Spikes Distortion Ground carried noise Noise can affect electronics Damage components Shorten life Cause mal-operation Noise can affect software Data errors Intermittent crashes Human Problems Inadequate crew experience Dilution of talent due to expansion 25 years without CAPEX 90% of fleet built since 1995 Short term management prevented proactive measures Talent gap Political oil prices destroyed drilling industry Minimal hiring and training, for 25 years Long stable crews protected shore based management Experienced staff is retiring Inexperience causes mistakes - 5 year learning curve More than 90% of power faults human error, caused or failed to correct Class and Regulatory and Vendors have the same problem 9

10 Questions? Lew Weingarth 10