Offshore Technology
Transcrição
Offshore Technology
Offshore Technology OMAE 2008 Underwater Vehicles: Propulsion: The Schottel Arctic shipping: Arctic “Neumayer III”: Ocean energy: Rexroth rises Ice barriers: Ice Protection Maritime robots for survey and security 3 Sauna at the South Pole Ship Design: Drilling in Ice 8 6 Combi Drive: suited to offshore application 10 to the Power Take-Off 12 knowledge at DNV informs risk management 14 Structures 16 Hydac: Condition monitoring Pipeline monitoring: Hydroof oil systems 13 carbon sensor systems 19 International Publication for Shipping and Marine Technology PUBLISHER DVV Media Group GmbH | Seehafen Verlag Postbox 10 16 09, D-20038 Hamburg Nordkanalstraße 36, D-20097 Hamburg Telefon: +49 (0) 40 2 37 14 - 02 MANAGEMENT Dr. Dieter Flechsenberger (CEO) Detlev K. Suchanek (Publishing Director) [email protected] EDITOR Dr.-Ing. Silke Sadowski (resp.) Phone: +49 (0) 40 237 14 -143 [email protected] ADVERTISING Florian Visser (resp.) Phone: +49 (0) 40 2 37 14 - 117 fl[email protected] SUBSCRIPTION AND DISTRIBUTION Riccardo di Stefano [email protected] SERVICE Phone: +49 (0) 40 2 37 14 - 260 Fax: +49 (0) 40 2 37 14 - 243 E-Mail: [email protected] REPRESENTATIVES: Germany, Austria, Switzerland : Con’Media GmbH Friedemann Stehr, Bad Hersfeld Telefon: (0 66 21) 9682930, Fax: (0 66 21) 9682933 [email protected] France AD Presse, E. Costemend, Paris Telefon: +33 (0) 686646285, Fax: +33 (0) 1 45 25 14 28 [email protected] Great Britain, Ireland: UK Transport Press, Cuckfield Phone/Fax: +44 (0) 14 44 41 42 93 bernardsteel@uktpl. com Poland, Russia, Baltic States: Promare Sp.z.o.o., Gdynia Phone: +48 (0) 5 86 64 93 92, Fax: +48 (0) 5 86 64 90 69, [email protected] Scandinavia, Finland: Örn Marketing AB, Ystad Phone: +46 (0) 411 1 84 00, Fax: +46 (0) 411 1 05 31 [email protected] USA, Canada: Weidner Communications, Matthew T. Weidner, Downingtown, PA, USA Phone: +1 610 486 6565, Fax: +1 610 486 6527 [email protected] SUBSCRIPTION RATES Germany: EUR 174,00 (incl. postage) plus VAT Europe: EUR 193,00 (incl. postage) )FSFJTUIFSJHIU BEWFSUJTJOHNFEJVNGPS UIFNBSJUJNFTFDUPS 5BLF 'PSPWFSZFBST4DIJGG)BGFOPGGFSTUPQ JOGPSNBUJPOGPSFYQFSUTPGUIFNBSJUJNF CSBODIF&VSPQFXJEFUIFEFDJTJPONBLFST SFBEUIJTNBHB[JOFUPJNQSPWFUIFJSLOPX MFEHFJOUIFNBSJUJNFXPSME "TLGPSPVSDVSSFOU 6TFUIJTGPSZPVSFGGFDUJWFBEWFSUJTJOHQMBU NFEJBQBDL GPSNUPNBLFZPVSDPNQBOZZPVSTFSWJDFPS 8FBSFMPPLJOHGPSXBSEUP ZPVSQSPEVDUXFMMLOPXOJOUIFNBSLFU IFBSJOHGSPNZPVTPPO %77.FEJB(SPVQ(NC)]4FFIBGFO7FSMBH /PSELBOBMTUSBF)BNCVSH 1IPOF'BY &[email protected] World: EUR 216,00 (incl. postage) Single copy: EUR 17,50 (incl. VAT) SUBSCRIPTION TERMS The minimum subscription period is one year. Subscriptions may be terminated at the end of any subscription period by giving six weeks‘ notice. The publishers accept no liability if it is impossible to publish the magazine due to force majeure or any other cause beyond their control. COPYRIGHT The magazine and all the individual articles and illustrations contained in it are protected by copyright. It is not permitted to reproduce or distribute any part of this magazine without the publishers‘ prior written permission. This prohibition extends in particular to any form or commercial copying, inclusion in electronic databases or distribution on CD-ROM or DVD. The publishers are not liable for unsolicitedly sent manuscripts and images. PRINT: Druckerei Knipping, Düsseldorf, Germany WEB: www.schiffundhafen.de www.dvvmedia.com ISSN 1436-8498 Maritime robots for survey and security UNDERWATER VEHICLES Maritime investigations, measurements and inspections with autonomous underwater vehicles (AUV) are a core element of ATLAS Elektronik to discover the underwater resources for economic use as well as for the protection of maritime facilities. The operation under extreme and difficult environmental conditions requires the use of robots of the newest technology with high degree of automation and extreme navigation accuracy. Willi Hornfeld E conomic use of the seas and oceans as well as protection of the ports and their access has a top-ranking position – the maritime market has reached world-wide an enormous order of magnitude. In this market a German company in general has not only a strong position, but in some special maritime engineering fields even a top place. In this environment the substantial target areas of the German maritime technologies are: The strongly growing and important market segments such as oil and gas production from the sea bottom, underwater mining, exploration and exploitation of gas hydrates, etc.. Maritime Homeland Security, one of the highest priority missions around the world with the strategic objectives Prevent terrorist attacks within and terrorist exploitation of the national domain Reduce the countries vulnerability to terrorism within the maritime domain Protect the population centres, critical infrastructure, maritime borders, ports, coastal approaches, and the boundaries and seams between them Protect the marine transportation Minimize the damage and recover from attacks that may occur in the maritime domain as either the lead federal agency or a supporting agency. One of the core elements for a Maritime Homeland Security is the protection of harbours, a razor edge of danger. Sea Ports and Sea Lanes are the primary gateways for global trade and commerce. Ports are the nerve centers of the international supply chain network. Operational drop-outs of any of such critical hubs and bottlenecks will hence generate consequential damages on a truly global scale. The European Sea Ports Organisation (ESPO) determines that “the Eu- Fig. 1: ATLAS’ UUV family Schiff & Hafen | June 2008 | No. 6 3 Special SPECIAL | OFFSHORE TECHNOLOGY Parameter SeaFox Length [m] 1.3 Width [m] Ø 0.4 (max) Weight [kg] 40 Speed [ktd] •max 6 •min 0.5 (backwards) Diving depth [m] 300/600 Payload [kg] 5 Obstacle avoidance yes Hover capability yes Tab.1: SeaFox parameter Parameter SeaWolf Length [m] 2.0 Width [m] Ø 0.5 (max) Weight [kg] 110 Speed [kts] max 8 min Minus 0.5 Turn radius <3m Diving depth [m] 3 to 300 Payload [kg] > 30 Fig.2: The SeaFox family ropean Union without its seas port cannot act directly. The entire foreign trade of the community and nearly half of their domestic trade are almost conducted via the more than 1,000 sea ports in the coastal member states of the European Union.” Obstacle avoidance yes Autonomous underwater vehicles Hover capability yes Navigation INS + DVL + (D)GPS + pressure sensor + compass Maritime investigations, measurements and inspections with autonomous underwater vehicles (AUV) are a core element of the above mentioned market and growth fields. The fundamental pre-condition is however the ability for precise acting in unknown waters as well as the technologies for the protection of maritime facilities (e.g. inspection of berthing areas, piers and ship hulls) under extreme and difficult environmental condition. This requires the use of robots of newest technology with high degree of automation and extreme navigation accuracy with high manoeuvrability. Such unmanned underwater vehicles are one of the main product areas of ATLAS Elektronik. The company has been developing and delivering such vehicles for military and commercial applications for about thirty years. Current products to be noted are the SeaFox, the SeaWolf and the SeaOtter Mk II. The development of these AUVs respectively HAUVs (Hybrid Autonomous Underwater Vehicles) happens under consistent attention of as far as possible synergies between the individual systems. Beyond that the underwater vehicles are based substantially on dual use, i.e. they are designed for military and commercial missions, with that due to better serial production figures for the basic systems, a more attractive price for the customer can be reached. This philosophy shows Fig.1, the ATLAS UUV (Unmanned Underwater Vehicles) family which includes not only the Autonomous Tab. 2: SeaWolf parameter Parameter SeaOtter Mk2 Length [m] 3.45 Width [m] .90 Height [m] .48 Weight [kg] 1000 Speed [kts] •max 8 •optimal 4.0 •min 0.5 (backwards) hover Diving depth [m] 5 to 600 Duration [h] 24 @ 4 kts Obstacle avoidance Yes Hoover capability Yes Navigation MARPOS II (INS+DVL+DGPS+CTD+ pressure sensor) & CML Tab.3 : SeaOtter parameter TYPICAL USERS OF UUV´S Defence Forces Coast Guard Maritime Administration Customs and Immigration Port Authorities Environmental Agencies Commercial Operators Maritime Scientific Institutes Special 4 Schiff & Hafen | June 2008 | No. 6 Underwater Vehicles (AUV) but also Remotely Operated Vehicles (ROV). A further characteristic of the here discussed underwater vehicles is their modularity which, depending on the specific payload capacity, will be realized by the possibility of plug and play integration of quasi any payload. Finally all ATLAS UUVs can be mission-specifically equipped by the user with a fiber-optic cable (FOC), so that a wide-band, real time transmission to the surface of all sensor and status information can take place. Such hybrid AUVs (HAUVs) will open wider and completely new application areas. The UUVs SeaFox, SeaWolf and SeaOtter are characterised by most different users and several areas of application. With other the following applications are standing in the centre: Mine counter measure Damage assessment Intelligence Rapid environmental assessment Route survey Maritime border control Waterways and port surveillance Passenger terminal protection Maritime science. The following features are, depending upon payload capacity, realized or will be realized in the systems: Autonomous or operator supported inspection and classification of all kinds of underwater areas, structures and objects Adaptive autonomy in relation of the mission On line data link via fibre optic cable on request (hybrid) Operation in confined and tidal areas Inspection sensors of latest technologies in underwater vehicles Navigation/positioning of highest accuracy Standard interfaces for simple integra- tion of customer specified sensors and software (plug and play) High-performance multi sensor image processing on board or in the surface console 100% inspection of selected object assured CAD base inspection on request CAD object data creation during the inspection Alarm function in relation to the identified anomaly Prepared for team operation Object oriented mission planning and control. The UUV SeaFox is a small and lightweight (see Tab. 1) vehicle with an endurance of more than one hour. The vehicle is available in several configurations from the military systems (SeaFoxC for mine disposal and SeaFoxI and T for inspection and training) till the modular one IQ, predominately used for commercial survey missions. Thanks to this modularity, missionadapted sensor suits with e.g. 360° and side looking sonar as well as a tiltable TV system are installable as shown in Fig. 2. The HAUV SeaWolf is a multirole system for all kinds of underwater inspection and anomaly identification. The propulsion philosophy is comparable with the Seafox (four main propellers and one vertical thruster). Due to a special adjustment of the main motors a high efficiency was achieved. The vehicle is equipped with the latest sensor and software technologies and therefore able to inspect autonomously even very complex 3D objects. For real time data transfer, the SeaWolf can be connected with the control console by a fibre optic cable. In this case the mission will be executed autonomously but with a real time data transfer. SeaWolf achieves versatility and flexibility of mission and payload configuration by using plug and play modules for software, electronic and sensor devices within a generic architecture. The vehicle’s basic payload is a side scan and obstacle detection sonar as well as a TV camera with LED illumination. For operation in water with low visibility a three dimensional high frequency multibeam sonar and/or a laser projection unit are additional available. The navigation is of a very high accuracy and based on an IMU with DVL and differential GPS. Therefore the use of an acoustic positioning system is not necessary. Due to its relatively low weight, the system is easy to operate and applicable from all kind of vessels or from the shore. Fig.3: SeaWolf configurations Fig.4 : SeaOtter Mk II The mission planning, control and evaluation is done from a portable console, the same as used for the SeaFox. Tab.2 shows the SeaWolf parameter and Fig. 3 the system configuration. The HAUV SeaOtter Mk II is based on the proven MARIDAN 600 and the SeaOtter Mk I, which have been in operations throughout the world. Due to the design and the flexible payload concept, the system is easily adaptable to various military and commercial missions. The SeaOtter Mk II also offers the benefit of a real time data transfer to the operator consol through the fibre optic link option. The standard version of the vehicle is equipped with side scan sonar, a multi-beam echo sounder, a sub-bottom profiler, obstacle avoidance sonar, a TV camera and a precise navigation system. Due to its serious payload compartment (approx. 150 kg) the vehicle can per plug and play be adapted to nearly all kinds of required missions from scientific till maritime security applications. Tab. 3 gives the SeaOtter Mk II figures and Fig. 4 an impression of the design. Willi Hornfeld ATLAS ELEKTRONIK GmbH, Bremen [email protected] www.atlas-elektronik.com Schiff & Hafen | June 2008 | No. 6 5 Special SPECIAL | OFFSHORE TECHNOLOGY Sauna at the South Pole RESEARCH STATION “NEUMAYER III” Germanischer Lloyd’s Business Segment Oil and Gas offers its wide range of services all over the world. Just recently the experts also conquered the ‘sixth continent’: they certify the new research station “Neumayer III” N ot a single ray of sunlight penetrates the darkness of the polar winter night. The thermometer drops below 50°C as storms whip across the icy landscape. In this environment, buildings must be designed to withstand extremely hostile climate conditions. Materials must be selected carefully and the functional fitness of elements must be tested in realistic simulations. A house in Antarctica: In December 2006, Germanischer Lloyd received an order from the Alfred Wegener Polar and Marine Research Institute (AWI) in Bremerhaven, Germany, to certify the institute’s new research station “Neumayer III” in Antarctica. Even for an experienced classification society, this project is rather challenging. The station, named after the German polar explorer Georg von Neumayer (1826 to 1909), will consist of a structure supported by sixteen hydraulically operated posts. By moving up and down on these support legs, the building will adjust continuously to the changing level of the snow surface. As a consequence, the research station will not gradually disappear under masses of snow, as its predecessor did. Submerged in ice After 15 years of operation, the current Neumayer station has sunk twelve metres deep into the ice and will have to be abandoned in the near future. Built in 1992, the tube-type structure was state of the art at the time. But the two steel tubes that form its outer shell have been deformed over the years by the movement of the shelf ice and the constantly increasing load of snow. Today, the once elliptical shape of the station is no longer discernible. Time and again, bolts burst with a loud bang, unable to withstand the weight of tons of snow bearing down on the station. The engineering concept of the new station consists of a building to be erected on top of a platform above the snow surface. The building will accommodate rooms for research and operations as well as living quarters. To construct this unique facility, a pit eight metres deep will have to be excavated for the foundations of the hydraulic support pillars of the station. Later on, the pit will also be used as a parking area for tracked vehicles and snowmobiles. A workshop, the hydraulics centre, exercise rooms and food stores will be located directly below the cover of the pit. The station itself will be positioned on stilts six metres above snow level so even high winds and dense snowfall will not cause any major snowdrifts. The two-story building will be standing on a platform 68 by 24 metres large and provide space for common rooms, a kitchen, an infirmary and operating theatre, 15 bedrooms with 40 beds, as well as twelve laboratory and office rooms. Nine so-called “overwinterers” – scientists, physicians and technicians – will have nearly twice as much space for their work as in the subterranean station “Neumayer II”. For leisure, there will be a lounge with a bar and a sauna. Once the basic structure has been completed, a protective shell 120 mm thick with a blue, white and red coating – the colours of the AWI – will be placed on top of it to reduce wind loading. The roof offers enough space to accommodate a chamber for helium sounding balloons, as well as antennas and other measuring equipment. Certified containers Assembly of the “Neumayer III“ in Bremerhaven Special 6 Schiff & Hafen | June 2008 | No. 6 AWI-employees at the underwater acoustic measuring station “Palaoa“ The entire building itself will be assembled from containers certified by Germanischer Lloyd. GL has many years of experience in container certification. Today, the society certifies up to 360 000 containers each year. After the design review, GL subjected the thermally insulated containers to spe- The model shows the hydraulic posts of the garage level cial tests to check their fitness for transport. Those tests included stackability, as well as loading and unloading strength, which ensured that the containers were taken safely to Antarctica aboard a Danish freighter. Now, the GL experts main task is to review the documentation for safety-relevant equipment for the entire station – including evacuation and survival systems, fire extinguishing and fire alarm systems, automation and alert systems. “Due to the exposed location, the system as a whole has to meet the most stringent reliability requirements,” says An- BACKGROUND: ANTARCTICA The Antarctic Zone comprises the land and sea areas of the South Pole region. It covers a surface of approximately 12.5 million square kilometres. 98 percent of this area is permanently covered by ice. The continent of Antarctica is located in the centre of the region. The Antarctic was explored by various scientists and seafarers from 1920 onwards. The continent is characterized by an extreme climate: It is the coldest, driest and most wind-ridden part of the earth. There have been reports of temperature readings as low as – 89 °C and wind speeds exceeding 300 km/h. According to CONMAP (Council of Managers of National Antarctic Programs), there are currently more than sixty active research stations on the continent. dreas Mäscher, project manager of GL. “In this respect we can draw on our experience in offshore installations.” The AWI order also includes tests of the energy supply systems as well as the acceptance inspection of a combustion engine-based cogeneration plant at the manufacturer site. “Supplying the station with heat and energy is a particular challenge, considering the extreme climate conditions – low temperatures, large quantities of snow, high winds,” Andreas Mäscher emphasizes. Thanks to more efficient generation of heat and electricity in the cogeneration plant, the future station will need only 30 percent more polar diesel (diesel plus kerosene) than its predecessor although it is twice as large and will be exposed to greater wind loading. GL conducted the component acceptance tests for both, the diesel-operated generator and the hydraulically operated stilts. Last year, the lifting units were tested under low-temperature conditions to ensure flawless operation in the extreme temperature environment (+4 to -50° C) of Antarctica. In November 2007, the components were loaded onto the Danish freight vessel “Naja Arctica”, which reached the Antarctic Atka Bay on schedule in mid-December. However, a sea ice barrier of several metres thickness prevented the vessel from moving ahead. The research icebreaker “Polarstern” was appointed to free a navigation channel to the ice edge and helped “Naja Arctica” to reach her planned unloading position at the edge of the ice shelf only in mid-January 2008. Despite the one-month delay, the construction of Neumeyer Station III moved rapidly ahead in good weather conditions. In only eight weeks, the entire steelworks of the underground garage section with 16 hydraulically operated posts as well as the first floor of the future station were erected. The unfinished building is intended to be used as a store room for construction equipment and materials until the next Antarctic summer. The completion of the new station is scheduled for spring 2009. Then, a GL surveyor will join the construction site at 70° 40.8‘ south and 8° 16.2‘ west, 6.5 km away from the old station, to inspect the construction of the Neumayer III station and conduct the acceptance tests. The new research station, which will cost about 36 million euros, is designed for a service life of at least 25 years. The Alfred Wegener Institute, the operator of “Neumayer III”, will continue its research activities in Antarctica, recording important meteorological data and taking measurements of the earth’s magnetic field as well as atmospheric readings of climate-relevant gases. GL will continue to keep an eye on the station as well, says Andreas Mäscher: “There are plans for periodic inspections of the structure and its equipment.” Germanischer Lloyd, Hamburg www.gl-group.com Schiff & Hafen | June 2008 | No. 6 7 Special SPECIAL | OFFSHORE TECHNOLOGY Drilling in ice SHIP DESIGN The challenge for discovering Arctic oil and gas reserves will be to find solutions to produce gas and oil with the highest safety and environmental standards. For ice going drill vessels the Hamburg Ship Model Basin (HSVA) has done various innovative frontier developments. Karl-Heinz Rupp, Walter L. Kuehnlein I t is estimated that the Arctic contains more than one third of the world’s undiscovered oil and gas reserves. Although some developments have already occurred, the region remains one of the last energy frontiers. But the region is also one of the most difficult areas in the world to work at, due to its remoteness, the extreme cold, dangerous sea ice and its fragile environment. Big energy companies are preparing to go into the Arctic, they are taking measures in order to ensure that they will operate safely and responsibly. This is not the first run to the Arctic. Petroleum companies entered into the Arctic already half a century ago. Experiences from past Arctic developments show the potential hazards of further exploration. A key challenge will be developing and deploying solutions, which are currently at the cutting edge of technology. The Arctic Ocean is the only major sub-basin of the world’s oceans that has only occasionally been sampled by deep sea drilling. Today the properties of the Arctic Ocean are being focussed upon by both researchers and commercial oil and gas drilling companies. Research core drilling is of great impor- tance for the researchers because it allows them to increase their knowledge about that large ice covered area. And of course the present high prices for energy make it profitable to explore for reserves and to produce energy even in the ice covered waters of the High North. Drilling operations in ice have been already carried out at the ice border with “open water drill ships“, mainly with the support of icebreakers (e.g. “Joides Resolution” with “Maersk Master”). Some drill ships are reinforced for operation in ice, but this reinforcement is limited to the strengthening of the ship structure and does not include the propulsion and operational outfitting. An ice-breaking drill ship should be capable of keeping its position so that the drilling operation can be continued, also when it is surrounded by drifting ice. Existing designs concepts Some of the challenges which a drill ship in ice will experience, have been already described in 1983 (Dynamic Response of a Moored Drill ship to an Advancing Ice Cover, T. Kotras, A. Baird, E. Corona, Poac 83, Volume 3, Fig.1.: The cross section shows the sloped side of the HSVA drill ship design with ice accumulated Special 8 and Schiff & Hafen | June 2008 | No. 6 page 433, Helsinki, Finland, 1983): “The ability of a vessel to stay within a prescribed operational radius is greatly enhanced when impacting ice in a head-on condition. Beam-on collisions cause excursions from two to five times larger as those occurring head-on. The ability of a drill ship to quickly yaw into a heading inline with the advancing ice is directly related to the maximum excursion seen. In the Bering Sea, an unassisted drill ship may not be capable of year round operation during the heavy ice periods, ...“. Almost 30 years ago, in 1980, a drill-platform from Gulf Canada (Conical Drilling Unit) was tested in ice by HSVA. It was found that the rig could operate in an environment up to about one meter level ice thickness. This platform, the “Kulluk“, was kept in position with a mooring system. The shape of the platform was circular in the plan view and the section was similar to an asymmetrical sandglass. The turret was placed in the centre of this floating island. This platform was not suitable for being moved over a long distance at sea. In the last decade improvements in manoeuvrability and ice breaking performance have been achieved by applying azimuth propulsors. Nowadays several ice going and ice breaking vessels, e.g. icebreakers, supply vessels, tankers and multi-purpose container vessels are equipped with this type of propulsion system. New technical developments In 2000 contracted the AlfredWegener-Institut (AWI) in Bremerhaven Germany (www. awi-bremerhaven.de) the Hamburgische-Schiffbau Versuchsanstalt (HSVA) to carry out a draft design study for an Arctic Drilling Research Vessel with dynamic positioning capabilities in ice. The project was entitled “Aurora Borealis”. Drifting ice may change in both in speed and direction. Furthermore the ice conditions vary from easy to heavy (e.g. ice ridges), therefore the drill ship must be able to keep position within a very narrow margin. All of these requirements, as well as the technological developments described above have been taken into consideration for HSVA’s conceptual design for the “Aurora Borealis”. The technical features of the HSVA design are: Fig.2: Side view of “Aurora Borealis“ with two moonpools (as designed by HSVA) Low ice resistance of the drill ship at both bow and stern. This was achieved with an optimized icebreaking hull shape, similar to that of an icebreaker. High ability to turn the vessel in ice in order to follow changes in ice drift. This was achieved by implementing a strong slope at the side of the vessel (see cross sections). This hull shape allows the vessel to break ice over the entire ship length. In order to break the ice the azimuth propulsors deliver the required thrust for turning the drill ship. The vessel is able to operate in ice without icebreaker assistance up to very severe ice conditions, far above of the capabilities of all existing ice going drill vessels. With icebreaker assistance the operational limits of the drilling vessel can be further extended. Consequently, the HSVA design is the first design world wide, which will allow drilling in ice with a dynamic positioning, i.e. no fixed mooring system will be required. The HSVA design study for “Aurora Borealis” has been presented in several publications and presentations since 2001. The figures 1 and 2 are from: European Polar Board (EPB), Aurora Borealis “A long term European Science Perspective for Deep Arctic Ocean Research 2006-2016”, June 2004. Logistics in ice management In addition to the technological improvements, the logistics in ice management are also of great importance. The use of modern satellite ice and weather data are a first step for obtaining information about the ice conditions ,ice drift speed and drifting direction over a large area. Closer to the drill ship, ice drift speed and direction can be detected by sensors installed on board of the drill vessel. The ice thickness can be measured with electro magnetic ice thickness measurement devices and together with visual ice observations, severe ice conditions can be detected and traced, and the potential danger to the drill ship can be calculated and predicted. An example for excellent ice management was the core drilling research work of “Vidar Viking” in 2004 close to the North Pole. “Vidar Viking” was built as an ice breaking supply vessel and was equipped with a drilling rig. The vessel alone was not able to keep position during drilling in the Arctic ice, although it is equipped with a dynamic positioning system (DP) for ice free waters. Manual DP in ice was only possible in well managed ice. The Russian nuclear icebreaker “Sowjetski Sojus“ and the Swedish Icebreaker “Oden“ broke the drifting ice into small pieces (well managed ice). Fig. 3: The vessel is rotated around the centre of the turret using the thrust of the azimuth propulsors Tests with a moored drilling vessel in drifting ice HSVA has tested several drilling, production and storage vessels in managed and in well managed ice. In these tests the ice drift is supposed to hit the vessel under different angles. Such “oblique towing tests” generate large deviations to the vessel’s position and the corresponding loads in the mooring systems. During the last few years HSVA has designed and/or optimized several of these vessels and consequently HSVA has gained a tremendous amount of expertise for such highly complex systems in ice. As an example: From 2006 until 2008, HSVA carried out several ice model testing campaigns for a moored drilling vessel for the Norwegian engineering company LMG Marin in Bergen and Statoil (now StatoilHydro). The tests demonstrated the excellent ice breaking capabilities of the unit in level ice of up to 1.60m thickness, in ice ridges and in ice rubble fields. The main target of the investigations was to develop a concept for enabling the vessel to follow the ice drift change in order to keep the vessel within the range of the lowest ice resistance and therefore within the defined operational working area. The pictures 3–6 give an overview of several ice scenarios which have been tested. Fig. 4: The propeller wash is a useful tool for breaking ice or to wash ice away from the vessel Fig. 5: Track behind the drill ship after an ice drift course change of 20° Dr. Karl-Heinz Rupp, Dr. Walter L. Kuehnlein Hamburg Ship Model Basin (HSVA), Hamburg [email protected] [email protected] www.HSVA.de Fig. 6: Tests in broken irregular thick ice Schiff & Hafen | June 2008 | No. 6 9 Special SPECIAL | OFFSHORE TECHNOLOGY The Schottel Combi Drive: suited to offshore application PROPULSION Schottel which develops, designs, manufactures and sells propulsion and manoeuvring systems with power ratings of up to 30 MW for vessels of all types and sizes set new standards for the manoeuvrability in the early 1950s with their Schottel Rudderpropeller (SRP). The SCHOTTEL Combi Drive (SCD) combines the main technical and economic criteria of both mechanical Rudderpropellers and pod drives. S chottel builds combi drives both in a twin-propeller version and as a ducted single-propeller system, at present covering a power range from 2,100 to 3,300 kW. In contrast to pod drives with an electric motor inside the underwater pod, the motor in the Combi Drive is integrated vertically into the support tube of the Rudderpropeller. Neither an above-water gearbox nor a cardan shaft is required, making the system extremely compact and easy for the shipyard to install in the vessel with very low space requirements. Since the market launch, 16 of these innovative propulsion systems have already successfully entered everyday service. Three double-ended ferries built for Fjord1 Fylkesbaatane in Norway by the shipyard Aker Brattvaag AS are each equipped with four gas-electric powered Schottel Combi Drives of type SCD 2020 in twin-propeller configuration (4 x 2,750 kW). The ferries operate between Bergen and Stavanger. An ecological and safety-oriented concept The SCD has a promising future in the offshore sector. The Norwegian Ulstein Verft, for example, has chosen it as the propulsion system for two platform supply vessels of type PX105. These 4700 dwt ships with the distinctive Ulstein X-Bow™ were built for the shipping company Bourbon Offshore Norway IS KS, a subsidiary of the French Group Bourbon, based in Marseille. With their new bow, they are “highly-developed, large and reliable multifunctional platform supply vessels, which distinguish themselves particularly in terms of fuel consumption, good sea-going characteristics, positioning, speed, stability and loading capacity”, as the shipyard emphasizes. Both vessels are equipped with two SCD 2020 twin-propeller systems (max. 2,700 kW). The decision to combine a diesel-electric propulsion concept with an azimuth drive system means a significant improvement to the performance of Special 10 Schiff & Hafen | June 2008 | No. 6 the vessels. The concept allows flexible power distribution and offers a higher degree of redundant safety. The lower fuel consumption also makes the PSVs more environmentally friendly. The shipping company had stipulated that the vessels were to be equipped in accordance with the requirements of the DNV Clean Design Class. This means that the equipment had to meet strict criteria with regard to its environmental impact. BP Norway, the operator, also stressed that the ecological and safety-related concept of the new vessels had played a decisive role in the awarding of the contract. The economic expectations of Bourbon Offshore Norway with regard to these two innovative vessels were quickly confirmed with the result that the company has meanwhile placed a further order with Ulstein Design for the design and technical equipment of four more vessels of the same type, also with Schottel SCD 2020 Combi Drives. The construction contract was awarded to Zhejiang Shipbuilding Co. Ltd. in Zhejiang, China. The shipyard will be delivering the vessels in late 2009 or early 2010. Both Neptune Offshore in Norway and EDT on Cyprus have ordered two further vessels of the same design in the meantime. US owners such as Otto Candies LLC in New Orleans, a major offshore shipping company in the Gulf of Mexico, are also focussing on this innovative propulsion concept. For two of its new offshore supply vessels, built by Dakota Creek Industries (DCI), the company has chosen the Combi Drive. The ships are each to be equipped with two SCD 2020 systems (2 x 2,250 kW and 2 x 2,500 kW). Following the successful market launch of the twin-propeller version, intensive market research culminated in the decision to introduce a ducted variant of the SCD. Ducted variant of the SCD While the twin-propeller SCD is mostly used in vessels with an operating profile in the transit range at medium to high speeds, the ducted propeller operates at its best in the lower speed range and at static thrust. Especially for vessels with an operating profile characterized by dynamic positioning (DP) and partial-load operation, the ducted variant represents a particularly efficient solution. Anchor Handling Tug Supply vessels (AHTS), seismic research vessels, cable ships and other work vessels are ideally suited to this propulsion solution. This presupposes, of course, that the vessels are equipped with a diesel-electric propulsion system. This is usually the case with cable ships or seismic research vessels; AHTS vessels, however, are still an exception – and not always with good reason, as investigations have shown. Side view of a new Offshore Supply Vessel for Otto Candies LLC in New Orleans A diesel-electric propulsion system is endowed with a power management system that ensures that only the currently required power is generated and distributed to the various units in the vessel. The connected generators always run at the optimum operating point. In combination with a ducted fixed-pitch propeller, as in the Schottel Combi Drive, such a system offers very high efficiency, especially in the low-load range. In a diesel-electric fixed-pitch system, the required thrust is regulated via the electric motor speed (frequency control). The connected generators run at the optimized operating point – as does the fixed-pitch propeller if designed accordingly. Furthermore, for low to medium vessel speeds, a well-designed fixed-pitch propeller with frequency control is more efficient at the rated speed than a controllable-pitch propeller. The trend towards diesel-electric powered vessels has sharply increased over the last few years. This is due to the fact that particularly work vessels in offshore operations are becoming ever more complex. Moreover, the leading seafaring nations in this segment, such as Norway or the USA, are enforcing more restrictive environmental and climate protection measures. Above all in harbours, the amount of pollutants emitted by conventional diesel engines is considerable, due to operation in the unfavourable partial-load range. Under the working title of “Green Tug”, dieselelectric concepts for harbour tugs have for the first time now been developed in the USA for the harbours in Los Angeles and Design: MMC Ship Design & Marine Consulting, Ltd, Poland Houston. For example, in Los Angeles it is planned to allow tugs to operate only under battery power in the city area of the harbour. In the outer area of the harbour, the batteries can then be recharged via the generators. If such plans are implemented – and there are many arguments in their favour – the Schottel Combi Drive undoubtedly represents the optimal propulsion solution for harbour tugs meeting these requirements. Schottel GmbH Spay/Rhein www.schottel.de The platform supply vessel “Bourbon Mistral“ has already fulfilled the shipping company´s economic expectation in just a short space of time. Photo: Tony Hall Increased economic efficiency The space saved by the diesel-electric concept, together with the flexible design of the vessel’s interior (the SCD requires no space-intensive shaft lines), result in a substantial increase in the usable volume. This is of particular importance with such complex vessels as AHTS, and increases their economic efficiency. These arguments convinced the shipowner Great Offshore Ltd., based in Mumbai, India, so that it ordered for the first time a 150 t anchor handling tug with diesel-electric propulsion and two ducted SCD 3030s (2 x 3,300 kW) from Bharati Shipyard Ltd. in Mumbai. The newbuilding is scheduled to go into service at Great Offshore at the end of 2008. Schiff & Hafen | June 2008 | No. 6 11 Special SPECIAL | OMAE 2008 Wave ernergy utilisation Rexroth rises to the Power Take-Off UTILIZING OCEAN ENERGY One of the main challenges at the concept of ocean power stations which extract power from ocean energy lies in devising a suitable “power-take off“ system for converting the kinetic energy of the water into electrical power Nik Scharmann E xperts tell us that within a few decades, innovative systems for the sustainable use of ocean energy may generate as much electricity as 150–200 nuclear power stations. On the one hand the important advantages of utilizing ocean energy here is that around two third of the world‘s inhabitants live in coastal regions. The close proximity of ocean power stations to consumers simplifies the infrastructure and minimizes power losses. On the other hand ocean energy is always available: tides, currents, and – to a certain extent – sea swells are ever present, thus enabling more long-term planning. As a result, ocean power stations are a much better option for providing the base load of the electricity networks. A number of companies are currently working on different concepts for large-scale facilities that will extract power from this renewable energy source. The main challenge lies in devising a suitable “power-take off“ system for converting the kinetic energy of the water to electrical power while ensuring that generation costs remain competitive. The development of the plants and the necessary PTOs is only in its infancy, but Rexroth is already supporting numerous projects with tailored solutions, just as it did for wind energy a few decades ago. These solutions Special 12 Schiff & Hafen | June 2008 | No. 6 are based on Rexroth hydraulic components and cross-technology systems, which have already proven extremely robust and reliable in a range of maritime applications. The ocean energy industry currently consists of two main sectors: tidal energy and wave energy. Tidal energy Tidal power stations use the energy of currents to power rotors – be they tidal or natural sea currents. Water has a density one thousand times greater than air and can thus generate significant power even from low flow velocities. This requires specifically tailored solutions. The diameter of underwater rotors does not have to be large for them to be able to con- Mechanic Power-Take-Off duct energy effectively. Even at low speeds, the forces acting on the entire system are significant. Rexroth is currently pursuing a development concept that adopts the generator gearbox technology employed in the wind energy sector, an area in which the company has established itself as a worldleading supplier for renewable energies. Research is also being conducted into the use of hydraulic converters. This simple yet highly robust concept transforms rotary motion into hydraulic flow, which powers an adjustable hydraulic motor for the generator with great efficiency. A slow-running radial piston motor with constant displacement is employed on the pump side. It generates a volumetric current based on the rotor speed. A fast-running axial piston dis- placement motor is connected on the motor side, which can be fitted directly to the generator shaft. The motor-generating set is then operated directly at mains frequency. There is no need for elaborate control electronics or frequency converters. It is also possible to implement a continuous transmission ratio. The system can thus be used to quench short-term peak demand while also enabling long-term adaptation to the changing current flow rates throughout the tide cycle. A pitch system is not required. Since the displacement motors employed can be operated in dual-quadrant mode, it is even possible to reverse the direction of the rotor when the tide changes. It is not necessary to rotate the system. Another advantage of this system is the positioning of the gearbox components: while the highly robust radial piston pump is installed under water, the motor-generating set remains above water. However, the high level of flexibility of a hydrostatic power train over a mechanical gearbox results in lower efficiency overall. It is not yet clear which power train technology will eventually prevail, but it will certainly depend on the activities of the plant suppliers. Increased efficiency, particularly in the case of the fast-running displacement motors, could result in the hydraulic concept gaining the upper hand. Wave energy Fluid technology is particularly well suited to meeting the requirements of wave energy utilization. In a system with a nominal power of 150 kW, travel speeds will gener- Hydrostatic Power-Take-Off ally range between 1 and 2 m/s at forces of 500 kN to 1 MN. It should be noted that the maximum forces and speeds do not correlate: high travel speeds are usually the result of small waves over short periods, while high forces are produced by high waves over longer periods. The challenge for the PTO is posed by the specific attribute of waves: within a wave period, the input power of the machine fluctuates twice between zero and the maximum value. A typical wave period lasts 10 s, i.e. 0.1 Hz; the main frequency is between 50 and 60 Hz. This effectively requires a transmission ratio of i = 500-600. Furthermore, the power of a wave increases approximately with the square of the significant wave height. As a result, a power ratio of 1/100 can soon develop between the lower and upper operating window of the WEC (wave energy converter). to catch the eye: the more efficiently a PTO converts the energy, the more electricity is produced. However, the target variable that will ultimately overshadow all activities is the cost of electricity generation in c/kWh. As well as the afore mentioned system efficiencies, this index also incorporates the facility costs, including operating and maintenance costs, as well as the service life of the installed systems. Only a comprehensive optimization of all variables will lead to the minimization of electricity production costs. The development of a WEC and PTO that generates competitively priced electricity under the described conditions is a challenge which the entire industry is currently tackling with great vigor. Efficiency is not everything Nik Scharmann Bosch Rexroth AG, Lohr a. Main From a technical point of view, the efficiency of the PTO is the first target variable [email protected] www.boschrexroth.com Condition monitoring of oil systems HYDAC | One customer of Hydac AS com- petent clientele is Maskindynamikk AS in Spjelkavik, which develops complete solutions for periodic and continuous monitoring of rotating machinery with varying loads. Maskindynamikk has extensive experience with vibration analysis and have now implemented Hydac’s particle counter if oil cleanliness should be monitored as well. The hydraulic market shows great interest in monitoring oil cleanliness through online particle counting, relative humidity and pressure measurements. This makes it possible to use condition based maintenance instead of periodic solutions. The advantages are many, but of course to have maximum up-time on the machinery to a minimized price is the most important one. The fear of choosing an alarm point which could be wrong has been one of the most difficult obstacles in the way of condition based maintenance. If it is able to define what is „normal“ it is also possible to define Example: Thruster systems for ships are a very good example of a system which is interesting to monitor. Both the manufacturers and the ship owners are very interested in online monitoring of the condition of the thruster system. If the monitoring system is approved by a classification society, it is possible to reduce the amount of visual inspections of these systems. what is irregular. With continuous signals Maskindynamikk’s system is able to „learn“ and define what is normal and one is able to use all logic ( „OR“, „AND“, „THEN“ etc.) commands to interconnect different signals which give the basis for the alarm. This means an alarm triggers only if it’s real and important to act upon. HYDAC International GmbH, Sulzbach/Saar [email protected] www.hydac.com Schiff & Hafen | June 2008 | No. 6 13 Special SPECIAL | OFFSHORE TECHNOLOGY Arctic knowledge at DNV informs risk management ARCTIC SHIPPING DNV has class notations covering the entire spectrum of cold climate operations ranging from control of icing in open waters to ice-breaking abilities in temperatures as low as -55˚C and in recognition of the rapidly changing physical and business environment in the Arctic. This offers now greater flexibility in winterisation notations. Wendy Laursen A s recently as two years ago, it was estimated that the north-eastern Arctic shipping route would be open for most of the year in ten to 15 years time, but the latest Norwegian research predicts that this may happen earlier than that. Icebergs forming in the region, some weighing over six million tonnes, are the largest moving objects on earth. Johan Tutturen, DNV business director for tankers, presented research results at the Mare Forum, Athens, in March 2008 that quantified the value of the most important risk control options for Arctic shipping. Based on a shuttle tanker project intended for operation in Arctic waters, the research used known risk elements from worldwide operation but added additional risk elements for both cold climate and ice. The project revealed that redundant propulsion offers a 6 % reduction in the likelihood of accidents involving collision, grounding, fire and explosion. Use of an automatic identification system and electronic chart display as well as information systems offer a further 6 % reduction. Setting high standards in bridge resource management and the selection and training of crew can reduce risk by 44 % and minimising noise and vibration levels when travelling through ice can reduce risk by a further 12 %. Previous studies have shown that ships built with additional DNV class notations for nautical and bridge safety experience risk reductions of nearly 50 %. Most accidents at sea are caused by human error and harsh climatic conditions can result in poor quality rest, reduced alertness and concentration and poor speech intelligibility. The main objective of DNV’s NAUT notation is to reduce the risk of human failure in bridge operations by specifying requirements for workplace design, equipment standards and operational procedures. “There are many types of mitigating measures that can be introduced to reduce cold stress and they should be considered as safety investments,” says Tutturen. “It all boils down to risk management: identify- ing the hazards, measuring specific risk elements and the way they interact and then evaluating and implementing control options.” Oil and gas recovery in the Arctic is increasing and DNV undertakes feasibility studies and concept evaluations for these cold climate activities. They use integrated risk management tools that assess the total investment risk over the full project life cycle. Factors such as component reliability and production profiles are used to develop forecasting models and the use of probability distributions in simulation model input parameters allows uncertainty and variation to be used in the development of a quantified risk picture for any revenue stream. “It is vitally important that ship owners contemplating Arctic operations are aware of the possible challenges connected with their intended trading patterns. Our research capability, extensive experience and state-of-the-art simulation techniques bring value to these of- “Arctic Discoverer“ will be trading out of Hammerfest close to the Barents Sea. The vessel is managed by K Line and classed to DNV. Special 14 Schiff & Hafen | Juni 2008 | Nr. 6 Photo: DNV ten multi-billion dollar decision making processes,” said Tutturen. Once a project is live, DNV can assist with quality control, maintenance and repair evaluations. Vessel category and availability can be an important consideration and limited accessibility for remedial action if incidents occur means extra planning effort is essential for safe Arctic operations. The protection of Arctic and sub-Arctic environments has been of increasing importance in recent years. Petroleum and shipping companies are facing rising demand for environmental safety. DNV participates in baseline studies and environmental monitoring. Their environmental risk analysis approach gives decision makers a transparent and efficient tool for identifying and quantifying risk due to accidental oil spills. It includes probabilistic oil drift modelling and toxicity and impact assessments on sensitive environmental resources. Their contingency planning toolkit includes an electronic map interface for oil spill response operations that is distributed in real time to all involved parties. More tanker operators are looking to venture into the Arctic as a means of shortening voyage times from Europe to Japan and the US. “Allowing for changing climatic conditions is an important consideration on a day-today basis for ship operators but I believe that operating flexibility will grow in importance in the future,” said Tutturen. “This is already the case with the newbuildings we are involved in. Hull fatigue damage accumulation is about twice as rapid in North Atlantic conditions compared to the comparatively more benign environment of traditional LNG routes, for example, and there is an increasing trend amongst owners to specify 40 years of fatigue life in the North Atlantic to ensure trouble free operation in these more demanding cold climates.” Traditional open water accidents such as groundings and collisions are more likely to occur in cold climates. Fires are responsible for 10 % of all fatalities at sea and fire fighting in severe weather is more complicated and therefore more likely to cause critical damage. In addition to this, new sources of accident are introduced in cold climates. Ice may damage a vessel or force it aground. Icebergs and ice floes can cause serious damage to a vessel in the zone between open sea and solid ice and sea spray can lead to severe icing and damage from the clogging of vents and the freezing of pipes. Extra notations DNV has been delivering standards for ice class shipping since 1881. Currently, over 1900 vessels carry DNV ice class notations, including the four highest specification LNG carriers in operation. They incorporate Finnish and Swedish Maritime Authorities’ rules in their Baltic specifications and although unified International Association of Classification Society rules are under development, DNV’s extra notations offer a greater depth of operational security based on extensive experience and intimate local knowledge. Safe ship operations require more than just ice strengthening of the ship’s structure and propeller, says Tutturen, and DNV has developed technical standards for all ship’s equipment and structures where reliability is important. DNV’s latest Winterised notations have been expanded effective 1 January 2008. The notations recognise that some vessels spend shorter times in cold climates than others and the expanded rules define three different levels of cold climate safety design. Each has separate designations for temperature in material selection and extreme temperature performance. Nevertheless, emergency features relating to escape exits, lifeboats, towing and evacuation play an important part in all notations. The highest level, Winterised Arctic, is for ships such as ice breakers that are operating in the harshest cold climate conditions and the notation calls for redundant propulsion. “A loss of power in extremely low temperatures can quickly lead to a critical situation and freezing of water and vital parts in the engine room may reduce the possibility of a re-start. Ideally, a blackout period longer than ten minutes should be avoided,” says Johan Tutturen. “Emergency generators should be located in a tempered location to avoid starting problems at low temperatures and additional heating arrangements ensure that temperatures in the engine room are maintained above freezing point during a blackout.” Winterised Basic and Winterised Cold cater for vessels operating in cold climates on a seasonal basis. Winterised Basic includes anti-icing precautions for communication and navigation equipment, sea chests, fire fighting capacity and some vents and valves. Winterised Cold specifies additional requirements including temperature protection for equipment and spaces, stability under ice loads and the use of low temperature steel for some of the structures above the waterline. Vessels travelling in the Arctic tend to try and follow the same ice channel as each other to navigate a path of least resistance and often the most favourable ice conditions will be close to shore. In practice, though, ships may sometimes operate under heavier ice conditions that those stipulated for their ice class. As well the safety risks associated, this can bring vessels into contact with the Russian authorities. “Arctic Discoverer“ will be crossing the Northern Atlantic where the weather condition will create challenges Photo: DNV DNV’s established relations with Russian institutions, means that they can offer valuable assistance in meeting local regulations. In Russian waters, it may be necessary for a vessel to have an ice passport. This is not a building standard but a description of safe operating modes for a particular vessel based on how the ship is actually built. It is based on the ship’s structure, hull lines, dimensions, displacement, propulsion power, propeller thrust, age and the state of the shell plating. DNV contributes actively to the development of technical and operational codes and directives for offshore petroleum activity in the Arctic and they proactively maintain their position at the forefront of research and risk management solutions for cold climate business. Over the next three to six years their strategic research initiatives are focusing on extreme ice shipping and human responses to the associated cold, noise and isolation. They will also research best practice emergency evacuation from ships and platforms in the Arctic and work on achieving a greater understanding of the ever-changing Arctic environment from a risk acceptance perspective. Wendy Laursen Det Norske Veritas [email protected] www.dnv.com Schiff & Hafen | June 2008 | No. 6 15 Special SPECIAL | OFFSHORE TECHNOLOGY Ice protection structures ICE BARRIERS For over 25 years IMPaC Offshore Engineering has gained substantial knowledge and experience in numerous ice engineering projects. One area of special expertise is the design of ice protection structures. Joachim Berger T he increasing demand for hydrocarbons requires offshore exploration and production drilling activities in ice infested areas. In shallow water areas like the North Caspian Sea, purpose-designed ice protection structures also called ice barriers can lead to solutions that provide technical and economical advantages compared to field developments without ice protection measures. For the protection of offshore production facilities in shallow water areas permanent ice barriers made from rock or concrete structures are often the appropriate solution. For drilling exploration facilities, which usually have to change their location after they have sunk the well, ice barriers made from steel are mostly the better solution as they are easier to install and de-install. Ice barriers can also be used to protect offshore wind parks or harbour installations. Advantages Ice barriers allow designing of an exploration platform or other offshore facility for re- duced ice loads. The ice load reduction is a function of the type and number of ice barriers. Less expenditure for the protected platform requires additional costs for the design construction, installation and operation of the ice barriers. However ice barrier structures also considerably improve the conditions under which supply of the offshore unit is possible. In some cases platforms can only be operated during the winter season with ice barriers in place. Also during the non-ice season ice barriers can improve the platform supply conditions by reducing wave heights in the vicinity of the offshore installation. Thus, ice barriers can considerably extend the availability of the platform with large positive effect on the overall economics of the offshore field operation. Ice barriers can also be required to facilitate evacuation of the crew from the platform under ice conditions. Production on offshore platforms has to be stopped under extreme environmental conditions where rubble ice piles prevent the emergency Fig. 1: Drilling unit with driven piles as ice protection structure Special 16 Schiff & Hafen | June 2008 | No. 6 evacuation of personnel. Therefore, ice barriers whilst protecting the integrity of the offshore platform structure also increase the availability of the platform’s production, thus improving the economics of the project. Requirements An ice protection structure has to be a simple, yet robust structure as it is exposed to harsh environmental conditions and has to withstand large ice loads. The main requirement on ice barriers is a high technical reliability at a minimum material expenditure. For the protection of mobile units like offshore exploration drilling rigs the de-installation and re-use of an ice barrier are also of importance. Full compliance with environmental protection requirements is mandatory for all ice barriers. Determination loads of design The technical reliability of an ice protection structure is strongly dependent on the correct ice load. In some cases especially in deeper water areas the hydrodynamic forces due to waves and current can become the dominating load situation. Deterministic methods are mostly applied to predict the ice loads as the data basis for a probabilistic approach is often insufficient. When the ice protection structure is of simple geometry analytical methods can be applied to establish the ice loads. When the shape of the ice barrier is too complicated for analytical methods ice model tests have to be carried out. In practice, the prediction of ice loads is not the major challenge but the determination of realistic full-scale ice conditions from which the ice loads will be derived. The uncertainty in the ice load conditions and the lack of full-scale data often require a conservative design approach and do not allow full design optimisation of the ice barrier structure. Due to the lack of ice data satellite imaging has been utilised to determine ice conditions. The satellite images allow a fairly good estimate of the ice coverage and the thickness of sheet ice. But in many Fig. 2: Ice protection piles, view from drilling unit Fig. 3: Drilling unit with barge type ice barriers to protect against excessive ice loads cases the dominating ice loads for an ice protection structure result from the interaction with pressure ridges, which cannot be identified from the satellite pictures. In such cases field observations and surveys are of particular importance. Driven piles as ice protection structure Driven piles have been used as ice protection means at the first two exploration sites of a mobile drilling barge, which has been operating since 1998 in the shallow water areas of the North Caspian Sea. The piles also serve as berthing and mooring piles for the supply vessels. The optimum pile arrangement has been determined in ice model tests. The main parameters influencing the ice load reduction for a given ice thickness are pile diameter and pile spacing. With the optimised pile arrangement the ice loads could be reduced by 60 percent compared to the solution without any piles. Simple pontoons as ice protection structures As a larger number of wells had to be drilled as originally Fig. 4: Design options for optimised barge type ice barriers structures anticipated the piles have been replaced at later sites by pontoons, which have the advantage of easy re-usage. After de-ballasting and refloating the ice barrier barge can be towed to the next exploration site of the drilling unit. At the drilling site the ice barrier barge needs to be ballasted with sea water in order to create sufficient sliding resistance. In some cases concrete can be used as fixed ballast. However, due to draft limitations fixed ballast cannot always be used. Due to the simple geometrical form of the barge type ice barriers the ice loads could be established by analytical methods. However, for establishing the minimum number of ice barrier barges and their optimal arrangement relative to the drilling unit ice model tests have been carried out. In future, ice model tests may only be required for verifications purposes as latest developments of computer models allow a relatively good analytical simulation of the interaction of drifting ice with ice barriers of different arrangement. Fig. 5: Ice barrier structure providing shelter for a supply vessel Schiff & Hafen | June 2008 | No. 6 17 Special SPECIAL | OFFSHORE TECHNOLOGY Fig. 6: Sketch of a light-weight ice barrier © IMPaC Purpose-designed ice protection barges Various types of barges have been developed by IMPaC aimed to optimise performance as an ice barrier. The vertical wall design has been compared to sloped walls with different slope angles. For sheet ice the sloped surface has advantages but often the interaction with pressure ridges is the dominating load scenario for which the slope angle of the wall is of lesser importance. Ice protection barges with one vertical long wall have advantages during site installation and de-installation or when the barge needs to be moored in a harbour or yard for inspection purposes. During operation the vertical wall normally facing towards to the drilling unit has the advantage of providing a berthing and mooring place for marine boats and barges. Sloped walls also have the advantage of smaller local ice loads compared to vertical walls. The weight of the steel shell of a barge type ice barrier strongly depends on the size and distribution of the local ice loads. The smaller the ice load exposed area considered in the stress analysis the larger the local design ice load to be applied. The distribution of the local ice loads including so-called “ice background pressures” acting on the sloped or vertical shell usually leads to a vertical stiffening of the shell. For economical reasons plastic deformations of the outer steel plate and the stiffening bulb profiles are normally accepted while stresses in frames and bulkheads have to remain within the elastic range. In Figure 5, a barge type ice barrier with one sloped and one vertical wall is shown, providing shelter for an ice breaking supply vessel. While the local ice loads have a large impact on the design of the steel shell the global ice loads usually dictate the overall height and bottom width of barge type ice protection structure. The ice barrier has to provide sufficient sliding and overturning resistance. In very shallow water areas sliding failure is more of a risk than overturning. When the seabed is of the non-cohesive type (sand) the overall design of the ice barrier is weight driven. The larger the contact pressure from the bottom plate to the top layer of the seabed, the larger the sliding resistance of the ice protection barge. The sliding resistance can be further improved by using skirts. Spray ice could also be used to increase the weight of the barrier. The larger weight of the barrier structure leads to larger sliding resistance. When the seabed is of the cohesive type (clay) the footprint of the ice barrier becomes important while the weight has less impact on the sliding resistance. At sites with cohesive seabed material, underwater berms or backberms can lead to an improvement of the sliding resistance. Light-weight ice protection structure Fig. 7: Light-weight ice barrier with accumulated rubble ice and indicated ice drift direction Special 18 Schiff & Hafen | June 2008 | No. 6 IMPaC has developed a light weight ice barrier structure, which is based on the idea that the broken ice pieces will be collected and the mass of the accumulated rubble ice contributes to the overall resistance of the barrier. The principle of the lightweight ice barrier can be seen in Figure 6. It shows the first stage of the interaction with drifting ice in early winter when relative thin ice has failed at the sloped wall and the broken ice piece start to accumulate. Various ice model tests have been carried out to verify the function of the light-weight ice barrier. The ice model tests were also performed to measure the ice forces acting on the structure during the different phases of the interaction with drifting ice features. Also the mass of the accumulated ice was determined which allowed checking the sliding stability of the light-weight barrier structure. Figure 7 shows the situation after the light-weight ice barrier has been filled-up with rubble ice. The research project was supported by the German Federal Ministry of Education and Research. Outlook Future exploration and production activities in the North Caspian Sea and other ice infested shallow water areas will require a considerable amount of ice protection structures, which need to be designed, built and operated. IMPaC Offshore Engineering will continue to play a leading role in the realisation of these projects and also in the future development of new ice protection technologies. Joachim Berger IMPaC Offshore Engineering Hamburg [email protected] www.impac.de Hydrocarbon sensor systems PIPELINE MONITORING To improve detection efficiency and to eliminate the need to introduce additional potential pollutants to underwater pipeline systems CONTROS has developed a new leak detection method, a “Hydrocarbon Sniffer System”, called HydroC™. Daniel Esser T he global demand for energy challenges the offshore oil & gas industry to go for deeper regions and the arctic areas. However, environmental awareness and concern puts the focus on effective and reliable monitoring systems to avoid leaks and spills of harmful fluids. Subsea production systems are getting more and more common for these applications. Globally subsea pipelines and production systems are becoming a major concern as authorities are less tolerant to leaks of polluting material into the marine environment. In this respect, the ability to detect and also to locate any leakage of oil or gas to the surrounding water and environment is of utmost importance to safeguard a green and healthy planet. At a depth of 3,000 meters operation of a subsea production installation is a great challenge and a high risk. Not only are the costs for deep sea installation high, but the risk for the environment is evident – is it possible to detect or repair a leak? Subsea field development and long pipeline transport may be the only alternative to develop a deep sea installation; if sufficient water depths, infrastructure on the seafloor can be advantageous. However, in Arctic areas where the surface ice and iceberg conditions can be problematic. Subsea processing is regarded as an efficient way to safe energy; reduce the use of chemicals and to reduce discharge of produced water. In the past three main methods of subsea leak detection have been used for leaks where obvious visual signs of large leaks such as bubbles, large clouds, etc. are either not present or have failed to locate these problems. These three main methods used are fluorometric measurement, pig-systems (not useable for all types of pipelines of today) and passive acoustics, which listen for ultrasound created by fluid leaking under pressure. The systems mostly used these days for permanent monitoring or pipeline inspection by ROV (Remotely Operated Vehicle) or AUV (Autonomous Underwater Vehicle) seem all to have disadvantages in detecting very small and non visible oil or gas leaks. In an effort to find new leak detection methods that improve detection efficiency and also eliminate the need to introduce additional potential pollutants to pipeline systems, CONTROS has been working on a “Hydrocarbon Sniffer System” called HydroC™ for the last five years. This unique system which is now available has a worldwide patented optical analysing system. Hydrocarbon molecules diffuse through a special membrane (which keeps the water out) and enters into the detector chamber. The adsorption of light in gas leads to change of intensity which is measured electronically. The HydroC™ can detect the higher order chain of hydrocarbons or just CH4 if Methane is of primary interest; which is a huge advantage as CH4 is the smallest molecule in nearly every crude oil and natural gas. A system can consist of one HydroC™ or an array of sniffers, current meters and other instrumentation required covering a large subsea installation or an area of manifolds. This HydroC™ system is unaffected by turbidity or other interferences such as H2S or any other gaseous substances in the environment. This system was developed specifically to allow fast, real-time and in-situ detection of dissolved and gaseous hydrocarbons/methane in water, whatever the source. It has been successful used in hydrocarbon surveys and pipeline inspections to water depth up to 3,000 metres worldwide. The very high sensitivity (down to 30 nmol/l) of the HydroC™ Monitoring of critical paths and pipelines system also makes it ideal for the detection of methane seepage from the seabed. Here it is also widely used for the exploration and the production process of methane hydrates in different projects around the world. CONTROS is also partner of the German Gashydrate Organisation (www.german-gashydrate. org) where another CONTROS HydroC™ instrument for CO2 detection is used for the CO2 sequestration process, which has become an important topic for the international oil companies. The calibrated HydroC™ (Hydrocarbon or CO2) plug & play system records data either internally or externally in units of hydrocarbon or methane concentration. By careful logging around an area of leakage from a pipeline, the seabed or a manifold, an estimate of the amount of leaking gas or oil can be made directly. HydroC™ is in use by several pipeline inspection companies and CONTROS has close cooperation with the leading ROV manufacturers to equip their inspection ROV’s with the latest leak detection technology. In summary CONTROS provides offshore pipeline inspection and long term monitoring solutions. HydroC™ leak detection product line, field experience and advanced data management systems meet demanding regulatory requirements and enhancing safety during production from subsea production systems. Daniel Esser CONTROS Systems & Solutions GmbH, Kiel [email protected] www.contros.eu Schiff & Hafen | June 2008 | No. 6 19 Special Oil and Gas: a new perspective Your business is oil and gas – and our business is your safety. From industrial plant to pipelines, from planning to maintenance, whether its advice, testing or certification you require: Germanischer Lloyd Oil and Gas (GLO) is your reliable serviceprovider when it comes to verification, certification and quality assurance for your systems – anywhere in the world. Our range of services revolves around the safety and health of people, the protection of the environment, and the securing of investments. Welcome to GLO, your partner for the utmost safety, on- and offshore. Germanischer Lloyd Industrial Services GmbH Oil and Gas Steinhöft 9 · 20459 Hamburg, Germany Phone +49 40 36149-750 · Fax +49 40 36149-1707 [email protected] · www.gl-group.com/glo