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insensysIntelligent Sensing Solutions

Alistair BirnieBusiness Development Manager

O&G Eastern Hemisphere

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Copyright Insensys Ltd 2005 www.insensys.comAll rights reserved

Insensys Company originated in Southampton in 2002 Aberdeen and Houston offices opened in 2004

Core Competences Composite design and manufacturing Structural analysis Fiber optic sensing applications

Acquired Indigo Photonics June 2003 Large fiber sensing patent portfolio Optical sensor manufacture capability

Insensys Overview

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Integrity MonitoringCritical Areas Covered

Condition monitoring for mooring tethers

VIV, riser bend, axial strain & fatigue

Riser & mooring line top tension

Pipeline buckle monitoring

Small bore pipe connections

Flexible jumpers

Flex joint Loading

Pipeline Pressure& temperature

Bend restrictor Monitoring

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Identify risks earlyMonitor and prepare contingencyLegislation Prosecution

Influence operational decisions Schedule inspectionExpand operation envelopes

fundamentals of structure responseimpact of environment on fatigue build up

Monitor system integrityProjectDemand

OperationSupport

RiskMitigation

DesignValidation

Drivers for Integrity Monitoring

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OPTICAL FIBRE BRAGGE GRATINGMEASUREMENT TECHNOLOGY

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Technology Platform

Sensors

Presentation hardware and software

Optoelectronics

The Three key Elements:

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Glass cladding (0.125 mm diameter)

Polymer coating (0.250 mm diameter)

Glass core (0.09 mm diameter)

Refractive index layers form fibre Bragg grating structure

Fibre Bragg Grating Sensor

Optical fibre (0.25 mm diameter)

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Wavelength

Refl

ecte

dlig

ht

Apply strain to fibreFBG wavelength increases

linearly with applied strain

Strain Response of FBG Sensors

Direct Strain Measurement No Calibration Required

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A Unique Approach Delivering Significant Benefits

Hundreds of sensors can be deployed in one fibre Optimised for fast deployment – subsea or on deck Robust stand-alone system – no external optical fibre

connections Unaffected by long term immersion at pressure Opto-electronics designed for 25 year life High signal to noise ratio and accuracy with no

calibration / re calibration required Very high speed acquisition capability for vibration

analysis (~ 2kHz)

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Composite Carrier Deployment

Interrogation Unit

Interconnecting Fiber

Connector Box

Optical Fiber

Fiber Optic Strain Sensors

CompositeCarrier

Power & Comms

StructureBeing

Monitored

Electrical Umbilical Battery & Memory Battery & Modem

pat pending US & EU 4255194.5

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Direct Measurement

Direct measurement Bending strains Axial strains Hoop strains Curvature Torsion Temperature

Derived values Fatigue history / Remaining Fatigue Life Riser Global response Pressure VIV, modes and amplitudes Risk factor / margin before disconnect, etc

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APPLICATION TO SUBSEA INTEGRITY MANAGEMENT

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Sensor geometry – Bend Radius

L + L

L - L

LTension

CompressionSensors in plane of bend

Sensorsin both axes

Strain, = r/R

R

r

Strain sensors set on opposing sides

Differential strain between inner and outer sensors gives the bend radius

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High accuracy demands The ‘Mat’ was conceived Increased separation from

neutral axis High material stability Easy/fast deployment/recovery


The Mat fits over the riser and measures its shape

Shape Measurement Mat

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Mat arrangement

Parallel fibres for additional redundancy

Composite structure moulded to fit host structure

Integral low-power electronics and processing

Options for direct cable, subsea tie-in, acoustic telemetry, data-logger ROV stab for data retrieval

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Measurement Methodology

Equivalence

Calculation

Calculation

Strain Measurements in Mat

Mat Geometry

Curvature in Mat

Curvature in Pipe Pipe Geometry

Strains in PipeCalculated from Mat

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Sub C matExample Specification

Electrical wet/dry-mateConnector

3WPower

RS485Communications

up to 2,000HzMeasurement Frequency

5VSupply Voltage

2D2DCurvature Measurement

4x10-6 m-1 (2με)1x10-5 m-1 (2με)Curvature Resolution

1x10-5 m-1 (5με)2.5x10-5 m-1 (5με)Curvature accuracy

60kg48kgWeight

StrapsStrapsAttachment Mechanism

10’18’Length

±0.005m-1±0.01m-1Curvature Range

20 inch pipe8 inch pipeParameter

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FIRST APPLICATIONBP THUNDERHORSE

RISER STRAIN MEASUREMENT

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Thunder Horse Project Requirements

Requirement to measure strain on a particular riser joint close to sea bed

Very low strain levels Direct measurement of shape Data collection in Real-Time Decisions based on real-time riser information

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ThunderhorseDeployment to 6000ft

8” completion work-over riser

Strapped onto riser in Tower

Data sent real time to surface

Magnitude and direction of principle bending

Current fatigue damage rate

Remaining fatigue life

Deployed on 6 plus occasions


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Hyperbaric Test to 300bar

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SOME OTHER APPLICATIONS

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Completion Workover Riser

Splash Zone on upper taper joint Splash zone on lower intermediate joint


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Flex Joint MonitoringRetrofit Solution

Flex joint showed signs of premature fatigue

Retrofit monitoring solution required

Measurement of shape and axial strain

Fully operational when replaced with stress joint


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Flow Induced Vortex Shedding

Vibration and fatigue failures on gas lift riser flow terminal

Retrofit monitoring solution required

Measurement of high frequency vibration modes on complex structures

Direct strain real-time monitoring with no signal processing


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Pipeline Buckle MonitoringLateral and Upheaval Movement

0.00

0.02

0.04

0.06

0.08

0.10

0.12

110 115 120 125 130

Distance along pipe (m)

Cur

vatu

re (m

-1)

BP Data

2.5m

1.25m

5m

Flowline fatigue failures at buckle section

Dry and subsea retrofit solutions depending on application

Measurement of buckle shape, extent and number of cycles

Direct strain measurement across the entire buckle area real-time and during life of flowline


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Bend Stiffener Monitoring

Flexible riser bend stiffener monitoring Fixed platform conductor monitoring

Splicing sleeve

Sensing area 6m long

IP 67 rated 4 channels optical fibre connector

SMR Rod 40m long

Bull nose

Water resistant coating

GRP rod with 4 grooves at 90°

4 optical fibres at 90°

Epoxy binder

SMR Rod cross section


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Completion Tubing Testing

Measuring strain on the well casing and on the production tubing between packers

axial, hoop, bending, torsion and temperature using a single fibre Axial strain: 5με Hoop strain: 8με (6psi)

Correlate strain levels against well completion activity


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Summary

Proven technology High level of measurement accuracy Direct measurement Simple operational installation and data output Easily interpreted data for design feedback Robust construction with built-in redundancy Cost effective

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