MPD Manifold 4-1/ psi with Integrated Control System

Transcription

1 MPD Manifold 4-1/ psi with Integrated Control System The MTC Managed Pressure Drilling (MPD) manifold has been designed to automatically maintain the annulus surface back pressure during drilling operations within a predetermined pressure operating window using a set of two tight shut off capable actuated full bore drilling chokes which are controlled by a PLC based control system to maintain the selected set point pressure using an HMI interface panel for operator input of required settings and for displaying control system output parameters. Manifold hardware Manifold hardware consists of a double block and bleed API 4 1/ psi Gate valve integral manifold assembly with independent flow paths to dual pneumatically actuated API 4 1/ psi 3 full bore tight shut off capable drilling chokes and with full bypass or gut line capability. Each flow path and bypass or gut line has both manually operated and hydraulically operated (pump open / pump close) WOM Model 200M API high performance gate valves installed with bleed off between to provide the double block and bleed capability required to allow for repairs or maintenance to be carried out during operations if required. The MPD manifold assembly is housed in an offshore skid and crash frame with lifting sling set and fork lift pockets and is supplied with explosion proof lighting, large general purpose toolbox, air supply scrubbers, hydraulic control panel, electronic pressure and temperature sensors, Zone 1 PLC enclosure and HMI operator interface panel and all interconnecting instrumentation and cabling. Manufacturing codes are in compliance with API 6A, API 14C, NACE MR01-75, ATEX Zone 1 & DNV Choke control system hardware Choke control system hardware is a fully compliant hazardous area Zone 1 package consisting of an explosion proof Eexd PLC enclosure which houses the PLC system components, data storage, power supplies, intrinsically safe barriers and input-output connectors. An intrinsically safe operator control panel powered from the PLC enclosure which houses a touch screen HMI panel and a set of selector switches and buttons to allow full local control of the MPD choke manifold functions. A set of intrinsically safe pressure and temperature transmitters mounted on the inlet and outlet of the MPD manifold assembly and connected to the PLC enclosure via armoured cable and explosion proof glanding. An intrinsically safe integrated alarm beacon and sounder system installed on the MPD manifold assembly and connected to the PLC enclosure via armoured cable and explosion proof glanding. 01

2 Choke Control System Software Choke control system software has been designed to automatically control the pneumatically actuated drilling chokes either independently or in parallel to accurately maintain a predetermined upstream set point pressure. This is achieved by processing the data from the drilling choke and pressure, temperature transmitters through the software package which then outputs the required pneumatic signals to the choke actuators to maintain the selected set point pressure during the drilling operation. The main operating functions and features of the Choke control system are summarized below. The operation of the Choke control system has the options of either LOCAL via the Operator control panel mounted directly on the MPD manifold or REMOTE via a third party SCADA package connected to the PLC enclosure and communicating via Modbus TCP. There is also the option of transmitting the primary parameters via a WITS interface when required. The Local operator control panel houses the main mode selection switches, push buttons and the interactive HMI panel which are listed and described below. Lamp test button to confirm panel indicator lamps are functioning. Alarm silence button to acknowledge the alarm situation and silence the audible alarm. Panel control 2 way selector switch with options of LOCAL or REMOTE control of the Choke control system. Choke selection 3 way selector switch with options of Choke A, Choke B or combined Choke A& B in operation. Auto or Manual operation 2 way selector switch with options of AUTO or MANUAL control of the Choke control system. Raise and Lower push buttons to increase or decrease the set point pressure when in AUTO mode and to increase or decrease the choke orifice size in MANUAL mode. Touch screen HMI panel with specifically designed graphical and tabular control system screens to allow both operator and protected engineer level interaction with the Choke control system including monitoring of multiple parameter trends, re-tuning of PID parameters in real time to provide accurate and secure control of the annulus back pressure during MPD drilling operations. 02

3 Additional safety features In addition the built in safety features of the MTC MPD manifold package are listed below. 100% operational redundancy of the Drilling chokes. Digital and backup mechanical choke position indicators on Drilling chokes. Fail in last position logic in case of power failure on Drilling chokes. 100% redundancy of the upstream and downstream pressure transmitters. Includes upstream and downstream temperature transmitters. Choke failure and choke plugging logic activates audible and visual alarms. Total of 33 critical and non-critical alarms are available in the system. Double block and bleed API gate valve philosophy on all flow paths. Includes set of hydraulic double acting (pump open / pump close) gate valves on each flow path. Includes set of 30 meter long hydraulic hose extensions and set of 30 meter long SCADA and WITS cable extensions to allow remote operation of the manifold valves and control system if required. 03

4 Technical Data Summary MPD Choke Manifold assembly Maximum Working Pressure Maximum Working Temperature Service conditions Maximum Gross Mass Tare Mass (Actual) Payload External dimensions Inlet / Outlet connections Skid lighting Power supply requirements Air supply requirements 4 1/ psi Double block and bleed Gate valve Managed Pressure Drilling manifold with Dual API 6A Drilling chokes in DNV Skid and crash frame 5000psi as per API 6A 121 Deg C as per API 6A H2S / CO2 14,000Kgs 12,200Kgs 1,800Kgs 4.200mts x 2.438mts x 2.591mts (LxBxH) 6 GR52 Grayloc hubs with Test plugs and clamps 2 x Zone-1 4ft x 40W twin tube fluorescent light fittings mounted on roof of skid frame 220 VAC for Skid lighting 24 VDC for Choke control system psi Integrated Hydraulic control panel Stainless steel hydraulic control panel integrated into the MPD manifold skid to operate 5 x DA (double acting) hydraulically actuated gate valves which are installed upstream and downstream of each choke and on the gut or bypass line of the manifold Integrated Choke control system Zone 1 certified Choke control system integrated into the MPD manifold skid to operate the Drilling chokes which is housed in a compact Eexd PLC enclosure and Intrinsically safe Operator control panel with HMI touch screen and set of selector switches 04

5 Technical Data Summary Pressure transmitters Set of dual Zone 1 certified Eexd Pressure transmitters with psi range mounted on each of the inlet and outlet blocks of the MPD manifold and connected to the Choke control system to display and record fluid pressures. Temperature transmitters Set of single Zone 1 certified Eexd Temperature transmitters with -40 to 120 degrees C range mounted on each of the inlet and outlet data headers and connected to the choke control system to display and record fluid temperatures. Manufacturing codes API 6A / NACE MR01-75 / ANSI B31.3 / DNV / E&I package compliant with Offshore Zone 1 area classification. 05