Byford Dolphin Semi-Submersible Rig
1: Byford Dolphin SPS / Belfast
Toolpushers Emergency Control Centre: A new console was designed, manufactured, assembled and installed in the Toolpushers office. The console incorporated Heli-Deck Monitoring, Rig CCTV, Watertight Door Monitoring, Fire Damper Monitoring, Tank Gauging and Fire and Gas Monitoring. The new control console allows for operation and visualisation from one central point on the rig.
Harland and Wolff has been awarded the contract for the dry docking and renewal / (SPS) Special Periodic Survey of the Byford Dolphin Semi-submersible rig by Aberdeen based Dolphin Drilling.
< Image inset: Design (assembly view) of Toolpushers Emergency Control Centre.
The Aker-H3 design semi-submersible drilling rig will have several major modifications and upgrades. The project will also include numerous renewal and maintenance scopes of work such as repairs, system renewals and refurbishments.
The Byford Dolphin is a semi-submersible rig known very well to Monitor Systems. Prior to the current SPS scope of work, Monitor Systems carried out various design and installation projects on the rig. Bespoke systems designed and delivered over the years include Anchor Winch Monitoring, Bulk Tank Monitoring, Draft Level Monitoring, Emergency Ballast, Helideck & Environmental Monitoring, Leak Detection, Fire Damper Monitoring.
Our SPS scope of work contracted by Dolphin Drilling included the design, manufacture, installation and commissioning of many integrated instrumentation monitoring and control systems. In general, the project involved the design and replacement of the existing Emergency Ballast Control System, the upgrade and expansion of the Fire Damper Monitoring System, Water Tight Door Control Monitoring System, Anchor Winch Emergency Release system and a new Toolpushers Emergency Centre.
Brian Sinclair, Managing Director at Monitor Systems commented, ... “The project had enough scope for Monitor Systems to demonstrate its combined design, engineering, project management, manufacturing and installation capabilities.
We are pleased to build on our longterm relationship with Dolphin Drilling following the work undertaken for the Borgsten Dolphin last year and we are delighted to be part of the Special Periodic Survey that will deliver the Byford back into service in the next few months.”
Emergency Ballast Control Panel: The new Emergency Ballast Control System was given its own ET200S I/O rack, making the ESD segregation simpler; simplifying any future maintenance and fault finding. The new panel and system was designed, engineered, manufactured, tested and installed on the Byford Dolphin. A shared I/O enclosure was used, housing the Watertight Door and Fire Damper monitoring I/O in the SCR Room.
Water Tight Door Monitoring: A replacement panel and system was designed, engineered, manufactured, tested and installed in the same location as the existing panel. A Siemens PLC along with I/O Rack was utilised to control the watertight doors. A new UPS was provided giving a minimum autonomy of 30 minutes.
Anchor Winch Emergency Release: The scope of work included four new Pusnes Winch Exd Enclosures and control panels, one Zone 1 pilot house Control Panel, four Zone 1 Bratvaag Winch Control Panels and four Zone 2 Battery Enclosures. All design and assembly was undertaken in-house, supplied to the Byford with full engineering support documantation including FAT, Atex documemnt, commissioning procedures and work pack.
Fire Damper Monitoring: Two Zone 3 I/O panels were designed, manufactured, tested and installed on the rig, monitoring up to 24 additional fire dampers per panel. A fourth allowance for I/O was built into the new Process Enclosure. An allowance was made for 32 inputs, 16 Fire Dampers. The SCADA Software on the Toolpushers, Control Room and Pilot HMI’s were upgraded to include the additional dampers being monitored.
2: Anchor Winch Monitoring System
The Anchor Winch Monitoring System installed onboard Dolphin Byford by Monitor Systems is designed to monitor anchor tension, chain length, payout speed and motor current in addition to providing control outputs for overspeed on all twelve winches holding the rig. Utilising a fibre optic network for communicating between winches and the control room, the system uses a Siemens PLC with remote HMI's in each windlass cab and two IPC's in the control room and pilot-house.
300 tonnes load pins on the Brattvagg windlasses and hydraulic load cells with pressure transducers on the National windlasses measure anchor tension. Chain length and speed is verified by proximity sensors picking up targets on the main gypsy wheel.The system graphically displays tensions, speeds and chain lengths as well as providing trending of anchor tensions and built in alarm functions via colour touch screens in all winch cabs and the main control room. It also allows viewing of data from all winches at any station.
The four Industrial Computers were configured as a redundant system meaning that if any computer failed it would not affect nor limit the operation of the other computers.
The Anchor Winch Monitoring system includes HMI displays in the Control Room and Pilot House, along with (8) eight bulk tank guided Wave Radar Sensors.
Having the Anchor Winch Monitoring system installed on the rig is a big benefit to Dolphin Drilling. Reliable state-of-the-art monitoring technology to control the bulk material safely and in a controlled manner for the Bulk Tank System is a step forward in the right direction for rig efficiency and safety. The same display units for the system monitors the tension, chain length and pay out speed of all twelve (12) anchor winches.
A highly trained in-house engineer from Monitor Systems was invited to survey the rig, compile a report and provide all the consumables that would be required to furnish the project.
During the Rig Survey the Engineer suggested to the OIM that a display panel would be required in the Sack Store to display Bulk Tank Levels to the Control Panel Operator. The current design was based on individual Panel Meters displaying the Tank Levels. A HMI display was considered as it would look better and be capable of providing more information to the user.
Dolphin Drilling were then provided with detailed drawings and plans to help them with the system and for easy use onboard . Monitor Systems engineers have a close working relationship with Siemens, who helped provide the technical knowledge of the system including the 15” HMI touch screen monitors.
After initial project survey and reporting, Monitor Systems were awarded the contract in the first quarter of 2012 based on having a 'can do approach' to the project including key project management parameters. The project included the FAT and commissioning of the system once installed.
4: Draft Radar / Sea Level Monitoring
Monitor Systems were approached by Dolphin Drilling to supply and install four Draft Radar Sensors on the Byford Dolphin semi-sub. The Radar Sensors will measure and monitor the continuous level of the sea in relation to the rig. The advantage of these ultrafrequency sensors is that they have a constant speed (of light) offering height measurements over short distances, unaffected by environmental conditions.
Today, these radar level sensors are commonly used in hydrometry and are becoming the standard for tide stations and offshore installations around the world because of the increased need for accurate and reliable sea level measurement and monitoring.
The Draft Radar Sensors used in the project has a maximum measuring range of 75m and meets all the accuracy requirements. The transducer was installed, referenced vertically from the rig structure.
A Draft Level Display (analogue input panel meter), 5-Digit 0.56” red sunlight readable display with 85 - 250 VAC supply was also installed and calibrated as per customer requirements.