General meeting NFLB 25th of September 2009 Step …nflb.no/wp-content/uploads/STEP_Offshore.pdfSTEP...

part of Aker

© 2008 Aker Solutions

General meeting NFLB25th of September 2009

Step Offshore presentation

”Advanced Mud Systems”

Arild Grasdal – Sales Manager North Sea

© 2008 Aker Solutions part of Aker

Topics

■ About Step Offshore

■ Efficient agitator design

■ Automated tank washer systems

■ Derrick dual pool shaker

■ MRD unit

■ LCR reservoir tank

■ Auto addition

■ Automated control systems

■ Auto density systems

■ Example upgrades

■ Where are we in 5 years?

Confidential Slide 2

part of Aker


About STEP Offshore

ConfidentialSlide 3


About us

■ STEP Offshore is a leading supplier of high quality drilling fluid management solutions for oil and gas applications

■ Typical STEP Offshore deliveries are automated systems to semi submersible drilling rigs, drill ships, jack ups and land rigs, both new builds and upgrades

■ STEP Offshore has a highly qualified group of service engineers that travel throughout the world to assist customers with installation, commissioning and servicing assignments.


© 2008 Aker Solutions part of Akerto edit this text Slide 5

STEP Offshore AS

Main Office/ workshop, Asker

■ Established : 2004

■ Main office : Hvalstad (Asker)

Regional Sales office : Forus, Stavanger and Aberdeen

■ Workforce : 55

■ Qualified in the Achilles Joint Qualification System

■ ISO 9001 : 2000 certified

© 2008 Aker Solutions part of Akerto edit this text Slide 6

FACILITIES

■ Office space: 1050m2

■ 1500m2 workshop for assembly and test (2,5 ton crane capacity).

■ In-house testing facilities for full scale test of mud mixing skids, PLC based control systems and various equipment.

■ Access to Aker MH facilities

Main office/ workshop, Asker

Sales Office, Stavanger

Sales Office, Aberdeen

../../Admin/QA/STEP DNV ISO 9001_2000 certificate of 08.10.07.pdf


Part of Aker Solutions

■ STEP Offshore is a subsidiary of Aker Solutions, a contractor and supplier of advanced technologies, products and services

■ The clients are typically owners and operators of facilities such as offshore oil and gas fields, offshore drilling rigs, and onshore plants for processing or power generation

■ With the support of the mother company, STEP Offshore is a trusted and innovative player in its markets, for solutions in today’s and tomorrow’s drilling fluid applications

to edit this text Slide 7


Health, safety and the environment

■ In STEP Offshore, respect for health, safety and the environment is a core value

■ This HSE mindset is founded on the beliefthat all incidents can be prevented, and isthe key to the company’s work within health,safety and the environment

■ An HSE program has been introduced to emphasize the personal element of HSE, while a group wide HSE operating system, HSE training and focus on leading indicators, are all elements of STEP Offshore’s systematic efforts to achieve world class HSE performance

to edit this text Slide 9


Quality system

■ STEP Offshore is committed to challenging goals for controlling quality and ensuring that customer expectations are met

■ Conformance with contractual requirements and statutory regulations is a minimum requirement for all areas of work.

■ To secure all operations STEP has established a quality system in accordance with the requirements of ISO 9001:2000.

■ STEP is qualified in the Achilles Joint Qualification System for suppliers to the oil industry in Norway and Denmark.



Engineering capabilities

■ STEP Offshore helps design your system the optimum waythe first time by involving engineers with a extensive productknowledge and drilling fluid process understanding

■ As a complete supplier of drilling fluid management solutions,STEP Offshore provides multi-discipline engineering supportand design assistance to ensure that the final product meetsspecified requirements

■ Equipment selection and location

■ Piping design and routing assistance

■ ISO review for optimal pipe routing

■ All-systems design assistance



After sales

■ The after sales division provides the servicesneeded to ensure excellent lifecycle performanceand the safe operation of all parts of aSTEP Offshore delivery

■ Technical and operational support

■ Spare parts support

■ Support agreements

■ Overhaul and repair

■ Completion services

■ Training courses

■ Consultancy



Product and system level deliveries

■ The company offers an extensive line of products for drilling fluid management applications

■ To offer maximum value to our customers STEP Offshoreoften deliver complete integrated systems, controlled and/oroperated through advanced automated control systems

■ STEP Offshore offers products and solutions such as:

■ Automated control systems

■ Drilling fluid management

● Mud mixing

● Mud circulation and transfer

● Bulk storage and transport systems

■ Other equipment

● Solids control

● High pressure pumps and manifolds

■ …and more



Automated control systems

■ STEP Offshore combine decades of process experience with top of the line automation technology to design advanced, but well proven and operator-friendly control system

■ The control system topology design will reflect the plants individual process design

■ We focus on the operations when designing HMI (Human-Machine Interface) systems to ensure fast, safe and easy-to-use actions, whether the operator wants a fully manually controlled process, or an advanced and automatic software application



Mud mixing

■ STEP Offshore provides market leading system for mixing of drilling fluids

■ Supplied as individual equipment or as a complete mud mixing system, the equipment offers unprecedented accuracy and control for the operator, to ensure the best possible mixing results


Mud hopper Liquid chemical skid Rapid barite mixer Sack cutting unit

Big bag unit Multi reservoir dosing unit Caustic mixer


Mud circulation and transfer

■ The company offer a wide range of products for circulation and transfer of drilling mud

● This includes state-of-the-art agitators, LP mud pumps, mud guns, shear mixers and much more.

■ The agitators are designed to achieve the best possible mud tank agitation by using advanced CFD (Computational Fluid Dynamics) and 3D modelling techniques


Agitator

LP shear mixer LP Mud pump

Agitator CDF simulation


Bulk storage and transport systems

■ STEP Offshore’s line of products for bulk storage and transport provides an efficient system for dust free handling of powder based mud additives


Dust cyclone and collector Bulk storage tank

Surge tank feeder Surge tank


Other equipment

■ STEP Offshore cooperates with leading suppliers to provide our customers the best equipment and solutions the industry has to offer

● Gumbo conveyors

● Flow dividers

● Shale shakers

● Mud cleaners

● Desanders

● Desilters

● Centrifuges

● Degassers

● Agitators

● Cuttings dryers

● Cuttings blowers

● Centrifugal pumps

● Hose loading stations



Our people

■ STEP Offshore deliveries are the sum of decadesof expertise and experience. The diversity ofpersonal capabilities and the interaction betweenthem liberates energy and generates newtechnology, creative solutions and lasting value

■ STEP Offshore actively strives to attract anddevelop talented individuals who understand ourcustomers’ needs and requirement and who canproduce and deliver the best solutions


part of Aker


Efficient Agitator Design

STEP Offshore AS Rotomud 2000 series


Rotomud 2000

■ Market release late 2008

■ Goal: be the preferred partner for agitator selection

■ New high efficiency impeller blade designed to achieve the best possible mud tank agitation.

■ Designed using advanced CFD* and 3D modeling techniques. The impeller accelerates the fluid evenly over the entire blade, optimizing energy transmission and efficiency.

■ Drive unit and strengthened gear box are made specifically for top mounted agitators and are extensively oilfield proven.

■ ”One way – fool proof” installation



CFD – Computational Fluid Dynamics

■ Ansys CFX analysis for Computational Fluid Dynamics (CFD) simulations


CFD – Computational Fluid Dynamics


■ CFD calculations and reports available upon request.

■ Verifies performance of installed configuration.

■ Enables optimization of location by identification of low flow areas caused be restrictions, corrugations, etc.


Development facilities

■ Development lab● Measuring instruments

including electronic oilfield viscosimeter

● 1:10 scale model tank with two agitators

● Tools

■ Test Tank● Near full scale slug pit (12 m3)

● 18,5 kW Agitator with frequency converter

● Test instrumentation with data logger

● Continously tested prototype 600 hrs under different operating and overload conditions


Efficient agitator design


■ Efficiency:

■ Benefits:● stable mud properties from proper circulation

● reduced cleaning time

● reduced slop generation from quick tank cleaning

AgitatorRot. speed

[rpm]

Avgerage fluid

velocity [m/s]

Power

[kW]

Impeller

diameter

%diff.

power

RotoMud 71 RPM 0,71 7,94 1600 0

Konkurrent 60 RPM 0,64 8,53 1580 6,9

Flatjern 50 RPM 0,71 9,48 1600 16,2

part of Aker


Automated Tank Washer Systems

The effective and HSE friendly approach to tank cleaning



Dual nozzle machine

■ For difficult installations

■ Complete unit inside tank

Tank cleaning pump skid

■ Recirculation of cleaning water

■ Soap / solvent addition

Single nozzle machine

Programmable

■ Tank roof

■ Tank botton

■ Walls

■ Concetrated areas

■ Pattern density



Tank cleaning and re-

circulation pump

Soap / solvent

addition

Dual suction strainer

Suction/discharge/

circulation manifold

Ejector for suction

from cleaned tanks

Benefits:

■ Continuous circulation on empty tanks

■ 3-4 cleaning heads can be run simultaneously

■ Downstream treatment of waste water possible



Efficiency benefits:

■ Reduces waste / slop

■ Fast & thorough cleaning

● Dense washing patterns

● High Pressure Flow

● Soap / solvents mixed while pumping

■ No extra personnel needed

■ No tank entry permits

■ All equipment serviced on surface

HSE benefits:

■ Less waste handling

■ Eliminates tank entries

■ No exposure to mud or chemicals

■ Personnel removed from the cleaning operation

■ Automatic cleaning without personnel lets the Derrick man focus on the primary operations.


part of Aker


Derrick Dual Pool 626/628High ”G” Shaker


Features

■ Dual Pool Screen Frame

■ Actuated Screen Compression System

■ Optional Scalping Deck

■ Super G3 Vibrating Motors

■ Pyramid and Pyramid Plus Screen Technology

■ Hydraulic deck angle adjustment


Features

Long life lightweight

urethane screens.

Dual pool screen frame

Pneumatic screen

clamping. Two hand

release operation.

HVAC hood

http://www.derrickequipment.com/swf/video.swf?flv_path=/Images/Documents/DP600ASCSJan20082.flv&width=320&height=277


Flow rates

© 2008 Aker Solutions part of Aker24. okt. 2009 STEP Offshore ASSlide 34

Noise and vibration testing

■ Tested in Norway (noise and vibration) in January and February 2009

■ The tests were performed at STEP Offshore’s facilities at Hvalstad

■ Lifetec AS performed the test according to the relevant standards

● NS-EN ISO 9614-2:1996 (sound)

● NORSOK Standard S-005


Noise Measurement Results

■ Sound power level is 83.5 dBA

● Upper boundary = 85.0 dBA

■ Sound pressure level is 64.9 dBA

● 1 m distance from the shaker is 64,9 dBA

● Upper boundary = 66.4 dBA (incl. uncertainty)


Vibration test results

■ Category 3 - Limits for process, utilities and drilling areas

■ Category 4 - Limits for vibration locally to equipment

■ Category 5 - Maximum limits (normally unmanned areas)

■ Note: category 4 applies for these tests (limits locally to equipment)

■ Complete vibration test report available upon request.

part of Aker


MRD Unit

Multi Reservoir Dosing Unit


MRD Unit


■ STEP Offshore’s MRD (Multi Reservoir Dosing) unit is designed to lighten the operator’s workload when it comes to adding chemicals from sacks.

■ The chemicals are filled to the different reservoirs from a sack cutting unit. The operator can fill all four reservoirs in one go and program the MRD unit to automatically dose the desired amount of chemicals from any of the four reservoirs to either of the two mixing lines thus relieving the operator to do other work.


MRD Unit


Bi-directional Screw Conveyors

Air filtersPowder inletPowder reservoir

Powder outletOutlet valves


MRD and sack cutting units


part of Aker


LCM Reservoir Tank

Independent LCM Feeding System


LCM Reservoir Tank

Specification:

■ 4 mt Lost Circulation Materials≈ 160 sacks / 4 Pallets

2 Containers

≈ 15 – 30 hr drilling with Preventive LCM Treatment

■ Discharge: 50 kg/hr – 4000 kg/hr

■ Remote PLS automatic control

■ Load cells

■ Cell feeder with agitation

■ Anti Plugging: Air and vibration

■ Filled from sack cutter

■ Dust Free

■ No Pressurizing

■ Footprint: Ø 1.5 m

■ Height: 4 m


LCM Reservoir Tank

Preventative Loss Treatment

■ 10 – 100 kg/m3 LCM in active drilling fluids.

■ Purpose:

● Seal formation while drilling

● Strengthen formation

● Reduced losses = reduced drilling cost.

● Drill string lubricity / Torque Reducer

■ Constant maintenance of programmed concentration while drilling and circulating as LCM is lost on shakers.

■ Additional LCM needed on rig in case of uncontrolled down hole losses


LCM Reservoir Tank

Preventive handling of LCM offshore.

■ 2 – 4 products delivered in 25 kilo sacks

■ Mixed sack by sack into the active mud system while drilling

■ Concentration of LCM maintained with addition of 4 – 10 sacks/hour

■ 10 to 50 mt LCM used per section. 400 – 2000 sacks.

■ Ties up mixing equipment & personnel

■ LCM treatment stops if other mixing is needed on the active mud system

■ LCM treatment stops if personnel has to prioritize other tasks

▼ If severe down hole losses occur several hundred LCM sacks are needed to stop the loss.

Container emptying – Crane lifts - Sack cutting – Manual mixing

Stress for personnel - HSE regulations

Loss of Time – Mud - $$$$


LCM Reservoir Tank

Installation Benefits:

■ Even chemical additions independent of personnel & equipment

■ Personnel & equipment free to prioritize other operations

■ Tank can be filled at any time ● Fill before the section starts or before drilling trouble zone

■ Quick response to Down Hole Losses: ● No container lifts or sack handling● High Feed capacity if needed.

■ Automatically operation from MCS:● Start/Stop● Feed Rates

■ Can be used for other drilling fluid chemicals

■ Easy upgrade installation


HSE Bonus

■ Remote operating

■ Dust Free

■ Time saving

■ Eliminates stress for operator

■ Preparedness for operational challenges

■ Space Saver: 4 pallets emptied – 2 containers back loaded

part of Aker


Auto addition - batch


Auto Addition System

How it works:

■ Establish circulation on the mixing lines for the active or reserve mud tanks

■ Input desired batch weight and dosing speed into the Mud Control System

■ The Barite Surge Tanks will discharge barite according to preset values

■ When the barite level in the surge tank reach a preset low limit, the Automatic Refill Program will refill the surge tank to set high limit

■ Surge tank are refilled without interrupting the continuous addition of barite to the mixing line


part of Aker


Automated Control Systems


Mud system overview screen



Mud mix system



Column storage tanks



Bulk barite/bentonite surge tanks



Mud treatment tanks



Mud treatment – shale shakers



Mud treatment - centrifuges



Alarm overview screen



Transmitter data input selection


part of Aker


Auto Density System

Automatic control of drilling fluid density


Auto Density System

How it works (1/2):

■ Establish circulation on the mixing lines for the active or reserve mud tanks

■ Input desired mud weight into the Mud Control System

■ Density sensors in the mixing lines continuously monitor the fluid density and displays the measurements in the Mud Control System.

■ The Barite Surge Tanks will discharge barite accordingly to achieve the preset mud weight

■ The premix pump will add low density premix to reduce weight to set point if density is above this level



Auto Density System

How it works (1/2):

■ When the barite level in the surge tank reach a preset low limit, the Automatic Refill Program will refill the surge tank to set high limit

■ Surge tank are refilled without interrupting the continuous addition of barite to the mixing line

■ The Mud Control Display will display the current mud weight, along with the desired mud weight to the drill floor and mud control room for real time continuous control



Auto density system – System layout

Barite surge tank

Measured Density


Auto Density System

Select Surge tank

Auto Fill and source

bulk tank


Auto Density System

•Set target density

•Target density can be

changed at any time

•Surge tank cell feeder

delivers barite to target

density


Auto density system – benefits (1/2)

A fully automatic system that maintains a controlled mud weight in the active drilling fluid system increases well bore stability.

Automatic line-ups and refills reduce the risk of human error.

Automatic density measurements reduce the operators exposure to the drilling fluids and by products i.e. vapors and barite dust.

Automatic continuous weight measurements eliminates fluctuations in mud weights. “Light spots” are treated before going down hole.


Auto density system – benefits (2/2)

Maintains the programmed mud weight as increased temperature and expansion lowers mud density

Increasing mud weight and displacements while drilling can be performed at an accurate and programmable rate.

Reserve mud can be weighted to spec without removing the operator from the ongoing drilling operation.

part of Aker


Example – Transocean Leader upgrade

© 2008 Aker Solutions part of Akerto edit this text STEP Offshore ASSlide 77

MUD MIX - TRANSOCEAN LEADER UPGRADE

Scope of supply:

■ Turn-key upgrade of mud mixing facilities and systems

■ Pre-study, design, engineering, equipment delivery, installation and commissioning

BEFORE

© 2008 Aker Solutions part of Akerto edit this text STEP Offshore ASSlide 78

MUD MIX - TRANSOCEAN LEADER UPGRADE

STEP equipment delivered:

■ Sack cutting unit

■ Screw conveyors

■ Big bag unit

■ Mud mixing hoppers

■ Surge tank feeders

■ Dual liquid pump skid

■ VFD/PLC panels

■ Misc.

AFTER

© 2008 Aker Solutions part of Aker24-Oct-09 STEP Offshore ASSlide 79

TO Leader Upgrade, Scope of Supply

1 x Sack Cutting Unit w/ skid

5 x Screw Conveyors

1 x Lifting Table

2 x Mud Hopper

2 x Surge Tank Feeders

6 x Load Cells

1 x Big Bag Unit

1 x Liquid Chemical Skid w/ 2 pneumatic pumps

2 x Density Measuring Units

1 x Mud Control System

1 x Pneumatic hoist w/mono rail

New covering to Mud Mixing House

Mechanical and electrical installation


TO Leader Upgrade

BEFORE


TO Leader Upgrade

AFTER


TO Leader Upgrade

BEFORE


TO Leader Upgrade

AFTER

part of Aker


Where are we in 5 years?


Important Goals for the industry the next 5 years

■ We see 3 main focus areas in the drilling fluid management industry the next 5 years

■ Reliability

● Increased up-time is very important

■ HSE

● This is a key area where “Norway” is world class

● Expect even more focus

● The rest of the world is getting there!

■ Cost Efficiency

● The cost of drilling will be a key concern in the years to come


Reliability

■ Reliability

● More automation reduces human error

● Remote surveillance and diagnostics

■ Prevent failures

■ Rapidly fix failures


HSE

■ HSE

● Eliminate human exposure to mud additives

● Eliminate manual operations

● Reduce CO2 emissions

● ISO 14001 Certified


Cost Efficiency

■ Better recirculation of mud

● Reduce generated waste

● Recover more fluids

● Recover and re-use additives like barite

■ Optimized process design

● Reduce power consumption

● Reduce installed equipment weight


Summary

■ STEP Offshore is investing today to stay ahead of our competitors in the future by

■ Increased focus on Reliability, HSE and Cost Efficiency


Thank you for your attention, please contact us for further questions and discussions!


Copyright

Copyright of all published material including photographs, drawings and images in this document remains vested in Aker Solutions and third party contributors as appropriate. Accordingly, neither the whole nor any part of this document shall be reproduced in any form nor used in any manner without express prior permission and applicable acknowledgements. No trademark, copyright or other notice shall be altered or removed from any reproduction.


Disclaimer

This Presentation includes and is based, inter alia, on forward-looking information and statements that are subject to risks and uncertainties that could cause actual results to differ. These statements and this Presentation are based on current expectations, estimates and projections about global economic conditions, the economic conditions of the regions and industries that are major markets for Aker Solutions ASA and Aker Solutions ASA’s (including subsidiaries and affiliates) lines of business. These expectations, estimates and projections are generally identifiable by statements containing words such as “expects”, “believes”, “estimates” or similar expressions. Important factors that could cause actual results to differ materially from those expectations include, among others, economic and market conditions in the geographic areas and industries that are or will be major markets for Aker Solutions’ businesses, oil prices, market acceptance of new products and services, changes in governmental regulations, interest rates, fluctuations in currency exchange rates and such other factors as may be discussed from time to time in the Presentation. Although Aker Solutions ASA believes that its expectations and the Presentation are based upon reasonable assumptions, it can give no assurance that those expectations will be achieved or that the actual results will be as set out in the Presentation. Aker Solutions ASA is making no representation or warranty, expressed or implied, as to the accuracy, reliability or completeness of the Presentation, and neither Aker Solutions ASA nor any of its directors, officers or employees will have any liability to you or any other persons resulting from your use.

Aker Solutions consists of many legally independent entities, constituting their own separate identities. Aker Solutions is used as the common brand or trade mark for most of these entities. In this presentation we may sometimes use “Aker Solutions”, “we” or “us” when we refer to Aker Solutions companies in general or where no useful purpose is served by identifying any particular Aker Solutions company.

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