How has Statoil implemented 3D laser scanning technology into its business? Presenter: Terje Birkenes, Company representative 3D laser scanning contract Technology & Projects, Statoil ASA SPAR 2006 27-28 March, Houston
In this presentation I will not discuses if 3D laser scanning is beneficial, we have past that level, our focus now is on how we best can implement this technology 2 But if I shall highlight some of the benefits, these will be in order of priority 1. Improved HES( Health Environment Safety). Also valid for listed points listed bellow. 2. Improved quality, the design is more fit for operation purpose 3. Eliminate field rework 4. Improved design gives a reduction in amount of installation hours 5. Reduce offshore survey travels, limited bed capacity 6. Reduced project execution time 7. More accurate estimate prior to contract award Note: This priority can vary from project to project (excepted point number 1, HES)
Agenda: 1. Statoil, key figures. 2. Examples of typical plants. Projects, yearly Maintenance & Modification budget. 3. Statoil history regarding laser scanning 4. Statoil s Best practice, this method was developed in a Snorre modification project. It is now full implemented in all Snorre projects. 5. How will we continue the implementation of this method 6. The future. Future development. Where can we use this technology to improve our business 3
4 Statoil key figures Statoil is an integrated oil and gas company with 25 600 employees and activities in 32 countries. (February 2006) Established 1972. Den norske stats oljeselskap a.s - Statoil. Its total revenues in 2005 came to billion 14,2 USD(NOK 95,1) A major oil and gas producer: 1.1 million barrels of oil equivalent per day. World s third largest net seller of crude oil Covers 10 per cent of the European gas consumption Statoil is operator for 60 per cent of all Norwegian oil and gas production In 2004 90 per cent came from Norwegian Continental shelf. International production is growing rapidly. It rose from 67,000 barrels of oil equivalent (boe) in 2001, to 115,000 boe in 2004 an increase of 72 per cent. The target is to achieve about 25 per cent of the group s total production outside Norway by 2007. Several new international project are under development The group has service stations in the Scandinavian countries, Ireland, Poland, the Baltic states and Russia. 2,000 service stations in nine countries Statoil is one of the world s most environmentally-efficient producers and transporters of oil and gas Statoil is listed on the Oslo and New York stock exchanges
Technology development in Statoil A 20-year history of successful technology implementation Statoil has been a pioneer in adopting new technology. The prime motive has been to make the development and operation of its facilities as cost-effective as possible. Benchmarking has shown that Statoil s ability to innovate is three times greater than the industry average NEWS: World's largest project to use CO2 for enhanced oil recovery offshore Shell and Statoil have signed an agreement to work towards developing the world's largest project using carbon dioxide (CO2) for enhanced oil recovery (EOR) offshore. The concept involves capturing CO2 from power generation and utilising it to enhance oil recovery, resulting in increased energy production with lower CO2 impact. The project consists of a gas-fired power plant and methanol production facility at Tjeldbergodden in Mid- Norway, providing CO2 to the Draugen and Heidrun offshore oil and gas fields. Power from the plant will also be provided to the offshore fields, enabling near zero CO2 and nitrogen oxide (NOx) emissions from these installations. New technology Statpipe 1985 - Platform based Sleipner Gullfaks 1986 1993 Statfjord satellites 1994 Troll 1996 Subsea & floating Åsgard Norne 1997 1999 Glitne 2001 Snøhvit 2006 Significant step changes Time 5 Subsea to land
Examples from our plants, Maintenance & Modification sector, new projects. 1/2 6 On the Norwegian continental shelf we operate 24 offshore platforms. Many of them are large facility's like Gullfaks A. Lifetime for these platforms can typically be 40 years. Troll A has even a lifetime of 60-70 year Many of these installations will therefore go through several large revamp projects. Like IOR (Increased Oil Recovery) projects. Gullfaks A Troll A
Examples from our plants, Maintenance & Modification sector, new projects. 2/2 7 In Norway we have 5 large onshore plants, Kårstø, Mongstad, Kolsnes, Tjeldbergodden and the new Snøhvit LNG plant Early total project/service providers budget is billion 9,4 USD Maintenance & Modification sector: Our largest ongoing M&M project is the Statfjord Late life project, cost estimated to approximately billion 3 USD Under planning we also have the large Troll Future Development project, cost estimated to billion 7,5 USD In general we expect increasing activities in the M&M market
Statoil s history with regards to laser scanning/as- Is documentation. Headlines:1/2 Mid 90-present. The majority of our contractors still use the Total Station. We have in this period not established any requirements with regards to use of this engineering tool. Laser scanning, we expected that our engineering contractors should lead on with regards to implementation of this new technology, but that has not been the case. Therefore we started an investigation around this technology, now we see that we were the only player that could put together this method. (Re-using/storing of laser scanning data and sharing this data between the different company's via a internet based 3D design model) 2002. Test project on Statfjord A, wellhead area. Service provider Capnor 2003. Pilot project on Snorre A. Service provider Grenland Framnæs. 8
Statoil s history with regards to laser scanning/as- Is documentation. Headlines: 2/2 2004. Langeled project, modification of the Sleipner Riser platform. Statoil initiated a process resulting in a laser scanning contract that was established by our EPCI contractor Vetco Aibel. The laser scanning activity was after the project completion mentioned as a major contributor for making this project a success. Same method was also established for the Visund Gas project. Service providers was in both projects Capnor. 9 2005. Statfjord late life project. Statoil decided to start the laser scanning and re-modeling before the project start-up. This re-modeling scope was in this project huge, Statoil will in the future not initiate re-modeling scope in this size. The company's that won the EPCI contract received the data, but Statoil did not establish any work requirements with regards to use of this data. Service providers Capnor and Aker Kvarner. 2005. Snorre Vigdis IOR(FEED/Pre Engineering) Statoil s best practice has been developed in this project. Service provider Grenland Framnæs.
Statoil s Best practice (Snorre Method) Headlines: 10 The point cloud is part of the Life cycle information (LCI) documentation for the plant. Establish a common laser scanning point cloud database, a service provider administers the database (PCA) A 3D Design PDMS Global model is established (internet solution where our contractors work online at the same time, the model contains data from As-Built, As-Is, new projects and studies. Keyword is sharing of data Statoil governing documents/internal specification are established to document this solution/method, and secure the use of the model and the point cloud database. (TR technical requirements) New project will at start-up have access to all data available, model established in the study phase and As-Is/As-Built documentation New requirements to the engineering process All engineering/installation contractors are forced to use the model and the point cloud database(pcd)
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Facts: Snorre laser scanning point cloud database Point cloud database (PCD) 1050 scans are registered, 8 billion points, 400 GB of data Roughly 50% of the topside is scanned, after the shutdown (April 2006) is completed we will continue the scanning with goal to cover near 90% Scanners used: 3D Guru, HDS 3000, HDS 4500,Trimble GS 200, Surphaser. Scanning files processed in Cyclone Scanning service providers: Grenland Framnæs (PCA) and Capnor 12
13 Facts: 3D Design PDMS Global model 3D Design PDMS Global model 5 different projects are logged on 3 new projects are expected to log-on in the near future. The only contractor that is not performing its design in the Global model is now the drilling contractor, we expect to have them in during June/July.
Scope: Laser scanning point cloud database administrator. PCA contract: Administer the database 14 Receive new point clouds for registering in the database Quality check of new data Deliver data on request Receive dgn files with demolished element for updating of the database (remove points from the database) Scanning on request Modeling on request, deliverables to the 3D PDMS Global model Establish/administer the master grid system Support design/installation contractors on request, clash checking PDMS Laser Model Interface LMI. Integration and coordination with the Global model.
15 TR 1965 Technical Requirements Laser scanning Main purpose for this documents/specification is: Secure the quality of incoming data to the PCD, keyword: 1. Prerequisites (Hardware requirements, targets) 2. Scanning requirements (resolution, infield QA check, target, documentation) 3. Data handling process (Registration, geo reference, naming conventions, 4. Deliverables (Individual scans, registered point clouds) 5. Procedures for establishing the master grid. Onshore plant, Semi sub, FPSO, concrete gravity base structure and jacket platforms 6. Master Grid plate, duplex plate. TR1965 Amendment. Master grid index for each individual facility Will approximately be updated every second year The list is administered by the PCA
TR 1966 3D PDMS Global and laser scanning model 1/2 Roles and responsibility (Contractor versus Company) Secure a uniform use of the model Naming conventions Modelling work requirements, level of detailing Database schedule Interfacing work requirements (other engineering tools) Controls the re modelling from the As-Built drawings Phases and phase transition 16
17 TR 1966 3D PDMS Global and laser scanning model 2/2 Laser scanning interface If the database is missing data from an area, the Contractor shall supplement this database with new laser scanning data. The EPCI contractor can choose if it will perform the scanning it self or if it will use our PCA. Before approval for IFC (Issued for construction) new elements/objects from the 3D design model shall be merged and clashed check against the point cloud database (PCD) Demolition object shall be re modelled from PCD and report back PCA Statoil does not set any requirements with regards to how much that shall be re modelled from the point cloud Re modelling requirements PDMS Laser Model Interface LMI
Examples from Snorre 18 New firewater pump. The EPCI contractor did on project start up receive: Access to the PCD, the model developed in the study phase (Yellow), re-modeled element from the PCD (green). Global connection. We are scanning the internals of our separator for future revamp project (Target: Reduce shut down hours) We plan to perform scanning of mechanical packages before delivery from vendor. Scanning of prefabricated sections/modules for verification against the PCD
How will we continue the implementation of the laser scanning technology. Capacity in the laser scanning service providers market are limited: 19 We know that the market is growing, but if we implement this method now on all of our plants the market will not be able to serve the demand required. Therefore: We will prioritize plants/fields where we are planning large modifications projects. Next up will probably be Heidrun and Troll A When we implement the method the whole organization must live up to the governing documents not only the main project. Our engineering contractors must be trained in using the method. It will also take some time for them to purchase laser scanning equipment, internal training etc. Establish new PCA frame agreements and scanning frame agreements.
Future laser scanning contracts (PCA) We have separated the NCS in 4 areas. For each area we have an M&M( small projects) EPCI contractor We are now considering if shall do the same in laser scanning or if we shall have one PCA contractor to serve all of our activities. Tampen field area 20
21 Future development We are looking for: Improved capabilities for LMI, PDMS Laser Model Interface. Since the beginning we have looked for software that can utilize point clouds inside the design environments, we will like to contribute to further development of this new possibility. Improved software for viewing of 3D models and laser scanning point clouds. Users: Operation personnel, project personnel with no knowledge to PDMS Software for PCA, point cloud administration Software for analysis, example helicopter downwash, wind and explosion Internal: We will continue the development of our work process and technical specification for laser scanning Governing document, TR XXXX Administration of laser scanning point clouds
Example of the future, where can we use this technology to improve our business Facility for the Future-JIP project, a joint venture project with Norsk Hydro, BP and Statoil. Design contractor Aker Kvaerner Oslo. We have under development a platform concept where the main goal is to reduce the need for offshore operation personnel. The main feature of the concept is to use remote assisted tool (RAT), consisting of robots with different types of inspection and sensing technologies. Also larger robots that can be used for maintenance purposes are needed (to be operated with personnel assistance). The laser scanning technology can be used to assist with steering of the robots. 22
Thank you for your attention 23