final interim design presentation

8/12/2019 Final Interim Design Presentation

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Concept Design of an Ultra-Deepwater

Rare Earth Mineral Mining System

Ranald Cartwright Christopher Blake David Fraser

Euan Greer Russell Torrance Luke Chapman

Interim Design Presentation

17thof March, 2014


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Presentation Overview

Current Stage of Project

Change of Project Focus

Overview of Design Configuration

Main Design Elements

Riser System

Mineral Collection Tool

Flow Assurance

Processing and Separation Systems

Powering and Control Installation and Maintenance

Project Time Plan

Next Steps


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CHOSEN DESIGN CONFIGURATION


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Depth:

4970m

5000m

CHOSEN DESIGN CONFIGURATION

Installation

Processing &Separation

Riser System

Flow

Assurance Mineral

Collection Tool

Powering


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Depth:

4970m

5000m

Hydrocyclones

Boost Pump

Hopper

FLOATING HUB


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RISER SYSTEM


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RISER STRUCTURE

Initial Configuration

Component Selection

Riser Joint Burst and Loading Criteria specified by ABS


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Depth:

4970m

5000m

Integrated Lines

Gas/Power/Comms

Buoyancy Module

(Balmoral)

5.2IDRiser

Riser Configuration


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Depth:

4970m

5000m

RISER CONFIGURATION


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MINING AREA ENVIRONMENTAL CONDITIONS

5000m Water Depth

Hs = 4m and Tp = 9s

Unidirectional and Bi-axial CurrentProfiles

WD (m) Current Speed (m/s)

1 0.4500 0.3

1000 0.35000 0.2


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OrcaFlex9.7a

Vertical CurrentProfile

Speed(m/s)

0.80.60.40.20

Z(m)

0

-1000

-2000

-3000

-4000

-5000

OrcaFlex9.7a

Vertical CurrentProfile

Speed(m/s)

0.40.20-0.2-0.4

Z(m)

0

-1000

-2000

-3000

-4000

-5000

OrcaFlex9.7a

Spectral Densityfor WaveTrain 'Hs=4m'

Frequency(Hz)

0.40.30.20.10

SpectralDensity(m^2/Hz)

40

30

20

10

0

Unidirectional

MINING AREA ENVIRONMENTAL CONDITIONS

Bi-Axial Wave Spectra


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KEY CHALLENGES

Determining the slip-joint and tensioner orientation

Buoyancy Placement to be Sympathetic to Installation

Vessel Loading during Operation

Modelling Challenges


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MINERAL COLLECTION TOOL


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Depth:

4970m

5000m

COLLECTION TOOL CONTROL


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Subsea Electromagnetic Hydrocyclone

Assess forces required to effectively move and control the system

Create a dynamic model of collection tool and assess motion underapplied forces: Control rams

Hub Motions Seabed Friction

Impact of Motions Collection Efficiency and Operability

Environmental Considerations

Investigate the method of operation

COLLECTION TOOL ANALYSIS


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Depth:

4970m

5000m

OPERATION


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FLOW ASSURANCE


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Depth:

4970m

5000m

Bundled Gas Lines x2

Flow

Assurance

Centrifugal Boost Pump[Provides Seabed to Hub Lift]

Massive Topsides Compressor[Tengiz Field Khazakstan 10,000 psi]

LIFT MECHANISM CONFIGURATION

Gas Injection at Hub


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Depth:

4970m

5000m

TOPSIDES GAS COMPRESSION


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Depth:

4970m

5000m

SUBSEA GAS INJECTION


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REQUIRED FLOWRATE

Hjulstrm Diagram


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Subsea Electromagnetic HydrocycloneFLOW PARAMETERS

Gas Lift with Boost Pump

Required Mass : 100 t/hr (dry weight)

Flow at Inlet: 221 t/hr (slurry)

Flow to topsides : 108 t/hr (partially dewatered)

Flow Rate to meet target : 3 m/s


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Subsea Electromagnetic HydrocycloneCHALLENGES

Key Issues:

Required Mass of lifting gas

Supercritical Liquids

Change in Lifting Properties

Gas Expansion towards surface


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Subsea Electromagnetic HydrocycloneCHALLENGES

Key Issues:

Required Mass of lifting gas

Supercritical Liquids

Change in Lifting Properties

Gas Expansion towards surface

Air Phase Diagram


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PROCESSING & SEPARATION SYSTEM


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Separation and Processing

Subsea electromagnetic

hydrocyclone

Topside gravity concentrator

Tailings disposal

SYSTEM CONFIGURATION


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Watson Magnetic Cyclone Design:

Magnetic force coupled with

centrifugal force

Magnetic/Dense particles forced

outward

REEs collected from underflow

Water/Clay to overflow and

discharged

SYSTEM CONFIGURATION


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Hydrocyclone size

Inlet velocity

Required magnetic field

strength Hydrocyclone Equilibrium Conditions

SEPARATION ANALYSIS OUTCOMES


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Assumptions for clay properties

Magnetic susceptibility of particles

Compatibility with desired flow conditions

CHALLENGES


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Knelson Concentrator:

High capacity

Established method

Able to process desired particle

size

TOPSIDE GRAVITY CONCENTRATOR


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Analysis:

Based on subsea separation

results

Catalogue selection to meet

requirements

TOPSIDE GRAVITY CONCENTRATOR


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System:

Topside and Subsea Disposal Systems

In accordance with ISA guidelines

TAILINGS DISPOSAL


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POWERING & CONTROL SYSTEMS


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The umbilical will be a dynamic design, due to the depth of operation.

Will be attached to the riser during installation (similar to current drilling

operations).

Will contain powering and control to the hub components.

UMBILICAL DESIGN


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Selection of the power and communication cables currently being chosen

with reference to,

IEC 60502-1 (Power cables: 1 kV up to 3 kV)

IEC 60502-2 (Power cables: 6 kV up to 30 kV)

DNV-RP-F401 (Electrical Power Cables in Subsea Applications)

Internal structural design of the umbilical to be produced, outlining

materials and components.

UMBILICAL DESIGN


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CONTROL SYSTEMS

Buoyancy Modules

Automated control of buoyancy modules no longer required.

Pipe Control

The control of the pipe will be via a hydraulic ram system located in the

hub.

3D model of the hydraulic system and its operation.

A mathematical model of the control of the hydraulic systems operations

(varying control inputs, to find the best operating conditions of the ram).


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Pump and compressor selection yet to be confirmed as operation

conditions are required.

Once selected, specification of each will be compiled (supplying powering

requirements).

A total power amount for various operational conditions will then be

specified with a suitable generation method chosen.

A distribution diagram will be construction outlining power draws and

potential losses.

POWER REQUIREMENTS


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INSTALLATION & MAINTENANCE


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INSTALLATION AND MAINTENANCE OF MINERAL RECOVERY SYSTEM

Huisman Dual Multi Purpose Tower (DMPT)

Possible hook load of 1,090 tonnes

No V-Door limitation due to box shape and not lattice

Compatible with specified riser tensioners

Moonpool skid cart capable of moving 800 tonne

structure such as mineral recovery tool

Using Aker CLIP risers it is possible to deploy rapidly


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RESPONSE OF RISER DURING INSTALLATION

Using Orcaflex model to calculate riser response

Continuation of Static Analysis from Riser Section

Completed every 20m until riser depth is 200m to accurately measure bending and

deflections through splash and wave zone

Every 200m thereafter until target depth reached

Analysed to find limiting environmental conditions for installation and retrieval of

system

Excess loads assessed during loading and retrieval phase


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SYSTEM MAINTENANCE

Investigate components used within project to detail

maintenance intervals and procedures

Establish the operating window of the system

Will allow the maintainability of the system to be

assessed and cost estimates provided

FMECA undertaken to establish how a failure effects

the system as a whole

Initial operability found and measures to increase

operability window implemented


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GOING FORWARD

Properties of buoyancy to be received from BalmoralOffshore

Run initial Orcaflex model for first iteration of buoyancyplacement

Ascertain if parameters such as stress in riser are withinacceptable limits in varying environments

Compare deck layouts and derive an effective and safepositioning of installation and maintenance equipment

Consider procedure if a storm is to hit mining area

Construct FMECA of equipment and investigate effects ofpreventative measures


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CONCLUSION & NEXT STEPS


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Time Plan

Mining System Concept (Gantt Project)


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Next Steps

Further analysis on each section as has been summarised Several minor challenges to overcome

Still to receive information for certain sections

Continue to complete analysis and link sections together

Upon completion of the main elements described theoperability and economic viability of the system can beassessed

Next major deadline is final report hand-in on May 7th


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Conclusion

All main elements of project progressing well

Project has satisfied all aims and objectives thus far

Currently slightly behind schedule

Will change after exams

We have a 2 week contingency built into schedule

Confident in delivering a high-quality final project in May


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Thank you for listening

Any Questions?

final interim design presentation

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