U.S. patent application number 17/235306 was filed with the patent office on 2021-11-04 for method and apparatus for a mdoiular jack up rig assembley.
This patent application is currently assigned to Electronic Power Design, Inc.. The applicant listed for this patent is Electronic Power Design, Inc.. Invention is credited to JOHN NORWOOD, IV.
Application Number | 20210339989 17/235306 |
Document ID | / |
Family ID | 1000005720305 |
Filed Date | 2021-11-04 |
United States Patent
Application |
20210339989 |
Kind Code |
A1 |
NORWOOD, IV; JOHN |
November 4, 2021 |
METHOD AND APPARATUS FOR A MDOIULAR JACK UP RIG ASSEMBLEY
Abstract
A system and method are disclosed for building a modular
electrical system for a jack up rig, the method including but not
limited to identifying rig equipment on the jack up rig that will
be connected to the modular electrical system; selecting electrical
equipment to control the rig equipment; placing the electrical
equipment in an electrical module; and electrically connecting the
electrical equipment to power cables and control cables inside of
the electrical module; and testing the electrical equipment inside
of the electrical module.
Inventors: |
NORWOOD, IV; JOHN; (HOUSTON,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Electronic Power Design, Inc. |
Houston |
TX |
US |
|
|
Assignee: |
Electronic Power Design,
Inc.
Houston
TX
|
Family ID: |
1000005720305 |
Appl. No.: |
17/235306 |
Filed: |
April 20, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14447522 |
Jul 30, 2014 |
10984142 |
|
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17235306 |
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61859867 |
Jul 30, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E02B 17/08 20130101;
G06F 2111/20 20200101; B66C 23/16 20130101; B66C 2700/08 20130101;
H02P 3/12 20130101; G06F 30/00 20200101; B66C 13/22 20130101; B66C
13/18 20130101; G05B 15/02 20130101; B66C 13/14 20130101; B66C
23/88 20130101 |
International
Class: |
B66C 13/18 20060101
B66C013/18; B66C 13/22 20060101 B66C013/22; H02P 3/12 20060101
H02P003/12; B66C 13/14 20060101 B66C013/14; B66C 23/16 20060101
B66C023/16; B66C 23/88 20060101 B66C023/88; G06F 30/00 20060101
G06F030/00; G05B 15/02 20060101 G05B015/02 |
Claims
1. A method for building a modular electrical system for a jack up
rig, the method comprising: identifying rig equipment on the jack
up rig that will be connected to the modular electrical system;
selecting electrical equipment to control the rig equipment;
placing the electrical equipment in an electrical module;
electrically connecting the electrical equipment to power cables
and control cables inside of the electrical module; and testing the
electrical equipment inside of the electrical module from outside
of the electrical module.
2. The method of claim 1, the method further comprising: locking
the electrical module and shipping the module to a jack up rig; and
connecting rig equipment to the outside of the locked electrical
module.
3. The method of claim 2, the method further comprising: connecting
the control cables for the electrical control equipment to a
control cable marshaling panel inside of the electrical module;
connecting the power cables for the electrical control equipment to
a power panel inside of the electrical module; connecting control
cables connected to control test equipment simulating the rig
equipment to the control cable marshaling panel thereby providing
control connectivity between the electrical equipment inside of the
electrical module and the test equipment; and connecting power
cables connected to the power test equipment simulating rig
equipment to the power panel thereby providing power connectivity
between the electrical equipment inside of the power test rig
equipment; and certifying that the test module is working properly
before shipping the electrical module for installation.
4. The method of claim 2, the method further comprising: connecting
the control cables for the electrical control equipment to a
control cable marshaling panel inside of the electrical module;
connecting the power cables for the electrical control equipment to
a power panel inside of the electrical module; connecting control
cables connected to the rig equipment to the control cable
marshaling panel thereby providing control connectivity between the
electrical equipment inside of the electrical module and the rig
equipment; and connecting power cables connected to the rig
equipment to the power panel thereby providing power connectivity
between the electrical equipment inside of the rig equipment.
5. A modular electrical control system for a jack up rig, the
system comprising: a module housing; a plurality of equipment
sections connected together inside of the module housing; a control
cable marshaling panel mounted on the module housing; a plurality
of control cables connected between the control cable marshaling
panel and the plurality of equipment section installed inside of
the module housing; a power panel mounted on the module housing; a
plurality of power cables connected between the power panel and the
plurality of equipment sections inside of the module housing; a
plurality of control cables connected between the control cable
marshaling panel and the rig equipment, thereby providing control
connectivity between the rig equipment and the plurality of
equipment sections installed inside of the module housing; and a
plurality of power cables connected between the power panel and the
plurality of equipment sections inside of the module housing and
the rig equipment, thereby providing power connectivity between the
rig equipment and the plurality of equipment sections installed
inside of the module housing.
6. A computer based system for designing an electric module, the
system comprising: a processor in data communication with a
non-transitory computer readable medium; a computer program stored
in the computer readable medium, the computer program comprising
instructions that when executed by the processor perform function
that design the electric module, the computer program comprising:
instructions to input design parameters to a module design
computer, the design parameters comprising: shape parameter
dimensions into which each of the modules is placed; and
instructions to determine in and output from the module design
computer a module design having a shape in accordance with the
shape parameter dimension wherein the module shape conforms to the
structural environment into which the module is placed.
7. The system of claim 6, wherein the design parameters further
comprise: physical space, size and volume limits and wherein the
module design has a physical space, size and volume in accordance
with the physical space, size and volume limits.
8. The system of claim 6, wherein the shape design parameter
comprises a ship hull shape, wherein the computer program fits the
module shape into the existing shape of the ship's hull where in
the module becomes an integral part of the ship's hull and outputs
the module shape to a design computer output device.
9. The system of claim 6, the computer program further comprising:
instructions to input a load bearing module roof design parameter;
and instructions to determine in and output from the module design
computer a propose module design having a load bearing capacity in
accordance with the load bearing module roof design parameter.
10. The system of claim 6, the computer program further comprising:
instructions to input a module design parameter for a module
weight; and instructions to determine in and output from the module
design computer a propose module design having a weight in
accordance the module weight design parameter.
11. The system of claim 6, the computer program further comprising:
instructions to input to the module design computer a lifting
capacity design parameter of a crane on the jack up rig; and
instructions to determine in and output from the module design
computer a module design having a weight that is less that the
lifting capacity design parameter.
12. The system of claim 6, the computer program further comprising:
instructions to input a module weight design parameter for a jack
up rig module comprising a current jack up rig weight and a maximum
jack up rig weight for to keep the jack up rig module light enough
so that the added weight of the module does not exceed the maximum
jack up rig weight; and instructions to determine in and output
from the module design computer a module design having a weight
that is less than the maximum jack up rig weight.
13. The system of claim 6, wherein the design parameters further
comprise an identification of existing equipment inside the
electrical module, the computer program further comprising:
instructions to determine in and output for the module computer, a
module design minimizing electrical cable connection run lengths
between equipment inside of the module and electrical interference
between equipment inside of the module, minimizing electrical cable
connection runs length and electrical interference between
equipment in the module.
14. The system of claim 6, the computer program further comprising:
instructions to input to the module design computer a list of
equipment outside of the module to which the module connects; and
instructions to determine in and output from the module design
computer a module design having cable connection paths
substantially minimizing cable lengths between equipment inside and
outside of the module, minimizing electrical cable connection runs
length and electrical interference between a module and existing
equipment outside of the module.
15. The system of claim 14, the computer program further
comprising: instructions to input to the module design computer a
temperature design parameter for equipment inside and outside of a
module; instructions to determine in and output to the module
design computer a module design addressing the temperature design
parameter of equipment inside and outside of a module; outputting
to the module design computer a layout that substantially minimizes
electrical interference between equipment inside of a module and
electrical interference between equipment inside of a module and
equipment outside of a module; and instructions to output from the
module design computer a module design that addresses accessibility
to equipment for equipment install, repair and control inside of
the module and accessibility to equipment in the module for
equipment install, repair and control of the equipment in side of
the module.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims priority from U.S.
Provisional Patent Application Ser. No. 61/859,867 filed on Jul.
30, 2013 and entitled A Method and Apparatus for a Modular jack Up
Rig Assembly, which is hereby incorporated by reference herein in
its entirety; and this patent application claims priority from U.S.
patent application Ser. No. 14/447,522 filed on Jul. 30, 2014 and
entitled A Method and Apparatus for a Modular jack Up Rig Assembly,
which is hereby incorporated by reference herein in its
entirety.
BACKGROUND OF THE INVENTION
[0002] In the past jack up installations have been complex
operations requiring the interconnections of hundreds of parts used
to construct equipment to be positioned on an off shore jack up
rig.
SUMMARY OF THE INVENTION
[0003] A modular electrical control system for a jack up rig, the
system is disclosed, including but not limited to a module housing;
a plurality of equipment sections connected together inside of the
module housing; a control cable marshaling panel mounted on the
module housing; a plurality of control cables connected between the
control cable marshaling panel and the plurality of equipment
section installed inside of the module housing; a power panel
mounted on the module housing; a plurality of power cables
connected between the power panel and the plurality of equipment
sections inside of the module housing; a plurality of control
cables connected between the control cable marshaling panel and the
rig equipment, thereby providing control connectivity between the
rig equipment and the plurality of equipment sections installed
inside of the module housing; and a plurality of power cables
connected between the power panel and the plurality of equipment
sections inside of the module housing and the rig equipment,
thereby providing power connectivity between the rig equipment and
the plurality of equipment sections installed inside of the module
housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIGS. 1A and 1B are plan view schematic depictions of an
illustrative embodiment a power system is provided as a set of
prefabricated and pretested electrical modules 100;
[0005] FIGS. 2A and 2B are plan view illustrations an illustrative
embodiment of the present invention comprised of 3 modules
interconnected on a jack up rig;
[0006] FIG. 3 depicts a plan view of a module design computer in
data communication with a non-transitory computer readable
medium;
[0007] FIG. 4 depicts a flow chart for a portion of a computer
program that runs on the module design computer; and
[0008] FIG. 5 depicts a plan view of a system 500 provided in a
particular embodiment of the present invention.
DETAILED DESCRIPTION OF AN ILLUSTRATIVE EMBODIMENT
[0009] Portions of this specification and figures are subject to
copyright protection. The applicant has no objection to patent
office personnel making copies for us in official patent business
but retains all rights in copyright in this patent application. In
the past jack up installations have been complex operations
requiring the interconnections of hundreds of parts used to
construct equipment to be positioned on the platform of a jack up
rig. The present invention preassembles components into modular
sections into a modular jack up rig assembly so that there is an
order of magnitude less complexity to assemble the jack up rig
assembly once the jack up rig assembly arrives at a foreign
destination. The modular jack up rig assembly comprises modules
containing hundreds of parts and numerous sections of equipment
bolted together and place in a housing, referred to herein as a
"module", which can be tested and sealed and then certified during
manufacture. The certified modules are then shipped to a foreign
destination where the modules are connected together for a
simplified assembly. The simplified modular approach helps to
overcome the limitations of language barriers and available
documentation during assembly at a foreign destination on a jack up
rig. The equipment is usually installed in 2 to 3 modules.
[0010] In a particular illustrative embodiment, a module design
computer is provided having a non-transitory computer readable
medium having a module design computer program stored therein. The
computer program provides instructions, that when executed by the
module design computer perform the functions of design a module. In
another particular embodiment the computer program is a neural
network that learns from prior designs and performs to design a
module based on design parameters input to the module design
computer.
[0011] In a particular illustrative embodiment of the invention, a
computer based system and method designs a module(s) and reduces
efforts required to install the module(s) a modular electrical
control system. In an illustrative embodiment, modules are designed
on the module design computer and built to perform as an ECR, an
Engineer Operator Station (EOS) and an Electronic Power Room (EPR).
The modules are designed to according to a plurality of design
parameters that are set to accommodate the requirements of and
improve upon the environment in which they are placed. In a
particular embodiment, the modules are designed for and place on an
offshore jack up oil rig. In another particular embodiment, the
modules are designed for and place on a ship.
[0012] When a module is prepared for a jack up rig, several design
parameters are considered in laying out the equipment into modules
for installation on the jack up rig. The shape of each module (ECR,
EOS and EPR) are designed to conform to the physical space
limitations on the jack up rig into which each of the modules is
placed. Each module has a separate space, size and volume design
parameter. In an illustrative embodiment a jack up rig a module
design parameter includes but is not limited to a load bearing
module roof. On a jack up right, the roof a module can also become
a part of the rig floor and be required to have a load bearing
weight room exceeding 50,000 pounds. A hole is cut or designed into
the rig floor so that a module can be lifted by a crane and lowered
into the hole in the rig floor. The hole in the rig floor is the
shape of the module so that the module is placed in the hole and
welded to the surround rig floor so that the roof of the module
becomes part of the rig floor. On a ship, a module shape design
parameter fits the module shape into the existing shape of the
ship's hull where in the module becomes an integral part of the
ship's hull.
[0013] In another illustrative embodiment of the invention, another
design parameter is set for a module weight. A module on a jack rig
floor is designed to be as light as possible while still meeting
other design considerations. One module weight design parameter for
a jack up rig module includes the lifting capacity of the cranes on
the jack up rig. One module weight design parameter for a jack up
rig module includes a current and maximum weight for the jack up
rig to keep the jack up rig module(s) light enough so that the
added weight of the module(s) does not make the total weight of the
jack up rig so heavy that one of the 3 or 4 legs of the jack up rig
punches through the ocean floor and upsets the balance of the jack
up rig resting on 3 or floor jack up rig legs. The module weight
design parameter ensures that a crane capacity on the jack up rig
is sufficient to lift the module off a delivery barge and place it
into position on the jack up rig. Modules that are not part of the
rig floor on a multiple floor jack up rig do not require a heavy
load bearing roof. Additional design parameters for a module
include but are not limited to module height, weight, shape, width;
existing equipment to which the module must connect and or control;
minimizing electrical cable connection runs length and electrical
interference between equipment pieces inside of a module;
minimizing electrical cable connection runs length and electrical
interference between modules; minimizing electrical cable
connection runs length and electrical interference between a module
and existing equipment on the rig; fitting the module shape, size,
volume and foot print into an existing jack up rig; fitting the
module shape, size, volume and foot print into an existing jack up
rig design; putting control functions in a module near a function
to which the module connects and controls; connection path lengths
between equipment inside of a module; temperature considerations
for equipment inside and outside of a module; ventilation of
equipment inside and outside of a module; electrical interference
between equipment inside of a module; electrical interference
between equipment inside of a module and equipment outside of a
module; accessibility to equipment for equipment install, repair
and control inside of a module; and accessibility to equipment for
equipment install, repair and control outside of a module.
[0014] When a modular electrical control system, the following
tasks have to be performed on an active oil rig or ship,
effectively taking the oil rig or ship out of operation until the
installation of the electrical control system is installed tested
and commissioned, which can take 4-6 weeks and cost $50-100 million
dollars in lost rig time or ship time and huge monetary penalties
that have to be for vendor delays and rig or ship overhear during
the installation down time.
[0015] In a particular embodiment, a particular module, an
integrated engine control room (ECR) module is furnished as a
deliverable. If the ECR module is not furnished as a deliverable,
the following list is to help understand what extra work is
involved in stalling the equipment that would otherwise have been
delivered in tested and working order inside the module.
[0016] In a particular embodiment of the present invention, a
method is disclosed for building a modular electrical system for a
jack up rig, the method including but not limited to identifying
rig equipment on the jack up rig that will be connected to the
modular electrical system; selecting electrical equipment to
control the rig equipment; placing the electrical equipment in an
electrical module; electrically connecting the electrical equipment
to power cables and control cables inside of the electrical module;
and testing the electrical equipment inside of the electrical
module. In another particular illustrative embodiment of the
present invention the method further includes but is not limited to
locking the electrical module and shipping the module to a jack up
rig; and connecting rig equipment to the outside of the locked
electrical module. In another particular illustrative embodiment of
the present invention the method further includes but is not
limited connecting the control cables for the electrical control
equipment to a control cable marshaling panel inside of the
electrical module; connecting the power cables for the electrical
control equipment to a power panel inside of the electrical module;
connecting control cables connected to control test equipment
simulating the rig equipment to the control cable marshaling panel
thereby providing control connectivity between the electrical
equipment inside of the electrical module and the test equipment;
and connecting power cables connected to the power test equipment
simulating rig equipment to the power panel thereby providing power
connectivity between the electrical equipment inside of the power
test rig equipment; and certifying that the test module is working
properly before shipping the electrical module for
installation.
[0017] In another particular illustrative embodiment of the present
invention the method further includes but is not limited connecting
the control cables for the electrical control equipment to a
control cable marshaling panel inside of the electrical module;
connecting the power cables for the electrical control equipment to
a power panel inside of the electrical module; connecting control
cables connected to the rig equipment to the control cable
marshaling panel thereby providing control connectivity between the
electrical equipment inside of the electrical module and the rig
equipment; and connecting power cables connected to the rig
equipment to the power panel thereby providing power connectivity
between the electrical equipment inside of the rig equipment.
[0018] In another particular illustrative embodiment of the present
invention a modular electrical control system for a jack up rig is
disclosed, the system including, but not limited to a module
housing; a plurality of equipment sections connected together
inside of the module housing; a control cable marshaling panel
mounted on the module housing; a plurality of control cables
connected between the control cable marshaling panel and the
plurality of equipment section installed inside of the module
housing; a power panel mounted on the module housing; a plurality
of power cables connected between the power panel and the plurality
of equipment sections inside of the module housing; a plurality of
control cables connected between the control cable marshaling panel
and the rig equipment, thereby providing control connectivity
between the rig equipment and the plurality of equipment sections
installed inside of the module housing; and a plurality of power
cables connected between the power panel and the plurality of
equipment sections inside of the module housing and the rig
equipment, thereby providing power connectivity between the rig
equipment and the plurality of equipment sections installed inside
of the module housing.
[0019] In another particular illustrative embodiment of the present
invention a computer based system for designing an electric module
is disclosed, the system including, but not limited to, the system
a processor in data communication with a non-transitory computer
readable medium; a computer program stored in the computer readable
medium, the computer program comprising instructions that when
executed by the processor perform function that design the electric
module, the computer program comprising: instructions to input
design parameters to a module design computer, the design
parameters including but not limited to a shape parameter
indicating dimensions into which each of the modules is placed; and
instructions to output from the module design computer a module
design having a shape in accordance with the shape parameter
dimension wherein the module shape conforms to the structural
environment into which the module is placed.
[0020] In another particular embodiment of the computer based
system for designing an electric module the design parameters
further include but are not limited to physical space, size and
volume limits and wherein the module design has a physical space,
size and volume in accordance with the physical space, size and
volume limits. In another embodiment of the computer based system
for designing an electric module the shape design parameter include
but are not limited to a ship hull shape, wherein the computer
program fits the module shape into the existing shape of the ship's
hull where in the module becomes an integral part of the ship's
hull and outputs the module shape to a design computer output
device. In another particular embodiment the computer program
further includes but is not limited to instructions to input a load
bearing module roof design parameter; and instructions to output
from the module design computer a propose module design having a
load bearing capacity in accordance with the load bearing module
roof design parameter. In another particular embodiment the
computer based system, the computer program further includes but is
not limited to instructions to input a module design parameter for
a module weight; and instructions to output from the module design
computer a propose module design having a weight in accordance the
module weight design parameter.
[0021] In another particular embodiment the computer program
further includes but is not limited to instructions to input to the
module design computer a lifting capacity design parameter of a
crane on the jack up rig; and instructions to output from the
module design computer a module design having a weight that is less
that the lifting capacity design parameter. In another particular
embodiment the computer program further includes but is not limited
to instructions to input a module weight design parameter for a
jack up rig module comprising a current jack up rig weight and a
maximum jack up rig weight for to keep the jack up rig module light
enough so that the added weight of the module does not exceed the
maximum jack up rig weight; and instructions to output from the
module design computer a module design having a weight that is less
than the maximum jack up rig weight.
[0022] In another particular embodiment the computer program the
design parameters further comprise an identification of existing
equipment in side module, the method further includes but not
limited to instructions to output a module design minimizing
electrical cable connection run lengths between equipment inside of
the module and electrical interference between equipment inside of
the module, minimizing electrical cable connection runs length and
electrical interference between equipment in the module. In another
particular embodiment the computer program further includes but is
not limited to instructions to input to the module design computer
a list of equipment outside of the module to which the module
connects; and instructions to output from the module design
computer a module design having cable connection paths
substantially minimizing cable lengths between equipment inside and
outside of the module, minimizing electrical cable connection runs
length and electrical interference between a module and existing
equipment outside of the module. In another particular embodiment
the computer program further includes but is not limited to
instructions to input to the module design computer a temperature
design parameter for equipment inside and outside of a module;
instructions to output to the module design computer a module
design addressing the temperature design parameter of equipment
inside and outside of a module; outputting to the module design
computer a layout that substantially minimizes electrical
interference between equipment inside of a module and electrical
interference between equipment inside of a module and equipment
outside of a module; and instructions to output from the module
design computer a module design that addresses accessibility to
equipment for equipment install, repair and control inside of the
module and accessibility to equipment in the module for equipment
install, repair and control of the equipment in side of the
module.
[0023] In an illustrative embodiment of the invention, the
electrical module is an integrated ECR electrical module design.
The ECR module lowers the cost and reduces risk for shipyards. The
ECR module allows to pretesting systems and deliver them as fitted
on the vessel inside the ECR. There is no shipyard involvement
inside the ECR, so there is no chance for accidental damage to the
equipment. The equipment is protected by the steel ECR. The
switchboards do not have to be re-tested once on site in the
shipyard because they are never disassembled for shipment;
therefore the original tests are still valid.
[0024] The time it takes the shipyard to connect power and control
cables to the supplied ECR module is greatly reduced when compared
to connecting another system that requires heavy shipyard
involvement for the success of the project. In an illustrative
embodiment of the present invention, the system and method supplies
specifically centrally located easy access marshalling panels for
all shipyard connections. This speeds up the time it takes for the
shipyard to make the control connections.
[0025] Commissioning time is especially important on these types of
vessels due to the number of vendors required on aboard during this
time. Problems with any one vendor or system greatly increases cost
overruns due to standby time that would be incurred by the shipyard
from all vendors that wait while the problems are resolved. The
pre-tested ECR module insures that no one is waiting for electrical
power to perform dockside testing or sea trials. Without electrical
power, no other vendors can test or commission their systems. The
electrical system is the heartbeat of the vessel. The ECR
electrical module greatly reduces the responsibility of the
shipyard, as well as, reducing the learning curve that would be
required on conventional systems provided by our competitors.
[0026] The electrical module of the present invention greatly
reduced the unknowns which arise during these types of
diesel/electric projects. This in turn saves the shipyard time and
money and allows the operator to get the vessel on day rate
sooner.
[0027] Turning now to FIG. 1, in an illustrative embodiment of the
present invention, a pretested electrical modules 100 are
configured and pretested for installation on a jack up rig. As
shown in FIG. 1, a house or module housing (hereinafter referred to
as a module, module housing or electrical module) is provided. A
plan view of a first module 102 is shown with a door 104 and
interior chamber containing electrical equipment. The housing
itself is a steel rectangular housing total self-contained with air
conditioners 105. The present invention serves to provide modular
control systems for offshore jack up rigs that have to generate
their own electric al power. The present invention provides modules
for providing a power system to generate, manage, transforming and
distributing the power and rig equipment on the off shore jack up
rig. In a particular embodiment an engineering control modules
(ECM), an engineer operator station (EOS) and an electrical power
module (ECM) are provided as modules, also referred to herein as
electrical modules.
[0028] In an illustrative embodiment, a first module 102 is
provided containing a switch board 106, circuit breakers 108 and
generator controls 110 and other related electronics related to the
tasks to generate, manage, transform and distribute the power on
the off shore jack up rig. Several generators are provided for
various voltages which may include but is not limited to a 690 V
generator switch board, a 230 V generator switch board and a 480 V
switchboard. The module also may include but is not limited to a
desk 112 and control cabinet 114 for containing an automation
system which includes a processor and a non-transitory computer
readable medium. A control cable marshalling panel 115 is provided
containing cabling connections. Control cables that are connected
to the electrical equipment inside of the electrical module are
connected to the control cable marshaling panel. Control cables
that run to the rig equipment or to another module are connected to
the outside of the module to an exterior side of the control cable
marshaling panel is covered by a removable door for protection
during shipment and foreign objects on the rig until installation
personnel are ready to connect the module to the rig equipment or
another module. The control cable which tie in from the jack up rig
to the equipment inside of the module 102.
[0029] Substantially all equipment inside of the module 102 that
need a connection with the jack up rig external to the module 102
tied to electrical connectors at the control cable marshalling
panel from connection to wiring to equipment on the jack up rig
external to the module 102. All equipment inside of the module 102
is wired to the control cable marshalling panel so that when the
module is delivered to a destination ship yard, the shipyard
personnel do not have to enter the module to connect to the
equipment inside of the module. The shipyard personnel need only
remove the cover to access the external portion of the control
cable marshalling panel. This cuts down installation time and
expense for installing the equipment inside of the module to the
jack up rig. In the past substantially all the equipment inside of
the module was delivered for wiring and assembly at the ship yard.
Many of the pieces of equipment were typically destroyed during the
process causing reorder and reinstall on much of the equipment. In
an illustrative embodiment, the module is prefabricated and
pretested at the factory and delivered in a sealed container which
accessed electrically from outside via the marshalling panel
without the need to enter the module. The ship yard can
electrically access the electrical equipment inside of the module
using the electrical connections thereto via the marshalling panel
115. The equipment inside the module is assembled and tested at the
factory and sealed inside the module for easy installation without
requiring access to the inside of the module 102. All the cables
are already run between the equipment inside of the module. The
power to the generators 110, 114 and 118 is provided through a
power panel 111 which is an electrical connector which is covered
and protected until it is connected to electrical power cables for
the rig equipment from the outside and does not require entry into
the module at the jack up right to connect power cables to the
generators 110, 114 and 118. Thereby limiting the ship yard
personnel access to exposure to only the outside connectors and the
ship yard personnel does not have to come inside of the module to
connect to the sensitive electronics inside. In an illustrative
embodiment, the first module 102 contains switch gear. A second
module 140 is provided containing drilling drives that may include
but is not limited to a first set of drilling motor drives 142 and
a second set of drilling motor drives 144. In another embodiment a
third module is provided containing additional equipment.
[0030] Turning now to FIG. 2, an illustrative embodiment is
depicted showing three modules 102, 140 and 202 located on a jack
up rig platform 200. A first module 102, a second module 140 and a
third module 202 are positioned between support beams 203, 204, 206
and 208. Support beams 203, 204, 206 and 208 run between a first
floor 222 and a second floor 220 comprising the jack up rig
platform. The jack up right platform is supported by three geared
vertical supports 250, 252 and 254. The geared supports are also
referred to herein as legs. In one particular embodiment, the
electronics are grouped for functional proximity and proximity to
exterior devices such as a mud pump, which the electronics inside
of the module control. For example, a mud pump controller will be
located in a module proximate the mud pump. Each installation is
different and the grouping the electronics in 1, 2, 3 or more
modules.
[0031] In the past, all the electronics inside of the modules were
delivered to the shipyard in separate switch board assemblies. Each
switch board assembly was delivered separately to the ship yard. It
was up to the ship yard personnel to connect these electronics
together and test them. The ship yard personnel would then build a
metal box containing the electronics. Each switch board comprised
many cabinets and the switchboard would have to be broken up into
separate shipping splits. Thus a switch board would be delivered in
3 separate pieces instead of a single unit contained inside of a
module. The three separate subassemblies were wired up separately
and the buss structure for each sub assembly was designed to be
disconnected between separate switch board assemblies for shipping.
The switch board assemblies were wired together and the busses
connected together between the switch board assemblies for testing.
After testing the switch board assembly wiring and buss connections
were removed for shipping. The ship yard would receive the switch
board assemblies and put them in a ware house for several months
until they were ready to install them on a drilling rig such as an
off shore jack up rig. The ship would then build a metal room and
drop in each of the shipping splits separately and hope not to
damage anything in the process of dropping the switch board
assembly into the metal room with a crane in sometimes adverse
weather conditions. The ship yard personnel would then wire the
switch board assemblies together and run wires to connect them to
external equipment on the rig. The shipyard personnel then weld a
roof on the metal room they had built. Each of the walls of the
metal had to be welded along with a roof/upper deck. During the
construction of the walls a lot of grinding dust and filings are
generated that can foul or damage the electronics and switch board
assemblies.
[0032] The interior of the metal rooms has to be painted also.
Thus, the electronics inside of the housing are exposed to damage
during crane transit, metal filings and dust from welding and
grinding during construction and damage from paint over spray. In
addition, shipyard personnel stand on the equipment and equipment
door handles during construction and painting of metal room,
thereby further damaging the switch board assemblies. Thus, a brand
new installation could look 30 years old right after construction
due to the abuse it had to withstand during construction of the
metal housing by the shipyard personnel on the jack up rig. The
metal housing is made of steel that has to be cut, ground smooth
and welded together in the presence of the sensitive electronics
that do inside of the metal housings. Thus metallic shaving end up
inside of the electronics and failure due to short circuits
commonly occurs upon initial power up. Thus, it requires more spare
parts to fix the shorted electronics. There is also time lost by
having to reenter the metal housing to figure out what electronics
have failed and replace them. In addition, there is a lack of
quality control from the originating company that manufactures the
equipment based on the lack of communication and understanding
between the manufacturer and the ship yard. There can also be
problems due language barriers and a lack of appropriate
documentation to enable the shipyard personnel to properly connect
and construct the electronics inside of the metal room. It costs a
lot more and is substantially more difficult to install the
electronics on the jack up rig using the old method of building the
metal room on the jack up rig and installing the electronics there
in. There can also be delays in ordering spare parts and procedural
delays over who is responsible for such failures and who should
replace the damaged parts.
[0033] In an illustrative embodiment, the preassembled electrical
modules, are constructed and painted before any equipment goes in.
Large pieces of switch gear are brought into the module through a
large entry door to the module via a fork lift door eliminating the
crane and eliminating exposure of the electronics inside of the
module to metal filings, metal dust and paint. Additionally the
equipment is not used as a stepping and standing stool during the
building and painting of the module. Also, since the electrical
module is delivered as a sealed unit, it is easy to determine who
is responsible if the electrical module fails, since there were not
shipyard personnel inside the electrical module, the manufacturer
of the module is responsible for problems that occur inside of the
electrical module. The module manufacture knows based on their
testing at the manufacturing site, that if the external connections
to the electrical module are properly made, everything is going to
work properly. Thus, commissioning of the modules is an order of
magnitude less complex and cheaper than the old method of
delivering separate pieces on the jack up rig. Thus, the present
invention saves a lot of time and money. In one embodiment, a
module is 24 feet wide by 57 feet long and 10 feet high. The
modules will be installed along with other equipment and facilities
such as a drill floor for the drilling derrick and the drilling
drives inside one of the modules would be cabled to the drilling
derrick.
[0034] In a particular embodiment of the invention, electrical
equipment is contained in electrical equipment modules, referred to
herein as modules that are pretested and preassembled and are ready
for installation on a ship or jack up rig with minimal set up time.
In a particular embodiment of the present invention a modular ECR
can be cut out of a jack up rig deck and placed elsewhere on the
jack up rig floor using an existing crane on the jack up rig. A
replacement modular ECR is then dropped into place by the existing
crane.
[0035] FIG. 3 depicts a module design computer 300 in data
communication with a non-transitory computer readable medium 302.
The term "data communication" is used in this patent application to
mean data is exchanged between two devices that are in "data
communication". A computer program is stored in the non-transitory
computer readable medium. A presentation display 304 in data
communication with the processor is also provided for presenting
module designs to an operator. A computer program 306 is embedded
in the non-transitory computer readable medium.
[0036] FIG. 4 depicts a flow chart for a portion of a computer
program that runs on the module design computer. As shown in FIG. 4
the computer program executes instructions. The computer program
410 executes instructions to input design parameters to a module
design computer, wherein the design parameter is a shape parameter
dimensions into which each of the modules is placed. At 420 the
computer program executes instructions determine in and output from
the module design computer a module design having a shape in
accordance with the shape parameter dimension wherein the module
shape conforms to the structural environment into which the module
is placed. At 430 the computer program determines in and output for
the module computer a module design minimizing electrical cable
connection run lengths between equipment inside of the module and
electrical interference between equipment inside of the module,
minimizing electrical cable connection runs length and electrical
interference between equipment in the module.
[0037] FIG. 5 depicts a system 500 provided in a particular
embodiment of the present invention. A module housing 510 a
plurality of equipment sections 511 connected together inside of
the module housing are shown. A control cable marshaling panel
mounted on the module housing; a plurality of control cables 524
are connected between the control cable marshaling panel 514 and
the plurality of equipment section installed inside of the module
housing. The control cables are held in a control cable tray 525. A
tray for holding the control cables is shown in the FIGS. below. A
power panel 520 is mounted on the module housing and a plurality of
power cables 521 connected between the power panel and the
plurality of equipment sections inside of the module housing. The
power cables are held in a control cable tray 525. A plurality of
control cables connected between the control cable marshaling panel
and the rig equipment 550, thereby providing control connectivity
between the rig equipment 550 and the plurality of equipment
sections 111 installed inside of the module housing 510. A
plurality of power cables connected between the power panel and the
plurality of equipment sections inside of the module housing and
the rig equipment, thereby providing power connectivity between the
rig equipment and the plurality of equipment sections installed
inside of the module housing.
[0038] Another illustrative embodiment of the invention includes
but not limited to a module housing with interlocking panel design
with separate internal control and power rooms. Wall mounted A/C
and field viewing window.
[0039] Another illustrative embodiment of the invention includes
but not limited to a module housing with internal of power section
with integrated Motor Control Centers (MCCs) and Automation I/O
Cabinets.
[0040] Another illustrative embodiment of the invention includes
but is not limited to a module housing with internal of power
section showing 230 volt distribution panels and UPS mounted and
interconnected.
[0041] Another illustrative embodiment of the invention includes
but is not limited to internal of control section with module
housing with a field viewing window, place for customer supplied
desk and automation screens for control of the complete plant.
[0042] Another illustrative embodiment of the invention includes
but is not limited to internal of control section of a module
housing during customer integrated test at factory. Once complete
automation screens are packed up for shipment.
[0043] Another illustrative embodiment of the invention includes
but is not limited to a view in control room behind automation desk
with computer main frame and UPS mounted and interconnected inside
of a module housing.
[0044] Another illustrative embodiment of the invention includes
but is not limited to module housing with a corrugated seam welded
design power module with redundant roof mounted A/C and side
incoming/outgoing cable connection stainless steel gland
plates.
[0045] Another illustrative embodiment of the invention includes
but is not limited to a module housing redundant roof mounted A/C
with safety railing and access ladder with safety backscratcher.
Another illustrative embodiment of the invention includes but is
not limited to a 6 kV and 440 volt AC switchgear and Motor Control
Centers inside EPR power module.
[0046] Another illustrative embodiment of the invention includes
but is not limited to a 6 kV customer incoming and outgoing
connections are made external to the module housing.
[0047] Another illustrative embodiment of the invention includes
but is not limited to an integrated 6 kV Solid State Starters with
480 volt Emergency MCC and CO2 fire suppression system in a module
housing.
[0048] Another illustrative embodiment of the invention includes
but is not limited to an integrated 440 volt Motor Control Center
in a module housing.
[0049] Another illustrative embodiment of the invention includes
but is not limited to an interlocking panel design power and
control module with redundant wall mounted A/C, integrated
transformer porch and field viewing window in a module housing.
[0050] Another illustrative embodiment of the invention includes
but is not limited to an integrated 690 volt power generation
switchboard, 440 volt distribution switchboard and vessel
automation I/O inside a module housing.
[0051] Another illustrative embodiment of the invention includes
but is not limited to a control desk for redundant vessel
automation computer system inside of a module housing.
[0052] Another illustrative embodiment of the invention includes
but is not limited to an exterior removable covers for shipyards
power connections to all switchboard inside of a module housing.
The shipyard does not access the inside of the module housing. This
keeps the internal electrical equipment safe and clean during
installation at the shipyard. Reducing onsite commissioning time
and cost.
[0053] Another illustrative embodiment of the invention includes
but is not limited to an exterior having installed power cables run
underneath the power module housing and terminated between
switchboard and porch transformers. Another illustrative embodiment
of the invention includes but is not limited to an exterior
installed control cables run in cable tray internal to the module
housing. All internal controls are interconnected and brought out
to a central control cable marshalling panel for shipyard
connections. This greatly reduces shipyard time and cost. These
connections are checked and system tested at the factory.
[0054] Another illustrative embodiment of the invention includes
but is not limited to an exterior having a power Module housing
being lowered into place by the shipyard onboard a marine offshore
support vessel. Another illustrative embodiment of the invention
includes but is not limited to an exterior ABS Certified 1200 kW AC
Top Drive House Complete. Another illustrative embodiment of the
invention includes but is not limited to a 690 Volt power generator
(EPR) module housing. Another illustrative embodiment of the
invention includes but is not limited to an exterior a general
arrangement schematic drawing for a 480 Volt power generator EPR
module housing. Another embodiment of the invention includes but is
not limited to an exterior a general arrangement schematic drawing
for a 690 V drilling drive & 480 V 230 V RIG SERVICE EPR module
housing.
[0055] The foregoing examples of illustrative embodiments are for
purposes of example only and is not intended to limit the scope of
the invention. Dedicated hardware implementations including, but
not limited to, application specific integrated circuits,
programmable logic arrays and other hardware devices can likewise
be constructed to implement the methods described herein.
Applications that may include the apparatus and systems of various
embodiments broadly include a variety of electronic and computer
systems. Some embodiments implement functions in two or more
specific interconnected hardware modules or devices with related
control and data signals communicated between and through the
modules, or as portions of an application-specific integrated
circuit. Thus, the example system is applicable to software,
firmware, and hardware implementations.
[0056] In accordance with various embodiments of the present
invention, the methods described herein are intended for operation
as software programs running on a computer processor. Furthermore,
software implementations can include, but not limited to,
distributed processing or component/object distributed processing,
parallel processing, or virtual machine processing can also be
constructed to implement the methods described herein.
[0057] The present invention contemplates a non-transitory machine
readable storage medium containing instructions, so that a device
connected to a network environment can send or receive voice, video
or data, and to communicate over the network using the
instructions. The instructions may further be transmitted or
received over a network via the network interface device. The
non-transitory machine readable storage medium may also contain a
data structure for containing data useful in providing a functional
relationship between the data and a machine or computer in an
illustrative embodiment of the disclosed system and method.
[0058] While the non-transitory computer-readable storage medium is
shown in an example embodiment to be a single medium, the term
"computer-readable medium" should be taken to include a single
medium or multiple media (e.g., a centralized or distributed
database, and/or associated caches and servers) that store the one
or more sets of instructions. The term "computer-readable medium"
shall also be taken to include any medium that is capable of
storing, encoding or carrying a set of instructions for execution
by the machine and that cause the machine to perform any one or
more of the methodologies of the present invention. The term
"computer-readable medium" shall accordingly be taken to include,
but not be limited to: solid-state memories such as a memory card
or other package that houses one or more read-only (non-volatile)
memories, random access memories, or other re-writable (volatile)
memories; magneto-optical or optical medium such as a disk or tape;
and carrier wave signals such as a signal embodying computer
instructions in a transmission medium; and/or a digital file
attachment to e-mail or other self-contained information archive or
set of archives is considered a distribution medium equivalent to a
tangible storage medium. Accordingly, the invention is considered
to include any one or more of a computer-readable medium or a
distribution medium, as listed herein and including art-recognized
equivalents and successor media, in which the software
implementations herein are stored.
[0059] Although the present specification describes components and
functions implemented in the embodiments with reference to
particular standards and protocols, the invention is not limited to
such standards and protocols. Each of the standards for Internet
and other packet switched network transmission (e.g., TCP/IP,
UDP/IP, HTML, and HTTP) represent examples of the state of the art.
Such standards are periodically superseded by faster or more
efficient equivalents having essentially the same functions.
Accordingly, replacement standards and protocols having the same
functions are considered equivalents.
[0060] The illustrations of embodiments described herein are
intended to provide a general understanding of the structure of
various embodiments, and they are not intended to serve as a
complete description of all the elements and features of apparatus
and systems that might make use of the structures described herein.
Many other embodiments will be apparent to those of skill in the
art upon reviewing the above description. Other embodiments may be
utilized and derived there from, such that structural and logical
substitutions and changes may be made without departing from the
scope of this disclosure. The figures are also merely
representational and may not be drawn to scale. Certain proportions
thereof may be exaggerated, while others may be minimized.
Accordingly, the specification and drawings are to be regarded in
an illustrative rather than a restrictive sense.
[0061] Such embodiments of the inventive subject matter may be
referred to herein, individually and/or collectively, by the term
"invention" merely for convenience and without intending to
voluntarily limit the scope of this application to any single
invention or inventive concept if more than one is in fact
disclosed. Thus, although specific embodiments have been
illustrated and described herein, it should be appreciated that any
arrangement calculated to achieve the same purpose may be
substituted for the specific embodiments shown. This disclosure is
intended to cover any and all adaptations or variations of various
embodiments. Combinations of the above embodiments, and other
embodiments not specifically described herein, will be apparent to
those of skill in the art upon reviewing the above description. The
Abstract of the Disclosure is provided to comply with 37 C.F.R.
.sctn. 1.72(b), requiring an abstract that will allow the reader to
quickly ascertain the nature of the technical disclosure. It is
submitted with the understanding that it will not be used to
interpret or limit the scope or meaning of the claims. In addition,
in the foregoing Detailed Description, it can be seen that various
features are grouped together in a single embodiment for the
purpose of streamlining the disclosure. This method of disclosure
is not to be interpreted as reflecting an intention that the
claimed embodiments require more features than are expressly
recited in each claim. Rather, as the following claims reflect,
inventive subject matter lies in less than all features of a single
disclosed embodiment. Thus the following claims are hereby
incorporated into the Detailed Description, with each claim
standing on its own as a separately claimed subject matter.
* * * * *