해양산업과해양전문가 ( 한국해양대학교특강 ) 2013. 11. 12 현대중공업 (1988 현재 ) 해양사업본부해양설치담당김종배상무 1978 1982, 한국해양대학항해학과 1985 1988, 한국해양대학해상환경공학석사 1991 2000, 울산대학교해양공학박사 2008, HHI Global Manager Program ( 울산대, Univ. of Washington) 2011, 해양정책최고과정 ( 서울대 12 기 ) 2012, 현대중공업 CEO Academy (2 기 )
해양산업 1 차산업 수산 / 양식업 해저광물채취 ( 석유, 가스, 망간단괴 ) 심층수 2 차산업 수산물가공업 ( 냉동 ) 해상원유정제및천연가스액화설비 (FPSO, FLNG, FGTL) 제작 해양에너지 ( 풍력, 조력발전 ) 설비제작 조선, 담수 Plant 제작 3 차산업 해상운송 ( 화물, 여객 ), 북해항로 ( 쇄빙선 ) 해양건설 ( 항만, 교량, 어초, 해양구조물설치및계류 ) 해양플랜트생산운전 해양레져 해양환경
해양유전개발 Upstream Downstream 조광권확보 탐사 : Seismic Survey, Wild Cat Drilling 경제성평가 : Feasibility Study ( 매장량, 유가, Capex, Opex) FEED ( 개념설계, Route Survey & Selection) 입찰 (Bid Package Proposal Evaluation LOI or NTP - CA) 해양설비 (Fixed Structure, Floater, Movable Production Unit + Pipeline) 설계, 구매, 제작, 운송, 설치및시운전 Production Drilling Production (Operation and Maintenance) LOI: Letter of Intent, NTP: Notice to Proceed, CA: Contract Award
해양유전개발동향 유가인상 (20 USD/Bbl 40 USD/Bbl 100 USD/Bbl) Conventional (Shallow) Sea Deep sea (Perdido is the world s deepest offshore platform. Moored in 8,000 feet of water in the Gulf of Mexico) 가스전개발 (Shale Gas, Methane Hydrate) Marginal Field 개발 ( 소규모유전, 극히얕은수심, Sand Oil, Tight Oil) 기존시설노후 (25 년이상 ) 에따른해체및설비교체 매장량소모에따른 Production 설비보강 (Gas Lift, Water Injection, HP Compressor) 중국 / 인도의원유수요증가 (1- 미국 20.6mil, 2- 중국 7.5mil, 6- 인도 2.6mil, 7- 한국 2.3mil Bbl/day, 2007) (1- 미국 17mil, 2- 중국 8.2mil, 4- 인도 3mil, 8- 한국 2.1mil Bbl/day, 2009) 북아프리카 / 중동민주화운동 자원전쟁 ( 중국, 유럽, 미국, 러시아 ) ============================================ 강재가인상 (2003 년 400 USD/ton 1200 USD/ton) 유전개발비용증가 ( 제작 / 설치비용증가 ) Oil Major 의소극적투자 ( 매년투자금액 20% 증가 )
가스전개발 천연가스 (LNG) 수요증가 : 국내년 3,500 만톤수입, 15$/MMBtu (87.45 $/boe, Oil: 5.83 MMBtu) 심해가스전개발 ( 브라질, 인도, 서아프리카 ) 2013 July, Drilling in 10,411ft water depth of India (ONGC) by Transocean Deepwater Nautilus Dhirubhai Deepwater KG1 육상가스전 ( 북극, Shale Gas) High Pressure & High Temperature (12.5 ksi,180 deg C) ============================================ 기술개발가속 ( 가스처리장치, 고강도 / 고급자재, 안전강화, 극지 ) 연안 / 육상가스전 : 대구경 Pipeline 발전소, 액화플랜트 ) 심해 / 원양가스전 : LNG FPSO(FLNG) LNG Shuttle Tanker MOSS or Membrane FSRU (Floating Storage & Re-gasification Unit) 대규모육상플랜트 Module 화 (Gorgon, 3,000 10,000 톤급 51 개, 전체 25 만톤물량 )
심해유전개발
원유 ( 포화탄화수소, Alkane) 의구성 분자식 명칭 비등점 (deg C) 구분 비고 C 1 H 4 Methane -164 C 2 H 6 Ethane -89 Natural Gas C 3 H 8 Propane -42 (LNG) LPG (Liquid C 4 H 10 Butane -0.5 Petroleum Gas) C 5 H 12 Pentane 36 C 6 H 14 Hexane 69 Condensate C 7 H 16 Heptane 98 C 8 H 18 Octane 125 C 9 H 20 Nonane 151 C 10 H 22 Decane 174 Oil C 11 H 24 Undecane 196 C 12 H 26 Dodecane 216
LNG FPSO Process
해양석유및부수가스생산공정개요
해양가스생산공정개요
천연가스하이드레이트 (Natural Gas Hydrate) 란? 천연가스가저온, 고압하에서물분자와결합하여자연적으로형성된고체물질 발화가어려워 LNG 에비해안정함 심해저및영구동토지역퇴적층에수백 m 두께로부존 (0 o C 26 기압, 10 o C 76 기압등 ) 온도압력변화시해리되어물과가스로분리됨 Hydrate 1 cc (Solid) : 물 0.8 cc (Liq.) 및메탄 164 cc (Gas) 포함 Oil & Gas 를대체할 21 세기청정에너지원으로잠재력이큼 < 하이드레이트연소성 > <Hydrate 구조 > <Volume 비교 > - 11 -
동해가스전 1998 년 7 월울산남동쪽 58km 고래 5 구조탐사시추 (1 공 ) 에성공 ( 가채매장량 1,856 억입방피트의양질의천연가스층확인 ) 2002 년 3 월 15 일생산시설착공 2004 년 7 월 11 일생산개시 2005 년초에는가스전남쪽 2.5 km지점에서추가가스전 (B5) 발견 (508 억입방피트의매장량 ), 2008 년 11 월개발완료 현재하루평균생산량은천연가스가 5 천만입방피트, 원유는 1,000 배럴로약 2 억 5 천만불의수입대체효과 ( 천연가스는하루 34 만가구, 원유는하루자동차 2 만대를운행할수있는양 ) 동해 -1 가스전개발을통해우리나라는세계 95 번째산유국
동해가스전
대우인터네셔널미얀마 SHWE 가스전
해양플랜트설비유형 해상생산시스템 - 고정식및부유식구조물 - Topside processing 시스템 URF system - Umbilical - Riser - Flowline/Pipeline 해저생산시스템 - 해저생산 (Production) 시스템 - 해저처리 (Processing) 시스템 - 연결시스템 (jumper, PLET)
해양공사 Process PM 해양영업 설계 구매 제작 H/up OIM Installation Coordination 설치영업 설계 구매 운송 설치
해양설치 (Offshore Installation) 공사이해 - 1 해상작업의특수성 Dynamic (Adverse weather, Motion, Safety Factor) Distant (Isolated, Limited) 3-Dimensional (Water Depth) Wet (Corrosive, Diving) Oil or Gas from Seabed (Soil interaction)
해양설치 (Offshore Installation) 공사이해 - 2 해상장비에의한집중작업 Stable & Position keeping (Jack-up, Multi-point Mooring, DP) Workable (Heavy lifting, Heave Compensating, Constant Tensioning Machine) Production Efficient (7/24 Working, Automatic Welding, Multiple joint welding, High Capacity Anchor Handler) Accommodation (Independent Offshore Society composed of 300 500 work crew) Marine Spread (Work barge, AHTs, Material Barge/Tug, DSV, Survey vessel and Supply Boat) Onboard Workshop and material ready including spare parts Strict Safety and Contingency Requirement
해양설치 (Offshore Installation) 공사이해 - 3 해양설치구분 Fixed Structure Sub-Structure (Jacket, Piling, Guyed tower) Topside (Lifting, Float-over) Combined (Gravity, Jack-up) Floating Structure (FPSO, FSO, FPU) Deep sea Diveless Mooring Installation (Suction Piles with 12 or more mooring lines) Floater Mooring Pipeline including riser (S- or J-lay) Sub-sea Facilities (PLEM, Sub-sea well completion) Oil Loading/unloading system (SPM or Jetty) Cable (Power, Fiber Optic) or Flexible Pipeline Platform demolition and Pipeline replacement
1.0 Offshore Installation 개요 Conventional Offshore Installation For Subsea Pipelines/Cables Transportation Shore Pulling & HDD Pipeline/Cable S-Laying Surface/Subsea Spool Tie-in Hyperbaric Welding Pipeline/Cable Crossing Pipeline Free Span Rectification CALM Buoy Installation PLEM/Subsea Skid Installation Pipeline/Cable Protection Pre-/Post- Trenching & Backfill Transportation For Offshore Platform Jacket Installation by Launching Jacket Installation by Lifting Topside Installation by Lifting Topside Installation by Float-Over Riser Installation Boat Landing/Barge Bumper/ Riser Guard Installation Flare Boom Installation Bridge Installation Hot Tapping Decommissioning & Removal
2.0 Offshore Installation (HHI) Jacket Installation Fabrication Load-out Transportation Launching Lifting Up-ending Positioning -21-
2.0 Offshore Installation (HHI) Pipeline Installation Pipe Transportation Pipe Load-in Welding Preparation Pipe Welding Initiation Normal Laying -22-
2.0 Offshore Installation (HHI) Subsea Cable Installation Cable Transportation Pipe Load-in Laying Preparation Cable Drum Setting Cable Laying Cable Laying by HD-1000-23 -
2.0 Offshore Installation (HHI) Platform Float Over Docking Undocking - 24 -
2.0 Offshore Installation (HHI) Marine Construction Fleet (HHI) Type of Vessel Name Capacity Remarks Derrick & Pipelay Barge HD-60 HD-2500 HD-423 Pipelay Barge HD-289 48 Derrick Barge HD-1000 1,000T Work Barge Launch Barge Offshore- 1 HDB- 1006 1,800T/60 /Double JT 2,500T/60 750T/ 66 150T/ 160 bunker 30,000 DWT Self propelled Up to 16,000T Jacket Cargo Barge HDB- 1008 3,600 DWT Submersible Barge HDB- 1011 HDB- 1012 35,000DWT 35,000DWT Up to 26,000T vessel Up to 26,000T vessel Tug & AH Boat HY-5 3,500 HP
해양설치 (Offshore Installation) 공사이해 - 4 해상설치현장작업분류 Barge Operation Marine Rigging Welding Maintenance Survey (GPS/Sonar Position, Bathymetry, SSS, Sub-bottom Profile, UXO, Cable Detector, LBL Metrology, CP Survey) ROV (Inspection or Work-class) Diving (Air/Mixed gas and Bounced/Saturation) NDT (Internal X-ray or Automatic UT with ECA) Field Joint Infill (Corrosion Wrapping, Infill with Mastic or HDPF) Free span Rectification (Grouting with pre-formed sleeper or bag) Pre-commissioning (Flooding, Cleaning, Gauging, Hydrotest, Caliper & Intelligent pigging) Weather Service (Forecast and Site Measurement with wave rider buoy)
해양설치 (Offshore Installation) 공사이해 - 5 해상설치지원작업분류 Design & Engineering Detailed Engineering (Permanent Material) Installation Engineering (Construction aids and consumables) Procurement Fabrication Pipe Coating Transportation and rental Vessel Logistics Permits Taxation and Customs Clearance Supply of Material and Provision Personnel mob and demob Coordination of HSE and QA/QC Contract administration (Client and subcontractor)
해양설치 (Offshore Installation) 공사이해 - 6 Project Management Counterpart to Client Plan and Reporting (Weekly and Monthly progress) Contractual Document approval (Document register) Invoice and Payment Company furnished material Cost control Schedule and Progress monitoring Design Procurement Construction (including Subcontractors) Logistic support Risk Management Risks forecasting Proactive action and optimization
해양설치 (Offshore Installation) 공사이해 - 7 Insurance Insurances CAR (Construction All Risks) normally by Client CGL (Comprehensive General Liability) P&I Club - Oil pollution and crew injury/missing ITC Hull Physical damage to be covered Insurance Claim Stipulation in the policy MWS approved Work according to the approved procedures Incident notification, survey and assessment by Loss Adjuster Remedial work Decision by Insurer and co-insurers Claim with Deductible Consequential losses normally not covered by Insurance
Challenge in Offshore Installation Subsea System Installation Production System (X-mas Tree, Manifold, Flowline & Jumpers) Control System (Subsea and Topside Control Module, Umbilical & Flying leads ) Deepsea Installation Subsea System Mooring System (Suction Pile) Subsea Umbilical, Riser and Flowline (SURF) Offshore Wind Farm Installation Substructure (Mono pile to Jacket Type) Wind Turbine Generator (High lifting point and Static) Maintenance in 500 m Grid (DP Vessel)
해저생산시스템 (Subsea System) 해저생산 (Production) 시스템 원유생산제어 / 차단 주요제품 : Subsea Tree, Manifold, 제어및전원시스템 2015년까지전체 Subsea Well의 61% 가심해가될전망 해저처리 (Processing) 시스템 원유생산성및효율향상 - 기존해상공정을해저에서수행 - 해저오일 / 가스 / 물분리 해저부스팅 주요제품 : Subsea Pump, Separator, Compressor 심해개발을위한신기술상용화임박 Flying Leads Manifold/Controls Wellhead Tree/Controls Subsea Separator Subsea Compressor Jumpers PLETs Flowlines Subsea Pump
심해설치 SURF Subsea 시스템
심해해양환경 Wave & Swell, Current : 설치선의운동및이동 심해설치의어려움 대수심 : 와이어로프하중의증가 => 설치선 ( 대형크레인, 동요저감및 DP 시스템 ), ROV, 심해설치공법개발등
4.0 Offshore Installation 의미래 J-lay and FPSO Mooring -34-
4.0 Offshore Installation 의미래 Offshore Wind Farm Development (Wind Energy Cumulative Capacity) - 35 -
4.0 Offshore Installation 의미래 Offshore Installation Other Fields 조력발전시설설치 Existing Structure Decommissioning Subsea Mineral Resources Development etc. Arctic Resources Development (Ice Breaker) - 36 -
수중작업 (Underwater Work) 의이해 수중작업 : 검사 vs 작업 (Sling 해체, Spool 연결, 절단 ) Diving (Commercial) < 300m ROV (Remotely Operated Vehicle) < 3000m AUV (Autonomous Underwater Vehicle) < 10,000m
잠수작업 (Diving) 호흡장비 호흡매체 Sports Diving Skin diving 압축공기 SCUBA diving 압축공기 Commercial Diving Surface Supplied diving (Bounced diving) Saturation diving 압축공기혼합가스 혼합가스 Commercial Diving 수상 - 수중연결 (Umbilical) 교신 호흡매체 온수 ( 저체온방지 ) 대부분 Diver 혼자작업 Standby Diver 대기및제한된작업시간 (Saturation Diving 인당 4 시간, 2 인 1 조 3 교대 ) 수중에내리기전수상에서철저한준비및확인 100% 대화 ( 헬륨가스에의한 Donald Duck 효과 ) 및 Diver Helmet 에부착된 CCTV 에의존
수중생리학 호흡매체 압축공기 수심 (m) 0 10 20 30 압력 (ata) 1 2 3 4 분압 (ata) 산소 질소 0.21 0.78 0.42 1.56 0.63 2.34 0.84 3.12 감압병 ( 밴드 ): 몸속에용존되어있는불활성기체 ( 질소, 헬륨 ) 이완전히빠져나오지못하고남아서혈관을막아저산소증이나조직손상 수심 35m 에서 60 분작업 ( 전체 90 분이상감압 ) Saturation Diving 혼합가스 40 50 60 5 6 7 1.05 1.26 1.47 3.90 4.68 5.46 수심 (m) 6 9 수중 22 분 2 분 감압시간 Chamber 45 분 22 분 35 60 분 ( 작업 ) 질소마취 ( 마티니효과 ): 수심 30m부터환각증세느끼며 60m 안전감각상실 Mixed Gas 산소중독 : 분압 1.6ata부터구토, 현기증, 경련, 의식상실 Diving
포화잠수장비 (Saturation Diving system) 9 man in Sat. Control Cabin Bell Handling System Deck Decompression Chamber (Living Chamber) Diver Bell TUP (Transfer Under Pressure) Chamber HRC (Hyperbaric Rescue Chamber) & Control Cabin 6
포화잠수 (Saturation Diving) Saturation Compression Rate Saturation Decompression Rate Depth Range 0 ~ 60 fsw 60 ~ 250 fsw 250 ~ 750 fsw 750 ~ 1000 fsw Rate 0.5 ~ 30 fsw/min 0.5 ~ 10 fsw/min 0.5 ~ 3 fsw/min 0.5 ~ 2 fsw/min Depth Range Rate 1600 ~ 200 fsw 6 fsw/hour 200 ~ 100 fsw 5 fsw/hour 100 ~ 50 fsw 4 fsw/hour 50 ~ 0 fsw 3 fsw/hour fsw: feet in sea water 250ft(76m) Saturation 상태로들어가는데 30 분, 그러나 Decompression 하는데 3.5 일소요. ( 작업수심과동일한압력으로생활하며최대 30 일까지작업 ) 혼합가스는주로 Heliox 사용하며산소 : 헬륨 (2%: 98%) 사용시 180m 수심에서 19 배산소흡입하게되며 0.38 ata 분압으로문제없음. 최대잠수작업수심은? 혼합가스비율 (1% 산소 ) vs 압력용기제작기술 (30 bar) vs 인체조직 (500m 이상 ) 현재기술로 300m 정도까지상업잠수가능
UTM 도법? (Universal Transverse Mercator) 경도 : 서경 180도부터 6도간격으로나누어 60개구간에대해 1 60까지번호부여위도 : 남위 80도부터북위84도까지 8도간격으로C- X(I와 O는제외 ) 까지번호부여마지막북위 72도 84도는 12도간격한국은 UTM 좌표계 51S, 51T, 52S, 52T에해당 51: 동경 120도 126도, 52: 동경 126도 132도, S: 북위 32도 40도, S: 북위 40도 48도
Acoustic Positioning System USBL(Ultra Short Base Line) SBL(Short Base Line) LBL(Long Base Line)
해양전문가 인생의성공은? 돈 권력 명예 Engineer 의미래는? Global Competition! 지식전문가 경영자 평범한직장인 ( 불안한미래 )
5.0 Offshore Installation Engineer 의 Vision Worldwide Offshore Company - 45 -
해양전문가 공학전문지식 구조 + 해양 / 유체 + 토목 설계 용접 /NDT + 도장 / 방식 + 조선 / 선박 생산 + 측량 + 잠수 (+ Heavy Lifting + Marine) 설치 Process ( 화공 + 열역학 ) 설계 / 시운전 안전 + 환경 안전관리 해양산업의전문가로서미래보장 (Worldwide) 외국어 ( 영어 ) 주고객이외국사 (3 rd Party/Marine Warranty Surveyor 포함 ) 모든 Specification 및지시서를포함한 Documentation 공용어 작업자및제반하청사가대부분외국인
해양전문가 관리전문지식 경영학 해상법 / 해상보험 해양법 / 해운실무 / 선급규정 유능한 Project Manager 해양관리전문가 ( 보험전문가가능 ) VIP ( 이지훈의 혼창통 ) Vision, Insight, Philosophy 많은독서를통한인문학과의통섭이필요함.