message from the machine
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Message from the Machine. Who are we ?. Worldwide leader in the design, manufacture and sale of equipment and components used in oil and gas drilling The provision of oil field inspection and other services and supply chain integration services to the upstream oil and gas industry. - PowerPoint PPT PresentationTRANSCRIPT
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Message from the Machine
Who are we ?• Worldwide leader in the design, manufacture and sale of equipment and
components used in oil and gas drilling
• The provision of oil field inspection and other services and supply chain
integration services to the upstream oil and gas industry
Established: 1841NYSE: NOVEmployees: 60,000Revenue (2012): $20b
Not just the Oil Field…
• We solve really big problems
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So what does that mean ?
• Condition Monitoring
• Condition Based Maintenance
• Predictive Maintenance
• No way.. Not in the drilling
industry !!!!
Message from the machine….
The challenges we face
• Extremely Remote Locations
• Extremely Rugged (Rough Neck Proof)
• Low Connectivity
• Extremely Expensive when things break
• Antonov AN 124 rented to fly equipment
• Technology Averse (unless it turns to the right !)
• Tried and Failed a few times… No Trust it will work…
Why can’t we (Drilling Industry) do it ?Automotive
100 + prototypes, 30 cars at each pre-production
Airlines747 Example – Redundancy of Systems. Collaboration of partners
ProductionBeen doing it since the 80s, no moving assets, but similar asset classes
Aerospace (NASA)Only one chance, it has to work – Testing simulation and softwareThis is the model NOV plans to replicate – Data Analysis, Correlation Analysis
Why we should be doing it ?
• Current Day Rate : > $500,000
• Typical Downtime on a fleet : 4%
• Annual Downtime for a 10 Rig Fleet: $72,000,000
• If Downtime is reduced to 3.75% from 4%: Savings of $4,500,000 / yr.
• That goes to the bottom line…
• Or increase Revenue by $18,000,000 @ 25% OP.
• Now imagine Spread Costs which is over twice those numbers
It’s not just the financial impact!
• Incidents in North Sea, Alaska, Gulf of Mexico
• We are all responsible
Maintenance Savings• Condition Based not Calendar Based
• Extend Maintenance Schedules
– Standard - 4 oil changes by 12000 miles
– New – 1 Oil change at 10500 miles
– Translate that to a fleet of 100 rigs x 3 engines or more
IADC/SPE 128865 - How do we do this ?
Specifications
• Continuous Torque 105,000 ft.-lbs.at 130 rpm
• Horsepower 2 * 1340 HP
• Max Speed 250 rpm
• Break-Out Torque 150,000 ft.-lbs.
• Static Load 1,250 Ton Hoisting• Drilling Load 1,226 Ton Rotating
One company … unlimited solutionsTorque Speed Bearing Life
Criticality Top Drives & Blow Out Preventers
Process• Analyzed Failure Data
– Over 5 Large Offshore Drilling Contractors
– Maintenance Data
– Operational Data
• Criticality of the failures
• Probability of Failures
• Consequence of Failures
• Why can’t we stick a sensor on there ?
Top Drive Boundary Diagram
Detailed Breakdown of Failures
TDS-5 41778Planned Service Pipe Handling; Top DrivesGEARBOX OVERHAUL & ELECTRICAL REPAIRS OF VARCO TDS-5H W/PH-85 Pending A 7684 2009-07-01 01:26 AM 1
PS2-650 41780Planned Service Mud Pumps; Drawworks; Top Drives Change out 400 CPU on MP/SCR and DW/TP PLC`s ClosedIN-15900-SUP R4115 2010-06-29 03:41 AM 1
HPS-03-1000 41782Failure gearbox--Top Drive HPS 1000 2E AC KT - Top Drive HPS 1000 2E AC KT - T4111
Deep Driller 2 are experiencing knocking noises in the gearbox when operating in low gear (glovia order WO/ NOV-41782WS) Pending 2010-06-22 02:34 AM 1
TDS-11 41797Support (I&C, survey, etc.) Top DrivesAssist with repairing TDS-11SA electrical short and possible fire on the TDS11SA top drive. Closed 2009-07-21 07:36 AM 1
HPS-03-1000 41800Failure Motor--Top Drive HPS 1000 2E AC KT - Top Drive HPS 1000 2E AC KT - T6309
West Polaris request new AC motor for the top drive, they don't get in touch with their sales contact. Closed 2009-07-07 12:41 AM 1
TDS-11 41801Support (I&C, survey, etc.) Top Drives Customer request TDS survey for install Closed CS41801 2009-07-30 09:46 AM 1
TDS-11 41802Support (I&C, survey, etc.) Top Drives Customer request TDS survey Closed CS41802 2009-07-30 08:45 AM 1
TDS-4S 41804Failure Control Control Systems; Top Drives Drive house CPU is going into SF ( System fault ) Closed 2009-08-18 04:20 PM 1
TDS-3 41810Support (I&C, survey, etc.) Top Drives
Disassembly Inspection and Repair of Hydraulic Lift Actuator Cylinder & Hydraulic Torque Cylinder for TDS Closed
DSW/5800, WO# 21374 2009-10-06 01:28 AM 1
TDS-8S 41812Support (I&C, survey, etc.) Top DrivesINSPECTION AND OVERHAUL OF VARCO TDS8 SA TOP DRIVE Closed
DSW/5801, WO# 21376 2010-03-16 02:48 AM 1
PS2-500 41813Failure IBOP Top Drives Trouble shooting of IBOP indication Lamp Closed453/DSO/7270 2009-07-02 01:08 AM 1
IDS-4 41820Failure Hydraulic Mud Pumps; Top Drives Issues with top drive when 3 mud pumps on line. Closed 2009-07-03 03:44 PM 1
TDS-9 41823Support (I&C, survey, etc.) Top Drives; Iron Roughnecks
To prepare the accidental report of TDS, AMC of TDS, also to perceive ST-80 operation and maintenance. Open
458/DSO/7270 2009-07-02 06:49 AM 1
TDS-11 41824Support (I&C, survey, etc.) Top Drives Start-up and commission top drive Closed 2009-08-24 01:35 PM 1
TDS-6 41831Failure Control Top Drives Top Drive RPMs not reading correctly Closed 2009-07-07 05:23 AM 1
TDS-11 41845Support (I&C, survey, etc.) Top DrivesComplete TDS-11SA Top Drive commissioning in the Patterson Victoria Yard. Closed 2009-07-20 09:20 AM 1
TDS-11 41848Failure Control Top DrivesChange out Off-Drillers-Side Motor on the TDS-11 shipped in from NOMAC 3. Closed 2010-05-21 02:19 PM 1
TDS-6 41866Support (I&C, survey, etc.) Top Drives Removal of TDS-6 for repair and storage. Closed 2010-01-06 09:50 AM 1
TDS-11 41870Support (I&C, survey, etc.) Top Drives Commissioning TDS-11. Closed 2009-07-09 07:14 AM 1
TDS-10 41880Failure Hydraulic --Top Drive - TDS-10 - TDS10SM09J017 hydraulic pump cracked love coupler needs replacing Closed 2009-11-09 09:18 AM 1
PS2-500 41881Support (I&C, survey, etc.) Top Drives XXXVth AMC Schedule Closed460/DSO/7270 2009-11-18 10:51 PM 1
TDS-11 41885Failure Control --Top Drive - TDS-11SA - TDS11SH16R654 Top drive will not rotate Closed VS 2009-07-04 10:05 PM 1
TDS-11 41899Support (I&C, survey, etc.) Top Drives Parts Only Closed 2009-07-20 09:21 AM 1
HPS-03-1000 41912Support (I&C, survey, etc.)
Other; Mud Pumps; Control Systems; Drawworks; Top Drives; --Statoil Stafjord B t6291-D1100-G0001 Hydratong MPT - -
Seawell requires training on NON equipment - Stavanger equipment and Kristiansand equipment Open 2009-07-06 06:16 AM 1
TDS-8S 41914Support (I&C, survey, etc.)
Other; Control Systems; Cranes; Pipe Handling; Drawworks; Top Drives; Iron Roughnecks; Hydraulic Power Units; Overhead/Traveling Equipment; Rotary Tables
Transocean requires training on NON equipment - Stavanger equipment and Kristiansand equipment Open 2009-09-02 12:47 AM 1
PS2-750 41919Support (I&C, survey, etc.) Top DrivesInstallation and commissioning of PS-500 A top drive in Saudi Arabia Pending KSA933 2009-07-06 07:13 AM 1
TDS-11 41923Failure Hydraulic Top Drives Problem on hydraulic pump of TDS Open JAC913 2009-07-06 07:56 AM 1
TDS-11 41925Support (I&C, survey, etc.) Top Drives The TDS-11 has no cycling time. Closed 2009-09-25 07:03 AM 1
TDS-4S 41927Support (I&C, survey, etc.) Top Drives PH-85 not working properly Closed DS-21042 2009-07-06 08:29 AM 1
TDS-11 41929Support (I&C, survey, etc.) Top Drives Commissioning TDS-11. Closed 2009-08-27 08:09 AM 1
HPS-03-1000 41930Failure Control Top Drives
Ability to set rpm then have a "Jog" button / function to turn in stages the TD at a predetermined speed clockwise / counter clockwise when button momentarily depressed Closed 2009-08-26 03:14 AM 1
46%
1%
7%
46%
FailureDropped Ob-jectsPlanned ServiceSupport
29%
5%
7%
4%
9%7%9%
5%
2%
19%3% 1%1%
ControlDolly / Derrick InterfaceElectricalGearboxHydraulicIBOPMotorMotor Housing AssyOperator ErrorPipe HandlerService LoopWashpipeUnknown
Data Analysis
27%
9%
6%7%
1%
6%
4%
10%1%
23%
6% 1% 1%
ControlDolly / Derrick InterfaceElectricalGearboxHydraulicIBOPMotorMotor Housing AssyOperator ErrorPipe HandlerService LoopWashpipeUnknown
• Started with 10 years worth of data
• Finally Ended up with 3 years worth of good data
• “Other” – largest cause of downtime
Quality of prediction
Intelligent data acquisition and analysis
Accounts for changing operating conditions
Accounts for random events such as jarring
Filters out ambient noise and resets baseline
Condition Monitoring System
Vibration Sensors
A day in the life of …. Boiler
• Gets to location
• Stays there
• +30 years
A day in the life of …. Top Drive
Advanced Rig Monitoring – Virtual Employee
eHawk introduces Machine Learning to learn from historical data an equipment’s “Normal” vs. “Abnormal” operations for multiple states.
Dynamically create profiles to monitor the equipment and listen
for abnormal signatures. Continuously adapts over time.
How do we do it ?
The Message….
What do we measure on a Top Drive then
• Upstream
– Engines, Generators, Drives
• Downstream
– Rock formations, DH vibrations, etc.
• Other
– Ambient Temperature, etc.
Bearing Status
Debris Status
Mud Ingress Status
Top Drive RPM
Torque
Load
Derrick Location
Motor Winding Temps
Left Right
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Machine Learning
Example 1 - Top Drive
Found 14 day Predictor for June 10th Top Drive Failure (Over Temp) due to Lube Motor Failure
• Created Supervised Learning Profiles to monitor for failure signature detected ongoing.
• Confirmed failure information with Rig• Root Cause: UV1 valve cycling lubrication fluid in 6 second intervals
Example 2 – Engine Temps
Example 3:– Mud Pump
Anomaly Detection triggered on June 9th for Mud Pump Drive fault
oDrive fault prediction found oCustomer notifiedoRig down 18 hours later
So... No sensors whatsoever ???Cam and Cam Main Bearings
Screen shot of Actual Alarm 3 Day Trend shows increased vibration. The spectrum and trend of the BPFI (Ball Pass Frequency Inner Race)
clearly indicated the presence of an early stage defect on the inner ring of the bearing
3 day trend of BPFI
Frequency Spectrum
Actual Failed Bearing
Repair Costs and Downtime with CM Repair Costs and Downtime without CMComponent Cost Total Downtime Component Cost Total Downtime
Cam Roller $ 12,000 Cam Roller $ 12,000
Eccentric Cam $100,000
Linear Rails $ 9,000
Labor(One Day, one technician)
$, 1,800 Labor (4 days, two technicians)
$ 14,400
Evacuation unit (4 days) $ 24,000
Total $ 13,800 8 Hrs. Total $159,400 196 Hrs.
NET $145,600 184 Hrs
Associated Costs of Components and Labor for this failure
Note: Spare Eccentric Cam was not available on Rig
Lead time for Eccentric Cam was extremely long at time of incident
Risk Analysis
The Numbers Say it All
Without solution$173,000 Lost Day Rate
With solution (2012)$33,000 Lost Day Rate
72% Reduction
in RigDown
Predictability• False Alarms
• Predictability is key
• When you call the rig with a problem…
Monitoring the BOP
• Current Demographic –
• Older, aging driller demographic
• Influx of younger inexperienced workforce
• New Deepwater Rigs being built – How will we staff them
• Compare Pilots and Drilling Crews ($650 Million Rig)
• Not enough time to train – Serve the iPad Generation
Do we have to do this?
Remote Monitoring – Too many rigs and too few PhDs
Norway Singapore Houston
Hawaii
Conclusion
• Are we there yet ?
• There is no end point.
– We can only get better
• Technologies and Capabilities exist
– Let’s use the tons of data
• We have no more excuses
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Questions?
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NOV I Rig Solutions I www.nov.com