Transcript The Message….

Message from the Machine
1
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: 1841
NYSE: NOV
Employees: 60,000
Revenue (2012): $20b
Not just the Oil Field…
• We solve really big problems
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Message from the machine….
So what does that mean ?
• Condition Monitoring
• Condition Based Maintenance
• Predictive Maintenance
• No way.. Not in the drilling industry
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
Airlines
747 Example – Redundancy of Systems. Collaboration of partners
Production
Been doing it since the 80s, no moving assets, but similar asset classes
Aerospace (NASA)
Only one chance, it has to work – Testing simulation and software
This 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 ?
Criticality
Top Drives & Blow Out Preventers
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
Torque Speed
Bearing Life
One company … unlimited solutions
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
Data Analysis
1% Failure
• Started with 10 years worth of data
46%
7%
• Finally Ended up with 3 years worth of good data
46%
TDS-5
41778 Planned Service
Pipe Handling; Top Drives
PS2-650
41780 Planned Service
Mud Pumps; Drawworks; Top Drives
HPS-03-1000
41782 Failure
TDS-11
41797 Support (I&C, survey, etc.)
HPS-03-1000
41800 Failure
41801 Support (I&C, survey, etc.)
41802 Support (I&C, survey, etc.)
Motor
TDS-11
TDS-4S
41804 Failure
Control
TDS-3
41810 Support (I&C, survey, etc.)
TDS-8S
41812 Support (I&C, survey, etc.)
PS2-500
41813 Failure
41820 Failure
TDS-11
IDS-4
gearbox
--Top Drive HPS 1000 2E AC KT - Top
Drive HPS 1000 2E AC KT - T4111
Top Drives
--Top Drive HPS 1000 2E AC KT - Top
Drive HPS 1000 2E AC KT - T6309
Top Drives
Top Drives
Control Systems; Top Drives
Top Drives
Top Drives
IBOP
Hydraulic
Top Drives
Mud Pumps; Top Drives
1
2009-07-07 12:41 AM
2009-07-30 09:46 AM
2009-07-30 08:45 AM
1
2009-08-18 04:20 PM
1
2009-10-06 01:28 AM
1
2010-03-16 02:48 AM
1
2009-07-02 01:08 AM
2009-07-03 03:44 PM
1
2009-07-02 06:49 AM
2009-08-24 01:35 PM
1
Closed
Closed
Closed
CS41801
CS41802
DSW/5800,
WO# 21374
DSW/5801,
WO# 21376
453/DSO/72
70
1
1
Closed
2009-11-09 09:18 AM
1
XXXVth AMC Schedule
Closed
460/DSO/72
70
2009-11-18 10:51 PM
1
Top drive will not rotate
Closed
VS
2009-07-04 10:05 PM
1
Closed
2009-07-20 09:21 AM
1
Open
2009-07-06 06:16 AM
1
Open
2009-09-02 12:47 AM
1
41880 Failure
Hydraulic
--Top Drive - TDS-10 - TDS10SM09J017
PS2-500
41881 Support (I&C, survey, etc.)
TDS-11
41885 Failure
Control
Top Drives
--Top Drive - TDS-11SA TDS11SH16R654
TDS-11
41899 Support (I&C, survey, etc.)
HPS-03-1000
41912 Support (I&C, survey, etc.)
Top Drives
Parts Only
Other; Mud Pumps; Control Systems;
Drawworks; Top Drives; --Statoil Stafjord B Seawell requires training on NON equipment t6291-D1100-G0001 Hydratong MPT - Stavanger equipment and Kristiansand equipment
TDS-8S
41914 Support (I&C, survey, etc.)
Other; Control Systems; Cranes; Pipe
Handling; Drawworks; Top Drives; Iron
Roughnecks; Hydraulic Power Units;
Overhead/Traveling Equipment; Rotary
Tables
PS2-750
41919 Support (I&C, survey, etc.)
Top Drives
TDS-11
Hydraulic
TDS-11
41923 Failure
41925 Support (I&C, survey, etc.)
41927 Support (I&C, survey, etc.)
41929 Support (I&C, survey, etc.)
HPS-03-1000
41930 Failure
Control
Gearbox
Open
Closed
458/DSO/72
70
26%
Hydraulic
23%
IBOP
9%
1
2010-05-21 02:19 PM
2010-01-06 09:50 AM
2009-07-09 07:14 AM
TDS-10
1% 1%
1
Closed
Closed
Closed
TDS-11
Top Drives
2009-07-21 07:36 AM
1
Top Drives
Top Drives
Top Drives
TDS-4S
Closed
Dolly / Derrick
Interface
Electrical
6%
2009-07-20 09:20 AM
Control
TDS-11
1
2009-07-07 05:23 AM
41848 Failure
41866 Support (I&C, survey, etc.)
41870 Support (I&C, survey, etc.)
Drives
Drives
Drives
Drives
2010-06-22 02:34 AM
Closed
TDS-11
Top
Top
Top
Top
Pending
Closed
41845 Support (I&C, survey, etc.)
Top Drives
1
Top Drive RPMs not reading correctly
Complete TDS-11SA Top Drive commissioning in
the Patterson Victoria Yard.
Change out Off-Drillers-Side Motor on the TDS-11
shipped in from NOMAC 3.
Removal of TDS-6 for repair and storage.
Commissioning TDS-11.
hydraulic pump cracked love coupler needs
replacing
41831 Failure
TDS-11
Top Drives
1
2010-06-29 03:41 AM
Closed
Closed
TDS-6
Control
A 7684
IN-15900SUP R4115
Trouble shooting of IBOP indication Lamp
Issues with top drive when 3 mud pumps on line.
To prepare the accidental report of TDS, AMC of
TDS, also to perceive ST-80 operation and
maintenance.
Start-up and commission top drive
TDS-11
TDS-6
Top Drives; Iron Roughnecks
Top Drives
Control
2009-07-01 01:26 AM
Closed
Drive house CPU is going into SF ( System fault )
Closed
Disassembly Inspection and Repair of Hydraulic Lift
Actuator Cylinder & Hydraulic Torque Cylinder for
TDS
Closed
INSPECTION AND OVERHAUL OF VARCO TDS8
SA TOP DRIVE
Closed
41823 Support (I&C, survey, etc.)
41824 Support (I&C, survey, etc.)
TDS-9
Pending
Planned
Service
Support
• “Other” – largest cause of downtime
GEARBOX OVERHAUL & ELECTRICAL REPAIRS
OF VARCO TDS-5H W/PH-85
Change out 400 CPU on MP/SCR and DW/TP
PLC`s
Deep Driller 2 are experiencing knocking noises in
the gearbox when operating in low gear (glovia
order WO/ NOV-41782WS)
Assist with repairing TDS-11SA electrical short and
possible fire on the TDS11SA top drive.
West Polaris request new AC motor for the top
drive, they don't get in touch with their sales contact.
Customer request TDS survey for install
Customer request TDS survey
Dropped
Objects
10%
5%
1%
4%
1
Motor
Housing Assy
Operator
Error
Pipe Handler
7%
6%
Motor
1%
Service Loop
1
1
1
Control
3%
1%
Dolly / Derrick
Interface
Electrical
1%
1%
29%
19%
Gearbox
Hydraulic
Transocean requires training on NON equipment Stavanger equipment and Kristiansand equipment
Installation and commissioning of PS-500 A top
drive in Saudi Arabia
Problem on hydraulic pump of TDS
The TDS-11 has no cycling time.
PH-85 not working properly
Commissioning TDS-11.
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
Pending
KSA933
2009-07-06 07:13 AM
1
Open
Closed
Closed
Closed
JAC913
2009-07-06
2009-09-25
2009-07-06
2009-08-27
AM
AM
AM
AM
1
2009-08-26 03:14 AM
1
Closed
DS-21042
07:56
07:03
08:29
08:09
1
5%
9%
7%
5%
IBOP
Motor
7%
9%
Motor Housing
Assy
Operator Error
1
1
Pipe Handler
4%
Condition Monitoring System
Intelligent data acquisition and analysis
Accounts for changing operating conditions
Accounts for random events such as jarring
Filters out ambient noise and resets baseline
Quality of prediction
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.
The Message….
How do we do it ?
What do we measure on a
Top Drive then
• Upstream
Bearing Status
Debris Status
Mud Ingress
Status
Top Drive RPM
– Engines, Generators, Drives
Torque
• Downstream
Load
– Rock formations, DH vibrations, etc.
Derrick Location
• Other
– Ambient Temperature, etc.
Motor Winding Temps
Left
Right
Machine Learning
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Example 1 - Top Drive
• 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
Found 14 day Predictor for June 10th
Top Drive Failure (Over Temp) due to
Lube Motor Failure
Example 2 – Engine Temps
Example 3:– Mud Pump
o Drive fault prediction found
o Customer notified
o Rig down 18 hours later
Anomaly Detection triggered on
June 9th for Mud Pump Drive fault
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
Frequency Spectrum
3 day trend of BPFI
Actual Failed Bearing
Associated Costs of Components and
Labor for this failure
Repair Costs and Downtime with CM
Repair Costs and Downtime without CM
Component
Cost
Component
Cost
Cam Roller
$ 12,000
Cam Roller
$ 12,000
Eccentric Cam
$100,000
Linear Rails
$ 9,000
Labor (4 days, two
technicians)
$ 14,400
Evacuation unit (4 days)
$ 24,000
Total
$159,400
196 Hrs.
$145,600
184 Hrs
Labor
(One Day, one
technician)
Total
Total Downtime
$, 1,800
$ 13,800
8 Hrs.
NET
Total Downtime
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
Do we have to do this?
• 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
Remote Monitoring – Too many rigs and too few PhDs
Hawaii
Norway
Singapore
Houston
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
Questions?
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NOV I Rig Solutions I www.nov.com
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