CATEGORIZED | News, The Efficient Rig

From passive to proactive, condition monitoring gives rig operators advance warning of failures

Posted on 31 January 2012

By Katie Mazerov, contributing editor

The vision for condition monitoring is to deliver actionable data that can be used to reduce the cost of repairs and downtime and increase productivity, said Sepideh Otmishi, product application specialist for Caterpillar’s Global Petroleum division, at the IADC Rig Condition Monitoring Workshop on 19 January.

As rigs and oilfield equipment are increasingly deployed to remote locations and equipped with complex electronic engines and control systems, the risks of failure, unplanned shutdowns and downtime are posing increasing challenges as well. “Fifty years ago, we were dealing with mechanical engines, and we really didn’t have to do anything with them. We just ran them until they died,” said Sepideh Otmishi, product application specialist for Caterpillar’s Global Petroleum division, a provider of electronic data and condition monitoring services for rigs worldwide.  “But now, with electric engines and equipment more complicated than ever, we have a tremendous amount of data to manage.”

That, combined with pressure to increase productivity and a changing work force, has pushed the industry to develop more sophisticated systems for condition monitoring (CM).

Speaking at the IADC Rig Condition Monitoring Workshop on 19 January in Houston, Ms Otmishi discussed the benefits of CM, specifically how electronic data can be used to offset engine and equipment challenges for rig operators. It is a more comprehensive process than health monitoring, which provides the current condition of equipment in real time with visual graphics but offers no analysis or indication of potential failures.

“CM is a proactive analysis process using equipment and application data from multiple sources to make critical maintenance, component replacement and repair decisions,” she said. “Our vision is to provide customers with an end-to-end solution by delivering actionable data that can be used to create an informed decision to reduce the cost of repairs and downtime, and increase productivity.”

Advance warning

At Caterpillar, CM involves five elements: electronic data, fluid analysis, site condition, equipment history and regular inspections. Benefits are reduced cost of parts and labor; greater availability and uptime of critical equipment such as compressors, generators and transmissions; and less collateral damage associated with unforeseen failures. “In gathering the information and analyzing and aggregating the data, by the end of the day we can tell you if something is going to fail,” Ms Otmishi said. “We correct emerging problems and move unscheduled repairs to scheduled shutdowns.”

The 24/7 monitoring process detects anomalies and abnormal signals by simultaneously looking at multiple parameters, allowing specialists to provide recommendations for checking assets long before problems are apparent. “The point is, we can provide advance warning of a problem days in advance, not a few hours in advance – which would defeat the purpose of CM,” Ms Otmishi noted. “We give the customer enough time to actually fix, inspect, replace and repair the situation when it is convenient.”

In one case on a Canadian work site, a signal indicated the air-restriction parameter on a piece of equipment was inconsistent and running significantly lower than required. Caterpillar informed the customer and advised an inspection, which revealed a broken air filter tube that was allowing dirt and debris into the air system. Within two days, the item was repaired and the system was back online with no unexpected shutdowns and no downtime.

Leave a Reply

*

FEATURED MICROSITES


Recent Drilling News

  • 22 April 2014

    Noble names Steven Manz as Senior VP And CFO of Paragon Offshore

    Steven A. Manz will serve as Senior VP and CFO of Noble Corp’s spinoff company Paragon Offshore, a standard specification offshore drilling company, Noble announced today...

  • 17 April 2014

    Shell makes deepwater gas discovery offshore Malaysia

    Shell has made an exploration discovery offshore Malaysia in the Rosmari-1 well located 135 km offshore Malaysia in Block SK318. The well was drilled to a total depth of 2,123...

  • 16 April 2014

    Maersk Drilling takes delivery of ultra-deepwater drillship

    Maersk Drilling has taken the delivery of its second drillship, Maersk Valiant from the Samsung Heavy Industries (SHI) shipyard in Geoje-Si, South-Korea. Maersk Valiant has begun its voyage toward the...

  • 16 April 2014

    Ensco orders new jackups from Lamprell

    Ensco has ordered two high-specification jackups, ENSCO 140 and ENSCO 141, for delivery in mid-2016 from Lamprell’s shipyard in the United Arab Emirates. The rigs will also...

  • 16 April 2014

    MPD/UBD successfully drills sidetrack after 6 failed conventional drilling attempts

    In the Brookeland Field in East Texas, conventional drilling methods failed in six attempts to drill a “straightforward” horizontal wellbore. The original well had surface casing installed...

  • Read more news