Predictive Maintenance in Oil & Gas Industry: The Complete Guide
Lenden Vaz, Vice President for Energy & Utilities at Birlasoft takes APMEN through on ensuring smooth operations with predictive maintenance.
Exxon Unveils Restructuring Plans In Latest Cost-Cutting Move
Exxon Mobil Corp (XOM.N) recently disclosed a sweeping restructuring of its global operations that will combine its refining and chemicals businesses into one, and put its energy transition business on the same footing as its other operations.
Providing Real-Time Intelligence & Precise Monitoring Of Oil And Gas Pipeline Operations
Schneider Electric, the global leader in the digital transformation of energy management and automation, and Prisma Photonics, a provider of next-generation fibre sensing for smart infrastructure, recently announced a partnership to help oil and gas pipeline owners and operators prevent accidental and malicious activity by providing real-time intelligence and precise monitoring of oil and gas infrastructure.
Oil And Gas Industry Embracing Drones for Remote Inspection
Drone technology is becoming a valuable tool in the oil and gas industry. Oil and gas companies are opting to use drones to address their inspection needs and reduce operational costs.
Manual inspections in the oil and gas industry are expensive, time-consuming, and demand exhausting work. The oil and gas companies handle highly flammable substances which are hazardous to the personnel performing inspections. Drones for industrial use are proving to be highly beneficial in remote monitoring and assessments. Remote inspections can be performed by inspectors remotely from on-site or off-site locations without physically being present at the site.
“Drones are a flexible and cost-effective way to conduct inspections across the oil and gas industry value chain,” said Prashanthi P S, Research Analyst at Beroe Inc. “Drones can increase the safety of workers, improve the quality of investigations, and reduce the high costs associated with manual reviews. Some of the other applications include pipeline inspections, deepwater offshore location assessments, offshore vessels, rigs, underwater services, security, surveillance, monitoring, mapping, delivery of goods and survey for the potential asset.”
Manual inspections of onshore and offshore locations are generally expensive. Labor cost is high, constituting up to 30 percent of the total cost. Drones allow cost-effective and faster inspections of pipelines, deepwater offshore, and underwater equipment. Analysis of drone data enables companies to predict the health of the equipment and foresee any potential failures. In addition, drones fitted with sensors can monitor methane emissions from assets in the oil and gas companies.
Manual inspections of offshore locations require helicopters to transport personnel. The cost of transportation for the inspection team and the cost for helicopter pilots is high. With remote drone inspections, these costs can be eliminated. The person in charge need not travel to the site; they can perform image inspection through the video, still, infrared, and thermal images captured by the cameras fitted on drones. Inspectors can then perform advanced analysis of drone data with the help of the company’s data analysis software.
Manual inspection of flare stacks requires the process production to stop for inspection. With remote drone inspections, flares can be kept online without interrupting production. This eliminates production loss of approximately $1 million per day per flare. Remote inspections of Fluid Catalytic Cracking Units with drones are more efficient since refinery downtime would not be needed, preventing production loss of approximately $2 million per day. Scaffolding costs in the oil and gas industry amount to $50 000 to $80,000 per stack. Remote drone inspections can save more than 80 percent of scaffolding costs. Upcoming new drone technologies such as 5G and high-speed drones are expected to further boost the adoption of drones in the oil and gas industry.
“The use of drones in the oil and gas industry adds enormous value in terms of ease of operation, the safety of personnel, continued production, and reduced operational costs.” said Prashanthi P S, Research Analyst at Beroe Inc. “With the continued development of drone technology, it’s interesting to look forward to seeing new commercial drone applications and how they can be integrated with quality control, quality assurance, and maintenance processes. And when you add AI and automation to this mix, the existing benefits compound tremendously.”
For more such market insights, procurement intelligence, supplier analysis, price, and cost benchmarking, https://www.beroeinc.com/beroe-live-ai/
SOURCE Beroe Inc.
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How Oil & Gas Companies Are Leveraging Emerging Technologies
Tech-enabled asset management holds key for oil & gas upstream industry, says GlobalData
GlobalData’s latest report, ‘Data is the new oil: how tech transformation can fuel efficiencies in oil & gas’ focuses on how the oil & gas sector is incorporating the use of emerging technologies to drive innovation and march towards a massive transformation.
Overview of Report:
- Theme Exposure: Presents the top themes impacting the sector over the last three years compared to other sectors.
- Innovation Map: key real-world innovation use cases of emerging technologies implemented by enterprises and startups in the sector.
- Innovation Insights: innovation examples by each value chain segment of the sector to present key trends.
- Vendor Map: represents a sample list of vendors in each use case highlighted in the report.
Regardless of the asset type, the need of the hour is to implement emerging technologies to optimize oil recovery and maximize output, says GlobalData, a leading data and analytics company.
Abhishek Paul Choudhury, Disruptive Tech Analyst at GlobalData, comments: “Oil & gas companies are increasingly adopting intelligent automation and other digital enablers to synthesize large amounts of data and derive useful insights to ease complex field activities that have defined the upstream value chain. IoT technologies coupled with AI algorithms are in action to screen and discover optimal acreage options, improve subsurface modeling, and enhance drilling performance.”
Convergence of emerging technologies for predictive asset maintenance
US-based energy company KBC co-launched an AI-powered predictive maintenance system with domestic software company OLI that integrates KBC’s Petro-SIM simulation abilities with OLI Alliance Engine. The combined software solution creates a digital twin, which integrates the IoT and AI of entire assets across the system to help with real-time predictions on corrosion, scaling, and fouling for upstream oil & gas players.
IoT-enabled remote oilfield monitoring
American oilfield equipment supplier ‘Sensorfield’ developed IoT-based remote monitoring solutions to provide real-time, round-the-clock operational data of the oil wells. The solutions were developed to withstand the harsh weather conditions and leverage tech advancements to provide real-time data and alarms for tank levels, pressure and flow rates, compressor health, and location security.
AI-augmented production optimization
Equinor developed a machine learning model to analyze mud-gas data to predict the gas to oil ratio of wells as they are drilled. It is written in python and can be embedded into existing commercial petrophysics software. As it happens in real-time, it can act as an alert system when drillers are tapping into uneconomic pay zones.
Mr Paul concludes: “As global oil & gas operators look to 2022 budgets, they must balance investor expectations to grow volumes and revenues. This can only be mapped with judicious upstream technological adoption that can not only keep downtime at bay but also help explore the function’s true potential to improve yield sustainably while avoiding hazards.”
This press release was written using data and information sourced from proprietary databases, primary and secondary research, and in-house analysis conducted by GlobalData’s team of industry experts.
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Exploring & Producing Cutting-Edge Solutions
Challenging the elements and pushing the boundaries of the physically possible, the oil and gas industry is a tough, competitive business that requires near-zero tolerances and equally tough, never-let-you-down products.
Article by MasterFluid.
A truly global industry, oil and gas upstream exploration and production takes place on all seven continents, major oceans, and deepest seas worldwide. It is a driving force of the global economy. The exploration and production pressures and temperatures are intense, the stakes are high, and error can be catastrophic. Premium pipes, seals, valves, wellheads, couplings, and connectors are essential. Dependable metalworking fluids ensure manufacturers can compete in the highly competitive arena of the oil and gas business to produce 100% reliable pipes and dependable parts efficiently and profitably.
Full Article Available >> https://bit.ly/3iu1UrO
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Shorter Cutting Times Even When Cutting Tougher Alloys
In light an increasing number of high-volume orders, a metal handler in the oil and gas industry decided to build a new facility to expand its capacity–and to broaden its sawing technology with the help of KASTO.
After experiencing several difficult years, the oil and gas industry is now on the upswing again. The Howat Group also benefits from this development: Located in Barnsley in the UK, the company is a supplier of special metals for this demanding industry. The product range comprises various nickel and aluminium alloys as well as numerous steel and stainless steels. The materials are used, for example, on offshore drilling platforms or in pipeline construction – at sites where they are exposed to extreme temperatures, high pressure, and heavy corrosion.
The Howat Group opened its new facility in Dearne Valley at the end of 2018. This facility provides 60,000 square metres of space, among other things, for a large sawing plant: A total of 14 automatic saws from the German manufacturer KASTO ensure fast and accurate cuts. Some of which have been in service since the 1990s and still cut as accurately as they did when first used.
Expanding Sawing Technology
To cope with an increasing number of high-volume orders, in the course of constructing the new facility, the company also decided to expand its sawing technology. Some of the existing models were retrofitted to update them to the current technology. In addition, the company invested in the KASTOwin pro AC 5.6, which is a high-performance bandsaw optimised for the use with bimetallic and carbide blades. Therefore, it is suitable to cut alloys such as tough nickel, titanium and stainless steel with diameters of up to 560 millimetres as well as for cutting low-alloy steels.
Howat’s operations director Emma Parkinson commented, “We have four dedicated carbide cutting bandsaws on site which include KASTOtec AC5s and now the KASTOwin pro, which is even more economical. They are ideal for cutting our Inconel materials.”
Particularly for the processing of these nickel alloys, the company wanted to become more efficient and therefore decided to acquire this new machine. Parkinson explains the decision, “I am quite familiar with the benefits of the KASTO saws since I have worked with this manufacturer during my previous employment.”
Easy Blade Change Saves Tool Costs
The remainder of the sawing plant, which comprises sawing with a cutting range of up to 800 millimetres, is intended mainly for the operation using bimetal blades – however, now and then carbide blades are used as well.
“The advantage of the KASTOwin pro is that we can use either type of blade economically,” explained Parkinson. “Whenever the material to be cut permits, we change to bimetal to extend the life of the expensive carbide blades.” Changing the blades is quick and easy – and since Howat frequently produces large batch sizes, the time spent on processing is virtually no concern.
Furthermore, KASTOwin pro excels with its high productivity. Depending on the type of blade, cutting times can be reduced by 50 percent and more. A frequency-controlled eleven kW motor drive provides plenty of capacity for the use of carbide blades. The cutting speed is infinitely adjustable from twelve to 150 metres per minute. The electro-mechanical feed system can be controlled using two ball screw spindles, each with a servo drive for precise, infinitely variable control. This system provides exact results and minimises material waste. The saw features a retraction unit for lifting the blade from the material when the saw head moves back to protect the cutting surface and the bandsaw blade. This minimises tool wear.
To continue reading this article, head on over to our Ebook!
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Large-Scale Metrology For Oil Industry Production
Introduction of dedicated metrology tools brings quality and efficiency improvements in large-scale subsea structure construction. Article by Hexagon Manufacturing Intelligence.
Situated approximately 15 km south of Singapore in a free-trade-zone on Batam Island, Profab has for 20 years been building a reputation as a leading producer of large-scale parts for the global oil industry. A part of National Oilwell Varco since 2015, the company manufactures everything from subsea structures, turrets and wellhead platforms to mooring systems and pressure vessels.
This level of large-scale construction involves a host of complex industrial processes, including rolling, cutting, assembly, welding, cladding and weld overlay, post-weld heat treatment, painting and coating, loadout support, hydrostatic testing, fitting, packing and sea fastening.
Ensuring client projects are completed properly at the first attempt is a core goal at Profab, requiring the employment of the latest technology and equipment and a highly trained team. Their 27,500 square metre workshop was purpose-designed to provide the most efficient fabrication lines by minimising handling interference within the production process. Profab can handle the production of equipment weighing in at up to 4,000 tons, which can be loaded out directly onto barges via a roll-on-roll-off system using self-propelled modular transporter trailers.
Focus on Accuracy
The manufacture of pressure vessels and mooring systems are key areas where accuracy is becoming more and more critical for Profab. A key example of this was in the creation of the Sergipe floating storage regasification unit (FSRU), where precisely measuring the angles, position and length of the umbilical support structure was of great importance, with measurement essential in the reporting and positioning of adaptor plates.
The accuracy requirements for such tasks are at the submillimetre level for the machined parts, which was beyond the capabilities of the quality assurance equipment previously employed in Batam. It was clear that something more was needed to satisfy these requirements.
“We did consider a high-definition surveying system, but with accuracy at just about 2 to 3 mm, such a solution was just not workable for us,” said Rajesh Moehamad, Quality Control Manager at Profab. “Some of our customers require better accuracy than this, even for very big parts.”
After consultation with a Hexagon representative, it was clear that the Leica Absolute Tracker AT403 delivered a range of features and capabilities that perfectly aligned with Profab’s production needs in Batam.
To continue reading this article, which appeared in the April 2020 issue of Asia Pacific Metalworking Equipment News, click here!
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Iscar F3S Chipformer For Finish Turning On Superalloys And Exotic Materials
Iscar F3S Chipformer For Finish Turning On Superalloys And Exotic Materials Intended mainly for aerospace industries as well as for the oil & gas market, the new efficient chip breaker for finishing operations is designed for working with unique and tough to machine nickel based alloys (Inconel, Waspaloy, etc.), as well as other exotic materials such as titanium based alloys.
The new F3S chipformer has a remarkable positive rake angle to ensure a smooth and easy cut, with significant reduction in cutting forces and notable chip breaking results.
The F3S chipformer has been designed with geometric features to improve tool life, with a reinforced cutting edge at the area where VG (notch wear) wear tends to occur when machining superalloys and exotic materials, which causes poor surface finish and risk of edge breakage.
The chipformer is available on the most popular inserts – CNMG, WNMG and SNMG – in two main grades, IC806 and IC804, and will be available in the future also on VNMG, DNMG, and TNMG inserts.
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Alaska & China Sign Deal For Gas Pipeline Project
Alaska, US: A new natural gas pipeline for Alaska has been proposed and will be jointly financed by the US and China. It will run parallel to the Trans-Alaska oil pipeline.
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