№3 March 2012Table of contents Issue Archive
№ 2 (February 2012)
Equipment readiness and reliability control are critical considerations in the job preparation process. Reducing nonproductive time (NPT) and costs associated with accidents is achieved by different means, including improving the reliability of equipment and downhole tools. With improper maintenance, even simple and reliable equipment can have a higher risk of accidents.
By Victor Lyashkov, Service Quality Engineer in Houston Conveyance and Surface Equipment, Schlumberger
Detailed equipment information helps mitigate risk of incidents
When traditional technologies undergo rationalization and development, and new technologies merge to the market, there is a need to collect detailed failures statistics. Oil and service companies have their own systems for monitoring and recording such data. This allows them to mitigate similar problems in the future.
Reliability and readiness impacts new and existing equipment
Along with rationalization and development of conventional downhole tools and surface equipment, Schlumberger engineers continually invent new tools and technology. Schlumberger invested $919 million into research and development of new technologies in 2010 compared with $802 million in 2009. Growing investment in improving and developing technology demonstrates that Schlumberger is working to meet the increasingly challenging demands of oil and gas reservoirs throughout the world. Tool condition and readiness is extremely important for new as well as conventional technologies. If an incident occurs, both the operator and the service company will incur direct and indirect losses.
How do we make sure that equipment is ready for the job and the utilization plan is well optimized? Those and similar questions are always relevant in large companies, and each company has its own solution.
Schlumberger implemented RITE.Net Web application to monitor tool status
To monitor the technical status of downhole tools, equipment, and their components, Schlumberger implemented the Routine Inspection of Tools and Equipment (RITE.Net) system. It administers and documents preventative maintenance and repair handling, engineering modifications, recording and analysis of equipment failure, and recording and reporting asset location and history. Functionalities include:
Creating records related to maintenance in the database.
Generating various reports related to equipment readiness before a job, equipment modification, and more.
Monitoring individual maintenance schedules.
Registering parts used for maintenance and repair.
Registering maintenance personnel.
Registering equipment failures.
Registering retired tools and equipment.
Initially the RITE.Net system was created and implemented for wireline operations. Since then, new functionalities to address other operational challenges have been added. The latest system release is suitable for a wide range of equipment, applicable for different business segments, and is an essential system in segment service cycles.
RITE.Net system provides valuable failure-preventive information
New technologies take years to get “tuned” and “polished” before the final release. Often, this process requires changes in design, components, materials, which has a direct effect on equipment reliability. The RITE.Net application provides information essential to improving the reliability of conventional and new technology, downhole tools, and surface equipment. Based on data from RITE.Net, engineers can define the failure mode and identify the root causes of problems, significantly reducing probability of reoccurrence.
RITE.Net system improves tool reliability through condition-based maintenance
Because tool components are often unique, it’s virtually impossible to create one universal maintenance schedule that will cover the tool and all of its components. The mechanical components of downhole tools are very different from the electrical components and must undergo different maintenance events. Even identical components working under different pressures, temperatures, and formation fluid conditions will have different maintenance schedules.
Maintenance events triggers for specific tools are defined by design engineers. They also depend widely on the downhole conditions. Individual maintenance schedules for tools and components undergo an approval process before they can be used in the RITE.Net system.
If a maintenance event is required, the RITE.Net system will notify the user and request the assignment of a responsible person for maintenance or repair. Upon completion of maintenance or repair, if data is incomplete, the technical and operational status will remain unchanged and will be displayed as “maintenance required” until the missing information is recorded in RITE.Net. This function ensures consistency and reliability of stored information for all created reports – from trademark tools to purchased equipment.
Users “see” every asset from anywhere at any time
Access to RITE.Net information is essential for job planning. With system and Internet access, users can monitor the status of equipment, maintenance personnel, all repairs and maintenance events, design modifications, certification status, and more throughout the life cycle of the equipment. This enables better quality control in the most relevant segments – wireline, coiled tubing service, artificial lift, and well testing – from nearly anywhere in the world. The system also has the ability to store different reference documents and instructions, enabling any user to download files remotely.
Unique serial number ensures proper tool tracking
There are currently tens of thousands of assets registered in the database of the RITE.Net system. Using that many tools in day-to-day operations without a systematic approach for status monitoring and maintenance can be difficult. Sufficient control, preparation and planning can eliminate most job complications. RITE.Net provides full control of conditions and physical location of registered equipment. By giving each tool a unique serial number, it’s possible to promptly evaluate technical, operational, and location statuses for individual tools. Furthermore, the system works in the way that after calculating equipment status, the results are displayed in color code without a need to scroll over additional “windows” (Fig. 3).
RITE.Net implementation helps Schlumberger accomplish major achievements
After Schlumberger implemented the RITE.Net system, it realized significant benefits:
The system helped improve tool reliability through full control of registered RITE.Net assets and timely maintenance.
It addressed client expectations by improving the accuracy and flexibility of equipment planning.
It helped prevent mistakes while choosing parts required for maintenance and repair by registering all equipment modifications and parts.
The system improved readiness control of legacy and trademark tools, as well as purchased equipment, with traceable, unique serial numbers.
It helped designers and sustaining engineers enhance equipment improvement by providing instant access to equipment utilization history, types of failures vs. conditions of use, etc.
RITE.Net application helped reduce NPT 50 percent in one year. Schlumberger is continually looking for ways to improve business efficiency, improve equipment reliability, reduce risk of accidents and minimize nonproductive time (NPT) to deliver highest service quality in the industry. Amongst other achievements, the RITE.Net system helped reduce NPT in 2010 by almost 50 percent versus 2009 (Fig. 2). RITE.Net holds an important and increasing role as an equipment readiness and reliability control tool.