Berg-2011.pdf

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NOV Drilling Simulator

Presented by Tore Berg

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ompany Overview

National Oilwell Varco is a worldwide leader in the design, manufacture and sale

of equipment and components used in oil and gas drilling and production, the

provision of oilfield inspection and other services, and supply chain integration

services to the upstream oil and gas industry.

Our main buisness topic in Norway is design and producing of machines used for

drilling on offshore vessels. We are also designing and producing cranes for the

offshore and marine market.

Revenue for NOV Norway in 2010 was 3,5 billion USD

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Global Presence

National Oilwell Varco have 41000 employees worldwide and 3000 employees in

Norway. In Norway are we located in Kristiansand, Stavanger, Asker, Tnsberg,

Molde, Arendal and Trondheim. The head office in Norway is located inKristiansand.

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Stena Forth

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Rig Solutions

Innovation

EVOLUTION OF DRILLING TECHNOLOGY

Mechanical

Independent Components

Manual Operations

1970s-Today Today - Future

The goal remains unchanged but the technology has evolved.

1930s-1970s

AC Power

System Integration

Automation

Total Integration

Remote control

Virtual Vision

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Drilling HIL Simulator

What is NOV Drilling HIL Simulator?

The DHS is a drilling simulator that uses

the original machine and HMI software to

make the drilling operation into real life.

It is designed so that it is possible to make

fault and scenarios by manipulating with

sensors and processes.

The DHS can be used either for training or

for testing of software before, while or after

a rig have come in operation.

All the models in the simulator is imported

from the engineering tools.

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UTM

Drilling Data Server

HMI Server A

Simulator Room

MACH.

PLCsHMI Server B

Main SimulatorServer

Chair

Controller A

Chair

Controller B

Drilling Control Network

High Speed Network

SCADA Network

KVM Extender Signals

Operator Chair A

4 x Projectors

CCTV RenderServers 4 x RenderServers

SIM

IPCs

Dome Display

InstructorTerminal

Operator Chair B

DHS Topology

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Development of 3D models

How do we develop 3D models for use in the simulator?

NOV are using a 3D Cad software called Autodesk Inventor to do the mechanical

design of the machines. The engineering models contain very detailedinformation.

To be able to use this models in a real time simulator, we import them into

3D studio Max and reduce the complexity of the model. The reducing of the

models are more or less done automatically.

In 3D studio Max, we link the different assemblies, add textures, shadings andphysics.

To be able to move the model based on an input signal from the simulation

controller we use a technic called key framing.

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Development of 3D models

When the models is ready in 3D studio we export them with use of Ofusion. This

exporter will generate one file for the model and one for the Physics.

The 3D engine we are using is Ogre (Object-Oriented Graphics Rendering

Engine). This is a open source scene-oriented, flexible 3D engine written in C++.

The Physics engine we are using is Nvidia Physx.

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3D Code

The code for the 3D engine is built up in a plugin structure.

Some of the functions we have in the 3D engine as plugins are

Waves

Shadows

Time of day (Sunlight)

Down hole simulating

Communications

We use .xml files to enable the different plugins.

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Development of Simulation code

What tools are we using for making the simulation?

NOV use different tools when developing simulation code. We use Math

lab/simulink, Simulation X and PLC code. We generate Math lab/Simulink into .dllfiles that we are running on IPCs.

We can also combine this .dll with PLC code. In that way are we not so

independent of who is making the simulation and what tool they are using for

each model.

The simulation code is built up with clear interface points. Because of this

structure is it easy for other vendors to make their own simulation and integrate it

into this simulator. Especially when using a independent supplier of the HIL test

this is useful.

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Development of Simulation code

How do we develop a simulation?

The sketch contains a electrical controlled valveand a cylinder with position and pressure feedback.

This is a typical scenario that we are making

simulation for.

The next slide will show a signal flow chart for a

simulation like this.

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Development of Simulation codeMachine

Controller

I/O

Output

Simulation

Controller

Recv.

Area

Signal

HIL

Mech

HIL

Mach.

Sim and

Sensor

Sim

3D

Animation

I/O

Input

Send

Area

Sensor

Output

Signal

HIL

3D

Viewer

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HIL Simulation

What is the integrated HIL simulation in the DHS?

HIL (Hardware in Loop) is a intergrated tool that is a standard for all DHS.

This tool enables us to manipulate all sensors on the machines.

Verify the software for the drilling machines and all integrated systems.

For some machines/systems is it difficult to do this verification on the actualmachine. This tool allows us to do the test in a safe way.

We have developed some standard objects to do the sensor manipulating that

is explained in the next slide.

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HIL Simulation

DI/DO object is used for HIL simulation of digital I/O.

It is 3 functions in this object.

Force High, Force Low and Invert.

AI/AO object is used for HIL Simulation of analogue

I/O.

It is 5 functions in this object.Broken wire,Freeze, Manipulate, Expert and Slider.

The Expert object is used for extended HIL Simulation

of this data type

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Key Performance Indicator

Simulator Functions NOV KPI Customer KPI

General Operator training Business (course, seminars) Trained personnel

Increase system knowledge

Training on a dedicated process Safe operation

Effective operation

Risk reduction

Increase system knowledge

HIL Testing Business

QA - software / system

Product Improvements

Reduced commission time /

Cost

Improve Products

QA on the system

Reduced commission time /

Cost

Software development Product development

Integration verification

Process optimization Product development

Increase system knowledge

Effective operation

Increase system knowledge Increase revenue

Overview of different use and advantages (KPIs)

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Visions for next generation of DHS

Remote operations by use of real time cameras

Machine collision detection

Visualization of wells and drill string

Use the simulator to virtually drill wells

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Questions?