Corrosion Control

A Lighter Heart for a Heavy Lifter

NOV designed and built a durable, energy-efficient fiberglass ballast system, providing lifetime protection from seawater corrosion.

Corrosion Control

A Lighter Heart for a Heavy Lifter

Saltwater corrosion is the silent enemy of every seagoing vessel. Average ocean salinity is 3.5 percent, producing metal-eating corrosion rates as high as 2.5 inches/60 millimeters per year. Salt exposure is unavoidable: it flows through ballast pipes, splashes external surfaces and fills the air.

Pioneering Spirit was designed to thrive in ruthless ocean environments. This one-of-a-kind vessel performs single-lift installation and removal of large offshore oil and gas platforms, along with installation of oil and gas pipelines. A series of horizontal lifting beams can install platform topsides weighing 48,000 tons/43,545 tonnes all in one piece and remove 25,000-ton/22,680 tonne rig jackets in a single lift.

Measuring 1,253 feet/382 meters long and 407 feet/124 meters wide, Pioneering Spirit is almost the size of a floating Empire State Building. At its deepest draft it reaches a world-record displacement of one million tons of seawater, making it the heaviest floating object on Earth.

With measurements like these, pulling into a dry dock for repairs isn’t a practical option. The challenge was to build Pioneering Spirit with lighter materials that stopped salt corrosion before it could start.

Allseas commissioned Fiber Glass Systems to build a maintenance-free ballast system to protect their $2.9 billion/€2.6 billion investment. After intensive review of design specifications, the Bondstrand 2000M pipe series was selected for its corrosion resistance, toughness and temperature performance. With a projected lifespan of five decades or more, the ballast system will last for the life of the vessel and beyond.

Using detailed pre-design analysis, NOV Fiber Glass Systems produced almost five miles of custom fiberglass pipe of various diameters, along with 11,000 fittings. "Just-in-Time" technology delivered materials to the building site right before installation. This approach prevented exposure damage while the pipe spools were in the shipyard, freeing up precious yard space and eliminating warehouse costs.

The end result was a tough, maintenance-free ballast system that serves as the "heart" of this massive vessel. Resolving the threat of corrosion eliminated the need for periodic inspections of bulkhead penetrations. Time and labor costs were reduced, preventing cumbersome, expensive maintenance and schedule delays.

With a projected lifespan of five decades or more, the ballast system will last for the life of the vessel and beyond.

Pioneering Spirit could not have been built at its current size without the weight savings and smooth fluid flow benefits of fiberglass pipe. For example, a single foot of the 28-inch fiberglass pipe supplied for the ballast system weighs 240 pounds/109 kilograms, versus 480 pounds/218 kilograms for the same length of carbon steel pipe. Multiplied throughout the ballast system, this trimmed almost 1.42 million pounds/645 metric tonnes. Larger-bore carbon steel pipes would have been required for the same throughput of water, so Pioneering Spirit would have needed 48-inch steel pipe, rather than 40-inch fiberglass pipe.

Almost five miles of fiberglass pipe (green) was used to construct the ballast system for Pioneering Spirit. (Allseas)

A steel pipe ballast system would have experienced seawater corrosion almost immediately, requiring costly repairs. Pipe replacement has an estimated labor cost of $500/€443 per foot, not including materials and downtime. Selecting the Bondstrand 2000M pipe potentially saved $50/€44 million in labor cost alone to replace corroded ballast pipe.

Fiberglass is also a kinder choice for the environment. It eliminates the waste and disposal of replacing steel pipe, saving up to 80 percent of the energy required to produce new steel pipe. The smoother inner surfaces require less pumping energy, providing up to 90 percent of energy savings during a 20-year life cycle.

The corrosion-free ballast system forms the strong, pumping heart of the Pioneering Spirit. With a life expectancy of more than 50 years, this heart will definitely go on.

BOP Availability

Identifying Failure Before it Happens

NOV’s data platform, Max™, enables large-scale data management and predictive analytics.

BOP Availability

Identifying Failure Before it Happens

When a critical rig component is about to fail, rig personnel may have only hours to act before drilling comes to a halt. Unfortunately, the warning signs of failure are often fragmented and buried in sensor data without an easy way to foresee imminent issues.

Imagine knowing which changeable components are at high risk of failure with 14 days of lead time to make decisions about mitigation. End-of-well maintenance is no longer a mystery: it becomes targeted, efficient and proactive. Having this predictive capability isn’t science fiction – it’s proven problem-solving made possible by Max™.

Max is NOV’s industrial data platform and associated services that enable the large-scale collection, aggregation, accessibility and analytics of real-time equipment data. Max handles all data from a variety of sources including land rigs, offshore rigs, service equipment and manufacturing facilities.

Rig uptime is valuable, and it takes the right information to run operations with confidence. Through modern predictive analytics powered by an integrated data platform, we can maintain awareness of component health and provide the tools needed to detect degradation of components before it causes downtime.

Because NOV builds your tools and services your equipment, we understand the value in what the data is saying. Max allows us to analyze the sensor data and answer complex questions about equipment health and performance.

NOV's latest innovative breakthrough is the development of an end-to-end predictive solution to foresee operational failures in critical components of subsea blowout preventers (BOPs), with a prediction horizon of 14 days. This solution is the result of a team of engineers, data scientists and subsea experts analyzing more than 14 years of historical data and maintenance logs paired with 60 years of design and manufacturing experience.

BOPs are just the beginning. Early identification of failure modes will be made available to customers as part of RIGSENTRY™, NOV’s family of condition monitoring systems and services, to enable condition-based predictive maintenance of all rig equipment.

Because NOV builds your tools and services your equipment, we understand the value in what the data is saying.

NOV's investments in technology and expertise are part of an overall objective to develop smarter products and give our customers greater visibility into the health and performance of their equipment. Through these resources we can begin to identify anomalies and failure patterns across all product lines, providing you with the right information at the right time.

Optimization

A Big Step to the Rig of the Future

The NOVOS™ operating system gives you the control to oversee well construction processes without demanding constant attention.

Optimization

A Big Step to the Rig of the Future

Today's drilling environment demands faster, safer and more cost-effective drilling. Because operators require optimized and data-driven well creation, drilling contractors must seek new ways to keep their rigs competitive.

NOVOS™ is a Process Automation Platform that manages rig equipment to execute slips-to-slips drilling, much as the driller does today. The driller oversees the process and can easily take control when needed. Using an imported well program that describes the desired drilling parameter ranges, NOVOS performs planned operations unless human input is required or desired depth is reached. Process automation allows contractors to meet new operator requests – a big step toward the rig of the future.

To enhance overall well savings, operators use third-party optimization services for closing the overall drilling control loop with measured or modeled downhole data. Third parties are normally arranged by operators, so drilling contractors must find ways to safely and effectively manage many optimization services used on the rig. Third parties are often experts in downhole dynamics with little surface systems knowledge, potentially leaving drilling contractors in the unfavorable situation of giving control novices access to move equipment.

NOVOS enhances new and existing NOV control systems with safe, repeatable integration of optimization services. By limiting the knowledge transfer required for safe interaction, NOVOS provides a common interface to NOV’s land and offshore drilling systems. With predetermined limits and control functions, it allows drilling contractors to quickly integrate third parties with minimal risk to personnel and equipment.

On a single well with two 12-hour shifts, a number of contributors – drillers, assistant drillers, tool pushers, company men – can affect drilling. Different contributors make it harder to achieve drilling consistency and repeatability between shifts, making consistency between wells nearly impossible. Relying on the skill and experience of individual drillers makes the process prone to human error. Data from rig control networks shows that drillers can be highly inconsistent in the timing, depth, and speed at which a drill bit engages formations. Inconsistencies in tagging bottom and poor off-bottom parameter control can increase downhole vibration and drilling dysfunction.

NOVOS provides drillers of different skill levels to operate at their best.

NOVOS manages the drilling process with consistency and repeatability that human drillers simply cannot match. Downhole and surface tool life is greatly increased when this platform consistently carries out a drilling process designed to mitigate vibration and tool damage, creating substantial value for both contractors and operators. Once the most efficient drilling process is defined, it is easy to configure within NOVOS. This results in zero loss of knowledge transfer because repetitive tasks are handled automatically, allowing the driller to act as the process manager.

Applying automation to rig systems can be challenging because the potential risks and expense of adding equipment, maintaining drawings and training personnel can undermine its value. In existing rig systems, wholesale changes to the controls are a non-starter after the investment, developed experience and trust in the current system.

NOVOS is a Process Automation Platform that manages rig equipment to execute slips-to-slips drilling, much as the driller does today.

Instead of overhauling the rig's control system, NOVOS extends the capabilities of the NOV system already installed on the rig. The original control system remains functional, and the driller can engage automation or control tools through the original system, leaving existing safety mechanisms and interlocks intact. A small hardware footprint minimizes installation complexity and enables NOVOS to be installed across a rig fleet easily and quickly. NOVOS can also manage equipment suites with a wide range of highly automated and more manual equipment functions.

The NOVOS platform is propelling the oil and gas industry into the future of automation to allow drilling contractors to be more competitive. As this capability unfolds, process automation will enable hands-free, consistent well manufacturing.

A Lighter Heart for a Heavy Lifter

Corrosion Control

Saltwater corrosion is the silent enemy of every seagoing vessel. Average ocean salinity is 3.5 percent, producing metal-eating corrosion rates as high as 2.5 inches/60 millimeters per year. Salt exposure is unavoidable: it flows through ballast pipes, splashes external surfaces and fills the air.

Pioneering Spirit was designed to thrive in ruthless ocean environments. This one-of-a-kind vessel performs single-lift installation and removal of large offshore oil and gas platforms, along with installation of oil and gas pipelines. A series of horizontal lifting beams can install platform topsides weighing 48,000 tons/43,545 tonnes all in one piece and remove 25,000-ton/22,680 tonne rig jackets in a single lift.

Measuring 1,253 feet/382 meters long and 407 feet/124 meters wide, Pioneering Spirit is almost the size of a floating Empire State Building. At its deepest draft it reaches a world-record displacement of one million tons of seawater, making it the heaviest floating object on Earth.

With measurements like these, pulling into a dry dock for repairs isn’t a practical option. The challenge was to build Pioneering Spirit with lighter materials that stopped salt corrosion before it could start.

Allseas commissioned Fiber Glass Systems to build a maintenance-free ballast system to protect their $2.9 billion/€2.6 billion investment. After intensive review of design specifications, the Bondstrand 2000M pipe series was selected for its corrosion resistance, toughness and temperature performance. With a projected lifespan of five decades or more, the ballast system will last for the life of the vessel and beyond.

Using detailed pre-design analysis, NOV Fiber Glass Systems produced almost five miles of custom fiberglass pipe of various diameters, along with 11,000 fittings. "Just-in-Time" technology delivered materials to the building site right before installation. This approach prevented exposure damage while the pipe spools were in the shipyard, freeing up precious yard space and eliminating warehouse costs.

The end result was a tough, maintenance-free ballast system that serves as the "heart" of this massive vessel. Resolving the threat of corrosion eliminated the need for periodic inspections of bulkhead penetrations. Time and labor costs were reduced, preventing cumbersome, expensive maintenance and schedule delays.

With a projected lifespan of five decades or more, the ballast system will last for the life of the vessel and beyond.

Pioneering Spirit could not have been built at its current size without the weight savings and smooth fluid flow benefits of fiberglass pipe. For example, a single foot of the 28-inch fiberglass pipe supplied for the ballast system weighs 240 pounds/109 kilograms, versus 480 pounds/218 kilograms for the same length of carbon steel pipe. Multiplied throughout the ballast system, this trimmed almost 1.42 million pounds/645 metric tonnes. Larger-bore carbon steel pipes would have been required for the same throughput of water, so Pioneering Spirit would have needed 48-inch steel pipe, rather than 40-inch fiberglass pipe.

A steel pipe ballast system would have experienced seawater corrosion almost immediately, requiring costly repairs. Pipe replacement has an estimated labor cost of $500/€443 per foot, not including materials and downtime. Selecting the Bondstrand 2000M pipe potentially saved $50/€44 million in labor cost alone to replace corroded ballast pipe.

Fiberglass is also a kinder choice for the environment. It eliminates the waste and disposal of replacing steel pipe, saving up to 80 percent of the energy required to produce new steel pipe. The smoother inner surfaces require less pumping energy, providing up to 90 percent of energy savings during a 20-year life cycle.

The corrosion-free ballast system forms the strong, pumping heart of the Pioneering Spirit. With a life expectancy of more than 50 years, this heart will definitely go on.

Identifying Failure Before it Happens

BOP Availability

When a critical rig component is about to fail, rig personnel may have only hours to act before drilling comes to a halt. Unfortunately, the warning signs of failure are often fragmented and buried in sensor data without an easy way to foresee imminent issues.

Imagine knowing which changeable components are at high risk of failure with 14 days of lead time to make decisions about mitigation. End-of-well maintenance is no longer a mystery: it becomes targeted, efficient and proactive. Having this predictive capability isn’t science fiction – it’s proven problem-solving made possible by Max™.

Max is NOV’s industrial data platform and associated services that enable the large-scale collection, aggregation, accessibility and analytics of real-time equipment data. Max handles all data from a variety of sources including land rigs, offshore rigs, service equipment and manufacturing facilities.

Rig uptime is valuable, and it takes the right information to run operations with confidence. Through modern predictive analytics powered by an integrated data platform, we can maintain awareness of component health and provide the tools needed to detect degradation of components before it causes downtime.

Because NOV builds your tools and services your equipment, we understand the value in what the data is saying. Max allows us to analyze the sensor data and answer complex questions about equipment health and performance.

NOV's latest innovative breakthrough is the development of an end-to-end predictive solution to foresee operational failures in critical components of subsea blowout preventers (BOPs), with a prediction horizon of 14 days. This solution is the result of a team of engineers, data scientists and subsea experts analyzing more than 14 years of historical data and maintenance logs paired with 60 years of design and manufacturing experience.

BOPs are just the beginning. Early identification of failure modes will be made available to customers as part of RIGSENTRY™, NOV’s family of condition monitoring systems and services, to enable condition-based predictive maintenance of all rig equipment.

Because NOV builds your tools and services your equipment, we understand the value in what the data is saying.

NOV's investments in technology and expertise are part of an overall objective to develop smarter products and give our customers greater visibility into the health and performance of their equipment. Through these resources we can begin to identify anomalies and failure patterns across all product lines, providing you with the right information at the right time.

A Big Step to the Rig of the Future

Optimization

Today's drilling environment demands faster, safer and more cost-effective drilling. Because operators require optimized and data-driven well creation, drilling contractors must seek new ways to keep their rigs competitive.

NOVOS™ is a Process Automation Platform that manages rig equipment to execute slips-to-slips drilling, much as the driller does today. The driller oversees the process and can easily take control when needed. Using an imported well program that describes the desired drilling parameter ranges, NOVOS performs planned operations unless human input is required or desired depth is reached. Process automation allows contractors to meet new operator requests – a big step toward the rig of the future.

To enhance overall well savings, operators use third-party optimization services for closing the overall drilling control loop with measured or modeled downhole data. Third parties are normally arranged by operators, so drilling contractors must find ways to safely and effectively manage many optimization services used on the rig. Third parties are often experts in downhole dynamics with little surface systems knowledge, potentially leaving drilling contractors in the unfavorable situation of giving control novices access to move equipment.

NOVOS enhances new and existing NOV control systems with safe, repeatable integration of optimization services. By limiting the knowledge transfer required for safe interaction, NOVOS provides a common interface to NOV’s land and offshore drilling systems. With predetermined limits and control functions, it allows drilling contractors to quickly integrate third parties with minimal risk to personnel and equipment.

On a single well with two 12-hour shifts, a number of contributors – drillers, assistant drillers, tool pushers, company men – can affect drilling. Different contributors make it harder to achieve drilling consistency and repeatability between shifts, making consistency between wells nearly impossible. Relying on the skill and experience of individual drillers makes the process prone to human error. Data from rig control networks shows that drillers can be highly inconsistent in the timing, depth, and speed at which a drill bit engages formations. Inconsistencies in tagging bottom and poor off-bottom parameter control can increase downhole vibration and drilling dysfunction.

NOVOS provides drillers of different skill levels to operate at their best.

NOVOS manages the drilling process with consistency and repeatability that human drillers simply cannot match. Downhole and surface tool life is greatly increased when this platform consistently carries out a drilling process designed to mitigate vibration and tool damage, creating substantial value for both contractors and operators. Once the most efficient drilling process is defined, it is easy to configure within NOVOS. This results in zero loss of knowledge transfer because repetitive tasks are handled automatically, allowing the driller to act as the process manager.

Applying automation to rig systems can be challenging because the potential risks and expense of adding equipment, maintaining drawings and training personnel can undermine its value. In existing rig systems, wholesale changes to the controls are a non-starter after the investment, developed experience and trust in the current system.

NOVOS is a Process Automation Platform that manages rig equipment to execute slips-to-slips drilling, much as the driller does today.

Instead of overhauling the rig’s control system, NOVOS extends the capabilities of the NOV system already installed on the rig. The original control system remains functional, and the driller can engage automation or control tools through the original system, leaving existing safety mechanisms and interlocks intact. A small hardware footprint minimizes installation complexity and enables NOVOS to be installed across a rig fleet easily and quickly. NOVOS can also manage equipment suites with a wide range of highly automated and more manual equipment functions.

The NOVOS platform is propelling the oil and gas industry into the future of automation to allow drilling contractors to be more competitive. As this capability unfolds, process automation will enable hands-free, consistent well manufacturing.

About NOV

Every day, the oil and gas industry’s best minds put more than 150 years of experience to work to help our customers achieve lasting success. We have the people, capabilities and vision to serve the needs of a challenging and evolving industry. One the world can’t live without.

Throughout every region in the world, across every area of drilling and production, our family of companies provides the technical expertise, advanced equipment and operational support necessary for success – now and in the future.

News

Events

Aug
29
ONS

Stavanger, Norway
Aug 29, 2016 — Sep 01, 2016


Sep
19
FPSO World Congress

Singapore
September 19—22, 2016

Sep
26
SPE Annual Technical Conference & Exhibition (ATCE)

Dubai, UAE
September 26—28, 2016


Oct
18
Permian Basin International Oil Show (PBIOS)

Odessa, Texas
October 18—20, 2016

Nov
7
ADIPEC

Abu Dhabi, UAE
November 7—10, 2016