NOV Drilling Simulator

Presented by Tore Berg

Company 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

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 in Kristiansand.

Stena Forth

Rig Solutions Innovation

EVOLUTION OF DRILLING TECHNOLOGY
1930s-1970s 1970s-Today Today - Future

Mechanical Independent Components Manual Operations

AC Power System Integration Automation

Total Integration Remote control Virtual Vision

The goal remains unchanged but the technology has evolved.

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.

DHS Topology
Simulator Room
4 x Projectors KVM Extender Signals

Instructor Terminal

Operator Chair A

Operator Chair B Dome Display

Chair Controller A

Chair Controller B

UTM

HMI Server A MACH. PLCs SIM IPCs Drilling Data Server

Drilling Control Network

HMI Server B

High Speed Network SCADA Network Main Simulator Server

CCTV Render Servers

4 x Render Servers

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 detailed information. 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 and physics. To be able to move the model based on an input signal from the simulation controller we use a technic called key framing.

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.

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.

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 .dll files 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.

Development of Simulation code

How do we develop a simulation?

The sketch contains a electrical controlled valve and 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.

Development of Simulation code

Machine Controller
I/O Output Recv. Area

Simulation Controller
Signal HIL Mech HIL

3D Viewer

Mach. Sim and Sensor Sim

3D Animation

I/O Input

Send Area

Signal HIL

Sensor Output

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 actual machine. 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.

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

Key Performance Indicator

Overview of different use and advantages (KPIs)
Simulator Functions
General Operator training Training on a dedicated process

NOV KPI
Business (course, seminars)

Customer KPI
Trained personnel Increase system knowledge Safe operation Effective operation Risk reduction Increase system knowledge

HIL Testing

Business QA - software / system Product Improvements Reduced commission time / Cost Product development Integration verification Product development Increase system knowledge

Improve Products QA on the system Reduced commission time / Cost

Software development Process optimization

Effective operation Increase system knowledge Increase revenue

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

Questions?