SPE 86600
Improved Safety of Rig Automation with Remote Monitoring and Diagnostics
Bryce Levett, SPE / Varco International
Copyright 2004, Society of Petroleum Engineers Inc.
This paper was prepared for presentation at The Seventh SPE International Conference on
Health, Safety, and Environment in Oil and Gas Exploration and Production held in Calgary,
Alberta, Canada, 29–31 March 2004.
This paper was selected for presentation by an SPE Program Committee following review of
information contained in a proposal submitted by the author(s). Contents of the paper, as
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to
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Abstract
Rig automation has focused on improving safety with
equipment designed to reduce manpower/human interaction
and assume repetitive tasks and operations. As more parts of a
drilling rig become automated, there has been a change in how
rig personnel interact with equipment. A system of remote
monitoring, diagnostics and technical support has been
developed to make this interaction more seamless and expand
the focus of rig automation. Case studies are presented in this
paper of actual field conditions where the remote monitoring
system eliminated hazardous operations, discovered
operational ‘bad habits’, and identified areas requiring
additional training. Use of the remote diagnostic system
prevented the need for physical contact between human and
machine in order to solve problems. Documented field
incidents have shown benefits of increased safety in many
areas when using remote monitoring and management
compared to operations without.
Introduction
Rig automation (as pertains to discussion in this paper) is
defined as equipment designed to automate repetitive tasks,
reduce human intervention and error. These repetitive tasks
are associated with pipe handling operations on the drill floor.
Operations can include racking pipe in the derrick, bringing
drill pipe to well center, make-up or breakout of connections
and pick-up or lay-down of pipe from the derrick to a
conveyer.
One of the key drivers for the development of this rig
automation has been improved safety. The reduction of
human presence and physical interaction by humans has been
a major goal behind the design of automated equipment. The
equipment has evolved into complex robotic designs.
Sophisticated sensor technology is employed to determine
position relative to other equipment. The optimal
path/movement necessary to complete an operation is
determined with collision avoidance as a prime factor.
Joysticks and touch screens are utilized as control interfaces,
requiring only one person to operate the equipment.
The sophistication of the control technology has simplified
the interaction of the operator and the equipment, but has also
added a degree of complexity to troubleshooting when
something does not function quite right. Specialized
personnel from the equipment manufacturing companies are
sometimes dispatched to the rig to assist in troubleshooting.
Data about a failed operation is often sparse and personnel
have to rely on verbal data, which can be in error.
Troubleshooting techniques may require the use of manual
overrides to automated control sequences. Equipment can be
fully functioned in this mode, however the collision avoidance
systems are disabled or bypassed thereby increasing the risk of
operation. Even during normal (non-troubleshooting)
operations, manual override mode is available and if used can
increase the risk of operation.
The system discussed in this paper was developed and
designed to remotely monitor drilling equipment. Using
remote diagnostics, the system helps eliminate the need to
dispatch specialized personnel (both onboard rig personnel
and onshore specialists) and reduces the use of manual
override during both operation and troubleshooting.
System Description
The remote monitoring and management system connects
automated rigs to a service center (manned 24 hours a day, 7
days a week) utilizing Internet technology. First data is
collected from various equipment controllers and stored
locally on the rig in a data logger (similar in capabilities to
those in use on modern-day air transportation). The loss of
data due to communication link failure is prevented by
localized data storage. Figure 1 shows how equipment
controllers, the data logger and Human Machine Interfaces
(HMI) are linked together on board the rig in a local network.
Data from this network is routed to a Virtual Private Network
(VPN) device on the rig that encrypts the information before
passing it along to the rig’s routing and satellite transmission
system. The data logger collects data from each individual
controller. Data tags are assigned for each system based upon
what information (pressure, torque, temperature, position,
load, etc.) is required for diagnosis of operational problems.
The data logger is also equipped with controller programming
software to allow for reprogramming remotely. Figure 2
shows how both the data logger and local network are linked
to the remote monitoring system. The data logger transmits
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encrypted data packets through the rig’s existing
communications system using a VPN device. Information is
“piggy backed” onto the existing communications link and
transmitted to the client’s network. The encrypted data is then
passed from the client’s network via the Internet to a
centralized service center. The information packets are
unencrypted using another VPN device located at the service
center and used by personnel manning the center. Subject
Matter Experts (SME) can view the unencrypted information
by linking to a site provided by the service center. Linking
can take place either through the center’s company intranet or
externally via the Internet utilizing remote desktop
applications. Fast, efficient and low cost communications are
provided by this method in a non-intrusive, easily configured
and installed package. Only real-time alarms and system
parameter changes needed to identify problems, failures and
status changes in equipment are transmitted. All other data is
logged and stored locally. The remote monitoring system
sends encrypted data packets in very low bandwidth bursts
(less than 50Kbs). The additional load on rig communications
systems is minimal.2
Case Histories
The following case histories for the remote monitoring and
management system are classified according to the primary
safety benefit derived. The categories are Interaction
Reduction, Hazard Elimination and Operational Issues.
Interaction Reduction Case Histories. In the following case
histories, the primary benefit derived from the remote
monitoring system was a reduction in the amount of physical
interaction required by personnel to troubleshoot and fix the
problem. In all cases, dispatch of service personnel from
shore to the rig was avoided by using remote diagnostics.
Pick-up/Lay-down System. A Pick-up/Lay-down System
(PLS) is designed to hoist tubulars from a horizontal pipe
transfer conveyor located at the V-door to vertical position
inside the derrick and reverse. In this instance the PLS was
hoisting pipe into the derrick vertically, but would not lower
or allow setdown of the pipe while in the vertical position.
Impact. The rig was unable to use the PLS in automated
mode. Operation required the use of manual override in order
to lower or setdown the pipe. This disabled the safety
interlock system and resulted in very slow functioning due to
intentional speed controls associated with manual override
mode. All signals from sensors and encoders were bypassed
in manual override mode, leaving the operation vulnerable to
potential collision.
Approach. Using the remote monitoring system,
historical data for the PLS was checked and trended to reveal
that a sensor, which was part of a thread compensation
cylinder sub-assembly, was not changing states. This was an
indication of some sort of physical impediment. Sensor
failure was eliminated through internal diagnostic checks as
well as the trending data, which revealed a signal was present.
The rig crew was instructed to visually check the sensor and
discovered that a bracket holding the sensor was bent. A
repair was affected and the PLS was again operational. Total
time to check, trend data and pinpoint the sensor malfunction
was 5 minutes.2
Comparison. In order to determine root cause without
remote monitoring, the rig would have needed to operate the
PLS system while checking inputs and display counts in the
control logic as well as checking power supply to sensors.
Observation may have been required of the PLS in override
mode, which disables safety interlocks between the PLS and
other equipment. Operation in this mode would have required
other equipment operations to be suspended. Depending upon
the level of expertise onboard, service personnel may have
been required from shore. Physical inspection of the
equipment might have been carried out on areas not even
related to the problem. Unnecessary contact between
personnel and equipment would have occurred.
Benefit. Remote troubleshooting was carried out without
requiring operation of the PLS in manual override mode of
other operations, creating a safer environment. Physical
contact between equipment and personnel was limited to only
what was necessary to inspect and effect repair. Expertise was
involved using remote diagnostics rather than dispatch of
service personnel.
Pipe Handling Machine. A Pipe Handling Machine
(PHM) is designed to automatically trip stands of drill pipe
and collars, break them out or make them up and rack them
into the derrick for the next trip. In this instance, the PHM
was not lowering automatically to the proper position.2
Impact. The rig could not function the PHM without using
manual override mode. Operation in this mode was both slow
and dangerous due to disabling of the safety interlock system,
and collision with the drill floor was possible.
Approach. Historical data and present data of the PHM
function were queried from the data logger, trended and
displayed to reveal that the PHM had taken a false index. The
PHM would not lower any further because of interlock
programming. Identification of the root cause as a false index
allowed the rig to safely use interlock override to re-index the
tool and continue operations.2
Comparison. Without remote monitoring, the rig would
have investigated both control issues as well as mechanical
malfunction. This would have required physical interaction
with the equipment. Depending upon the level of expertise
onboard, service personnel may have been required from shore
to resolve the problem.
Benefit. A complete investigation of the control system
using historical trend data remotely accessed by expert
personnel negated having to utilize rig personnel. The need
for troubleshooting mechanical malfunctions was eliminated
which prevented sending rig personnel to physically interact
with the equipment. The procedure to correct the problem
mitigated risk and uncertainty and reduced human interaction
to a minimum.
Hazard Elimination Case Histories. This series of case
histories examines incidents diagnosed with the remote
monitoring system that otherwise would have resulted in
indiscernible root causes. Hazards are defined here as both
undiagnosed situations (potential for repeat) and unnecessary
risk to solve or correct a situation.2
SPE 86600
Fingerboard Latch. A Pipe Racking System (PRS) is
designed to move stands of drill pipe or casing in and out of
racks or fingerboards mounted in the derrick. Latches in the
fingerboards retain individual stands of pipe. After the PRS
had completed an operation to remove a stand of drill pipe
from the fingerboards, the next waiting stand of drill pipe fell
out of the fingerboards.
Impact. The unsecured pipe stand represented a serious
hazard in the derrick and on the drill floor. Potential existed
for injury or death to rig personnel from the falling stand.
Approach. Command signals involved in the racking
operation were trended using the remote monitoring system.
During an operation to grab and retract the stand of pipe, the
operator initiated a manual override command. This was done
to allow the lower jaw of the PRS to be opened and extended
in an attempt to get a better grip on the stand. After the lower
jaw was closed on the pipe stand, the operator left the PRS in
manual mode in order to slowly retract the stand. The
operator inadvertently pressed the fingerboard unlatch
command a second time when it was not required. Manual
override mode allowed the command and unlatched the next
fingerboard latch in the row. This left the next stand
unsecured. The operational error was identified within 15
minutes of the rig request using the command signal trends.
Operational training was conducted with rig personnel to
avoid this scenario when conducting manual override
sequences.
Comparison. Without remote monitoring, the rig would
have conducted a manual inspection of the fingerboards for
malfunction as well as the fingerboard control system. The
resulting troubleshooting would not have revealed any
problems with the system, however the root cause would have
remained unidentified, possibly to occur later if manual
overrides were initiated during racking.
Benefit. Signal trending allowed the exact operation
sequence to be easily illustrated and arranged chronologically.
The exact cause of the unlatch was clearly identified. Physical
interfacing with the equipment was avoided. It was not
necessary to operation the PRS in order to attempt a repeat of
the unlatch. An operational error was identified and corrected
instead of remaining unidentified.
Traveling Block Collision. An automated hoisting system
relies on sensing the Traveling Block vertical position to avoid
collision during raising and lowering operations. A controller
was reset by rig personnel causing the perceived block height
for the hoisting system to change from 181 feet to 81 feet with
respect to the drill floor. Subsequent hoisting of the Traveling
Block caused a collision between the Block and Derrick
Crown.
Impact. In addition to collision between the Traveling
Block and either the Derrick Crown or Floor, any equipment
or parts involved in a particular hoist could have fallen. This
could have caused major mechanical damage to other
equipment and injury or death to rig personnel.2
Approach. Using the remote monitoring system, the point
at which the controller was reset was clearly identified. After
the damaged Traveling Block was repaired, the hoisting
system was re-calibrated and operations resumed.
3
Comparison. Without remote monitoring, the root cause of
this incident may never have been revealed. Although the
hoisting system would have been re-calibrated, operations
could have continued with concern of the incident randomly
repeating and other unresolved issues.
Benefit. Accurate identification of the root cause allowed
for repairs to be carried out and the system re-calibrated
without initiating additional investigation into other areas.
Unnecessary physical contact with the hoisting system was
avoided. Operation of the hoisting system could be resumed
without concern of a randomly repeated incident.
Operational Issue Case Histories. This series of case
histories deals with incidents where historical data gathered
and trended by the remote monitoring system helped to
identify issues concerning proper operation of rig automation
equipment. Operational patterns can be obtained from
historically trended data that distinguish one individual from
another in the course of a piece of automation equipment’s
utilization. The pattern or fingerprint can help identify areas
of additional training in order to ensure proper operation.2
Automated Iron Roughneck. An Automated Iron
Roughneck is designed to spin-in, make-up, breakout and
spinout connections at well center. During this instance
(while in automatic mode), the Automated Iron Roughneck
was traveling to the pipe at well center but not stopping in the
proper vertical position.2
Impact. In order to overcome the positional error, the rig
had to place the Automated Iron Roughneck in manual mode.
This mode (for intentional safety reasons) is slower than
automatic mode. The entire operation took longer to complete
because of this.2
Approach. Using remote monitoring, operational trends
were accessed and plotted to reveal an improper sequence
used to teach the Automated Iron Roughneck where to stop
vertically after detecting the tooljoint position. The
Automated Iron Roughneck was re-taught properly by the rig
using the correct procedure. This allowed for operation in
automatic mode.
Comparison. Troubleshooting without remote monitoring
would have involved dispatching rig personnel to the
equipment to check sensors on the tool for correct adjustment
and verify signals. The improper teaching sequence would
have gone undetected and possibly repeated, causing the same
operational malfunction.
Benefit. By identifying the improper teaching sequence,
the rig did not have to continue slower operations in the
manual mode. Additionally the operator was relieved of
performing a manual repetitive task. Future improper teaching
sequences were eliminated.
PLS Excessive Overrides. A Pick-up/Lay-down System
(PLS) would not pick pipe up off the conveyor and bring it to
vertical in the derrick. Use of manual override was required in
order to operate the system.
Impact. The rig was unable to use the PLS in automatic
mode. Operation required the use of manual override in order
to lift the pipe off the conveyor. The system was very slow
while functioning in manual override mode (intentional by
4 SPE 86600

design) because safety interlocks were bypassed. All signals Acknowledgements

from sensors and encoders were bypassed, increasing the risk
of collision.
Approach. In this instance remote monitoring and trending
analysis of a Pick-up/Lay-down System (PLS) revealed
excessive overrides being performed. This was detected by
the remote monitoring service center without prompting by the
rig. The rig was contacted by remote monitoring service
personnel and queried about the overrides. Remote
monitoring service personnel were informed by rig personnel
that overrides were necessary because the PLS would not
allow pipe to be picked up off the conveyor and brought to
vertical. Analysis of trend data from both the PLS and
conveyor pinpointed a calibration issue with pipe length. The
system was set for hoisting longer lengths of pipe. Due to
safety interlocks, hoisting of a shorter length of pipe was not
allowed because of perceived collision between the bottom of
a long length pipe and the rig floor. The operator, in order to
bypass this interlock and bring the pipe to vertical, was issuing
override commands. The system was re-calibrated for the
shorter lengths of pipe and operations continued without the
need for manual override. Total duration for diagnosis took
30 minutes.2
The authors wish to thank the following Varco personnel for
their contributions: Silvestru Bondar, Gary Hervig, Tony
Hobbs, Clay Simmons, Duncan Sinclair and Matt Young.
References
1. Levett, B.A. and Suvans, L.P.: “Remote Monitoring and
Management: Maximizing the Safety and Efficiency of Rig
Automation,” AADE paper No. AADE-03-NTCE-45 presented
at the AADE 2003 National Technology Conference, Houston,
Texas, April 1 – 3.
2. Levett, B.A. and Suvans, L.P.: “Maximizing Rig Automation
Safety and Efficiency with Remote Monitoring and
Management” paper SPE 84169 presented at the 2003 SPE
Annual Technical Conference and Exhibition, Denver,
Colorado, October 5 – 8.
3. Disatell, J. and Knode, T.: “Mitigating Health, Safety, and
Environmental Risk with Remote Real-Time Technology,” Go
Gulf Magazine (May/June 2002).
SATELLITE DISH

Comparison. The rig may have never reported the need ROUTER

for conducting manual overrides during this operation.

Continued operations using manual override would have
increased risk of collision between the pipe being hoisted and
VPN
other equipment or the rig floor.
Benefit. The operational issue (excessive overrides) was
identified without relying on notification from the rig.
Detection and diagnosis took place without involving rig CONTROLLER HMI

personnel. The operational issue did not continue unresolved. CONTROLLER

Hazardous operation was eliminated.2 LOCAL NETWORK DATA LOGGER

Conclusions
Case histories of the remote monitoring system have shown CONTROLLER
CONTROLLER
HMI

that the overall safety of automated rig equipment operations

is improved in several ways. Root cause can be determined in Figure 1
situations where troubleshooting without the system might
never have revealed the origin (Incidents do not go RIG A RIG B
North Seas Africa
undiagnosed). It is no longer necessary to function the
equipment in an attempt to observe faults. This information is
SATELLITE RIG D
available historically and can be called up remotely, without RIG C Gulf of Mexico
Asia
interrupting operations. Troubleshooting procedures that
require personnel to come in contact with equipment can be
eliminated thus reducing the potential hazard of injury.
Expertise can be utilized without dispatch of personnel to the CLIENT
NETWORK
rig. “Reducing or eliminating the need for these individuals to
travel has several benefits. The most important benefit is that SUBJECT MATTER EXPERT SUBJECT MATTER EXPERT
it decreases exposure to the dangers of traveling to and from
the location.”3 Diagnostic accuracy reduces time, eliminates INTERNET
unnecessary troubleshooting procedures, and allows both
repair and operation to proceed with confidence.2
Elimination of potentially hazardous situations and reduction
VPN
of time and resources needed to solve issues equates to a safer,
more efficient work environment. The remote monitoring
CENTRALIZED SERVICE CENTER
system has proven to be an invaluable and essential
component for improving the safety of rig automation.
Figure 2