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Data-Driven Oil Fields 2017

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3 EPMAG.COM | DATA-DRIVEN OIL FIELDS | JANUARY 2017 benefits of about $2 million per year and has resulted in increased capability within the supply chain for fabricated assemblies. Many of GE's key manufacturing facilities now have wireless readers that detect when a part is within a defined area, helping to locate any asset's location within a factory. Anticipated annual cost savings associated with using a wireless reader on one site is estimated at $730,000. Digital manufacturing techniques GE Oil & Gas' recently inaugurated plant in Talamona, Italy, fol- lowing €10 million (US$10.7 million) of investment, is a digital center of excellence that embraces a number of new digital man- ufacturing techniques. The center houses, for example, the company's first completely automated line for the production of nozzles and a new additive manufacturing line using 3-D printing to produce end burners for gas turbine combustion chambers. The nozzle production line uses two anthropomorphic robots capable of employing 10 different technologies including electrical discharge machining, measurement and laser beam welding. This helps to produce components faster while adjusting the entire supply chain to focus on value creation. The additive manufacturing technology on site, also used in GE's aviation, medical and design businesses, offers increased speed and accuracy into component production. Having been used on GE's NovaLT16 gas turbine, it will now be moved into full production to leverage design enhancement capabilities, cycle time reduction and improved product quality. The new production lines are working and were scheduled to be fully operational by the start of 2017. Keeping rigs running Optimizing the production of the equipment is one thing, but supporting it throughout its lifespan is a crucial component for ongoing operations. In 2015 five of the top oil and gas companies in the world spent 55 times more money on assets than on other general expenses. Asset performance management (APM) solutions leverage sensors, connectivity, data and ana- lytics to improve the reliability and availability of assets and minimize the total cost of ownership. One of the most impactful GE digital technologies driving value in APM is a suite of software products connecting real-world assets to the digital world. This software was de- veloped on GE's operating system for the industrial internet, Predix, and optimizes data already generated by existing rigs. Currently, data collected from offshore platforms are used predominantly for anomaly detection and control, not for optimization and prediction. But these data can actually add the most value to the latter. APM also enables maintenance optimization through its capabilities in monitoring and an- alyzing performance data. Rather than performing reactive and ad hoc maintenance, companies are able to implement analytics-based, planned work management, therefore reducing downtime. Uptime is more valuable than ever, and APM helps operators ensure the viability and safety of their equipment in a truly revolutionary way. Automated processes The growth of digitization and advanced manufacturing tech- niques and their utilization are key differentiators for success in global business, and the oil and gas industry is well positioned to be at the forefront of this innovation. Key to this journey will continue to be an intentionally collaborative approach as operators, contractors and suppliers share best practices. These solutions are the future of the industry. GE Oil and Gas is going digital internally by using its own tools to optimize and drive leaner manufacturing, engineering, project man- agement and supply chain processes across the organization. Simultaneously it is investing in technological enhance- ments to continue driving the digital agenda and will continue to move forward through automat- ed processes to drive the future of manufacturing assembly lines. n References available. Jody Markopoulos is COO at GE Oil & Gas. To eliminate defects and improve efficiency, GE validates product designs using virtual reality tools to immerse engineers into near-full scale virtual assemblies to ensure parts and tools fit correctly. This is expected to result in up to $30 million of cost reductions in the company's Subsea Systems and Drilling division alone. (Image courtesy of GE Oil &Gas)

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