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
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
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.

UTM
Drilling Data Server
HMI Server A
Simulator Room
MACH.
PLCs HMI Server B
Main Simulator
Server
Chair
Controller A
Chair
Controller B
Drilling Control Network
High Speed Network
SCADA Network
KVM Extender Signals
Operator Chair A
4 x Projectors
CCTV Render
Servers
4 x Render
Servers
SIM
IPCs
Dome Display
Instructor
Terminal
Operator Chair B
DHS Topology
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
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

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
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)
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?