Use of intelligent monitoring and artificial intelligence for Smart Catwalk for Pipe Handling

New generation automated wireless-controlled Catwalk Pipe handling uses intelligent monitoring and artificial intelligence for the insights for operations and maintenance logs.

by Rina P
Pipe Handling Ltd

Many drilling equipment manufacturers has been using data logging for many years, but only portion of the data is really used to obtain insight on equipment health and convenice. Pipe handling limited has implemented new advancement in information analytics and machine learning technicalogy to provide to optimize pumping systems operation and maintenance, rather than use the conventional time-based care approach. This concept called “smart Catwalk system” is available as an option on the PHX-45 Catwalk Pipe handling system with many operational advantages and benefits.

Our Smart Catwalk system enable and enhance our offerings’ features and capabilities, especially remote condition monitoring, diagnostics and serviceability, while operators can realize savings in downtime and energy use.

The results in real time point to operational anomalies that can be investigated and mitigated or remedied before costly disruptions occur. And, with more proactive—even predictive—maintenance models, operators can extend component and system life cycles, lowering total the OPEX value (operational cost) for decades of use.

Smart Catwalk system is based on the Solidwork parametric 3D computer-aided design (CAD) and computer-aided engineering (CAE) software applications. In effect, these application outputs become inputs to even more sophisticated software running on workstations. They can also be used for virtual commissioning and personnel training, even before a pumping asset gets built.
Smart Catwalk system uses existing intelligent monitoring of catwalk systems (including the hydraulic power pack) is enabled through web-based analytics and visualization capabilities that can include:

  • physics- and rule-based analytics of pump performance key performance indicators (KPIs)
  • control loop and alarm system performance
  • AI-driven machine learning for monitoring and optimizing the performance of pumping system components, such as motor, cylinders and control drives
  • daily, weekly and yearly maintenance and operational KPIs
  • maintenance alerts

The visualization tools can boost real-time operational visibility and management of the catwalk system, showing KPI trends—as well as alerts and faults—graphically on a dashboard that is accessible via a PC, tablet or smartphone. If there is an issue, operators (or the OEM of catwalk system) can study its engineering, maintenance and operations data to find and mitigate or remediate root causes.

Intelligent monitoring within the Smart Catwalk can be a critical complement to the drilling contractors’ day-to-day operational expertise by detecting emerging performance issues before unplanned downtime or catastrophic failures. AI-enabled machine learning can compare KPI data, such as vibration, temperature, pressure and more, to baseline operating signatures to detect variations that could escape notice by human operators.

This kind of AI-enabled machine learning can prove an advantage compared to more reactive models that often can overlook a pump or pumping system’s impending failure. And this can be the case even if operators or their OEMs have installed digital diagnostic capabilities. With a more proactive and predictive operating model, maintenance can be done as-needed instead of as-scheduled, which can save labor and parts costs. Of course, it can also prevent costly production disruptions.

Conclusion

Together advanced analytics and AI-enabled machine learning can help the smart system simplify their deployments. Its digitalization technologies can also simplify operating complexities to reduce project risks while lowering OPEX (Operating Expenses) over a Catwalk system’s entire life cycle.

Among those advantages are real-time condition monitoring and condition-based, predictive maintenance. These can potentially boost the reliability and availability of pumping assets to ensure maximum use and minimize disruptive unplanned outages.

Then there are the benefits of improved operating visibility. This can help identify new efficiencies to enact and further enhance reliability.