All mobile offshore units generate a constant stream of data. But only a fraction of this information is utilized further than the nearest operator. However, when we store this wealth of data and analyze it intelligently, it transforms into something valuable.
Human operators still actively control the equipment and the process flow, whether they are drilling a well or installing a wind turbine. GustoMSC developed the new Operator Support System (OSS) enabling the operator to work more efficiently. The operator can maximize efficiency by having all relevant information available real time. At the same time, safety is maximized because the information of multiple sub-systems can be combined, and manual misinterpretation can be prevented. The OSS connects systems, extracts and intelligently combines the available data and translates the relevant information into key operational support. The system is built on NOV’s Industrial Internet of Things platform MAX. This platform allows real-time data to be handled, analyzed and stored, locally and in the cloud. The data can be shared and stored securely through the NOV access portal and cloud, when a connection is available. The data can safely be accessed by the operator in the cloud, anytime and real-time and it can be forwarded to any third-party cloud service.
Benefits for the operator
As overall unit designer and the supplier of key equipment, GustoMSC has the exceptional capability to combine decades of experience and insight in each onboard sub-system and in the interaction between the different systems. With this expertise integrated in operational algorithms and the availability of the data, valuable operational information can be obtained which was not available previously. The OSS enables the relaying of real-time operational information to the operators thus improving safety and efficiency. As the OSS runs autonomous onboard on the MAX system, connection to the cloud is not required for the system to work. The MAX platform allows for remote installation of updates and installation of new applications when a data connection is available. In this way, data security is always up to date and the operator is continually provided with the latest insights.
OSS.Jack, foundation capacity made objective
At present, operators use their personal expertise to determine at what point in time the foundation preload has been established, based on the load at which the foundation has been tested for a period of time. This makes the determination of foundation capacity sensitive to personal interpretation and errors.
The application OSS.Jack uses an algorithm to calculate the established preload in real time based on leg load levels, foundation settlement and time. The algorithm that is used for the objective determination of the achieved preload makes use of these real-time measured parameters. An essential parameter is time: one needs to apply a minimum load level for a sufficient amount of time, depending on the soil type. Furthermore, the foundation settlement needs to be below a threshold value in a specified period of time. It is only when a load level has been exceeded for a sufficient amount of time, while the settlement rate is below a certain threshold, that this load level becomes the established preload on the foundation.
The criteria that are used by OSS.Jack to determine the preload can be set by the operator. These can be job and site-specific and possibly determined in conjunction with the warranty surveyor. Based on the agreed combined criteria, OSS.Jack determines the foundation capacity objectively and in a repeatable manner.
The algorithm works in (near) real-time, so the operator is provided with direct feedback and insights on foundation and jack-up behavior during the preload operation. This allows him to focus on the jacking operation itself thus improving efficiency and safety. The final judgement of the preload operation remains
of course with the operator. His own personal judgement and expertise remain leading. With OSS.Jack, an automated jacking report can be generated to be send to those that need or wish to be informed, onboard and onshore.
Unlock the full potential, OSS.Lift
Crane operations on a jack-up do have an effect on the loads of the foundations. For relatively small cranes, this poses no threat to the overall foundation safety. This no longer holds for large cranes on a jack-up. Without the proper precautions, crane operations can lead to dangerous situations. When the load on the foundation or preload exceeds the foundation capacity there is a risk of punch through. Safety is currently ensured by calculating a truncated crane capacity/envelope using the foundation capacity as a limit. As this has to hold for all loading and environmental conditions, this results in a high degree of conservatism in practice and thus the full capacity of the unit is not utilized.
The application OSS.Lift monitors and verifies foundation loads in real time during lifting operations and the system provides both the crane and jacking operator with information about the interaction between the crane, the jacking system and the foundation. With OSS.Lift, the jacking operator is informed of the loads in the jacking system and the foundation it is positioned on. OSS.Lift informs the crane operators real time about how close the crane is to utilization of the foundation capacity, as established by the OSS.Jack application during jacking and preloading operations. In this way, OSS.Lift increases safety during heavy lifting operations.
By coupling real-time foundation loads and the crane operation, OSS.Lift can unlock the full potential of the jack-up unit. GustoMSC’s proprietary pre-torque technique optimizes the distribution of foundation loads between the jack-up legs, providing maximum crane capacity for lifting operations. To put it simple, the load on the leg where the crane is positioned can be reduced by operating the jacking system, thus creating leg load capacity to be utilized by the crane operation. As a result, the crane can be used at maximum capacity. This way, jack-up platforms can be outfitted with larger cranes without compromising safety.
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