In the industry, being able to keep a clear and continuous view of operations is essential for efficiency and safety. This can be obtained in multiple ways, often with the help of a broad range of devices, such as sensors and CCTV systems.

In this case, it sometimes looks as if the more complex a solution is, the better, but for Rolloos, this does not necessarily have to be the case. In fact, this Dutch company prefers to strive for robust and smart simplicity. As Joost Lasschuit, Managing Director at Rolloos, explains: “Why would you use a sledgehammer to crack a nut? It has always been our aim to look for the best fit-for-purpose solution for our customers, not to look for the most complicated. So far, this has resulted in many loyal customers within the industry.”

Innovative Solutions

Rolloos is a third-generation family company that creates cutting-edge solutions which contribute to a more efficient and safe heavy industry. Rolloos’ expertise lies in CCTV, connectivity, cyber security, data analytics and weighing systems. Through these solutions, the company transforms information into insights, which can be made available across all aspects of harsh and hazardous operations. Rolloos’ key strength is represented by its competence and proficiency in developing innovative automation, control & measurement technology solutions that are easy to install, implement and operate. Mr Lasschuit says, “Offshore operations benefit greatly from our expertise in creating solutions for remote and harsh environments. Our knowledge and experience with low bandwidth challenges and certified systems enable our customers to control every day’s challenges and risks. Our products are weather-protected and are designed to handle heavy impact, high-temperature ranges, and vibrations.”

 

Red Zone Monitoring

The perfect example of the way Rolloos works is the Red Zone Monitoring System. Mr Lasschuit explains, “On the drill floor, people may be required to perform specific jobs, such as placing manual slips in areas where heavy equipment can be moving around: the so-called red zones. One approach to prevent these hazardous situations is to fully automate the process. However, for most existing rigs, this is not a viable option, irrespective of whether it is even advisable. Another approach is to strengthen the discipline of the crew through stricter procedures, training and signing. But year after year, serious accidents show that this is not a 100% guarantee for success. This is why we have created our Red Zone Monitoring System.”

 

The Red Zone Monitoring video-analytics-driven -platform informs the crew when red zones are breached. “For this system, we first configure the desired operational procedures per situation”, Mr Lasschuit explains. “Then the various red zones are mapped in a Red Zone Matrix indicating the places which crew should avoid when certain machine operations are being performed.” In addition, a number of cameras are installed to constantly monitor the whereabouts of people on the drill floor. Using artificial intelligence and deep learning methods, these cameras know when someone is entering a red zone or even approaching one. Apart from the software and cameras, the system’s traffic lights are probably the most important part.
“It is as easy as crossing the road”, Mr Lasschuit says. “When the lights are green, it is safe for the crew to walk and -work in the red zone. When the lights are red, people know they must keep out of the red zone. If someone enters a red zone, a signal is given with the red light flashing and an alarm will sound. At that moment, the driller, who has a full view of the drill floor through the live user interface, can decide whether or not to stop the operation, depending on how the person entering the red zone responds to the alarm. With the traffic lights, crew always know the situation on the work floor, but in an interactive way, as they constantly have to be aware of what they are doing. This means they do not have a false sense of security.”

Tugger Load Monitoring

An inventive system, designed by Rolloos for safe lifting and hoisting, is the Tugger Load Monitoring System (TLMS). “Tugger winches are widely used for lifting purposes on the drill floor”, Mr Lasschuit continues. “They have a lot of advantages as they are easy to operate and maintain, and they also represent a cheap and efficient tool for lifting and moving diverse types of loads around the drill floor. But the main drawback of the tuggers is the fact that they lack real-time awareness regarding the actual load that is being lifted.

Tuggers only have an on/off mode, and this means they will try to lift anything, without taking its maximum loading capacity into account. Furthermore, the decision whether or not a load can be heaved safely and securely is assessed and determined solely by the tugger operator and, in most cases, lifting operations continue even when the operation is hindered by obstacles. This general scarcity of information on the load being lifted often leads to tugger overload failures and even accidents.” According to Mr Lasschuit, many different approaches have been attempted, but existing solutions are often inaccurate or far too complex, and therefore economically unappealing.

Rolloos’ solution, on the other hand, has been designed to fulfil the requirements of tugger lifting operations in a perfect way: simply and cost-efficiently, and suitable for every existing or new-to-build drilling asset. “The basic idea behind our TLMS is a load shackle equipped with a strain-gauged load pin. The top sheave of the tugger is connected with the shackle, enabling it to accurately measure the weight of the load”, Mr Lasschuit says. The shackle transmits real-time weight data wirelessly to the main display and to the zone 1 handsets. The receiving display is then wired to flexible combinations of displays. The system is also equipped with a sounder and a number of beacons to inform the operators and the drill crew as soon as the shackle registers a defined set-load, indicating the danger of potential overload.

Valuable Insights

Apart from generating real-time improvement in safety and efficiency, Rolloos’ systems also include the collection of an enormous amount of data. Mr Lasschuit explains, “People and equipment generate abundant knowledge and experience. This can be in the form of documents such as manuals and service reports, but it can also be data collected from sensors and CCTV systems such as those designed by Rolloos, and from our machine learning methods.” For companies it can be challenging to interpret the data and to share it throughout the organisation, and, as Mr Lasschuit states, “This really is a wasted opportunity.”

He concludes, “To stay competitive, companies must continually innovate, improve and streamline their operations. But accurately identifying how and where to improve can be challenging. Especially when the data that holds the answers is scattered through the organisation among different, often incompatible, systems, formats, and processes. Our flexible and robust solutions, such as OSIsoft PI and Viewport, are easy-to-use tools for the synchronisation, structuring, presentation, analysis and distribution of data. In this way, we create valuable insights that can improve operational quality, efficiency, and safety.”