he sea is beckoning to energy providers, with oil and gas drilling platforms moving into everdeeper waters. The US is seeing a rebound in offshore drilling after recovering from the BP Gulf of Mexico spill in 2010. Dana Scott of Mazak Corp. said 105 drilling permits were is-
sued through August 2012, compared to 79 in all of 2011. Whats more, Scott said the equipment is getting elderly, which means it will need to be replaced soona potential boon to manufacturers. Of the 474 jack-up rigs used in the worldwide fleet, 317 are 25 years and olderapproaching the end of their useful life, Scott said. There is going to be a tremendous amount of deep-water drilling.
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the parts are larger, Cotrino said. Harder materials that are more durable are another difference between sea and land, mainly in duplex materials. These include stainless steel with an Inconel inlay for grooves in piping and couplings, requiring high cutting forces. Bruce Cates, regional manager for Absolute Machine Tools (Lorain, OH), the supplier of the YouJi machine tools
Setting up for hard metal pocket to be machined.
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VTLslive tooling provides the third axis. He also noted that the bulk of what Absolute Machine Tools sells are three-axis machines, primarily for combined turning and drilling. Rockwell Precision uses YouJi vertical turret lathes supplied by Absolute Machine Tools. These are equipped with live tooling, needed for most offshore components, such as their YV1600 ATC+C, boasting a 1600-mm diameter table.
Riser flange machined on a horizontal boring mill at Rockwell Precision.
Live tooling means we can do the whole thing in one setup and not bottleneck a [separate] boring mill, to do the mill
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work, Cotrino said. We do a lot of our spherical BOPs with that machine, as well as pistons, adapter rings, locking rings, and valve bodiesall for offshore. He also owns a smaller YV1200ATC+C with live tooling and YV1600ATC without live tooling. A key difference that Cotrino has observed since the 2010 spill is the increasing amount of nondestructive testing of subsea components and the witnessing of those tests. They use primarily ultrasonic testing, magnetic particle testing, and liquid penetrant testing at different manufacturing phases. He reported that a third party must witness tests for practically every phase of the process.
future challenges to machining as they become larger and use ever more exotic materials. Downhole instruments are now made of titanium with very complicated structures, such as holes with angles that intersect other holes, Estes said. Some
All of the blow-out preventers in the deep sea are going to be changed out.
Richard Estes, corporate account manager, oil and gas for Okuma America Corp. (Charlotte, NC), deals with both major oil field equipment suppliers and small contract manufacturing shops. Since the 2010 Gulf of Mexico spill, all of the BOPs in the deep sea are going to be changed out, Estes said. They are all going to be redesigned. Although each company will have its own, unique design for BOPs, some of the new elements are common to all. These include much larger physical size, newer, more exotic materials, and more stringent machining accuracies. Tolerances that once were measured in millimeters are going to microns, he said. Surface finishes were largely ignored in the past. Today certain features have finishes that are found in the aerospace industry. He noted that tricky devices like BOPs and downhole instruments are
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Recent additions to Mazaks line of machining centers targeting oil and gas include the newer Integrex e-670. It is the anchor machine for the oil service group, because it allows them to machine parts for either subsea or land service, with more sophisticated features, on heavier parts, he said. For example, the e-670HS-II cuts parts to 42" (1067 mm) in diameter, and a maximum machining length of 160" (4064 mm). For smaller components, such as PCD drill bits, Mazak introduced their I- and J-Series Integrex multitasking milling/ turning centers. Stakes are High The 2010 Gulf of Mexico spill highlighted the inherent dangers in the business and the need for top-of-the-line engineering and manufacturing. Quality is paramount now in this
business. If we make a mistake, we can kill somebody, said Luke Brader, president and CEO of BHI Corp. (Houston, TX). His shop primarily supplies a single OEM oil services supplier, Schlumberger (Houston, TX), which has demanding standards. He compared the measurement, inspection, and documenta-
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need to automate. Competitive pressures from overseas, coupled with an apparent shortage of skilled machinists, is pushing him to automate. Machines with toolchangers, multiple spindles, multiple axesyou put the part in and push the
Okumas larger horizontal lathes meet increasingly stringent requirements for oil and gas.
button, and it comes out complete with lathe and mill work all at once, that is becoming attractive, Brader explains. It needs to run 24/7. BHI Corp. received equipment that meets these goals from Methods Machine Tools Inc. (Sudbury, MA) via their
tion requirements as comparable to those for nuclear-powered submarines. We maintain and digitally archive a record on
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distributor Koch Machine Tool Co. Inc. (Houston, TX), including two Matsuura MAM63Vs five-axis in a 34-pallet cell, a Nakamura NTJX nine-axis turning cell, and two four-axis Fanuc RoboDrills. The Matsuuras are equipped with BigPlus 40 taper 12,000-rpm spindles both in one cell, sharing 34 pallets with a cell controller, and two setup stations. Both machines have spindle and tool probes and tailstocks. Automation can be tricky in this business, noted for small lot sizes. Brader noted that lot sizes vary from 10 to 30, with some orders up to a 100. This is a far cry from either aerospace or automotive. We are not a manual shop, we are a CNC/automated shop with two 12-hour shifts, he said. The trade-off is that you cannot run one piece on a CNC, like you can on a manual machine.
involved, said Peter Beyer, director of product strategy and product development for MAG IAS. In addition to milled, bored, and tapped features, there are turned features, such as threads and interior/exterior profiles, or grooves that require
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