IRE helps major oilfield service drilling operator cut its equipment downtime by 93% with supply of non-OEM parts

Client: Major oilfield service drilling operator

Industry: Upstream Oil & Gas

Location: Oman

Duration: 3 months from initial consultation to final delivery and installation of equipment.

Challenges

The client was struggling with recurring equipment failures, leading to significant downtime and operational inefficiencies. These issues were primarily due to common faults in their Floorhand iron roughnecks. The main objective was to reduce equipment failures in a cost-effective manner with a fast turnaround time.

Faulty OEM die block

Assessing our client’s requirements

IRE engaged with the client across multiple levels, including maintenance, operational, and supply chain teams, to gain a comprehensive understanding of the specific challenges they were facing with their iron roughneck equipment.

The client identified multiple failure points that frequently occurred with its iron roughneck, leading to excessive downtime. We conducted a thorough consultation with the client and its mechanics, reviewing all documentation and inspection reports related to the faults. Several failures were linked to common weak points in the equipment, similar issues that had affected many of our other customers. The client noted that instead of quoting for replacement spares, they wanted something that would address the root cause of the failures.

Solution assessment and qualification

We quickly recognised that our established partner, Ranger Oilfield Products, had the capability to address the challenges our client was facing. We immediately facilitated a meeting for Ranger to consult with the client on a solution. Ranger proposed a set of non-OEM (Original Equipment Manufacturer) components with an upgraded design, specifically engineered to mitigate and prevent the recurrent issues our client had encountered.

A key member of Ranger's technical team is Production Manager Keith Jarvis, a pioneer in the development of Floorhand Iron Roughneck units at Grey Engineering USA. His involvement and deep-rooted expertise in this domain were pivotal in developing the advanced solution offered to our client. Moreover, all of Ranger's equipment and spare parts undergo thorough testing and inspection to ensure complete interchangeability with OEM parts.

Keith's foundational work, alongside Ranger's proven track record of rigorous testing and successful implementations across the United States, instilled a strong sense of confidence in our client regarding the proposed solution.

Deliverables and Results

Ranger's strategic enhancements to the spare parts were designed specifically to address the prevalent failure points within our client's equipment. The introduction of these improved iron roughneck spare parts led to a remarkable increase in operational efficiency, achieving a 93% reduction in downtime for that asset. Specifically, downtime was reduced from an average of 100 hours to just 7 hours per rig annually, all within an investment threshold of less than $20,000 USD per rig.

As shown below, the OEM die blocks were damaged due to the clamp cylinders pushing against the plugs, damaging the threads and creating cracking.  Rangers eliminated the plugs by machining out this area, and inserted a ½” plate that was bolted in place. The solid plate caught the force and eliminated the issue.

OEM die blocks: before and after

This investment not only enhanced the durability and performance of the client's equipment but also resulted in significant long-term cost savings.

The project's success was a testament to the effective collaboration between IRE, the client, and Ranger, highlighting IRE's commitment to providing tailored, high-quality solutions that drive efficiency and cost-effectiveness for our clients.

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