NSF Workshop on

Advanced Manufacturing for the Oil and Gas (O&G) Energy Industry November 2-4 2014, Omni Houston Hotel, Houston, Texas

Sponsoring agencies U.S. National Science Foundation (Division of CMMI: MME, MES, NM, and MEP programs); Texas Engineering

Experimental Station (TEES) and Texas A&M University.

Satish Bukkapatnam, Arun Srinivasa, Andy Johnson, Michael Johnson, Dean Schneider Texas Engineering Experimentation Station-Texas A&M University

Institute for Manufacturing Systems satish@tamu.edu

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Summary Objectives

The purpose of the workshop was to bring together experts in oil and gas (O&G) industry practice and operations, materials processing (e.g., nanostructured coating processes, rock drilling), manufacturing machines and tools (e.g., precision machines, diamond bits), enterprise systems (e.g., energy supply chains, transport and storage), and public policy (e.g., environmental and workforce related) to (1) review the state‐of‐the‐art in manufacturing technologies and systems for the O&G energy industry; (2) assess the economic and technological trends and future prospects; (3) gather the O&G industry perspective of the short and longer term research needs; (4) identify and formulate technical gaps and challenges, especially in the upstream and the midstream of the O&G value stream; (5) formulate recommendations for research and education programs to advance manufacturing technologies and systems for the O&G energy industry.

For the foreseeable future, clean O&G is likely to remain the largest and the most economical source of energy. The advent of unconventional (shale) energy sources during the past decade offers an unprecedented opportunity to enhance manufacturing resurgence, which in turn is essential to absorb the projected abundance of energy (45 quadrillion BTUs of annual production) and chemical feedstock. Recent advances in manufacturing technologies offer a mostly untapped opportunity to create high-value products out of byproducts that are generally treated as waste in O&G value chains. These technologies can lead to an exciting possibility of transforming the O&G sector into a net-zero material footprint industry. Additionally, fundamental research that addresses key scientific and technological challenges in processing (e.g., drilling, and coating) complex and advanced materials (e.g., shale rock and alloy steel) pertinent to improving efficiencies of current O&G energy industry operations will also benefit other industries in the country.

Overview

The workshop consisted of three thematic sessions, namely, (1) research needs in the manufacturing technologies and machines, (2) research needs in manufacturing systems, and (3) education, industry-university cooperation and public policy needs. Each session included three to five presentations given by experts representing government, industry and academia to introduce the state-of-the-art in the theme area and to share views on the future directions and needs in that area. While the advanced manufacturing (AM) needs and issues pertaining to the entire value stream of the O&G energy industry were discussed, the issues and needs of the upstream (extraction) and midstream (transport) received particular emphasis due to the developments taking place in the unconventional shale and subsea sources. The presentations in each session were followed by a discussion that had all workshop attendees participating.

About workshop attendees

The workshop attendees included 19 invited speakers and panelists and 65 registered delegates that included organizers and students. The registered delegates were from diverse backgrounds:

• Researchers and educators interested in engaging in advanced manufacturing (AM) research and education for the O&G industry,

• Industry professionals interested in an industry-university partnership to address specific upstream and midstream AM R&D needs of the O&G industry,

• Administrators and decision makers who support and facilitate AM research, education, and technology transfer, and

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• Other advanced manufacturing and O&G industry stakeholders. Key findings

It has been noted that a need for significant research exists in advancing the drilling process, including tooling materials and design; understanding the fundamental mechanics; developing new path planning methods, and production control; as well as in developing novel materials processing technologies to realize functional components from materials peculiar to the industry. These materials are selected to suit the harsh operating environments. Additionally, the development of advanced material processing technologies is also necessary in areas such as nano-structured coatings that are resistant to fatigue, corrosion damage, extreme temperature and pressures; decision tools to relate various system design parameters to performance metrics; development and deployment of sensors, high temperature electronics and telemetrics to collect data; and advances in data analytics to harness often incomplete information gathered intermittently. Appropriate advances will permit more effective predictions about the performance and process states. Public-private partnership was noted as imperative to effectively address the lingering issues and emerging challenges in the industry pertaining to productivity and modernizing the operations (tooling, supply chains, etc.). In addition, workforce development remains a major challenge—novel approaches are needed to motivate students to pursue STEM disciplines, and consider engineering and/or associates degrees in manufacturing as attractive options. This can lead to the development of a strong workforce ecosystem to sustain manufacturing advances in the O&G energy industry.

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Introduction Context: For the foreseeable future, clean oil and gas (O&G) is likely to remain the largest and the most economical source of energy. The advent of unconventional (shale) energy sources during the past decade offers an unprecedented opportunity to enhance manufacturing resurgence, which in turn is essential to absorb the projected abundance of energy (45 quadrillion BTUs of annual production) and chemical feedstock. Recent advances in manufacturing technologies (e.g., additive, ultraprecision, and nano-manufacturing) offer a mostly untapped opportunity to create high-value products (e.g., nanowire thermoelectrics) out of byproducts (e.g., sulfuric compounds) that are generally treated as waste in O&G value chains. These technologies can lead to an exciting possibility of transforming the O&G sector into a net-zero material footprint industry. Additionally, fundamental research that addresses key scientific and technological challenges in processing (e.g., drilling, and coating) complex and advanced materials (e.g., shale rock and alloy steel) pertinent to the O&G energy industry will also be beneficial to other industries in the country.

Objectives: The workshop was held in Houston, the nation’s hub for the O&G energy industry, during November 2-4, 2014. It brought together a team of 19 invited speakers to identify research and education needs in advanced manufacturing for the O&G energy industry. The invited speakers brought distinct and complementary expertise in O&G practice, materials processing (e.g., nano-manufacturing technologies, rock drilling process), manufacturing machines and tools (e.g., precision machines, diamond bits for horizontal drilling), enterprise systems (e.g., energy supply chains, transport and storage), and public policy (e.g., environmental and workforce related). The workshop had several main objectives: (1) Examine and review the state-of-the-art in manufacturing process technologies, automation methods and equipment, and systems-level research for the O&G energy industry taking place in academia, industry, and research labs; (2) Assess future prospects and outlook, including the growth in energy supply and the demand for advanced machinery and processes; (3) Gather the O&G industry perspective of the short-term (1-3 years ahead) and long-term (3-10 years ahead) research issues; (4) Identify and formulate specific needs, gaps and challenges, especially in the upstream (extraction of oil and gas) and the midstream (storage and transport) of the O&G value stream; (5) Formulate recommendations for research and education programs, including follow-up workshops as needed, to advance manufacturing technologies and systems for the O&G energy industry.

Motivation and background: Availability of abundant, inexpensive energy is essential to sustain the nation’s nascent manufacturing resurgence. The manufacturing sector consumes the highest portion (30%) of the total energy generated, and the need for energy is anticipated to grow steeply as the U.S. manufacturing sector is adapting new paradigms of advanced and low-volume custom manufacturing.1 Advanced manufacturing processes, including novel energy beam processes and conventional processes adopted to actualize products from novel (e.g., composite, nanostructured) materials, consume significantly more energy to realize the same extent of material transformation compared to most conventional processes. Additionally, low-volume custom manufacturing systems tend to stretch machine tools’ capacities and do not necessarily operate under the most energy-efficient process conditions. This underscores the need for an abundant supply of inexpensive and clean energy.

1 U.S. Bureau of Economic Analysis, http://www.ihs.com/info/ecc/a/americas-new-energy-future-report-vol-3.aspx, http://www.manufacturetexas.org/manufacturing_matters)

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For a foreseeable future, clean oil and gas (O&G) is likely to remain the largest source of energy. It has been noted that the O&G share of the nation’s total energy consumption is set to rise from the current 53% to 58% in the next 20 years.2 More pertinently, the unconventional (shale) energy3 sources offers an unprecedented opportunity to establish an enduring growth in the manufacturing sector as well as the economy. Over 45 quadrillion BTUs of annual energy production and the resulting chemical feedstock (raw material for many industry sectors) are projected to result from the O&G sector as the U.S. transforms into a net-energy exporter.4

While the projections are mostly based on shale source availability across the nation, the unconventional (e.g., shale gas) energy sources, and their value chains present fundamental challenges in materials processing and equipment through the systems (logistics, quality and reliability) level. These challenges recur in all three stages of the O&G value stream:

1. Upstream exploration and extraction stage that uses the advances in hydraulic fracturing and horizontal drilling technologies,

2. Midstream material transport stage, especially long range material transport using extensive and durable pipeline and storage network, and

3. Downstream secondary manufacturing stage consisting of refinement and synthesis of various chemical products.

Currently the O&G industry is facing the following three main barriers that impede the achievement of the projected growth targets. The industry must:

1. Plateau and even shrinkcosts, and the dynamic cost structure of the industry, 2. Increase throughput rates to meet growing demands for O&G, as well as 3. Navigate environmental regulations and restrictions.

The industry is seeking technological innovations and a well-prepared workforce, especially in the upstream and the midstream of the O&G value chain as the best means to ensure its long-term growth.5 The following paragraphs detail some specific instances of these challenges.

To date, the manufacturing research community is not completely conversant with the wealth of key scientific and technological issues in this context. For example, in the upstream of O&G value chain, the extraction sites are typically graded into three tiers depending on the ease of extraction and the quality of the extract. An overwhelming majority (~ 90%) of the sites are considered to be in tier 3 where the return on investment (ROI) per current practice tends to be below 15%. The industry considers projects with projected ROIs as high as 30% as unviable under the present price points and cost structure.4 A significant portion of the costs is attributed to inefficient drilling practices and capital resource utilization.6 The

2 Annual energy outlook, http://www.eia.gov/forecasts/aeo/, 2014 3 Unconventional energy sources refer to the O&G feedstock extracted based on recent advances in hydraulic fracturing and horizontal drilling technologies opposed to conventional oil well methods. 4 The Remarkable Shale Oil Bonanza in ‘Saudi Texas’: Oil output has doubled in only 29 months to a 33-year high in September. Available: http://www.aei-ideas.org/2013/11/the-remarkable-shale-oil-bonanza-in-saudi-texas-oil-output-has-doubled-in-only-29-months-to-a-33-year-high-in-september/), 2013 5 America’s New Energy Future: The Unconventional Oil & Gas Revolution and the U.S. Economy. Available: http://www.ihs.com/info/ecc/a/americas-new-energy-future-report-vol-3.aspx, 2013. 6 J. Mpagazehe, Queiruga, A., and Higgs III, C.F., “Towards an understanding of the drilling process for fossil fuel energy: A continuum-discrete approach,” Tribology International, 59, pp. 273-283, 2013

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current practice is to employ the most conservative process settings that while safe, tend to be highly suboptimal from process time (apparently by orders of magnitude) and cost standpoints. There is a huge opportunity to develop equally safe methods that could could save time by orders of magnitude. In specific, scientific research to advance horizontal drilling technology can substantially transform the practice to minimize (i) tooling loss (from the design of tools and on-line adjustment of the process parameters), as well as (ii) process time from planning and execution of the best tool path (the objective is to create an opening through the rock but not necessarily a straight hole as in traditional manufacturing) through highly heterogeneous and uncertain rock compositions with little effect on safety and system integrity.

Similarly, from an environmental standpoint, handling procedures for many byproducts from the O&G value chain, including various gaseous and fluid materials at the upstream, as well as phenolic and sulphuric compounds, slag, fine metal chips from downstream refineries, steel and machinery plants have drawn the attention of environmental groups, as they can pose serious health and environmental hazards. Innovative manufacturing methods to create valuable products out of these byproducts that are commonly handled as waste have not received much attention thus far, and this presents an enormous opportunity. For example, sulphur is a prominent contaminant in many of the as-extracted compounds from the O&G industry. It is generally treated as waste in the current energy value chains. Fundamental science and procedures can be developed to synthesize nanostructures such as copper and zinc sulphide films and nanowires, which are of high value to renewable energy sector, from these sulphuric compounds.7,8 It is easy to envision an innovation culture that creates value for nearly every byproduct of the energy value chain transforming O&G sector into a near-zero material footprint industry. Such a transformation would not only address some of the environmental concerns associated with the industry but also spawn startups engaged in innovative, advanced manufacturing across the nation and foster enduring economic growth.

Additionally, industry leaders have noted significant gaps in the skills and preparation of graduates from traditional (petroleum and chemical) engineering programs. The industry currently seeks graduating engineers who are aware of the O&G practice as well as manufacturing technologies and systems. Few degree programs currently provide such skill sets. Identification of specific learning gaps would be helpful towards the development of appropriate education (degree, minor and/or certificate) programs targeted at the near and long-term O&G sector’s workforce needs.

While the academic manufacturing community is conversant with the process technologies, machine tools, best operating conditions, as well as the supply networks needed to produce components or products for automotive, aerospace and microelectronics manufacturing industry sectors, the processes and systems to create products and components (e.g., pipes, drill tools, pumps) pertinent to the energy industry have not received nearly the same attention. More pertinently, manufacture of these products is valuable and presents significant scientific and engineering challenges. The outcomes of the workshop presented in the following sections can be used to initiate a national agenda and roadmap for research and education in manufacturing technologies and systems for the O&G energy sector.

7 Y. Wu, C. Wadi, B. Sadtler, and A. Paul Alivisatos, “Synthesis and Photovoltaic Application of Copper(I) Sulfide Nanocrystals,” Nano Letters, 8/8, pp. 2551-2555, 2008. 8 I. O. Oladeji, and L. Chow “Synthesis and processing of CdS/ZnS multilayer films for solar cell application,” Thin Solid Films, 474, pp. 77-83, 2005.

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Outline of the workshop program

The workshop attendees included 19 invited speakers and panelists, and 65 registered delegates that included organizers and students. The registered delegates were from diverse backgrounds, including (a) Researchers and educators interested in engaging in advanced manufacturing (AM) research and education for the O&G industry, (b) Industry professionals interested in an industry-university partnership to address specific upstream and midstream AM R&D needs of the O&G industry, (c) Administrators and decision makers who support and facilitate AM research, education, and technology transfer, and/or (d) Other advanced manufacturing and O&G industry stakeholders. The workshop program was organized into three thematic sessions, namely, (1) Research needs in the manufacturing technologies and machines, (2) Research needs in manufacturing systems, and (3) Education, industry-University cooperation and public policy needs. Each session included three to five presentations given by experts representing the government, industry and university to introduce the state-of-the-art in the theme area and to share views on the future directions and needs in that theme. While the advanced manufacturing (AM) needs and issues pertaining to the entire value stream of the O&G energy industry were discussed, the issues and needs of the upstream (extraction) and midstream (transport) received particular emphasis due to the developments taking place in the unconventional shale and subsea sources. The presentations in each session were followed by a discussion on the theme that involved all workshop attendees. The most important outcome from the workshop was the industry’s articulation of the various advanced manufacturing needs and imperatives as detailed in the following section.

Summary of the Advanced Manufacturing Needs Identified

It was noted that the recent industry thrusts in shale and subsea extraction processes have led to huge opportunities for sustained growth in the manufacturing sector. However, this has also brought to fore gaps in research, knowledge and application infrastructure, as well as workforce preparation. The workshop identified technical challenges, such as (a) developing new generation of tooling materials, product designs and processing approaches to yield components that can withstand the wide range and variations of temperature and pressures during drilling and extraction operations; (b) new methods for process (e.g., tool path planning) that would effectively use the information on the underlying geology; (c) new paradigms for production organization and control considering the low volume and highly custom nature of O&G operations; (d) advanced materials processing methods for developing coatings on large components such as pipes resistant to corrosion and extreme temperatures and pressures; and (e) sensors that can withstand extreme environments to collect data downhole, and advanced data analytics methods. Additionally, the workshop identified education and public policy issues, and noted the need for public-private partnership to address key issues with productivity, modernizing the operations tooling, supply chains management, safety and sustainability in the O&G energy sector. It was also noted that the workforce development remains a major challenge. The need to develop mechanisms to tie K-12, community college and university efforts to motivate students to pursue STEM disciplines, especially to consider four year and associate degrees in manufacturing as attractive options, was emphasized. The details of these needs are presented in the following two sections.

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Research Needs

The O&G extraction and transport processes are capital intensive; costs of downtime and safety violation are prohibitively high. More than ever, technology is now required to enable discovering and accessing resources, once thought to be inaccessible, in an efficient and safe manner. For example, with proper technology it becomes possible to extract more energy from mature fields which were hitherto thought to be uneconomical. This reduces the total environmental impact of the O&G value stream without increasing the cost. The following case study in the subsea sector exemplifies some of the advanced manufacturing research challenges in the O&G energy industry.

The subsea oil and gas sector needs were delineated based on input from Transocean’s delegates and OneSubSea’s (a Cameron and Schlumberger joint venture) delegates. Currently there is not significant implementation or investment into novel manufacturing systems as part of subsea operations. The main research needs are imposed by the challenges with (a) design and manufacture of components to meet large dimensions of the domain, (b) sensors and electronics for sensing and safety assurance under extreme environments, (c) on-board control and operations management, (d) adaptation of novel materials processing methods, (e) remote operating vehicle coordination, (f) data analytics, and (g) costing.

The primary challenge in subsea are in the sheer dimension of the work environment and the components therein. A typical wellhead is 14 ft. X 8 ft. (this is often referred to as the desk space). The components must survive the trip 10,000 ft. down to sea floor, then descend another 2,900 ft. underground from the sea floor to the targeted location.

Another key component is the blowout preventer (BOP), which is referred to as a Christmas tree in industry parlance. It consists of valves, pumps and sensors installed redundantly in stacks to seal, control and monitor oil and gas wells, is stationed at the sea bed. It typically is 15 ft. high and weighs 20-50 tons. Another component is a pump station that is usually up to 30 ft. in height and weighs in the range of 100-500 tons. The design specifies that the size of every component including the pipes doubles in size for every 5,000 ft. of depth. The subsea surface installations are connected to the deck via subsea tiebacks (field connectors) that are typically 27 miles long to accommodate the deck’s motion caused by ocean currents. A single deck is typically connected to 3-5 subsea installations (BOPs).

The second challenge is in the control interface managing the underlying extraction processes. The cost on the deck of a commissioning vessel is high; one needs to design and develop small components on board to accomplish the necessary control and feeding operations while minimizing the total footprint. A new generation of shape optimization methods based on origami research9 would be an interesting possibility.

9 J. Hyun, S. Kumar, Y. Shao-Horn, and G. Barbastathis, “Origami fabrication of nanostructured, three-dimensional devices: Electrochemical capacitors with carbon electrodes,” Applied Physics Letters, 88, 083104, 2006

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Figure 1. (a) A representative blowout preventer (BOP),10 (b) Schematic of subsea installations showing (1) a BOP along with a (2) pumping station and (3) a remotely operated vehicle.11

The third challenge emerges from the need for the components to be able to deal with unconventional hydrocarbons. The surfaces of pipe should not degrade while being exposed to an uncertain mix of extracts, and the system should be designed to ensure structural and material flow integrity.

The fourth challenge is in developing sensors that do not exceed two inches in length to measure ambient temperature and pressure with 10% accuracies, functioning over a pressure range of 0-20ksi, and 0-350 F temperatures. The sensors are essential to detect leak and impacts and are considered important elements for safety and integrity assurance. Any damage to a BOP tends to be expensive. It takes about 4 days of work and costs about $8 per second. The sensor challenge is amplified by the requirement that these sensors need to be embedded as part of the structure and cannot be cut into the pipe. Due to extreme environments, they cannot be attached using epoxy glues, nor can the structure be tampered with using drilling (creates stress raisers) or welding (damages microstructures) that are known to accelerate corrosion and dynamic fracture in subsea structures.

The fifth challenge emerges from the fact that much of the current operations tend to be highly human centric, and automation issues have not been explored significantly in this sector. Human errors are not uncommon, and lead to significant, non-productive downtimes and integrity loss. The industry needs human-assisted controls. Data analytics applied to sensor data has the potential to help human operators in these tasks and thus is an immediate need.

The sixth challenge is associated with communication and coordination necessary to accomplish various installation, as well as MRO (maintenance, repair and overhaul) tasks in

10 Drillingcontractor.com 11 Oceaneering.com , f-e-t.com, 2014

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subsea environments. The industry also employs remotely operated vehicles (ROVs) to accomplish subsea component assembly, repair and monitoring tasks (see Fig 2). Recent developments in multi-robot communications as well as cyber-physical systems approaches12 offer new ways to accomplish various subsea monitoring tasks to significantly enhance safety, performance (reliability), and operational efficiency.

Apart from these, manufacturing process-related challenges, cost modeling, control and risk assessment are major challenges in subsea operations. Oil prices exceeding $95 per barrel are desirable for viable subsea operations. Most plans in the subsea sectors are based on $105-$110 per barrel oil prices ($115 per barrel for artic operations). The following parameters are employed for evaluating investments towards subsea installations: the operating costs accrue to $8 per second; wells and design and engineering (including the modeling efforts) cost $50M per well. Each well costs about $250M; the deck and the platform together costs about $700M. Significant costs are also incurred in the development of reservoirs (also called the phasing reservoirs) as well as hardware for seabed boosting, in-well lifting (dual-lift), and multiphase material separation11 that need to be operational for 20-25 years without intervention. Each of the manufactured hardware components for a subsea installation has to have a five-year certification requirement to facilitate multiphase and flow assurance in the wake of materials uncertainty, extreme environments, pH, pressure, strong currents and movements, and biological fowling (e.g., shrimp). There are questions that merit consideration: What are the key factors affecting the cost? Are there ways for technologies (such as composite pipes and sensors) to reduce cost, especially considering technology has not really improved since 1973? Expected revenue from a well is $500K per day, and the operations are typically contracted out at a price point of $1M per day for 3 years. The key metric employed in this context is the revenue efficiency, which is defined as the ratio of the realized return to the expected return ($500M/day). Most of the subsea installations operate at about 85% efficiency, i.e., they are down roughly 15% of the time. There appears to be an urgent need and a myriad of opportunities to develop creative approaches to enhance revenue efficiencies.

Thus, the O&G energy sector presents exciting challenges ranging from materials processing, machines, tooling and sensors, to the systems level production planning, control and costing issues. The following are some of the key advanced manufacturing research needs in the O&G energy sector: 1. Drilling process performance and drill bit design: Polycrystalline diamond compact (PDC) tool bits have found growing acceptance in the unconventional drilling operations during past twenty years (see Fig 3 for a drill tool assembly). About 70% of the unconventional O&G drilling operations employ PDC

12 K. Kyoung-Dae Kim; P.R. Kumar, "Cyber–Physical Systems: A Perspective at the Centennial," Proceedings of the IEEE , 100: 1287,1308, 2012

Figure 2. A representative remotely operated vehicle.11

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tools (See Fig 4a).13 They are formation-sensitive (see Fig 4b) due to nuances associated with the material shearing mechanisms.14 Limited tool design innovations, lack of fundamental understanding of the process as well as lack of sensing capabilities have been noted as three major barriers in advancing the PDC drilling technologies. Improvements in drill bits are critical for optimizing the rate of penetration (ROP).15 This significantly contributes to minimizing rig costs and shortening the time between project commissioning and first production. Examples of the key challenges that require transformative technology include developing manufacturing processes to produce PDC bits with the desired properties, instrumenting drill bits with sensors for downhole data monitoring, and developing models to support real time drilling optimization. Manufacturing of drill bits for both curve and lateral sections is an added challenge. The use of micro-scale thin film embedded sensors as part of the tools would provide an interesting possibility to advance drilling process performance. Efficient analytical/numerical modeling in both laboratory and industrial levels can provide an in-depth understanding of rock cutting mechanics. Advanced sensing, diagnostics, control technologies in complex down-hole conditions in directional and deep drilling processes, which the industry commonly refers to as managed pressure drilling, are promising to enhance drilling process efficiency, especially in terms of increasing penetration rates, reducing fluid loss and wellbore integrity in the unconventional energy (shale) parts of the O&G energy industry.

Figure 4(a) The share of PDC bits in O&G drilling market, (b) Suitability of PDC for different geological formations.16

13 D. Che, Han, P., Guo, P., Ehmann, K, “Issues in Polycrystalline Diamond Compact Cutter-Rock Interaction From a Metal Machining Point of View – Part II: Bit Performance and Rock Cutting Mechanics”, ASME J. Manuf. Sci. Eng., 134(6), p. 064002.0, 2012. 14 L.A. Offenbacher, et al, 1983, “PDC bits find applications in Oklahoma drilling,” IADC/SPE Drilling Conf., p. 11389-MS. 15G. Bruton, R. Crockett, M. Taylor, D. DenBoer, J. Lund, C. Fleming, R. Ford, G. Garcia, and A. White, “PDC Bit Technology for the 21st Century,” Oilfield Review, 26 (2), 2014. 16 D. Che, Han, P., Guo, P., Ehmann, K., 2012, “Issues in Polycrystalline Diamond Compact Cutter-Rock Interaction From a Metal Machining Point of View – Part II: Bit Performance and Rock Cutting Mechanics”, ASME J. Manuf. Sci. Eng., 134(6), p. 064002.0

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Figure 3. A representative PDC tool assembly (bakerhughes.com, 2014)

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2. Advanced manufacturing processes for safe and efficient O&G extraction and transport infrastructure elements: Material transport in both upstream and midstream processes rely on an extensive pipeline network. The importance of pipelines is amplified by the recent industry trends in both unconventional and deep water parts of the O&G energy industry. In the unconventional sector the thrust is to drill longer laterals. The average length for the horizontal wells, also referred to as the reach, has increased by 20% in seven years (2006-2013).17 In the subsea sector, operator’s desire to drill in deeper water is challenging the industry to develop new solutions. In addition to increasing reach, the industry expects line-pipes to possess higher pressure capacity, longer fatigue life and higher yield strength. The traditional approach to address this thrust has been to increase the rig’s size and that of the equipment, such as BOPs and pumps. The use of lightweight materials such as aluminum and composites with strong mechanical properties, coated with (nanostructural) films that offer superior resistance to various corrosion mechanisms as well as dynamic failure, would be of value to the industry.

Also, owing to the harshness of the operating environments, the O&G industry has been considering components made of advanced materials as part of its infrastructure. However, the process of adoption has been slow, and severely hampered by the lack of testing and material certification facilities. Nonetheless, a variety of alloy steels and superalloys have been considered as part of the line pipes, valves, and other ubiquitous components of the infrastructure. Recent national materials genomics initiative offers new pathways for materials “design” and “selection” by optimizing the composition and microstructure to optimally meet functional needs. Advanced materials processing approaches are essential in this context. For example, the extracted multiphase fluid is replete with gaseous phase compounds such as hydrogen sulphide and carbon dioxide, as well as saturated solutions that cause scaling and Asphaltene deposition on the surfaces. The fluid also attracts sulphate reducing bacteria that severely damage line pipe surfaces. The new nanostructure processing technologies can potentially alleviate issues with bacterial corrosion in the upstream and midstream transport processes. Novel materials processing approaches for in situ synthesis of zinc phosphide nanowires decorated with boron nitride on a line-pipe surface can lead to novel coatings that are resistant to water (bacterial) and acid-assisted degradation.18 Similarly, recent advances in constrained machining offers new opportunities to create surfaces on stainless steel and Ni-based materials with unprecedented flow localization, strain hardening capacity, and ductility.19 Some experimental evidence suggests that the resulting surfaces are more resistant to corrosion and fatigue damage.

Additionally, O&G industry is increasingly pursuing the use of new generation of “smart” materials and systems as part of reconfigurable seals, subsea pumps, self-torqueing fasteners, BOPs and other adaptive components to enhance safety of the operations.20 Innovative manufacturing technologies need to be developed to address this challenge so that the potential of “smart materials” such as shape memory alloys (SMAs) is fully realized in offshore O&G applications. Investigations into hybrid manufacturing processes to process these materials are in their nascent stage.21

17 Tenaris.com 18 V. Vasiraju, Y. Kang, and S. Vaddiraju, “Non-conformal decoration of semiconductor nanowire surfaces with boron nitride (BN) molecules for stability enhancement: degradation-resistant Zn3P2{,} ZnO and Mg2Si nanowires,” Phys. Chem. Chem. Phys., 16(30: 16150-16157, 2014. 19 N K Sundaram et al., Mesoscale folding, instability, and disruption of laminar flow in metal surfaces. Phys. Rev. Lett., 2012, 106001 20G. Song, et al. “Applications of Shape Memory Alloys in Offshore Oil and Gas Industry: A Review,” Earth and Space, 1551, 2013. 21 B. Lauwers et al., Hybrid processes in manufacturing, CIRP Annals (keynote), 2014

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3. Improving system-wide performance, reliability and safety: The upstream and midstream elements of the O&G enterprise hold unique characteristics including (a) Complex product structure with bill of materials for a typical product such as a pump, or BOP consisting of 1000+ components; (b) Harsh operating environments in both subsea and land-based with high temperature and pressure ranges, coupled with limited access to production zones; (c) Significant engineering design problems exemplified by thousands of hours of engineering time, and complex and consistently changing part and functional specifications; (d) Challenges associated with machining and fabrication of components arising from the use of special materials, high tolerances, large-sized components: (e) Limited and sparse supply chain, qualified vendors, machine tools and production ecosystem for making components even as simple as qualified castings, welded structures, and forgings; (f) Wildly varying demand cycles as the industry is lumpy and uncertain; (g) Quality control is limited as products are mostly engineered to order and therefore need specialized testing without any standardization; and (h) Challenging logistics to facilitate on-site assembly of heavy and bulky components (e.g., many of the components are primarily assembled by boat for subsea operations). Prior process improvement efforts such as the application of the customary lean and six sigma processes have only met with limited success due to the extreme uncertainties associated with this sector.

The workshop presenters and attendees noted the following research needs at the systems level:

(1) Analysis and optimization of engineering workflow to address lead times for various activities considering the product and functional dependencies as well as highly stochastic demands and workforce skill sets.

(2) Balancing Demand Cycles and Project Durations considering (a) the oil price and governmental regulation regimes and permissions, (b) lumpiness of the orders from customers (in a supply chain) that usually emerge in the form of large contracts and/or service orders depending on the company in this sectors, (c) in design cycles based on customer-specified revisions and performance challenges, (d) project durations that impede the assessment of the impact of design decisions, and (e) long ? lead times for equipment manufacture and installation.

(3) Joint Optimization of Manufacturing Strategy and Operations by considering the capital equipment capabilities and the labor pool availability and costs. Cost savings not only benefit the companies, but also benefit consumers of the products. Improved manufacturing technologies and practice reduce drilling and extraction costs to the company. When the technologies are available to multiple companies, a part of the cost savings will be passed along to consumer through lower price. This mechanism was observed in agriculture. It has been noted that the cost of food is a small fraction of the costs at the beginning of the twentieth century, even in real terms. The opportunity for a similar scale of cost reduction exist for the O&G industry.

(4) Addressing Risks with Flexibility in Subcontracting, which is and quintessential component of O&G Manufacturing to lower cost and increase the capacity and flexibility. Developing an optimization framework to determine what aspects of work to subcontract, how much and who to subcontract remains interesting issues.

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(5) Bridging Gaps in Planning and Execution Systems to optimize medium vs. short term objectives considering the vagaries of the O&G energy sector would be a useful planning tool for the small and medium sizes companies in this sector.

(6) Establishing functional relationships between manufacturing metrics remains a challenge in this sector. Developing dashboards based on measuring and visualizing trends in the relevant metrics, providing causal/effect analysis, as well as estimating the sensitivities of various system design parameters on the metrics would be of value.

(7) Leveraging Potential for Sensor Data Analytics for real-time feedback needs to be investigated. In this context, there are currently more than 2.6 million miles of pipelines in the U.S.22 This network is only expected to grow. The industry faces challenges to ensure that pipeline components meet tolerance requirements for high safety and reliability. Remote sensing capabilities are also needed to predict and prevent downtime (which, in this domain can be prohibitively expensive). The industry standards are shifting from device characteristic specifications to functional specifications, leading to the possibilities for major improvements in safety.

4. Integrated sensors for remote monitoring & prognostics: A transformative shift from detect-and-fix to predict-and-prevent is crucial for increasing the efficiency and decreasing costs associated with exploration and extraction. A holistic approach for manufacturing components for extraction (drilling tools, feeder line pipes and pumps) and transport (pipelines, valves) with integrated sensors from the early design stage is needed to enable this task. In this context, the O&G industry and U.S. Department of Energy have envisioned O&G production enterprise as a smart manufacturing system with sensors, data analytics, and control platforms that together bring substantial improvements in performance and efficiencies.

Sensors are essentially needed to measure the ambient vibrations and shocks, pressure and temperature fields during the drilling process, and to measure flow rates, structural integrity, temperature and pressure during extraction and transportation stages of the O&G value stream. Among the sensors, vibration sensors were noted to be of most value. Due to increasing reach for both unconventional and subsea operations, long pipes create significant wobble during the process. It was observed that harmonic distortion at certain rotary speeds and penetration rates causes unacceptably high levels of drill head wobble that affects hole size control. The phenomenon is akin to chatter in conventional machining processes. Methods to measure vibrations at the drill tip edges would be needed given the uncertainties associated with the rock formation (here, the “workpiece”) properties.

While some efforts have been made towards inserting vibration, temperature, pressure and load sensors into the PDC inserts (see Fig. 423) the issue of communication (telemetry) remains a challenge. Current

22 U.S. Dept. of Transp, Pipeline & Hazardous Materials Safety Admin. http://www.phmsa.dot.gov, 2013 23 D. Werschmoeller, K. Ehmann, and X. Li, ASME J. Manuf. Sci. Eng., 133(2), p. 021007, 2011.

Figure 4. Embedded sensors in PCBN tools.

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methods for long range communication between the drill bit and the on-ground control include the use of fluid acoustic waves, electric or optical cables, along-string acoustic signals, and formation electromagnetic waves. Significant advances in adaptations of these technologies are essential to facilitate effective measurement and data gathering.

For the sensor platform to be effective, high temperature electronics technologies need to be developed further. The industry needs substantial advances in high temperature electronics and hybrid packaging technologies to enable functioning of the sensing elements, active components, capacitors, magnetics, batteries, electric motors, and cooling elements up to 250 C. The current technologies are adequate for up to 150 C.

Also, as noted in the subsea sector case study, the industry is looking for sensor units with dimensions of the order of one-inch in length to measure ambient temperature and pressure with 10% accuracies, and functioning over a range of 0-20,000 psi pressures, and 0-350 F temperatures. Such miniature sensors are essential to detect leak and impacts and are considered important elements for safety and integrity assurance.

The extreme environments in the O&G operations drive the issues of sensing, actuation, as well as communication and control networks. From sensing standpoint, the O&G sector presents some unique challenges. Some of these challenges are as follows:

(a) Inaccessibility to the key processing zones (e.g., edges of the drill head during operation),

(b) High failure rates of the sensors and communication systems due to the extremities and uncertainties associated with the operating environments,

(c) Long range of communication due to ever-growing reaches of downhole operations, coupled with the limitations of the standard electromagnetic waves-based wireless networks in the unconventional and subsea environments.

Innovative approaches are needed to address these challenges. Some of the possible research directions in this context are as follows:

(1) About 70-90% of a data analyst’s time is spent cleaning the data to make it compatible as an input to various analytics tools. Given the challenges associated with data gathering, there is a need for methods to effectively use intermittent data from various sensors for longitudinal tracking of the process and performance variables in O&G manufacturing operations. Also, given the safety issues in this context, prediction and prognosis of impending faults and anomalies as opposed to detection would be of immense value.

(2) Robust sensors and communication systems, including optimal design of sensor and communication redundancies are needed due to the current levels of failure rates..

(3) Given the challenges with data acquisition, there is a need to fundamentally rethink the history matching approaches employed to model the O&G reservoirs to facilitate optimal extraction. The current history matching approaches are essentially based on elaborate computational models that are adjusted based on information from remote sensing data and downhole measurements. Recent industry R&D

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efforts have recognized the need to consider the inherent uncertainties, especially due to measurement errors, limited data resolutions, and dynamic variations in the domain parameters. While some interesting research possibilities exist in deriving uncertainty quantifications, there appears to be a need to address the key question of what is the simplest possible model to address a particular issue? Is the most informative model the best? Conversely, how much data is needed to address a specified issue (e.g., optimal planning to cutter head path for maximum extraction rates)? Predictive analytics approaches that can use intermittent, noisy data from heterogeneous and at times redundant sources may be necessary to address these challenges. Analytics tools for sparsification, binning and advanced regression (e.g., Bayesian splines) need to be advanced and/or adapted to address specific issues. Furthermore, there is a need for the industry to work with the academic partners to facilitate improved data sharing mechanisms.

(4) The increasing use of sensors in this domain opens the exciting possibilities for dynamic optimization of processes such as drilling, transmission, and extraction. The industry has been pursuing managed pressure drilling towards dynamic optimization of process parameters to maximize extraction rates. While optimal control theory can be applicable in this context, given the uncertainties inherent to this environment, guaranteeing of the performance becomes essential for these control techniques to be of practical value. The emerging area of cyber-physical systems can also offer new means for systems-level engagement to address the key issues. New analytical models and algorithms are also needed to extract knowledge from very large data streams and provide decision support to mitigate risk and optimize performance in various upstream and midstream processes.

5. Manufacture of components with complex internal features: Components with complex internal features (e.g. optimized cooling channels, casings or lightweight honeycomb structures) are potential game changers for tooling and components in the O&G industry. Also, much of the value added industry production processes take place in remote regions (e.g., rural areas of West Texas or Oklahoman panhandle) for the unconventional (shale) extraction, as well as hundreds of miles from the coast for offshore and subsea operations. Local availability for spare parts remains a major challenge. Localized production of custom components would be potentially transformative. Colloquially known as 3D Printing, Additive Manufacturing (AM) offers unique capabilities to produce a variety of arbitrarily complex physical parts directly from 3D CAD models without the need for expensive custom tooling.24,25 The “tool-less” production feature allows rapid production of components in remote locations and emergency situations. Technical challenges still need to be addressed regarding the qualification and certification of AM parts in the O&G industry, such that their properties are sufficient to withstand harsh operating conditions. Recent research interest among the manufacturing community with hybrid manufacturing processes, as well as development of machines tools to perform hybrid manufacturing was noted to be of immense value to the industry.

6. Lifecycle assessment of O&G value stream: Shale gas production has led to a new abundance of natural gas in the U.S., with a 12-fold increase in production over the last decade.1 There are a multitude of underlying technical challenges in the shale drilling and the completion, and production phases. The manufacturing community can specifically engage to (1) provide in-process reservoir monitoring capabilities through sensors and analytical models, and (2) assess the environmental and GHG footprints

24 T. Wohlers and T. Caffrey, 2013, “Additive Manufacturing: Going Mainstream,” Manufacturing Engineering, June, pp. 67-73. 25 J. Scott, N. Gupta, C. Weber, S. Newsome, T. Wohlers, and T. Caffrey, Additive Manufacturing: Status and Opportunities, Science and Technology Policy Institute, Washington, D.C., 2012.

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for shale gas production to ensure minimal environmental impacts. The workshop also noted that enhancing sustainability of fossil energy relates to advances in manufacturing technologies. In particular, further research in advanced manufacturing can lead to enhanced oil recovery (EOR), and effective utilization of resources employed in the unconventional sector can be realized. For example, in the current practice, surfactants are used to enhance oil recovery; however, about 65% of the oil is left behind (in the intermediate stage of extraction) in the reservoir. Manufacturing of surfactants can enhance oil recovery by 30-60% of the remaining oil compared to the current practice. The use of miniaturized sensors to monitor asphaltenes in oil wells is important as its presence in the pipeline is known to affect the transport systems’ structural integrity and degrades the production system’s performance. Detection and remediation of the tar balls (asphaltene) is therefore an impactful research challenge. There is a need to develop methods to process advanced materials such as bottom up engineering of well cement using a combination of experimental and modeling approaches. Advancing manufacturing technologies for the currently undesirable byproducts from O&G extraction would be of immense value. For example, synthesis of carbon nanotube soft conductors with strong repeatability from precursors such as asphaltene can be investigated. Additionally, bioconversion of natural gas can significantly reduce flare gas, thereby contributing to reducing this sector’s the environmental impact. The bioconversion gas to liquid (GTL) processes can generate water that can be employed as part in fracking operations. These advances can make O&G wells self-sustaining through water production in a GTL process (after the initial startup). In a similar vein, it was noted that issues with membrane fouling in the filtration steps employed in the upstream and midstream of the O&G energy industry can be addressed through innovations in nanomaterials processing.

Education, Public Policy and University-Industry Partnership Needs

Innovations and R&D drives competitive edge in manufacturing. There are several challenges towards developing stable workforce needed to sustain a competitive edge in advanced manufacturing for the O&G industry. Some of the challenges identified during the workshop are as follows: (1) Rapidly changing demographics, where workforce is graying to an extent that in some of the niche sectors the average age exceeds 70+ years: Less than 10% of the workforce engaged in advanced manufacturing is below 30 years old. (b) Higher skill levels are required to pursue a career in advanced manufacturing compared to those needed to begin a career in the service sector. (c) Shrinking number of qualified student (applicant) pool, as the industry is noticing deficits among the job applicants in critical thinking, communications, personal interactions, team and group interactions, and technical STEM disciplines, especially mathematics. (d) Poor perception of manufacturing careers among the general population: Manufacturing is typically associated with 4Ds, namely dirty, dangerous, demeaning, and decreasing.26 Supplanting these 4D's with 4I's (innovative, impactful, interesting and increasing) remains a key societal challenge and responsibility. (e) Social discipline needed for a career in advanced manufacturing including safety considerations sometimes are not instilled among the high school students.

26 http://newenglandcouncil.com/op-ed/advanced-manufacturing-key-to-growth/

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Towards addressing these challenges, it was noted that novel approaches are needed at K-12 through advanced stages of education, especially to develop a strong pool of qualified students to sustain competitiveness in advanced manufacturing. For example, gamification of the manufacturing processes associated O&G industry, would simplify the learning modules by making highly engaging gaming activity as a tool to get larger sections of the populations involved. Another imperative appears to be to partnering with community colleges to train (with a focus on the regional industry e.g., O&G advanced manufacturing technologies for the Houston region)and provide highly qualified employees after training. However, needs for training should be clearly identified. The education program at this level should provide wider access, and the curriculum should be shaped to meet the objectives keeping in mind the preparation of the general group of students enrolled in the program. Towards a strong thrust in this direction, there needs to be a strong investment on a new training facility. Innovative programs that create a pipeline for higher education from K-12 via community colleges would be helpful in attracting larger pool of students to pursue careers in advanced manufacturing. On the higher education front, it was noted that carefully designed co-op programs that do not adversely affect graduation timelines are essential. Currently graduation timelines for the best students in some of the premier engineering programs, key audience for participation in coop programs, are longer than those for average students. Universities have to work with industry partners to design innovative coop programs that will enable students to earn credits towards their degree as they engage in coop activity. A survey and formulation of best practices on this front would be of high value to the industry. It was also noted that the graduates from advanced degree programs are well trained in the analysis of the problems but are not experienced nor trained to innovate. Universities need to reevaluate DEng and MEng programs as possible routes to develop graduates who can pursue innovation and entrepreneurship as part of their careers. In addition to education, outreach agencies (e.g., Texas Engineering Extension, TEEX) need to play a vital role in training the workforce on the critical skills as well as to provide the facilities for testing and certification of critical manufacturing processes and their outcomes. For example, TEEX activities in the O&G sector include workforce development, training associated with fire protection, infrastructure and safety, OSHA safety center, water use/reuse, and operational testing. Copious opportunities exist in areas such as smart materials (nanosensors) and scaled coatings, and lean and data analytics practices. Public-private partnership involving such outreach agencies are also essential to promoting industry-driven research and open large data sets sharing. From a public policy standpoint, advanced manufacturing is a bipartisan issue, and is expected to see continued support, especially in the context of the O&G energy industry. The president's Climate Action Plan aims to reduce methane emissions includes modernizing natural gas infrastructure, reducing emissions in mid and downstream operations by supporting the development of advanced technologies for methane detection and measurement, and providing up to $8B in loan guarantees for advanced fossil technologies such as advanced wellhead technologies and flare reduction methods.

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Another major policy issue is presented by the culture of the O&G industry. The industry is highly fractionalized. Companies zealously protect what they perceive as their core and non-core capabilities. Such proprietary interests have impeded technology utilization and actually prevent any interest in funding research. Along similar lines, all processes are viewed locally, i.e., each company understands what they do and their processes to do it. There is no overall integration of processes. Thus there exists little understanding of cross-cutting problems or opportunities. It was also noted that a strong public-private partnership is essential to effectively address the whole gamut of advanced manufacturing needs in the O&G energy industry, and thus bring about a culture change. Such a partnership would help de-risk investments via shared data and cases, development of precompetitive technologies, and/or test-beds. The contributions and investments need to be made by public and local government, the private sector, the regional industry that would have the highest stake in attracting students from local educational institutions, and academia, including the universities, minority serving institutions and community colleges. An example of Smart Manufacturing Leadership Coalition (SMLC)27 a DOE project test ted with Praxair and other partners, was noted as a model. Here, dynamic energy management and cross-unit performance R&D activities were promoted with an $8M investment from public-private partnership. In the context of advanced manufacturing, such a partnership needs to be cross-disciplinary. Academic institutions should take the lead in bringing industry in as a participant and launching interdisciplinary partnerships. Issues such as sensors, application of controls, data analytics, and standardization of these technologies can be of great near-term value to the industry; opportunities exist for federal government support per AMP2.0.28

Summary of recommendations

The following recommendations to the federal and state agencies, academic community and the industry have been derived based on the discussions during the workshop.

1. Research: It was evident that the O&G energy industry presents key scientific challenges pertinent to advanced manufacturing. A specific recommendation is to pursue follow-on workshop(s) focusing on the following elements (these workshops may be supported by multiple federal agencies, especially the programs within CMMI division of NSF, jointly with DOE): (a) Tooling for downhole drilling operations, addressing the design issues, drilling process mechanics (combining geological science with modern machining, just as how early machining mechanics evolved from physical and inorganic chemistry experiments), sensing and quality monitoring; (b) Data analytics for quality and performance assurance approaches for custom manufacturing environments germane to the O&G sector (as opposed to the current quality control type methods that are mostly developed for high volume manufacturing systems); (c) Optimal operation planning based on rethinking the way geo-technical data and models of various fidelities are used (e.g., using the high resolution information of local geological structure to develop the drill path and pad walking strategies in horizontal drilling would be highly impactful in terms of transforming how drilling plans are developed); (d) Materials processing advances, especially in coating and joining and high temperature electronics and transduction technologies; (e) Nano-fab and nanomanufacturing technologies that can harness materials released into the environment as waste (e.g.,

27 https://smartmanufacturingcoalition.org/ 28 http://www.manufacturing.gov/amp.html

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one speaker noted that 30% of the gases extracted at O&G site is released in the form of flare, and the residues from a drilling site post water reclamation can have major engineering value); (f) Production control and logistics approaches for custom manufacturing as well as other such scenarios that are prone to large variations in demand and pricing, and have limited supply chain options (these scenarios pose significant modeling and policy challenges); (g) Promotion of a systems point-of-view for upstream operations (this point-of-view has led to great strides in improving quality and reducing risk in the aerospace industry which also operates in extreme environments). Some of these specific challenges need to be further articulated to facilitate suitable research initiatives.

2. Public policy: Public-private partnerships aimed at enhancing and translating academic research into precompetitive technologies are essential to improve the productivity of upstream processes in the O&G energy industry. The federal agencies, especially the NSF, can take the lead to encourage Industry-University cooperative research centers focused on advanced manufacturing aspects for the O&G energy industry. They should also provide seed funding to establish consortia along the lines of SMLC. Several members have also stressed the role of NSF in concert with the academic community to bring promote “culture change” in the O&G energy industry practice. It was recommended that the government, the industry and academic institutions work towards establishing an integrated manufacturing institute focused on custom distributed manufacturing of high value components, which is the predominant manufacturing paradigm of the O&G energy industry. The strategic imperative of such an institute was noted by several delegates.

3. Education and training of engineering and technical workforce in custom manufacturing has been noted as a major need for the O&G energy industry. It is recommended that multidisciplinary, and multi institutional teams involving universities, minority serving institutions, and community colleges be formed with support from NSF and industry to develop holistic education programs in custom manufacturing. It was also recommended that that such education and workforce development programs be expanded by involving state and local governments, chambers of commerce, and the regional industry to establish training and educational programs. Such programs should be offered via community colleges and technology schools. Additionally, hands-on project experiences in custom manufacturing, especially for the underprivileged groups should be provided by initiating REU programs. It was also recommended that universities explore creative co-op programs with support from NSF to allow high-achieving students to gain valuable practicum experiences.

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Appendix 1: Workshop Program

NSF Workshop on Advanced Manufacturing for the Oil and Gas Energy Industry

Program Details

Day 1 (Sunday, November 2, 2014): o Delegate arrival and check-in o 6:30-8:00 PM: Evening registration, reception and poster presentation.

Day 2 (Monday, November 3, 2014):

o 7:00-8:00 AM: Continental Breakfast o 8:00-8:15 AM: Host welcome and Advanced Manufacturing at Texas A&M/TEES, Dimitris Lagoudas,

Associate Vice Chancellor for Engineering Research, Deputy Director of TEES, and Senior Associate Dean, Dwight College of Engineering, Texas A&M University

o 8:15- 8:30 AM: Advanced Manufacturing for Oil and Gas Energy industry—NSF perspective, Z.J. Pei, Program Director, National Science Foundation

o 8:30 AM-12:30 PM: Research needs in advanced manufacturing technologies and machines for O&G energy industry Chair: Arun Srinivasa

8:30-9:15 AM: Research needs—Department of Energy perspective, M. Johnson, Director of the Advanced Manufacturing Office, Department of Energy

9:15-9:45 AM: Research needs in downhole processes, T. Collins, Technical Advisor, Schlumberger Enabling Technologies Group, Houston

9:45-10:00 AM: Coffee Break 10:00-10:40 AM: Research needs (downhole, transport technologies and machines):

10:00-10:20 AM: J. Mitre, Managing Director, Tenaris, Houston, TX 10:20-10:40 AM: E. Stull, Technology Leader, Alcoa oil and gas, Pittsburgh, PA

10:40-11:20 AM: Investigations of Rock Cutting Mechanics through Embedded Thin Film Sensor Arrays in PCD Inserts, K. Ehmann, Northwestern University, Evanston, IL

11:20-12:00 Noon: Transformative machining technology for mechanical drilling: S. Chandrasekar, Purdue University, J. Mann, CEO, M4 Sciences, West Lafayette, IN

12:00-12:30 PM: Brief panel discussion on research issues Collins Schlumberger, Chandrasekar Purdue University, Zhang Valv Technologies, Mitre Tenaris, Stull Alcoa

o 12:30-1:30 PM: Lunch o 1:30-4:00 PM: Research needs in manufacturing systems for O&G energy industry

Chair: Andy Johnson 1:30-2:15 PM: Subsea Challenges: Developing the next generation oil field, D. Grauer,

Technology Manager, OneSubSea, Houston 2:15-2:45 PM: NSF I/UCRC Program: developing Industry-University long-term partnerships, R.

Montelli, Program Director, National Science Foundation 2:45-3:00 PM: Coffee Break 3:00-3:45 PM: State of the art (systems): P.R. Kumar, Texas A&M, College Station, TX 3:45-4:15 PM: State of the art (informatics): Y. Ding, , Texas A&M, College Station, TX

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o 4:15-5:30 PM: Plenary discussion on research issues Grauer OneSubSea, Kumar Texas A&M, Ding Texas A&M, Krishnamurthy Wisconsin, Shivpuri Ohio State University, Bremner Hoerbiger

o 6:30-8:30 PM: Working Dinner (Future trends in offshore energy manufacturing: Gutierrez, Director of Technology and Innovation, Transocean, Houston, TX)

Day 3 (Tuesday, November 4, 2014): o 7:00 AM: Continental Breakfast o 8:00-11:00 AM: Education, industry-University cooperation and public policy

Chair: Michael Johnson 8:00-8:45 AM: Translation of the Smart Manufacturing Paradigm to Oil and Gas Production,

T. Edgar, University of Texas , Austin, TX 8:45-9:30 AM: Unconventional technologies for unconventional oil & gas, R. Gonzalez, Rice

University, Houston, TX 9:30-9:45 AM: Coffee Break 9:45:10:15 AM: Public policy and industry-University cooperation needs and opportunities

• M. Brewster (AAAS fellow), DOE, Washington, DC • Caleb Holt, TEEX, TX

10:15-11:00AM: Education and workforce development needs and opportunities • M. van den Elsen, MIC group, Houston, TX • D.Yeager, Blinn College, Brenham, TX • G. Stevens, Houston Community College System, Houston, TX

o 11:15-12:00 Noon: Panel discussion on education, industry-University cooperation, and public policy Mann M4 Sciences, Edgar University of Texas, Gonzalez Rice University, Stevens Houston Community College, M. Brewster (AAAS fellow), DOE, Kristina DeWitty Texas Workforce Commission

o 12:00-12:15 PM: Workshop conclusion and follow-up o Afternoon: Delegate departure

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Appendix 2: Speaker Information and Biography

Session 1

Advanced Manufacturing for Oil and Gas Industry—Welcome note from the National Science Foundation by ZJ Pei, National Science Foundation

ZJ Pei is the program director of the Manufacturing Machines and Equipment program at NSF. He is also a professor in the Department of Industrial and Manufacturing Systems Engineering at Kansas State University (KSU). He received his PhD in Mechanical Engineering from University of Illinois at Urbana-Champaign and has four years of industrial experience. He is an ASME Fellow and has received NSF CAREER award (2004), Commerce Bank Distinguished Graduate Faculty Award (2011, KSU), Iman Outstanding Faculty Award for Research (2013, KSU Alumni Association), Frankenhoff Outstanding Research Award (2008, KSU College of Engineering), and Outstanding Senior Scientist Award (2010, KSU Chapter of Sigma Xi). He serves as an associate editor for three journals (Journal of Manufacturing Science and Engineering, Machining Science and Technology, and Journal of Manufacturing Processes) and an editorial board member for seven journals (including International Journal of Machine Tools and Manufacture). He has published more than 130 journal papers, 130 conference papers, three patents, and eight book chapters. He has graduated 10 PhD students with six of them working in academia and the rest in industry.

Advanced Manufacturing—TEES/TAMU perspective by Dimitris Lagoudas

D. C. Lagoudas currently is the Associate Vice Chancellor for Engineering Research, Senior Associate Dean for Research, Deputy Director of TEES and the inaugural recipient of the John and Bea Slattery Chair in Aerospace Engineering at Texas A&M University. He serves as the Director for the Texas Institute for Intelligent Materials and Structures (TiiMS). His research involves the design, characterization and modeling of multifunctional material systems at nano, micro and macro levels with averaging micromechanics methods developed to bridge the various length scales and functionalities including mechanical, thermal and electrical properties of nanocomposites. He has co-authored about 400 scientific publications (more than 160 in archival journals) in the area of modeling and characterization of shape memory alloys. He also served as the co-chair of NASA's Roadmap panel for Nanotechnologies. He was the inaugural recipient of one of the two Ford Motor Company Professorships at Texas A&M University, he is a TEES fellow, a TAMU Faculty Fellow and he is an Associate Fellow of AIAA and a Fellow of ASME, IOP and SES. He served as an Associate Vice President for Research for Texas A&M University from 2001- 2004, and as the first chair of the Materials Science and Engineering Program at TAMU. He is the 2011 recipient of the SPIE Smart Structure and Materials Lifetime Achievement Award.

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Advanced Manufacturing—Department of Energy perspective, by Mark Johnson, Department of Energy

Mark Johnson serves as the director of the Advanced Manufacturing Office (AMP) at the Department of Energy (DOE), and has served as a program director at DOE’s Advanced Research Projects Agency - Energy. Earlier, he served as the director of the Industry and Innovation Programs for the Future Renewable Electric Energy Delivery and Management (FREEDM) Systems Center, a National Science Foundation Gen-III Engineering Research Center targeting the convergence of power electronics, energy storage, renewable resource integration and information technology for electric power systems. He is an associate professor of materials science and engineering as well as director of Engineering for the Technology, Entrepreneurship and Commercialization (TEC) Program at NC State University. His work focuses on the intersection between smart-grid; renewable energy, advanced semiconductors; communications and photonics technologies; entrepreneurship; tech-transfer and public-private partnership formation.

Advanced Manufacturing needs in downhole processes by Tony Collins, Schlumberger

Dr. Collins serves as a Technical Advisor in the Schlumberger Enabling Technologies Group and is the Schlumberger-wide contact for materials and manufacturing process related enquiries. He bring over 30 years of experience in quality and reliability, sustainable engineering, design for manufacturing, and materials selection and development, and serves as the Tasks Group Chair for API standards SC5. He received his MSc and PhD degrees in Mechanical Engineering Materials from the University of Waterloo, and MA in Engineering from the Cambridge University.

Investigations of Rock Cutting Mechanics through Embedded Thin Film Sensor Arrays in PCD Inserts, by Kori Ehmann

Professor Ehmann received his B.S. and M.S., degrees in 1970 and 1974 respectively from the University of Belgrade and his Ph.D. degree from the University of Wisconsin-Madison in 1979, all in mechanical engineering. He serves as a Professor in the Department of Mechanical Engineering at Northwestern University, and as an Assistant Professor from 1981 – 1985 in the Department of Mechanical Engineering at the University of Wisconsin-Madison. He has also held positions as an Adjunct Professor of the Department of Mechanical and Industrial Engineering at the University of Illinois at Urbana/Champaign, a Distinguished Honorary Professor of the Department of Mechanical Engineering at IIT-Kanpur, India, a University Chair Professor of Chung Yuan Christian University, Chung Li, Taiwan and a Visiting Professor at the University of Belgrade. He is currently the editor in

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chief on the Elsevier/SME Journal – Manufacturing Letters. He has served as the Technical Editor of the ASME Transactions: Journal of Manufacturing Science and Engineering, as the President of the North American Manufacturing Research Institution of the Society of Manufacturing Engineers (NAMRI/SME), as the Chair of the Manufacturing Engineering Division of the American Society of Mechanical Engineers (MED/ASME) and as the director of the International Institution for Micromanufacturing (I2M2). His main research interests are in the interrelated areas of machine tool structural dynamics, metal cutting processes and dynamics, computer control of machine tools and robots, accuracy control in machining, and micro/meso-scale manufacturing. Professor Ehmann was named in 2004 the James N. and Nancy J. Farley Professor in Manufacturing and Entrepreneurship at Northwestern. He was awarded a Distinguished Visiting Fellowship by the Royal Academy of Engineering at Cardiff University, the SME Gold Medal, MED/ASME Outstanding Service Award, NAMRI/SME Outstanding Lifetime Service Award, ASME: Blackall Machine Tool and Gage Award, and the ASME: Milton C. Shaw Manufacturing Research Medal and the ASME Ehmann Medal. He is a Fellow of ASME and SME.

Drilling challenges and leveraging aluminum and associated manufacturing technologies by Eric Stull, Alcoa

Two challenges the oil and gas industry face when drilling is the ability to drill longer laterals and the ability to drill in deeper waters offshore. Traditionally, the industry builds a bigger rig or drill ship to address these issues. The industry needs to look beyond these traditional approaches, including materials and manufacturing processes, to meet these challenges. The use of aluminum with its inherent material characteristics and the manufacturing processes associated with it has allowed for the development of proven products to address these challenges. Recent case histories have proven the value of aluminum products as an enabler in drilling applications, but there are still manufacturing challenges that need to be addressed to take full advantage of what the material has to offer. Our goal is to develop products that bring value to the industry by embracing this material and developing solutions to existing process or manufacturing challenges.

Eric Stull is the Business Technology Leader for Alcoa oil and gas located at Alcoa’s light metals research facility outside of Pittsburgh, PA. Eric is responsible for working closely with the Alcoa oil and gas business to develop, deliver, and implement technologies, products and solutions which are aligned with business strategies and market needs. He manages the Alcoa oil and gas technology team in identifying and assessing differentiated growth options, including synergies from adjacent markets and emerging technologies. Prior to oil and gas, Eric has spent 19 years at Alcoa holding various roles in technical and leadership positions supporting product development in a number of markets including automotive and defense. Eric earned a BS degree in mechanical engineering from Point Park University.

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Transformative machining technology for mechanical drilling by “Chandy” Chandrasekar and James Mann

Srinivasan Chandrasekar is Professor in the Schools of Industrial Engineering and Materials Engineering, and Director of the Center for Materials Processing and Tribology at Purdue University. His research and teaching interests are in manufacturing, materials processing, structural materials and tribology. He has authored or co-authored 140 journal papers and 14 patents in these areas. Dr Chandrasekar’s current research is supported, among others, by the NSF; U.S. Army Research Office; U.S. Department of Energy; and companies including Cummins, GM, Seco Tools, Third Wave Systems and M4 Sciences. During 1994-1999, Dr Chandrasekar served as co-PI of the 10 million dollar NSF-ERC for Collaborative Manufacturing at Purdue. Awards received include an NSF Presidential Young Investigator Award (1990); the ASME Burt L. Newkirk Award (1994); Visiting Associateship from Darwin College, Cambridge, U.K. (1992); R&D 100 Award (2010); and Brahm Prakash Visiting Chair (2009-2010) at the Indian Institute of Science.

James Mann is CEO and founder of M4 Sciences Corporation, a manufacturing technology company based in West Lafayette, IN; and Research Staff member in the Center for Materials Processing and Tribology at Purdue University. His research interests are in advanced machining processes, materials processing, machine design and tribology. At M4 Sciences, he has pioneered the development and commercialization, among other things, of modulation-assisted drilling technology. This technology has demonstrated 5X increase in productivity with 10X increase in drill tool life in industrial customer applications encompassing orthopedic, energy and transportation sectors. Product sales of TriboMAM drilling systems introduced in 2010 have reached 15 countries to date. M4 Sciences is the recipient of an R&D 100 award (2010) and the U.S. Small Business Administration Tibbetts award (2011).

Plenary session

Panelists: Johnson DOE, Collins Schlumberger, Chandrasekar Purdue University, Zhang Valv Technologies, Mitre Tenaris, Stull Alcoa

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Session 2

Subsea Challenges: Developing the next generation oil field, Diana K. Grauer

Dr. Diana Grauer (BSME 2006, Ph.D. 2010) is the Technology Manager for OneSubsea, a Cameron and Schlumberger company. OneSubsea provides complete, engineered subsea oil and gas production systems. Dr. Grauer manages the OneSubsea technology competitive landscape and product portfolio map. She leads all long term development efforts, including fundamental research supporting the next generation of subsea technology, and manages collaboration and outreach activities with universities and development partners. Dr. Grauer joined the OneSubsea family from Cameron, where she was the NPD Engineering Manager of Technology & Engine Development for the Process & Reciprocating Compression Division. She and her team were responsible for NPD in support of new and aftermarket reciprocating compression products, specifically stationary natural gas transmission engines, turbochargers, and related technology. Prior to Cameron, Dr. Grauer held several positions in various roles in academia and government, including working as a Research Engineer jointly engaged by the Advanced Process & Decision Systems and Energy Efficiency & Industrial Technology departments at the Idaho National Laboratory. She worked on the dynamic analysis of Hybrid Energy System integration, as well as large scale system optimization of dynamic combined heat and power generation cycle performance. Dr. Grauer earned both her Bachelor of Science and Doctorate in Mechanical Engineering from Kansa State University.

Manufacturing Systems Engineering opportunities for the oil and gas industry, P.R. Kumar

P. R. Kumar obtained his B. Tech. degree in Electrical Engineering (Electronics) from I.I.T. Madras in 1973, and the M.S. and D.Sc. degrees in Systems Science and Mathematics from Washington University, St. Louis, in 1975 and 1977, respectively. From 1977-84 he was a faculty member in the Department of Mathematics at the University of Maryland Baltimore County. From 1985-2011 he was a faculty member in the Department of Electrical and Computer Engineering and the Coordinated Science Laboratory at the University of Illinois. Currently he is at Texas A&M University, where he holds the College of Engineering Chair in Computer Engineering. Kumar has worked on problems in game theory, adaptive control, stochastic systems, simulated annealing, neural networks, machine learning, queueing networks, manufacturing systems, scheduling, wafer fabrication plants and information theory. His research is currently focused on energy systems, wireless networks, secure networking, automated transportation, and cyberphysical systems. Kumar is a member of the National Academy of Engineering (NAE) of the USA, and a Fellow of the Academy of Sciences of the Developing World. He was awarded an honorary doctorate by the Swiss Federal Institute of Technology (Eidgenossische Technische Hochschule) in Zurich. He received the Outstanding Contribution Award of ACM SIGMOBILE, the IEEE Field Award for Control Systems, the Donald P. Eckman Award of the American Automatic Control Council, and the Fred W. Ellersick Prize of the IEEE Communications Society. He is an ACM Fellow and a Fellow of

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IEEE. He was a Guest Chair Professor and Leader of the Guest Chair Professor Group on Wireless Communication and Networking at Tsinghua University, Beijing, China. He is an Honorary Professor at IIT Hyderabad. He is a D. J. Gandhi Distinguished Visiting Professor at IIT Bombay. He was awarded the Distinguished Alumnus Award from IIT Madras, the Alumni Achievement Award from Washington University in St. Louis, and the Daniel C. Drucker Eminent Faculty Award from the College of Engineering at the University of Illinois.

Data analytics challenges opportunities, Yu Ding

Dr. Yu Ding is currently a Mike and Sugar Barnes Professor and Associate Department Head for Graduate Programs in Industrial & Systems Engineering, a Professor of Electrical & Computer Engineering, and a Faculty affiliate of the Institute of Applied Mathematics and Computational Sciences (IAMCS), all at Texas A&M University. Dr. Ding received a B.S. degree from the University of Science & Technology of China in 1993, an M.S. degree from Tsinghua University in 1996, an M.S. degree from Penn State University in 1998, and a Ph.D. degree from the University of Michigan in 2001. His research interests are in the general areas of system informatics and quality/reliability engineering. Dr. Ding currently serves as a department editor for IIE Transactions. He is senior member of IEEE, and a member of IIE, INFORMS and ASME. More information is available on his Lab’s website, http://ise.tamu.edu/metrology .

NSF I/UCRC Program: developing Industry-University long-term partnerships by Raffaella Montelli

Dr. Montelli is a Program Director in the Division of Industrial Innovation & Partnerships (IIP), Directorate for Engineering, at the National Science Foundation, where she Co-manages the Industry/University Cooperative Research Center (I/UCRC) Program. She has also managed the Innovation Corps (I-Corps), I/UCRC and the Grant Opportunity for Academic Liaison with industry (GOALI) programs within the Directorate of Geosciences (covering four divisions, namely, Earth Sciences, Atmospheric and Geospace Sciences, Ocean Sciences, and Polar Programs). Prior to joining NSF she worked as a Senior Research Specialist for ExxonMobil Upstream Research Company, and as a Senior Exploration Geophysicist for ExxonMobil Exploration Company where she brought her expertise and experiences in Imaging, data processing, seismic interpretation, seismic attributes extraction and analysis, geophysical operations to handle technical assets transfer during ExxonMobil-XTO merger; aligned goals and plans to enable early drilling; and was part of the U.S. Onshore Unconventional Team at the Eagle Ford, Haynesville, Woodford shales. She received PhD in Geosciences from the Princeton University.

Plenary Panelists: Grauer OneSubSea, Kumar Texas A&M, Ding Texas A&M, Krishnamurthy Wisconsin, Shivpuri Ohio State, Bremner Hoerbiger

Ananth Krishnamurthy is an Associate professor in the Department of Industrial and Systems Engineering at the University of Wisconsin-Madison. His research focuses on performance modeling techniques and their applications in the design and analysis of manufacturing systems and supply chains. Topics of interest include product variety and customization, warehouse systems and distribution, and lead time reduction. He also serves as the Director of the Center for Quick Response

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Manufacturing at the University of Wisconsin-Madison. He has a Ph.D. in Industrial Engineering and MS in Manufacturing Systems Engineering, both from the University of Wisconsin-Madison.

Rajiv Shivpuri is a professor in the Department of Integrated Systems Engineering at the Ohio State University. His research focuses on modeling of manufacturing processes, design and analysis of machine tools, metal forming processes, fatigue and fracture, and finite element simulation. He also serves as the Director of the Center for Excellence in Forging Technologies at the Ohio State University. He received his Ph.D. and M.S. degrees in Mechanical Engineering from Drexel University and BS in Aeronautical Engineering from the Indian Institute of Technology.

Dr. Tim Bremner began his academic career in 1982 at the University of Waterloo in Waterloo, Ontario, Canada after obtaining both an Honors B.Sc. Degree in Applied Chemistry and a Ph.D. in Polymer Chemistry from that institution. In fall 1992, he took positions the University of Queensland in Brisbane, Australia to continue his research in the field of solid state NMR of polymers. In 1995, Dr. Bremner joined Nova Chemicals Research and Development in Calgary, Alberta, Canada, as a Senior Scientist engaged in polyethylene product development, polymerization process technology scale up and commercialization, as well as a wide range of methods development in the field of polymer characterization and melt processing technologies. In 2000, he joined Aspen Technology as a Senior Staff Engineer in the Polymer IBU, working to design and implement advanced process control (APC) and online predictive fundamental and hybrid model systems for polymerization units, and provided consulting services to international chemical and polymer companies. In 2004, Dr. Bremner joined his current employer, Hoerbiger Corporation of America, and is presently responsible for all commercial polymer products for the Hoerbiger Compression Technology division globally, including polymer based product formulation and design, materials characterization, and production oversight for all non-metallic components including supply chain issues. In the past 10 years with Hoerbiger, Tim has held positions as Production Manager, VP of Advanced Engineering, VP of Applications Engineering and Chief Scientist along with his VP of Materials Technology role. In his secondary role as the Co-Director of the APPEAL Research Consortium located at Texas A&M University, he acts to define scope and objectives of the industrially led, market focused research projects that are executed there, ensuring the requirements of the University system are met and that the member companies are getting the most value for their membership dollar.

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Session 3

Translation of the Smart Manufacturing Paradigm to Oil and Gas Production by Thomas F. Edgar, University of Texas, Austin Thomas F. Edgar is Professor and George and Gladys Abell Chair in McKetta Department of Chemical Engineering at the University of Texas at Austin, and Director of the UT Energy Institute. Dr. Edgar received his B.S. degree in chemical engineering from the University of Kansas and a Ph.D. from Princeton University. For the past 40 years, he has concentrated his academic work in process modeling, control, and optimization, with over 450 articles and book chapters. Edgar has co-authored two leading textbooks: Optimization of Chemical Processes (McGraw-Hill, 2001) and Process Dynamics and Control (Wiley, 2010) and has received major awards from AIChE and ASEE. Dr. Edgar was the 1997 President of AIChE. Tom Edgar is co-founder of the Smart Manufacturing Leadership Coalition (SMLC; https://smart-process-manufacturing.ucla.edu/), which developed a research roadmap to address smart, zero-emission, energy-efficient manufacturing. SMLC recently received an $8 million award from the Energy Efficiency and Renewable Energy program of DOE to develop software for saving energy in two industrial test beds. He was recently elected to the National Academy of Engineering.

Lifecycle issues by Ramon Gonzales, Rice University, Houston

Ramon Gonzalez is the Director of Rice’s Energy and Environment Initiative (EEi) where he leads faculty and programmatic development of university-wide energy and environment research to develop transformational and sustainable energy technologies. He is also a Professor in the Departments of Chemical & Biomolecular Engineering and Bioengineering and leads the Metabolic Engineering and Synthetic & Systems Biology Laboratory in the development of platform technologies for the sustainable production of fuels and chemicals. He has published over 60 articles in leading scientific journals, six patents or patent applications, given over 100 invited talks, holds several editorial positions in leading scientific journals, was the Program Chair of the 2011 Annual Meeting of the Society for Industrial Microbiology and Biotechnology (SIMB), and currently serves as a Director in the SIMB's Board of Directors. Dr. Gonzalez is co-founder of Glycos Biotechnologies, Inc., a Houston-based technology company.

Dr. Gonzalez is also a Program Director at the Advanced Research Projects Agency-Energy (ARPA-E) of the U.S. Department of Energy. His areas of technical focus include biological conversion of natural gas and other sources of methane to liquid fuels as well as direct synthesis of liquid fuels from carbon dioxide and energy sources (such as electricity and hydrogen). Dr. Gonzalez received a Ph.D. in Chemical Engineering from the University of Chile, a M.S. in Biochemical Engineering from the Pontifical Catholic University of Valparaíso (Chile), and a B.S. in Chemical Engineering from the Central University of Las Villas (Cuba).

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Industry-University cooperation issues in advanced manufacturing for the Oil and Gas industry

Caleb Holt, is an Economic Development Project Specialist at Texas Engineering Extension. Caleb Holt works closely with communities, economic development organizations and industry clients to provide technical assistance for economic and community development. A specialist in technology commercialization and market intelligence, Caleb is a graduate of Texas A&M University, where he is currently pursuing a graduate degree in AgriBusiness. His current focus is on economic catastrophe recovery. Marijn van den Elsen is the Director of Operational Excellence for the MIC Group. He started working for the MIC Group in 2008 where he previously held positions as Lean Operations Manager and Account Manager. Prior to working for the MIC group, he worked internationally with companies in both the USA and Europe. The industries served were semiconductor, process instrumentation & large steel infrastructure, where he held roles in Manufacturing Engineering & Quality Management. He holds a bachelor’s degree in Industrial Engineering from Texas A&M and a 4 year vocational degree in Precision Tooling from the Netherlands. Megan Brewster, Department of Energy Education issues in advanced manufacturing for the Oil and Gas industry

David Yeager serves as the Director, Workforce Education, Blinn College, Brenham, TX. He began his career at Blinn College, in 2010, as an Industrial Mathematics instructor in Brenham at the Hodde Technical Education Center. In 2012, he moved into the position of Director of Workforce Education in Brenham. Prior to coming to Blinn College, Mr. Yeager served 16 years as a Texas Public School Superintendent in Prairie Lea ISD, Three Rivers ISD, and Brenham ISD. He served in public education for a total of 29 years including as a mathematics teacher, high school coach, athletic director, assistant superintendent, superintendent, and field service agent for the Texas Education Agency. In addition to his service in public education, Mr. Yeager spent 2 years working with a large engineering firm in business development. Mr. Yeager has been Chairman of the Chamber of Commerce in Brenham and Three Rivers. Today, he continues his passion for education through the development of a stronger and highly skilled workforce in Brenham, Washington County, the Blinn Service Area and the state of Texas.

Dr. Genevieve Stevens is the Dean of Instruction at the Central College of the Houston Community College System. As dean of instruction, Dr. Stevens is responsible for providing primary administrative leadership and supervision of the academic and resource development area, technical education and workforce development programs. She works as a liaison with business, industry, public schools, colleges, and universities in forging partnerships for the development of a skilled work force and enhancing academic opportunities for students in the area served by the college. Dr. Stevens earned her Ph.D. in Counseling Psychology from the University of Houston in 1994. She also earned a M.Ed. from the

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University of Houston and B.A. in History from the University of Texas at Austin.

Panelists: Mann M4 Sciences, Edgar University of Texas, Gonzales Rice University, Stevens Houston Community College System, Brewster (AAAS fellow) DOE

Kristina DeWitty is a graduate of Huston-Tillotson University, the first HBCU in Texas, she earned her bachelor’s in business administration. Since joining the Texas Workforce Commission in 2012, she has worked in the Unemployment Division and the Office of Employer Initiatives. In her current position as Business Outreach Specialist, Kristina continues to demonstrate her passion for outreach, workforce development, and supporting the Texas business and education communities.

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presentation

Innovation Landscape in Offshore Drilling, by Jose Gutierrez, Transocean

Dr. Gutierrez is the Director of Technology and Innovation at Transocean. The objective of is department is to deliver sustainable innovation tailored for the Oil and Gas industry with the specific goal to develop and execute business and technology development activities focused in increasing revenue efficiency through the introduction of new products specially created for deepwater offshore drilling operations, augment safety, and ensure higher standards of operational integrity. This endeavor is the first in its kind in the Oil and Gas Drilling business.

In addition, Dr. Gutierrez was appointed in 2014, Adjunct Professor of Subsea Engineering in the Cullen School of Engineering at the University of Houston, providing guidance and expertize to the Subsea Engineering Program within this institution. Dr. Gutierrez has more than 20 years of experience managing innovation and technology strategy for entrepreneurial and Fortune 100 companies in multiple areas covering Medical, Residential, Commercial and Industrial applications. He received the B.S. degree in electronic engineering from Universidad Simón Bolivar in Caracas, Venezuela, M.S. and Ph.D. in electrical engineering from the University of Milwaukee – Wisconsin. Currently Dr. Gutierrez technology and innovation focus is centered on advanced drilling and well control technologies, as well as advanced man-assisted resilient and distributed control systems. Dr. Gutierrez is also author of multiple books, scientific papers, and patents.

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The Workshop Program Committees

Conference Chair

Satish Bukkapatnam, Director TEES Institute for Manufacturing Systems and Rockwell International Professor, Industrial and Systems Engineering, Texas A&M University

Co-Chairs:

Andy Johnson, Associate Professor, Industrial and Systems Engineering, Texas A&M University

Michael D. Johnson, Division Head of Manufacturing and Mechanical Engineering Technology and Associate Professor, Engineering Technology and Industrial Distribution, Texas A&M University

Arun Srinivasa, Associate Department Head and Holdredge/Paul Professor, Mechanical Engineering, Texas A&M University

Support and Advisory Group National Science Foundation Texas Engineering Experimentation Station Cesar Malave Reza Langari Andreas Polycarpou Rob Ivester

Host Organizing Committee Ergun Akleman Raymundo Arroyave Amarnath Banerjee Alaa Elwany Jonathan Felds Wayne Hung Matt Kuttolamadom Mark Lawley John Mander Bimal Nepal Sam Noyaert Dean Schneider Jerome Shubert Sreeram Vaddiraju Steve Suh Jyhwen Wang

Logistics and planning committee Cheryl Kocman, Amanda Krafft, Jose Vazquez, Satish Bukkapatnam

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