Drilling Control

System
PLC BASED CONTROL SYSTEM FOR THE OPERATIONS OF DW, MP AND
RT
VERSION 2.0
1
DePeuter Electrical Solutions, LLC
14814 Park Almeda Dr.
Houston, TX 77047
Read this entire manual before operating this equipment. Practice all rig and safety
instructions and precautions. Failure to follow instructions can cause personal injury
and/or property damage.
Any unauthorized modifications to or use of this equipment outside its specified
mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment. Any such unauthorized
modifications: (i) constitute misuse and/or negligence within the meaning of the
product warranty thereby excluding warranty coverage for any resulting damage, and (ii)
invalidate product certifications or listings.
This manual is intended to be an assistance in operating the PLC based control system, as
installed on this drilling rig.
It is the rig owners responsibility to make sure that all equipment operators and
maintenance personnel are properly trained and instructed in operating and maintaining
this equipment.
The system is outfitted with many operational safeties, but at all times the equipment
operator is responsible for verification of correct operation of the safeties and
equipment, prior to and during off the operation of the equipment.
As a minimum the IADC standards for checking safeties, as well as checking and
maintaining electrical and mechanical installations should be followed.
2
Disclaimer
This manual is written in the English language. Only personnel who fully understand English
will be allowed to operate the equipment (including normal operation, maintenance and
service).
3
Contents
Introduction5
Installation..6
OperationsStart Up7
..Set Up10
..Rotary Table.12
...Tongs13
..Mud Pumps..14
..Circulation.15
..Pit Levels...16
..Draw Works..17
..Block Calibration..18
..Crown and Block Saver.19
..Reaming.20
..Slip and Cut..20
..Auto Driller...21
..A2B....23
Alarms.24
Need to know.25
Maintenance..26
4
Introduction
The information in this manual covers the installation and setup of the DPES PLC based
drilling control system. This unit should be installed by a qualified technician using
approved materials in accordance with national, state and local codes. Read these
instructions through completely before attempting installation.
The DPES PLC based drilling control system provides controls for the MP, RT and DW on this
land rig.
5
Installation
All provided hardware needs to be used for the installation of the enclosures otherwise
NEMA / IP ratings cannot be guaranteed.
All local and international laws applicable for the installation and termination of the
electrical power supplies need to be taken in consideration when hooking up the electrical
power supply.
6
Operations
Start Up
After the engine generators are started
and the 480V breaker is closed, the PLC
system will start up. The complete PLC
control system is powered by an UPS,
installed in the main PLC cabinet inside
the VFD house. In case of a loss of
power the PLC control system will
remain on-line and running for up to 30
minutes.
When the 600V and 480V is available
you can close the breakers to power up
the rectifier sections of the VFD drive
system.
There are 2 rectifier sections, and these
can be powered up simultaneously.
In case of failure of one of the rectifier
sections the DC buss isolation switch
can be closed, and the system can be
run with one rectifier (overall available
power capacity to the VFDs will be
reduced).
Auxiliary switch on rectifier cabinet in
this position.
Main switch on Inverter Sections to be
in this position.
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For dual rectifier operation use the
controls as shown on the picture. Hold
the switch pictured bottom left until
both breakers are closed and charged.
In case of single rectifier operations, put the switch in the middle (picture above) in single,
and use the single main breaker control switch on the designated rectifier to close the
breaker of this particular rectifier section.
In dual rectifier operation the OETL DC buss isolation switch needs to be in the position as
shown below. When changing over to the single rectifier mode, than the switch needs to be
changed into the closed position, so the single rectifier will feed both sides of the VFD line
up.
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When the rectifier breaker is closed, there will be D voltage supplied to each inverter section
that has the main switch closed.
The rectifiers on this rig will supply approximately 820VDC to each inverter. You can check this
from the HMI inside the VFD house or drillers cabin.
See below for MP.
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Set Up
Before you will be able to run any of the equipment, the system will need to be set up.
This is done though the set up page.
The set up page is only available from the VFD house by means of entering a
password. The accuracy of all the data entered is the responsibility of the operator.
Entering incorrect data can cause equipment malfunction and may cause personal
injury and/or property damage, including damage to the equipment.
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Please contact DPES for any questions regarding these setpoints.
Diameter of the drum can be found by measuring the circumference of the empty drum,
and dividing this value by 3.14.
After entering all the setpoints you can calibrate the joystick.
Enter this page by pushing the yellow button at the bottom of the set up page.
To calibrate the Joystick:
1 Enter values of 20000 in the calibration value of both the joystick and joystick down.
2 Look at the joystick output value and see if this is close to 0.
3 If not close to zero than adjust either the calibration up or down calibration value to
achieve as close as to 0 as possible. The calibration value cannot be lower than
20000.
4 Pull trigger and move joystick all the way towards you. Look at the joystick output
and make sure it is positive and 20000.
5 Move joystick back to neutral position, and check that joystick value is again close to
0.
6 Pull trigger and move joystick all the way fromyou. Look at the joystick output and
make sure it is negative and -20000.
7 Move joystick back to neutral position, and check that joystick value is again close to
0.
8 Please contact DPES if there are any questions during this calibration sequence.
Once finished, press the home button.
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The operator needs to check the accuracy of all pressure sensors, hookload
readings etc, prior to running any equipment, and as required during operations.
Rotary Table
The Rotary table is an independent driven Rotary table, by an AC traction motor.
The RT has a separate airblower for cooling, and a lube pump for lubrication of the gearbox.
The RT brake is air actuated.
The motor starters for the auxiliary motors are located inside the VFD house.
The rpm and rotation of the RT is controlled through the HMI inside the drillers cabin. It can
rotate CW and CCW. Also the torque limit is set via the HMI.
The brake release is independent and the brake should be released (via HMI) prior to rotating.
The RT does not have to be ion for the operator to set or release the brake.
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RT operating screen on
the left.
RT VFD is ready for
operation when the RED
READY light shows on the
HMI.
With the START/STOP
button the VFD will be
started/stopped. Starting
the RT will cause the RT
blower and lube pump
also to start.
If both auxilaries start up
correctly, as verified by
the PLC control system,
than the RT will be
released for operation.
(GREEN RUN light will be
on)
For the RT to turn, there will need to be entered a Torque setpoint (Limit), in the
designated box on the RT HMI page. This value will need to be higher than the required
torque needed to turn the table, otherwise the table will be in torque limit and will not
rotate.
The brake can be released with the Brake Set/Release button. Under this button a green
light will show when the brake is released. Air pressure needs to be present for the
brake to be able to operate.
Required RPM by touching the blue box next to rpm. A positive value entered here will
result in rotating to the right, a negative value will result in the table to rotate to the
left.
Speed can also be controlled with the up and down arrows. The one arrow box is for
increasing/decreasing rpm slowly. The double arrow keys are for faster increasing or decreasing
of the rpm.
Push to zero rpm key, and the speed demand will reset to zero.
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Tongs
The tongs get controlled via the same HMI page as the Rotary table.
A torque setpoint needs to be set for the tongs to be able to move.
Tong CCW is the cathead on the off drillers side of the floor.
Tong CW is the cathead on the drillers side of the floor..
Mud Pumps
The rig has three MPs installed, all driven by a 1600hp AC traction motor.
Each pump is outfitted with a blower and a liner wash pump. Additionally stroke sensors are
installed as well as a pressure transducer on the output of the liner wash pump.
The MPs are controlled through the HMIs inside the drillers cabin.
The MPs can be controlled from either one of the below screens. The main MP screen (left)
shows more detail regarding the VFD system as well. The circulation screen (right) shows all the
information regarding flows, pressure and volumes of the mud system in addition to the pump
controls.
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To start a MP, you will push the start/stop button on the HMI. This will cause the MP blower
and liner wash pump to start.
When the auxiliaries are running and no faults are detected by the PLC control system, than
the system will release the VFD, and the run indication on the HMI for the MP will turn
green. The charge pump will not start at this time. It will start as soon as the pump is
running at a minimum of 1 spm.
To run the MP you can set the require SPM by either entering this into the blue box next
to the blue SPM indication, or use the up and down arrow keys.
The single arrow key is for adding or subtracting 1 spmto the pump speed. The double
arrow will add 5-10 spmper key stroke.
Pushing the zero SPM butto will result in the MP set speed to be reduced to 0SPM.
Pushing the suspend pumping button will result in the MP spmto go to 0. But the SPM
setpoint will remain at the previously set value. Pushing the suspend pumping key again
will result in the pump to accelerate back to the SPM setpoint.
Pushing the pressure Limit button will activate the pressure limiti function in the control
system.
When active, the pumps will not be able to have a pump output, as measured at the standpipe
than the limit as set in the box below the button.
When you run the pumps with this setting active, and the pressure exceeds the limit setpoint,
than the pumps will automatically reduce their setpoint, to lower the pressure output.
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Circulation
On the circulation screen you can
start/stop the MPs, control the speed
of the MPs.
All this is done in the same manner as
described in the MP section of the
manual.
On this screen you can also start/stop
the trip tanks pumps. This is done via
the RUN keys located in the middle
of the HMI screen. If the requested
pump is running them the run
indication on the HMI will turn green.
The circulation screen, also shows the level of the trip tank pumps and active mud volume.
Also shown are stand pipe pressure, gains and losses in mudvolume as well as flow out in %.
To set the gain/loss alarm, you will need to add a value to the gain loss setpoint. You can do
this by touching the setpoint box and entering the required volume for alarm in BBL.
To now activate the start point of the gain/loss alarm you will have to zero the logic. You will
have to push the zero gain loss., and after that the PLC control system will alarm the driller
at any time the gain or loss is more than the setpoint.
To set the flow alarm, you will need to add a value to the flow setpoint. You can do this by
touching setpoint box and entering the require volume alarm point in %.
To than set the zer / start point of the flow measurement you will have to push the zero
flow button located right below the measured value.
In case of either gain/loss or flow alarm, a yellow indicator will show on the alarm window
on the top right of the screen.
In addition alarm will show like any other alarm on the alarm page.
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Pit Levels
On the Pit level screen you will be able to monitor all pits, and the status of the main
pumps of the mud pit system.
On this page you also select which pits are the active pits. The active pit volume is
used for your gain and loss function (see circulation).
You activate a pit by pushing a pit button under each pit on the HMI. Green means
active, red means inactive.
The screen also shows the status of the main mud pit pumps. These pumps can
either be started locally on the pit, or directly from their starters in the MCC house.
All the starters for these pumps are located inside the MCC house in front of engine
#1.
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Draw Works
The Drawworks consists of 2 independently driven AC traction motors. The DW will under
normal operations always run with both motors powered. In case of emergency, or other
issues, you can select to run the DW by either DWA, or DWB. When running on 1 motor
the DW lift capacity has been limited to 375klbs. With 2 motors the lift capacity is
900klbs.
Full speed of the DW with the TD and block connected is about 3.3ft/sec. Maximum
speed is reduced automatically vy the control system based on hookload, or on the
position of the travelling assembly in relationship to the settings of the crown and or floor
saver.
For maintenance functions, a slip and cut function is available. When activated the DW
maximum speed is reduced to 0.25ft/sec. All system safeties are still active.
Air pressure and hydraulic pressure are required to operate the DW. Bot the rig
aircompressor as well the drill floor HPU need to be on-line prior to starting the DW.
The Dw is ready to be started when the ready indication on the HMI shows red. All
the alarms need to be acknowledged and the DW park brake button on the chair
needs to be released. Additionally prior to starting the DW the DW operation mode
needs to be assigned (DWAB, DWA, DWB).
When the DW is ready and the start button is pushed, the DW motor blower, lube
pump and the DB resistor blower will start.
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The DW brakes will not release at any time during the start up sequence.
To release the DW brake, the assigned motor or motor combination will need to show a
green light on the HMI. If this is the case and the hydraulic pressure is >1000psi and the
airpressure is >95psi, than the driller can release the brake.
He will need to hold the DW joystick trigger button and move the joystick either in the up
or down direction.
Either way he moves the joystick, the PLC control logic will send a signal to the VFD drives
that will result in the motors trying to move the block up. Because the brake is set this
will result into positive torque being developed in both motors, and once this torque
value passed the pre-set required torque, than the brakes will be released.
After the brakes are released the block can be moved either up or down depending on
block position and setpoint of crown and floor saver.
The control system will monitor that both motors are equally share the load. If a
discrepancy is noted during or after the brake release process than the brake will set and
a loadshare alarm will be shown on the HMI.
The control system will monitor the encoders on both motors as well as the drum
encoder. If a fault is detected during or after the brake is being released, than alarm will
sound, the brake will set and a alarm will show on the HMI.
Block calibration
Now that the brake has been released, this first thing to do is to calibrate the block
position.
Block calibration should be checked at any time before running the DW, after slip and
cut, after a loss of power, or at any time a height verification is required.
For this the block calibration screen needs to be accessed. The instructions on this
screen need to be followed, and after that the calibrate button needs to be pushed.
At all times the driller needs to verify the reading for accuracy, prior to operating the
DW.
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Crown and Floor Saver
Once the block position is calibrated, you will need to set the crown and floor saver. This
is done on the DW control page on the HMI inside the drillers cabin. The minimum height
for the floor saver is 0, and maximum height for the crown saver is the mast height.
The crown saver position is based on the height of the elevator plus the length of the
travelling assembly.
The operator needs to verify that in the set up page the correct length of the travelling
assembly has been entered. Failure to do so, can cause personal injury and or equipment
damage.
The floor saver position is based on the height of the elevator from the floor.
When either the crown or floor saver is activated the DW park brake will set. The DW can
still be moved in the opposite direction (floor saver active you can go up, crown saver
active you can go down). If you still require to move past the saver stop point, than you
can hold the bypass button on the HMI screen. This will allow you to travel past the stop
point to your required stop.
NOTE THAT IN BYPASS GREAT CARE NEEDS TO BE TAKEN ON POSITION OF TRAVELLING
ASSEMBLY AS ALL SYSTEM SAFETIES ARE BYPASSED.
Based on the settings of the crown and floor saver and location of the travelling assembly
in the mast, the control system will automatically reduce the maximum speed to
assembly is moving. This is required to ensure the DW stops moving right when the
travelling assembly is at the pre set stopping point.
When the mechanical crown-o-matic on the drum is activated than you will not be able to
move further up in the mast, even when utilizing the bypass button on the HMI.
You will be able to move down (at reduced speed) by pressing the override button on the
left arm rest of the drillers chair.
Pressing this button will result in the crow-o-matic air valve being by-passed, so that the
brake can be released. Pressing this button while running the DW bypasses all system
safeties.
Once the DW has lowered enough the override button should be released and the crown-
o-matic on the drum needs to be reset.
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Reaming
An automatic reaming function is available. When in operation the travelling assembly
will move up and down the mast at a pre set speed between a pre set high and low
stopping point.
To activate this function, the DW needs to be on and running and the brake needs to be
released.
You also need to enter the following information in their appropiate box (all located on
the DW HMI screen)
1 MinimumHookload (if HL measurement goes below this setpoint the reaming
function will stop)
2 MaximumHookload (if HL measurement goes above this setpoint the reaming
function will stop)
3 Elevator stopping point (low stopping point of the reaming)
4 Travel distance (distance up measured from the low stopping point)
After entering the above data the start button can be pushed. Once the reaming function
is active you can add the requested maximum speed in ft/hr. maximum speed is
1000ft/hr.
You can stop the reaming function by pressing the stop button, or by pulling the trigger on
the DW joystick.
Slip and Cut
The slip and cut function are available for
maintenance modes and raising/lowering of the
mast.
The system can only be put into slip and cut mode,
or taken out of slip and cut mode, when both DW
drives have been switched off and the brake is set.
In this situation a slip and cut button will appear and
the DW screen to activate or deactivate the slip and
cut mode.
When slip and cut mode is active, and indication can
be seen on the DW control screen indicating that the
slip and cut mode is active.
In slip and cut mode your maximum speed is
.25ft/sec, and you have full range of control with the
DW joystick
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Auto Driller
The autodriller is available for precise drilling operations in either ROP, WOB and DP
modes.
For the autodriller to be able to run the DW drives need to be running anf the brakes
need to be released.
If above permissives are met than the autodriller can be started by pushing the
autodriller on button the autodriller page on the HMI.
For the autodriller to run you will always require a setpoint in the ft/hr window of the
ROP
The setpoint entered here will be the maximum speed the autodriller will drill, regardless
of the mode of operations.
When choosing WOB, than you will need to enter a setpoint in the WOB area of the
screen (above the arrows). You can do this by entering a value of by moving the arrows up
or down. During operations of the autodriller you can always change this value.
You will also need to enter the limit. If the WOB exceeds the limit than the autodriller will
shut down.
Also the gain needs to be set. The gain values can be between 24.999 and 0.001. The
slower the drilling process the higher the gain. The gain controls the response of the
system and a properly set gain will result in an operation where the autodriller keeps the
measured value of the WOB very close to the setpoint.
Prior to starting the autodriller you will need to zero the WOB, and select WOB
operations.
When choosing DP, than you will need to enter a setpoint in the DP area of the screen
(above the arrows). You can do this by entering a value of by moving the arrows up or
down. During operations of the autodriller you can always change this value.
You will also need to enter the limit. If the DP exceeds the limit than the autodriller will
shut down.
Also the gain needs to be set. The gain values can be between 24.999 and 0.001. The
slower the drilling process the higher the gain. The gain controls the response of the
system and a properly set gain will result in an operation where the autodriller keeps the
measured value of the DP very close to the setpoint.
Prior to starting the autodriller you will need to zero the DP, and select DP operations.
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When choosing DP, than you will need to enter a setpoint in the DP area of the screen
(above the arrows). You can do this by entering a value of by moving the arrows up or
down. During operations of the autodriller you can always change this value.
You will also need to enter the limit. If the DP exceeds the limit than the autodriller will
shut down.
Also the gain needs to be set. The gain values can be between 24.999 and 0.001. The
slower the drilling process the higher the gain. The gain controls the response of the
system and a properly set gain will result in an operation where the autodriller keeps the
measured value of the DP very close to the setpoint.
Prior to starting the autodriller you will need to zero the DP, and select DP operations.
In autodrilling the regular floor saver is not active. On the autodrill HMI screen another
floorsaver setting is shown. The autodrill down floorsaver. This floorsaver can be set to
a negative value, meaning that if no great care is being taken by the operator, the
elevators can hit the floor, and may cause personal injury and/or property damage,
including damage to the equipment.
To shutdown the autodriller the operaotr can push the start/stop button on the autodrill
screen or pull the trigger on the DW joystick.
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A2B (crown saver function)
Introduction:
The L25 Radio Anti-Two-Block System provides a high reliability wireless link, from the
crown to the drillers cabin
The L25 system has a battery, with an estimated life span of 5 years.
READ AND FOLLOW THE INSTRUCTIONS OF THE LIFTEK L25 MANUAL WITH REGARDS TO
INSTALLATION, MAINTENANCE AND TESTING. FOLLOW THESE INSTRUCTIONS AT ALL
TIMES.
The L25 is linked to the rig plc control system by means of a relays that is directly
connected to the output of the A2B control unit that is mounted inside the drillers' cabin.
When the system is in operation and not activated than the output will be high, meaning
the relays will be picked up and an input will be send to the rig PLC.
This means that in case of an activation of the switch in the crown, power failure,
equipment failure, or any other issue pertaining this the A2B, the DW brake will set.
When the brake is set, and alarm will show on the Drillers HMI. The driller will be able to
lower the block by following the same instructions as when the electronic crown saver
has been activated.
There is no option to raise the block further by means of the crown saver bypass button
on the HMI. The only way you can continue to raise is by pushing the bypass button on
the control unit inside the drillers cabin.
PRESSING THIS BYPASS BUTTON BYPASSES ALL SYSTEM SAFETIES AND EXTREME CARE
SHOULD BE TAKEN BY THE OPERATOR, AS DOING THIS MAY CAUSE PERSONAL INJURY
AND/OR PROPERTY DAMAGE, INCLUDING DAMAGE TO THE EQUIPMENT.
Drillers cabin Crown
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Alarms
All active alarms are displayed on the Alarm page. Most alarms do require and
acknowledgement before they be reset.
Other alarms are self reset, like for example power limit
In all cases an acoustic alarm will sound.
Also from each operations screen the last active alarm can be seen. It is recommended
that the operator writes down the alarm number and time of the alarm prior to pressing
acknowledge. This will help in tracking alarms that have occurred and assist with
troubleshooting in case of problems.
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Need to Know
Please read the below to find some additional tips that will help with the operating of the
equipment.
To run any application, the red indicator needs to be shown. If this indicator is not
shown on the HMI than the application will not run.
After a Low DC Voltage alarm the VFD controllers will require a hard reset for the
VFD to work again. This is done by tripping the small control breaker that feeds the
power to each controller inside the VFD cubicle. Trip this little breaker for each VFD,
and set back after 30 seconds.
During lowering of the mast and substructure, the driller needs to keep a close eye on
the DC voltage for the DW drives. A voltage at 1000VDC will mean that the speed of
the lowering is too fast and the lowering speed will need to be reduced to prevent
damage of the dynamic brake resistors.
In case of RT and Tong controls, make sure torque limit is set, otherwise the application
will not move.
The Dw can lift with on motor maximum 375klbs, with 2 motors the limit is set for
900klbs.
DW max speed is automatically adjusted when getting closer to the crown saver and
floor saver setpoints. Dw max speed is also adjusted based on hook load.
Power limit setpoints of the engine generators is set at 85% of engine capacity.
Parameters like Tq limits, speed reference for RT and MP, various setpoints etc, can be
edited through the HMI. To do this, tap on the box representing this item, and a keypad
will appear on the HMI. You can now set the new setpoint by punching in the right
digits, and pressing enter. After you press enter the keypad window will close and the
updated value will be shown in the box.
The HMI inside the VFD, shows all applications and movements the drillers is doing. In
normal operatiosn no changes can be made from the screen. This screen is also the
only screen that will allow you to access the set up screen. To do this you will have to
access the commissioning pages. On the home screen press the commissioning
button. You will be requested to put in a password. Password is available though DPES.
Enter this information and press the commissioning button again. This will bring up a
new home page where for commissioning only will be flashing on the HMI. Now you
can access the set up screen and other screens that require change.
For any of the DW functions to work (autodriller, reaming) the brake will have to be
removed from its parked position. The only way to do this is to move the DW joystick
and the control system will go though its load proving logic, and if correct it will release
the brake. After the brake is released you can utilize any of the DW functions.
The DW brake will automatically set after 2 minues if the DW drum has not been
moved within this time frame.
There are 2 shutdowns on the right hand side of the drillers chair. The VFD e-stop shuts
down all VFDs. The All Kill shuts down the engine generator and kills all the power on
the rig.
Maintenance
PRIOR TO THE START OF ANY MAINTENANCE ON THE SYSTEM THE OPERATOR AND TECHNCIAIN
NEED TO SWITCH OFF AND ISOLATE ALL ELECTRICAL POWER CIRCUITS TO THE CONTROL
SYSTEM.
IN ADDITION ALL AIR AND HYDRAULIC SUPPLIES NEED TO BE SWITCH OFF AND ISOLATED AS
WELL.
LOCK AND TAG OUR PROCEDURES SHOULD BE IN PLACE AND THESE PROCEDURES NEED TO BE
FOLLOWED.
ONLY QUALIFIED AND WELL TRAINED TECHNICIANS SHOULD ACCESS AND MAINTAIN THIS
SYSTEM.
Every 6 months:
1 All electrical connections need to be checked for tightness, cleanliness and corrosion.
2 All airlines need to be checked for tightness and cleanliness.
3 All hydraulic lines need to be checked for tightness and cleanliness
4 All wiring to be checked for cracks and other damage.
5 All airlines to be checked for cracks and other damage.
6 All hydraulic lines need to be checked for cracks and other damage.
7 All filters inside VFD house to be checked for cleanliness.
8 Check all pressure transducer for operation and accuracy of read outs.
9 Check pressure gauge and verify correct reading.
10 Complete system to be checked for operations and malfunctions.
Incase of doubt in reliability of a inspected part, replace with spare or contact manufacturer.
Do not operate equipment of not 100% sure about proper functionality of system.
Support:
24/7
DPES
14814 Park Almeda Dr.
Houston, TX 77047
+1 281.509.9452
support@depeuter-es.com
www.depeuter-es.com
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