User Manual
Contents
1. 13 5 Screens of EPST touch panel 11 iecit casse sk 14 5 1 General for all Screens 5 eii Eee dele a OR e 14 51 41 Bottom section of the cite ea settee dence eoe 15 54 2 Upper section of the Screen Be ren a PR edet ene aee DR 15 5 2 Home 16 5 2 1 Procedure manual input Kf and 19 5 3 UE 20 5 4 Bottom Hole assembly 5 21 5 5 Drill Pipe Entry SCrOON eio ttt ee ergo via enge us bent sewer eee erneuert ex eene eu pants 23 5 5 1 Procedure for Kf and Cf 25 5 6 5 m 26 5 7 User Settings 27 5 8 DYSISIN SCIOCN D ETT 28 6 NANTON AN CO cece tenn eaten NANNE ANN NARREN 29 6 1 Trouble shooting guide EPST 29 6 2 Procedure Disabling the EPST system 29 6 3 System Warhlngs ii esit teo 30 7 uc p 31 7 1 Overview installation iiec eerte ede eet edet einen e Ce d raa2. 245 203044 A xui 34 5138 ET alg erg Trg Orig 619 Tos enbia samo duo pe suuN J ot 32 s 100W enjoy T 00W quiedjas paeds 80189 paads aanisog duiey 4032ejuoo snq Peyoea juiodjes pejsenbai ouo On eAgoe 330 ON 2450 ON aane nej peey uo yams ay esiey Souanbes eseud eouanbas aseyd asiMyoo loquo 514 T 3g Burupur 0 5 S Jg pig MTL sapaa EHO Operation Manual ecc ENS aandrijftechniek Communication layout between EPST Server and VFD page 2 ElectroPro 7 3 sseippy OdEd3 9 JANI AJA Woy sjeubis SpoN Snauoid TRE TO tos 69 24s Electroproject Soft Torque ElectroProject Ar Operation Manual EPST aandrijftechniek
3. DINAS NALO 9 dd N ONAGET 1 0 0 SONVIVOS 94 05210 14 92154 snayoud 025909 NIAIS HOLIMS 1994009 OLLVIWIS 10100 05990 HOH D3d SANOO SLVO 37872 LINYA 95001 5100 13909 JONVIVIS Te 51205 15 2048 0 982 025000 SNINTIS HOLIMS LANYOdd SLATS A076 4 2 HEMI HONOL YOLINOW OXVC TOQ3 ce99AV9 SNAWEIS ENYd HONOL 5 TdL YOLINOW 14 WOO 1 TREW IT SE 78 version 3 0 page 32 Operation Manual Electroproject Soft Torque Operation Manual EPST ecc ENS aandrijftechniek Communication layout between EPST Server and VFD page 1 ElectroPro 7 2 SINAYAN wrpeloidlzda lode daid 05 26 S9 0 T FA q 9 909 ABJ Jo IUN ssauisng e eur 1efoiqo25a 3 N39 em s paw 0 v sulojs S BALIG a sur 600 NOLINOINQIWWOO da snayous 5815 wa1sAs AUVLOY 1405
4. 129 ae AWSSS03N 35179 LXAL JHL NLLIHM STUNDIS T stig for 9T eueds OETAN 19 erg T eJeds erg T aueds Tug eT eueds joug 05 619 OT eueds 6 aueds OTTANI 119 g meds 918 4 9 eueds I OTTAN Apes g eueds SOTM OT 32 90TAN 2159 OT 3 OTM SARM 5815 ankua 55 55 JAND G4A 91 2dI d3 Woy sjeubis Spon SARIS Snauaud version 3 0 page 33 Operation Manual Electroproject Soft Torque Operation Manual EPST SAL SIN3S43NLQUZd3l zd3 N35 _ jus se ET 5 eere 6002 90 60 0 NOISIA38 oy c gen sees C 6002 900 SE908M NOLLYOINNWWOD da snayod palone 05 26 bb 88 0 16 Fl sedia Aejoo Jo IUN e si ausis Valoo mag sureysAs NN SALS WALSAS AYWLOY 1405 122 040 2231 AWYSSZOSN JY SANWUd LXIL IHL NLLIHM 54915 Tw version 3 0 page 34 Japoou3 Jayunoo jeuuou
5. 3 3 Settings The system has user settings and system settings The user settings not protected by password can be found at the Settings screen System settings can be found at the System screen which is password protected The system screen is only for EPST specialists Q IMPORTANT The EPST system can only be used after been commissioned by an Electroproject EPST specialist 3 4 Speed and torque monitoring On the touch panel actual values of speed and torque can be monitored in real time These values can also be monitored graphically in a trend display of 100 seconds An adjustable filter time for all display values can be set in the settings screen to avoid aliasing of the sampled trend due to the communication speed between the touch panel and the EPST controller Electroproject Soft Torque Operation Manual version 3 0 9 ElectroProject ME aandrijftechniek Operation Manual EPST 3 5 Advanced data logging The EPST controller is programmed in an IPC Industrial PC The operating system is Linux The IPC also functions as a data server for logging purposes the EPST server The EPST server stores the actual values of all inputs outputs variables markers and parameters to hard disk When the VFD is operating the resolution of this log data is 5ms Depending on the size of the applied hard disk s log data can be hold for months 0000 Mg File Datamenu Tree vi
6. 7 4 Quick Guide manual input Kf and Cf EP soft torque controller Quick guide manual input Kf and Cf EPST ON OFF Only switch ON EPST in drilling operation mode Switch OFF EPST before drilling will stop For instance in case of adding new stand ON OFF can be done by touching the screen button in the Home screen Blinking Orange OFF CHANGE Kf and Cf Kf or Cf values must be adjusted during drilling according to the drill depth Check if Kf or Cf values according to the drill depth are corresponding as listed in the Kf or Cf data sheet Entering the right settings must be done on the Home screen of the touch panel by touching Kf or Cf value fields Select Kf or Cf value enter correct value by using numerical keyboard on screen Enter to save new value Electroproject Soft Torque Operation Manual version 3 0 page 35
7. aandrijftechniek Content 1 LEE 4 11 Purpose of this mian al 1 edet 4 1 2 Basic Knowledge Requirements 4 1 3 Position in the information scheme sse nennen ener entren 4 2 iesu mee 6 2 1 NEW Ces clc 6 2 2 Recognizing when Stick Slip is occurring 6 2 3 How to reduce SlCK slip 7 3 E 8 3 1 System Pax dee eee a Run DER 8 3 2 5 9 3 3 re 9 3 4 Speed and torque monitoring 9 3 5 Advanced ata logging teret me Pr ser lv Yu 10 3 6 Romolo c 11 3 7 a SNB 11 3 8 Unit system metric or Imperial etn eee ener ne oet exi tte Re depender RR DRE Lexi HERR 11 4 Kf and Cf tuning parameters 1 euer c ener ener rern runner nnn nnne erani nana nra une 12 4 1 Principle Of Operatlon eem 12 41 1 Manual input of KFandi Of ottenere tn Da tite ende e deut Y ene 13 4 1 2 Calculation with BHA and DP
8. 1 Torque variations due to stick slip Electroproject Soft Torque Operation Manual version 3 0 page 6 E lectroP roj ect Exec Operation Manual EPST aandrijftechniek 2 3 How to reduce Stick slip Stick Slip only occurs at a rotary speed below a certain threshold value The threshold value depends on system parameters such as design of the drill string mud bit BHA and weight on bit WOB The driller can reduce stick slip by 1 Increasing the rotary speed RPM 2 Reducing the weight on bit WOB 3 Add lubricants to the mud system 4 Install Electroproject soft torque system EPST to reduce Stick slip Please note that EPST is the first soft torque system specifically developed for AC top drives and modern DC drives Soft Torque technology has been in use since the early 90 s STRS OFF STRS ON T pu E jt 2 o ME HAE TEAM Hil 160 amp 5 0 100 1280 1290 1300 1310 1320 1330 1340 1350 1360 1370 1380 1390 Time sec Figure 2 Activating soft torque In Figure 2 at 1332 seconds soft torque is switched on Torque becomes smoother and speed variations are greater This is typical when soft torque is active Electroproject Soft Torque Operation Manual version 3 0 page 7 ElectroProject MM ij i Operation Manual EPST aandrijftechniek peration Manua 3 General 3 1 System overview The EPST system is designed to be easily implemented in modern drive systems The EPST controller
9. 32 7 2 Communication layout between EPST Server VFD page 1 33 7 3 Communication layout between EPST Server and VFD page 2 34 7 4 Quick Guide manual input Kf and nennen nennen 35 Electroproject Soft Torque Operation Manual version 3 0 page 3 ElectroProject Operation EPST aandrijftechniek peration Manua 1 Preface 1 14 Purpose of this manual This operation manual is part of the Electroproject Soft Torque EPST documentation The manual provides information and guidelines for the operation of the EPST system The manual is intended for drillers and engineers operating the EPST system 1 2 Basic Knowledge Requirements General knowledge in the field of drilling installations electrical installations and automation engineering is required to understand this manual Off shore installations Additional knowledge in the field of off shore electrical installations and requirements are needed Explosion Proof installations Additional knowledge in the field of off shore installations and requirements are needed 1 3 Position in the information scheme This manual is part of the Electroproject Soft Torque EPST documentation The information below presents an overview of the information landscape of EPST system e Technical request form Provides needed technical data from top drive system to start engineering
10. is a standalone but RIG specific based controller It can operate without any interface with the RIG controls To implement the system the following hardware is required see figure 3 Touch panel to operate the system Industrial PC IPC The Soft Torque controller Additional PROFIBUS communication interface with variable frequency drive VFD Ethernet communication between touch panel and IPC If not already present speed encoder at TOP DRIVE motor o RON ST control panel Profibus 2 PLC Controller lt 4 ST Controller IPC Profibus 1 Actual speed digital encoder feedback To make the controller work properly a fast connection between VFD and EPST controller is necessarily In the block diagram above this fast connection has been made with a second profibus interface to the VFD Drill string And bottom hole assembly Figure 3 EPST System overview Electroproject Soft Torque Operation Manual version 3 0 8 ElectroProject ij j Operation M I EPST aandrijftechniek peration Manua 3 2 EPST control and input With the touch panel the EPST controller can be operated and speed and torque variables can be monitored The EPST controls consist of Switching Soft Torque ST ON and OFF 1 2 Entering the right settings for the tuning parameters Kf and Cf 3 Alternatively calculation of Kf and Cf depending on BHA and Drill pipe specifications
11. of EPST system e Installation and mounting instructions Provides guidelines for the installation and erection of EPST system e Installation Rig System On Paper IRSOP procedure Provides guidelines for the commissioning and start up of EPST system e Operation manual e Quick reference quide to EPST touch screen We trust that following these instructions the EPST system will positively contribute to your operating results for many years to come We will be pleased to supply you with further information and assistance as regards installation of your EPST system Electroproject Soft Torque Operation Manual version 3 0 page 4 E lectro roject Operation Manual EPST aandrijftechniek The Electroproject address is Electroproject Aandrijftechniek Computerweg 21 1033 RH Amsterdam The Netherlands PO box 34 1000 AA Amsterdam The Netherlands Telephone 31 88 484 92 50 E mail softtorque electroproject nl Website www electroproject nl Electroproject Soft Torque Operation Manual version 3 0 5 ElectroProject Operation Manual EPST aandrijftechniek peration Manua 2 Stick Slip mitigation 2 1 What is Stick Slip Stick slip is a common occurrence in drilling operations that can result in harmful rotational vibrations in the drill string Although the drill string is continuously rotating at surface during the drilling operation friction on the bit bottom hole assembly BHA and or drill string i
12. the safety notes in this documentation qualified persons are defined as persons who are authorized to commission ground and label devices systems and circuits in accordance with established safety practices and standards Prescribed Usage Note the following The EPST system may only be used for the applications described in this manual and only in connection with devices or components from other manufacturers which have been approved or recommended by Electroproject Correct reliable operation of the product requires proper transport storage positioning and assembly as well as careful operation and maintenance When devices or components from other manufacturers which have been approved or recommended by Electroproject and which are connected with the EPST system changes due to hardware or software updates possible malfunction of the system arise Q IMPORTANT The EPST system will become RIG specific after commissioning Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described Since variance cannot be precluded entirely we cannot guarantee full consistency However the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions Electroproject Soft Torque Operation Manual version 3 0 2 ElectroProject Operation Manual EPST
13. 4965 2382 2114 4863 2369 This table is unique for each drill string and BHA Electroproject Soft Torque Operation Manual version 3 0 page 18 ElectroProject BEI Operation Manual EPST aandrijftechniek peration Manua 5 2 1 Procedure manual input Kf and Cf Check if correct Kf and Cf table is available for the current configuration Select Home screen Switch soft torque off orange button should flash Select Kf input field press at the current Kf numeric field Depending on total measured depth MD fill in the right Kf value see example Before pressing enter button check if the entered value at the Kf field is correct Confirm value by pressing enter button 1 2 3 4 5 Numeric keypad will appear 6 7 8 9 Enter the new Cf value same procedure as Kf step 4 to 8 4 0 EPST system is now ready to be started Example for selecting Kf and Cf values A new stand is inserted Current total MD 1975 meter The next total MD in the provided table is 2000 meter The corresponding values of Kf and Cf in the provided table are Kf 5290 and Cf 2422 Enter these values in the corresponding input fields at the Home screen Before switching ST on again check if values on the touch panel are correctly entered Speed meter The speed meter gives the value for the actual drill speed of the TOP DRIVE TD Torque meter The torque meter gives the value for the actual pipe torque applied at drill pi
14. ElectroProject aandrijftechniek Businessunit of Cofely Experts bv Electroproject Aandrijftechniek Computerweg 21 1033 RH Amsterdam PO box 34 1000 AA Amsterdam The Netherlands Telephone 31 88 484 92 50 E mail softtorque electroproject nl Website www electroproject nl Electroproject Soft Torque Operation manual V3 0 Electroproject Soft Torque ElectroProject Soft Torque MIMIC Home CONTROL en BES te PIPE TORQUE 15 10 i BHA Drill Pipe Wen Trend Entry Entry Messages Settings System Operation Manual version 3 0 page 1 ElectroProject Operation Manual EPST aandrijftechniek Revision History Rev Date Description Applicable from software version 2 1 01 oct 2009 Hans Deul amp Roger Lewis version EPST V1 060 HMI V1 3 3 0 12 April 2010 Update mimics amp DPE screen EPST V1 072 HMI V1 4 Safety Guidelines This manual contains notices you have to observe in order to ensure your personal safety as well as to prevent damage to property The notices referring to your personal safety are highlighted in the manual by a safety alert symbol notices referring only to property damage have no safety alert symbol Qualified Personnel The device system may only be set up and used in conjunction with this documentation Commissioning and operation of a device system may only be performed by qualified personnel Within the context of
15. PC has been exceeded See chapter 0 EPST time out display e the VFD speed setpoint is negative for a time longer then the auto switch off time See chapter 0 Auto switch off EPST Electroproject Soft Torque Operation Manual version 3 0 page 17 ElectroProject aandrijftechniek CONTROL Kf and Cf manual input Operation Manual EPST To make the EPST controller work properly the right Kf and Cf parameters must be entered depending on bottom hole and drill string assembly configuration This can be done by touching the input fields of Kf and Cf on the main screen and must be repeated after every stand For input of Kf and Cf a data sheet must be available with the pre calculated Kf and Cf values Normally provided by SHELL Q IMPORTANT Soft Torque must be in the off state before changing the Kf and Cf parameters Kf and Cf values must be adjusted during drilling according to the drill depth to make the EPST controller work properly Wrong settings can cause instability of the system Ask for new data sheet if drill string or BHA configuration is changed Example part of Kf and Cf sheet as provided by Shell Total Measured Depth along hole Tuned values Total MD Kf Cf m Nm rad Nms rad 1800 6188 2523 1829 6046 2508 1857 5909 2493 1886 5776 2478 1914 5649 2464 1943 5525 2449 1971 5406 2435 2000 5290 2422 2028 5178 2408 2057 5070 2395 2085
16. andrijftechniek peration Manua 3 6 Remote access If the IPC is connected to a WAN network logdata and status of the IPC can be remotely accessed Even remote assistance and updates are possible If a connection has to be made between the EPST network IPC and touch panel and another network a specific TCP IP setting has to be made These settings can only be changed by Electroproject personal The standard IPC TCP IP configuration is stand alone but RIG specific with a DHCP server enabled Please contact us for other configurations 3 7 EPST off line Since the EPST system is designed as a standalone but RIG specific controller the drill operation can continue if the EPST system is off line Drill operation can continue with disconnected EPST system If the EPST is turned off the original control of the VFD is restored 3 8 Unit system metric or imperial The unit system can be changed in the settings screen Q IMPORTANT A common cause of problems with operation is wrong data input Wrong data input can be caused by the wrong choice of unit system Electroproject Soft Torque Operation Manual version 3 0 page 11 ElectroProject BEI Operation EPST aandrijftechniek peration Manua 4 Kf and Cf tuning parameters 4 1 Principle of operation An oil rig s top drive is a multi purpose controllable high power drive During drilling the drill pipe is the intermediate between a drill and the top d
17. ation Manua 5 7 User Settings screen ElectroProject Soft Torque ElectroProject MIMIC Settings aandrijftechniek Filtertime signals sec Filter time for displaying signals Auto switch of STRS sec 02 no auto switch off STRS time out display sec 02 no auto switch off Change Actual unit system Imperial Torque Unit k bf ft 1 system ft Unit for displaying lenghts Version controller 1 077 Version panel 1 6 Project Electroproject Soft torque Messages Settings System Figure 15 Settings screen Filter time signals Filter time for displaying torque and speed signals To avoid aliasing of the displayed signals especially in trends a filter time greater than 0 5 seconds must be entered To read out a mean value over a longer time this setting can be set to a higher value Auto switch OFF If actual speed set point is in reversed direction or when the TD is switched off ST will be switch off automatically after the Auto switch of time This function can be disabled by entering 0 seconds A WARNING Soft Torque must be in the off state before changing the Kf and Cf parameters or when not in rotary drilling operation Always check if ST is switched OFF when there is no rotary drilling operation Electroproject Soft Torque Operation Manual version 3 0 page 27 ElectroProject BEI ij j Operation M I EPST aandrijftec
18. b ft NC50 11 5 1 2 DP 21 90 Ib ft FH 12 5 1 2 DP 24 70 lb ft FH 1316 5 8 DP 25 20 Ib ft FH 1416 5 8 DP 27 70 lb ft FH ON Total length When switching ON the EPST system for the first time during a drilling process the existing pipe configuration need to be inputted Start to fill in the lowest connected to the BHA pipe part and fill in the total length of the corresponding pipe by using the numerical keypad Drill pipe entry length Each time a connection has been made the length of the concerning drill pipe entry must be adjusted This can be done by touching the Length field of the current drill pipe entry and fill in the right length or by means of the button If the or buttons are used to adjust the drill pipe entry length the right actual One pipe stand length must be set up correctly This can be done by touching the one stand field in the current drill pipe entry row If applicable a new drill pipe entry must be added by selecting a pipe name at the next not used drill pipe entry row The and buttons is a tool to adjust easily a drill pipe entry length each time a stand is added The mean length of the used stands must therefore be filled in the One stand length field Calculate If the settings of the BHA have been altered at the BHA entry or the settings of the drill pipe have been changed the calculate button starts blinking This ind
19. be executed check BHA and drill string configuration 5 Warning Kf Cf Settings out of range If Kf or Cf value is to high or to low an out of range error will be generated Check if Kf and or Cf values are correct inputted Electroproject Soft Torque Operation Manual version 3 0 page 30 ElectroProject Operation Manual EPST aandrijftechniek 7 Annex 7 1 Overview installation 32 7 2 Communication layout between EPST Server and VFD page 1 33 7 3 Communication layout between EPST Server and VFD page 2 34 7 4 Quick Guide manual input Kf and Cf 35 Electroproject Soft Torque Operation Manual version 3 0 page 31 Operation Manual EPST ion tallat ect NM ENS aandrijftechniek iew ins ElectroPro Overv 7 1 mela ze tod sepe OG 26 SS O TE Aq 9 909 Apuon Jo JUN sseusng e si peloda E vus E s MEND pasus quru Popup 6002 90 60 0 NoIsIAgy ey 15 oana BENE 11 Ad wj 6002900 5 804 SE908M NOLLVOINAWWOD SULS WALSAS 300301 1405 212210 40 3231 35 p nue 10 NOLO 1075 S H0 58 X0 060 JAYA SNITITSG aa hie 0 2882 0 SO STAUOS ONY YS u3HIO YO ds rises 31800009 FAIUCUALS YH LWAONIS NOLLIANNOD
20. e above a threshold value Compared to normal operation EPST is off the threshold speed value above which stick slip cannot exist is lower when soft torque is on Q IMPORTANT Kf and Cf must be adjusted each time the drill string configuration changes e g adding a stand There are two ways to specify Kf and Cf 1 Manually input of Kf and Cf Home screen 2 Calculation with integrated BHA and drill string configuration BHA and Drill pipe entry screen Electroproject Soft Torque Operation Manual version 3 0 page 12 ElectroProject Operation Manual EPST aandrijftechniek peration Manua 4 1 1 Manual input of Kf and Cf Manual input of Kf and Cf is always possible Entering the right settings must be done on the Home screen by touching Kf and Cf input fields If working with manual input of Kf and Cf a table must be provided with Kf and Cf values for each bit depth This sheet is normally provided by SHELL 4 1 2 Calculation with BHA and DP entry Alternatively the EPST controller can calculate the values of Kf and Cf For this calculation the configuring of the bottom hole assembly BHA and the drill string data has to be inputted in the EPST The input of data and calculation is done on the BHA entry and Drill Pipe entry screen for a detailed description see chapter 5 4 and 5 5 The drill pipe entry screen does have a total of three different drill pipe parts to configure Item one i
21. en an overview of the system is shown Gauges and trends with actual drill speed and pipe torque are shown Changing the display values from metric to imperial can be done at the settings screen Warning if Flashing 140 160 180 _ 120 Sec D BH Drill Pipe Trend Entry Entry Messages Settings System Figure 8 Home screen Electroproject Soft Torque Operation Manual version 3 0 page 16 ElectroProject ij j Operation Manual EPST aandrijftechniek peration Manua CONTROL ST ON OFF Switching ON and OFF is done by the ST is ON OFF button toggle function The button flashes orange in OFF state and colours green in ON state Lee Figure 9 ST button OFF state If pressed ST is OFF ST will be switched ON STRS is ON Figure 10 ST button ON state If pressed ST is ON ST will be switched OFF Switching ON the EPST controller can be done bumpless while the top drive is running If the EPST controller is switched OFF the original speed controller of the variable frequency drive VFD become active again Q IMPORTANT Make sure that the right values of Kf and Cf have been set This can be done manually as explain below CONTROL Kf and Cf manual input or calculated see paragraph 5 4 and 5 5 ST will be switched OFF automatically when e acommunication error occurs between IPC VFD e communication timeout between touch panel and I
22. er and length can be entered by selecting it s numeric input field Because of the huge variety of BHA components there is no database of components implemented in the EPST system By lumping the BHA into four major items the BHA entry can be simple and it is not necessary to maintain a large data base The BHA items must be entered from the bit up Item one is closest to the bit Unused items will not be included in the calculations It is recommended to always use the four available items to input the BHA to make the tuning as accurate as possible Electroproject Soft Torque Operation Manual version 3 0 page 21 ElectroProject Operation EPST aandrijftechniek peration Manua Material The settings for material are 1 Normal 2 Non magnetic 3 No ltem If No item is selected as material this item will not be part of the calculation of Kf and Cf Outer diameter inner diameter Length Fill in the sizes of the configured BHA items Note The unit system can be changed in the settings screen BHA Calculations The calculation of Kf and Cf can only be started after the drill pipe has been configured at the Drill Pipe Entry screen Q IMPORTANT Once drilling has started with a certain BHA configuration the entries on this BHA entry screen don t have to be adjusted anymore Electroproject Soft Torque Operation Manual version 3 0 page 22 ElectroProject aandrijftechniek 5 5 Dril
23. er on the drive will operate normally with this alarm on Electroproject Soft Torque Operation Manual version 3 0 page 29 ElectroProject ij i Operation Manual EPST aandrijftechniek peration Manua 6 3 System Warnings If the text Warning if flashing in the upper section of the screen is flashing an EPST system warning is active By selecting the text Warning if flashing the warning screen will be opened Here can be seen which EPST warning is active ElectroProject Soft Torque MIMIC ST Warnings WARNING DISK PARTITIONS FAULT COMMUNICATION DISPLAY FAULT WATCHDOG WARNING FROM CALCULATION DRILL CONFIGURATION WARNING Kf Cf SETTINGS OUT OF RANGE Figure 16 ST Warnings 1 Warning Disk Partitions If the EPST IPC is supplied with two mirrored hard disks and one of the two gives a problem the gray box after the warning will flash The system can still be operated normally but if a second hard disk fails the system can not work properly Send the EPST IPC for repair and place if available a spare EPST IPC 2 Fault Communication Display When flashing a communication timeout between the control panel and the IPC is active Check EPST time out display settings in settings screen chapter 5 7 or check wiring 3 Fault watchdog No profibus communication between EPST IPC and VFD Check if VFD is powered up or check wiring 4 Warning from Calculation Calculation of drill string configuration can not
24. ew Window Help ziBixl Text 10 07 18 400 Variables anual activate STRS MD0D D 1 Speed measured radisec Filtered drillspeed RPM 45025 36 080 Speed setpoint rad s Speed ratelimited rad sec Speed shaped rad sec Speed error rad s Bus voltage measured Volt 6 SPEED P Torque setpoint out Nm T PROP Nm TINT Nm T COMP Nm TACCEL Nm TPIPE Nm ASTC TORQUE REFERENCE Nm Torque setpoint normal drilling Nm CF Nmsjrad KF Nmjrad Percentage 6 Torque limit Nm Torque limit max Nm 30 Time sec 09 34 07 000 MO00 0 1 Manual activate STRS 09 34 07 000 Q100 1 1 STRS Active 09 34 07 000 Q100 0 1 Activate torque controller 17 23 24 000 003 1 0 Fault communication display 17 21 21 000 003 1 1 Fault communication display 17 20 02 000 001 2 0 Warning disk partitions 16 07 01 000 001 2 1 Warning disk partitions zl 23 24 2009 10 12 39 Figure 4 Screenshot ST log data view program The log data can be viewed exported and analyzed with a special EPST data log view program The EPST data log viewer can be installed on a Windows based PC Electroproject Soft Torque Operation Manual version 3 0 page 10 ElectroProject Operation EPST a
25. hniek peration Manua EPST time out display If there is no communication between the control touch panel and the EPST IPC ST will switch OFF after the EPST time out display time This function can be disabled by entering 0 seconds only disable when there are communication problems and ST must be forced Q IMPORTANT Note This time should always be a minimum of 4 seconds Change Unit system Change over between kNm meter and k Ibf ft ft units Clean Screen Function The screen will be blanked for 30 seconds to make it possible to wipe the screen clean without accidently pressing buttons or changing values Exit runtime If pressed the running EPST control program will be shut down and the panel will return to its operating system Windows CE Settings of the touch panel it self can than be made A WARNING Be careful with the Exit to runtime function When the EPST control program is terminated ST will be switched OFF after the EPST time out display setting Also changing settings of the panel itself e g network settings can cause a malfunction of the EPST control panel 5 8 System screen This screen is for EPST specialists and will therefore not be described in this manual A password is required Electroproject Soft Torque Operation Manual version 3 0 page 28 ElectroProject Operation EPST aandrijftechniek peration Manua 6 Maintena
26. icates that a calculation of the Kf and Cf values has to be made Just press the calculate button to recalculate the Kf and Cf values Transfer If the calculated values differ from the current values of Kf and Cf the transfer button starts blinking Press the transfer button to copy the calculated values to the current active values of Kf and Cf Q IMPORTANT Soft Torque must be in the off state before changing the Kf and Cf parameters Wrong settings can cause instability of the system The current values of Kf and Cf on this screen are the same values showed on the home screen Electroproject Soft Torque Operation Manual version 3 0 page 24 ElectroProject 5 5 1 Operation EPST aandrijftechniek peration Manua Procedure for Kf and Cf calculations See also paragraph 5 4 and 5 5 New configuration D 0 A Gr m Select Home screen Switch ST OFF Select BHA Entry screen Fill in BHA settings at the BHA entry See chapter 5 4 Select Drill Pipe Entry screen Fill in existing Drill pipe settings at the Drill Pipe entry See chapter 5 5 Press calculate button Press transfer button Select Home screen 0 Switch ST ON Connecting new stand pe 09 e T 8 9 Select Home screen Switch ST OFF Select Drill Pipe Entry screen If applicable a new drill pipe entry must be added by selecting a pipe name at the next not used drill pipe ent
27. l Pipe Entry screen de Ed ElectroProject Soft Torque MIMIC Drill Pipe Entries No Pipe name Wee I 5 1 2 DP 21 90 lb ft FH Calculated values x 89506 9955 T BHA Drill Pipe Entry Entry Figure 13 Drill Pipe Entry screen Operation Manual EPST ElectroProject aandrijftechniek One stand ft Lenght ft 1027 00 Current values Length 1732 8 ft n 89506 5955 Settings System The drill pipe entry screen does have a total of three different drill pipe sections to configure Item 1 is the lowest connected to the BHA and must be entered first In case this drill pipe section runs all the way to surface items 2 and 3 will remain unused Pipe name and ID field There are currently 14 different pipe choices available Select one of the pipes from the pull down menu at each pipe name field corresponding or closest to your DP specification Electroproject Soft Torque Operation Manual version 3 0 page 23 ElectroProject BENI T Operation Manual EPST aandrijftechniek peration Manua Currently available pipes Pipe Pipe name number 3 1 2 DP 9 50 Ib ft NC38 3 1 2 DP 13 30 Ib ft NC38 3 1 2 DP 15 50 Ib ft NC38 4 DP 11 85 Ib ft NC46 4 DP 14 00 Ib ft NC40 FH 4 1 2 DP 13 75 Ib ft NC50 4 1 2 DP 16 6 Ib ft NC50 4 1 2 DP 20 00 Ib ft NC50 915 DP 19 50 Ib ft NC50 10 5 DP 25 60 I
28. nce 6 1 Trouble shooting guide EPST system Fault Cause Counter measure VFD trip F082 One of the 2 Communication board Power ON IPC profibus CBP fails Check profibus status lower slot card in VFD all 3 Led s should flash Check measure screen on IPC No value on Communication failure between Power ON IPC touch panel HMI IPC switch and HMI Check cat5 cable drillers cabin Check message screen on IPC Check message screen on HMI HMI not working Power supply missing check power supply and correct voltage for HMI ST switches off Communication lost with IPC for more Check cable connectors CAT5 sometimes than 4 seconds Check routing of CAT5 cable avoid noisy routing near noisy cables power motor cables 6 2 Procedure Disabling the EPST system The EPST system can be disconnected from the VFD after which the VFD can be operated normally without soft torque feature The following procedure will fully disable the EPST system Make sure EPST is switched off on the EPST control panel Disconnect the purple cable profibus from the IPC The VFD drive will trip The VFD can be reset on the VFD panel OP1S with the reset button The VFD will continuously give Warning A91 CB Alarm gu 0 If not sure EPST was switched off when disconnecting profibus from VFD restart the VFD by disconnecting 24V control power operator panel of VFD will be blank 7 After pow
29. ngs screen A value of 0 75 seconds is recommended Electroproject Soft Torque Operation Manual version 3 0 page 20 ElectroProject m aandrijftechniek Manus 5 4 Bottom Hole assembly screen Alternative to the manual input of KF and Cf the EPST controller can also calculate the values of Kf and Cf For this calculation the configuring of the bottom hole assembly BHA and the drill string data has to be inputted to the system The input of data and the calculation of the tuning parameters is done on the BHA entry and Drill Pipe entry screen see chapter 5 5 ElectroProject Soft Torque MIMIC BHA Entr Outer inch Inner inch Lenght ft Diameter Diameter Bes pees gt Bf non maoneic Ms e Hos 5 gt BHA Drill Pipe 5 Trend Entry Entry Messages Settings System Figure 12 BHA Entry screen The BHA entry screen has a maximum of four items to enter Obviously in practice a BHA will have more components The most significant components in the BHA in terms of weigth and length MUST be entered such as HWDP and or DC The length of smaller components like the bit motor stabilizers MWD and jars have to added to the main components in the BHA when using the BHA entry screen For each item four parameters should be entered Material gt No Item Normal or Non magnetic Outer diameter Inner diameter Length qe mc The outer inner diamet
30. pe Trend display The trend display shows the time related graph of drill speed and torque For a better indication of speed and torque choose the TREND display See chapter 0 The time scale x axis is fixed The graph shows the last 100 seconds The trend display does have auto scaling of Y values The scaling is only adjusted when the signals does not fit The scaling can be reset on the Trend screen See chapter 0 Electroproject Soft Torque Operation Manual version 3 0 page 19 ElectroProject ij i Operation Manual EPST aandrijftechniek peration Manua 5 3 Trend screen ElectroProject Soft Torque MIMIC Trend Graph Actual torque Reset N scales 0 Messages Settings System 20 15 10 BHA Drill Pipe Wer Entry Entry Figure 11 Trend screen Sec The trend graph shows three magnitudes 1 Drill speed at TD n drill speed at TD n motor gear ratio 2 Actual applied torque T TD T motor gear ratio 3 Actual pipe torque Calculated pipe torque from EPST algorithm The trend graph of torque and speed has auto scaling of Y values The scaling is automatically adjusted when the signals are out of range The scaling can be reset by pressing the Reset Y Scales button The values are read from the EPST server every 0 5 seconds To avoid a wrong interpretation of the signals aliasing a filter time for the displayed signals can be set at the Setti
31. rive A practical problem is so called stick slip while drilling Experience shows that a relatively constant speed of the bit is optimal for effective penetration low drill wear and good steering conditions At certain depths and depending on drilling conditions among others friction on bit drill speed and weight on bit the drill bit can stick down hole while the drillstring keeps rotating The drill pipe acts as a torsional spring Since the Top Drive does not recognize the stick of the drill bit the rotation of the drill pipe continuous and the drill pipe will wind up As a result the torque in the pipe builds up At a certain torque value the stick friction is overcome and the drill bit suddenly increase in speed while the drill pipe unwinds itself The large speed variations can damage downhole components including the bit itself Furthermore stick slip is known to decrease ROP by some 25 Also steering rotary drilling operation is very difficult under stick slip conditions The EPST system is designed to mitigate the stick slip behaviour The EPST controller is a speed controller tuned with the Kf drive stiffness in Nm rad and Cf drive damping Nms rad values Depending on the drill string and BHA configuration the tuning parameters Kfand Cfare calculated EPST will be able to improve damping of stick slip when the two tuning parameters Kfand Cf are on target or not too far from ideal values Also drill speed needs to b
32. ry row If necessary adjust length of one stand by using numerical keypad Press button or adjust the length field to add a stand length to the drill pipe entry with the highest number Press Calculate button to calculate new Cf Kf and length values Press Transfer button to make new calculated values active Select Home screen 10 Switch ST ON Electroproject Soft Torque Operation Manual version 3 0 page 25 ElectroProject Operation M EPST aandrijftechniek peration Manua 5 6 Messages screen ElectroProject Soft Torque MIMIC Messages 11 58 46 AM 3 9 2010 SETTINGS Kf Cf OUT OF RANGE 11 58 46 3 9 2010 FAULT COMMUNICATION DISPLAY 11 58 46 3 9 2010 The connection STRS Controller to http strs has been re 11 58 46 AM 3 9 2010 Change to operating mode online RA ER BHA Drill Pipe ORE Home Trend Entry Entry Settings Figure 14 Messages screen On the messages screen system messages are displayed There are four EPST system messages see chapter 6 3 On the messages screen also panel specific messages are displayed e g communication system diagnostic An explanation of panel specific messages will not be explained in this manual and can be found in Simatic Wincc manuals Pressing the clear button clears the list of system messages Electroproject Soft Torque Operation Manual version 3 0 page 26 ElectroProject ij i Operation Manual EPST aandrijftechniek per
33. s the lowest connected to the BHA and must be first selected A pipe part can be added by selecting a pipe name from the database and enter the TOTAL length of the stands Just adjust the length of the highest pipe part item connected to the top drive each time a connection has been made and then recalculate the Kf and Cf Electroproject Soft Torque Operation Manual version 3 0 page 13 ElectroProject Operation Manual EPST aandrijftechniek peration Manua 5 Screens of EPST touch panel In this chapter all EPST screens will be described 5 1 General for all screens Functions available on all screens will be explained in this section Buttons Buttons are operated by touching the displayed symbol on the screen Accidently touching the screen could activate unwanted functions To wipe the screen clean see chapter 0 Clean screen function Numeric input 9 Figure 5 Numeric key pad ESC Escape numeric input values Backspace Del Delete Ins Insert gt move cursor to left move cursor to right Num Toggle Numeric Alphabetic keypad The alphabetic keypad will not be described because no alphabetic input is required Electroproject Soft Torque Operation Manual version 3 0 page 14 ElectroProject MM Operation Manual EPST aandrijftechniek peration Manua 5 1 1 Bottom section of the screen Depending on the version of
34. the EPST control software and the options the below screen selection buttons will be present at the bottom section of each screen see figure 6 BHA Drill Pipe Home Trend Entry Entry Messages Settings System Figure 6 Bottom section of the screen By selecting one of the screen selection buttons the selected screen will be activated The screens will be described in the next chapters The menu structure of the panel software is only one level except for the System screen 5 1 2 Upper section of the screen Alarm sign button Actual mimic screen Info a E ms ElectroProject Soft Torque bs MIMIC Messages Figure 7 Upper section of the screen Alarm signal and button If a warning is active the text Warning if flashing will be flashing By pressing the button the warning screen will be opened Active warnings will be displayed See paragraph 6 3 Actual mimic In the middle at the upper section of the template the name of the actual screen mimic is shown Info screen button By pressing on the Electroproject Aandrijftechniek logo the info screen of the EPST system is shown The info screen gives the Electroproject contact data and some background information of the EPST system Electroproject Soft Torque Operation Manual version 3 0 page 15 ElectroProject Operation M EPST aandrijftechniek peration Manua 5 2 Home screen This is the start up screen On this scre
35. tself can cause it to stick down hole As rotation at surface continues and torque in the drill string builds up this stick friction is suddenly overcome causing a sudden increase in speed slip as the drill string unwinds itself When fully developed stick slip can cause the bit and BHA rotation to completely stop and accelerate up to 5 6 times the surface r p m Stick slip can cause damage to the bit broken cutters decreased rate of penetration ROP decreased bit life Furthermore it can also damage other down hole components such as rotary steerable systems and Measurement While Drilling devices MWD It can even cause down hole motors to stall 2 2 Recognizing when Stick Slip is occurring There are two clear stick slip indicators for the driller 1 Large variations in surface torque 2 Large variations in downhole RPM by groaning noise 3H coming from the top i drive Characteristic T 1 for the slip stick TH H ME TM i d behaviour is the saw lis He fii tooth behaviour of the un torque which can go 7 up to 50 torque UAS L LA IL _ ia The torque variations can be accompanied 4 Bg e LI o 5 o is an example of the characteristic saw tooth torque variations This behaviour can only be seen clearly when using data with at least 1 second sample time Figure
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