EPST Soft Torque with Auto Tuning
Contents
1. Electroproject Aandrijftechniek E lectroP OJGC L EE Computerweg 21 1033 RH Amsterdam MNOS aandrijftechniek PO box 34 1000 AA Amsterdam The Netherlands Telephone 31 88 484 92 50 E mail softtorque electroproject nl Website www electroproject nl Businessunit of Cofely Experts bv Electroproject Soft Torque EPST Auto Tune EPST AT Operation manual 2 3 Warning ElectroProject Soft Torque iffiashing MIMIC Home 140 160 sn i MERE 100 200 kNm d g Tu rei E N ka 5 in 0 kNm 90 60 lI BHA Drill Pipe E HE HE JE N Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 1 ElectroProject EI MNS aandrijftechniek Operation Manual EPST Autotune Revision History 2 3 12 09 20013 revision 0 00 00 PEH 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 the safety notes in this documentation qualified persons are defined as persons who a2. 4 1 1 gilree Ze dla lara kc amer ee _ mm m mcc m m_mcm 4 1 2 Basic Knowledge Requirements lli kk nennen K KEK nnns nnns 4 1 3 Position in the information scheme E Llii kk kk kk kk nennen nennen KK KK nnns nnns 4 2 UE K SHD TIL QA Li Ll e zikin d 5 2 1 What is UNI d 5 2 2 Recognizing when Stick Slip is occurring EEu Ek KK KK KK KK KK nnns 5 2 3 How to reduce StiCk Slip c cccccsecccseccceeeceeeesececaeeesseeeceeeceeesaeeesaeeesseeeeseesaueeseeeesaeessseesseeees 6 3 cip m k 7 3 1 DV SIC IOV TAY N HHHH HHHHHHH HHIDD DN MNINI 7 3 2 EPST conlrol ANGI UN ernster rara yana b diwa an Kekan d uh a b n kann bul e bad eken k Bac Wen dana 8 3 9 aa RR PRO 9 3 4 Speed and torque monitoring iu kk kk kk kk nnn nnn nnns near nnns KK nnn nnns 9 3 5 POV ANCES Cate JOGGING RR E 10 3 6 n c a z c gt x x a a c rm mm 10 of Fe ONING Mew 11 3 8 Unit system metric OF imperial u kk kk kk kk kk kK kk KK KK KK KK KK KA 11 4 PHACIDIC OF OD l a T O l 11 4 1 EPST AMI COMTO DA RENTEN 11 4 2 CONTROL PACU
3. 300 Cf 15000 and 300 Kf 10 Jtd Try to increase the initialization depth till the above criteria meets 5 Screens of EPST HMI touch panel In this chapter all EPST HMI screens will be described 5 1 Home screen This is the start up screen of the EPST HMI control panel On this screen 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 MIMIC M 140 190 i80 8 Ne i TORQUE E E rpm yi J p kN d dn DH Qo EL x B _ 1 g 5 320 i00 rpm ris Tmax 51 8 kNm 0 4 yu Pipe Auto A ae A omnes oats Figure 15 EN screen Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 25 ElectroProject EI NOS aandrijftechniek Speed qauqe Operation Manual EPST Autotune The speed gauge gives the value for the actual drill speed of the TOP DRIVE TD in rpm Torque qauqe The torque gauge gives the value for the actual pipe torque applied at drill pipe Tmax displays the actual Torque Limit SSI Stick slip indicator The value displayed by the stick slip indicator is the measured peak peak torque ripple on the pipe torque The red graphical bar has a 0 40 kNm scale The lower the showed values the better AT active and AT NV indicators The green AT active indicator will show up wh
4. AT NV Calculation of new values will last for at least 10 minutes If drilling while stick slip or heavy torque variations are present estimating new Auto Tuning settings will take much longer or will even not be available for the next stand Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 43
5. 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 Auto Tune Operation Manual EPST AT version 2 3 page 6 ElectroProject EBI NS aandrijftechniek Operation Manual EPST Autotune 3 General 3 1 System overview The EPST system is designed to be easily implemented in modern drive systems The EPST controller is a standalone but RIG specific u processor 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 HMI 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 ST control p HMI ae Profibus 2 PLC Coniroller aa 1 Actual speed digital encoder feedback Don E Drill string And bottom hole assembly pean es ol Figure 3 EPST System overview extra profibus example 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 Elect
6. 3516 000 sec VAO13 TPIPE kNm iVAO08 74 6272 VA016 CF kNms rad ivA013 74 6272 2 0 IVA016 1420 0000 1000 2000 Q a 11 41 00 000 M004 1 1 Autotuning new values calculated 11 38 00 000 M002 4 0 Pre sweep active 11 36 03 000 M004 1 0 Autotuning new values calculated 11 36 02 000 M000 2 0 Start sweep 11 36 01 000 M002 4 1 Pre sweep active 11 36 01 000 M002 3 1 Sweep active 11 36 01 000 M002 0 1 Auto tuning active E 02 Sep 2013 11 52 19 Figure 5 Screenshot ST log data view program The log data can be viewed exported and analysed with a special EPST data log view program The EPST data log viewer can be installed on a Windows based PC 3 6 Remote access If the IPC is connected to a WAN network log data 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 Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 10 ElectroProject EI NOS aandrijftechniek 3 7 EPST off line Operation Manual EPST Autotune Since the EPST system is designed as a standalone but RIG
7. EP ROT x x E T E 13 4 3 Kf and Cf tuning parameters l lS SE j huk nennen nnn nnns nnne nnns KK KK KK KK KK KA 13 4S1 Manual mput G and Of PCR 16 4 3 2 Calculation with BHA and DP entry E LL kk nennen kK KK kK k KK KK KK 18 4 3 3 Automatic calculation and activation by EPST Auto Tune algorithm EPST AT 23 Leo MEB aisud g 24 5 Screens of EPST HMI touch panel accuse cuum eria iuo nice sa sun suite sd kk kkkk eka k kk AKA AA KK A aio KAWA WAA WAA 25 5 1 Home Sore MMC mmm 25 5 2 Tend SEU CC MT r r HH 27 5 3 BAHA eny SCIIGON W o oo_ gt 05 gt M5Mp p p5p p5p p5p p M I M nnm_ mmmmgobmmmmmm a pp em 28 5 4 PRUTO Une S az a eoaoeaoe eeeemmmmmrmrmrmrmmmmnhrmr HH HHHH H e mh mm 28 5 5 WESTIN CJI RHHHHHHHHHHHHHHHRIEHH T 29 5 6 User Settings screen ME RITN 30 6 MaM Zala KANAN E E EE 31 6 1 Trouble shooting guide EPST system cccccsseeececccseseeceeceeeeeeeeeeeaeeeeeseeaaeeeesseeaeeeesesaaaeeeess 31 6 2 Procedure Disabling the EPST system kk nnn nnns 32 6 3 eA ISTA W UNMIS MENTRE 34 7 Qn c 36 7 1 Overview installatiOn Euu kk K k K k K KK K KEK KK KAK KA KA KK KAKA KK KK KAK kk 37 7 5 EPST co
8. J fij ja V j ne Ni i v ja behaviour is the saw ina q i i 1 t h h BA o ooth behaviour of the W 4 torque which can go IN up to 50 torque GOD oH t i variation In Figure 1 is an example of the characteristic saw tooth torque 1s data variations This behaviour can only be 1s data seen clearly when 20s data using data with at least 1 second an gan EI 34 sample time IME seconds Figure 1 Torque variations due to stick slip Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 5 ElectroProject EBI NOS aandrijftechniek Operation Manual EPST Autotune 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 30 p 250 Surface Torque kNm Surface Speed RPM Torque kNm Speed rpm 100 1280 1290 1300 1310 1320 1330 1340 1350
9. Manual EPST AT version 2 3 page 32 ElectroProject EB N m 08 Operation Manual EPST Autotune ENS aandrijftechniek 2 EPSTis connected in between the profibus communication cable a Make sure EPST is switched off on the EPST control panel b Make sure TD is not operate c Disconnect the purple cables profibus from the Beckhoff Master and Slave modules in the EPST controller cabinet d Connect these 2 connectors to each other and set the switches on the connectors as indicated on the drawing from Annex 7 3 e It could be that the VFD gives a communication error The VFD can be reset on the VFD panel with the reset button f EPST controller is now disconnected and TD system will operate without NOTE When installing the EPST system back again don t forget to set the switches on the profibus connectors as indicated in the drawing from Annex 7 4 3 EPST is connected to the TD system by controlling the analog I O signals 9 9 0 _ Make sure EPST is switched off on the EPST control panel Make sure TD is not operate Disconnected the communication connector Connected the bypass connector It could be that the VFD gives a communication error The VFD can be reset on the VFD panel with the reset button EPST controller is now disconnected and TD system will operate without Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 33 E lectroP rO ec t 3 Operation Manual EPST
10. according to the Shell Kf amp Cf Spreadsheet It still could be that not all pipes are known in the database Updating the database can only be done by an EPST engineer The moments to update the database are before or during the Installation amp Commissioning and during maintenance Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 20 ElectroProject EN NOS aandrijftechniek Available pipes in HMI version 1 18 7 7 Shell drill pipe database are 3 1 2 DP 9 50 Ib ft NC38 2 7 8 HWDP NC26 2 3 8 IF burom as at MON 2 3 1 2 DP 13 30 lb ft NC38 36 1 2 IF alaspror assomm neas arjin en EM 3 3 1 2 DP 15 50 lb ft NC38 37 IF TT 4 4 DP 11 85 Ib ft NC46 38 3 1 2 2 1 4 HWDP HT38 4 DP 14 00 Ib ft CYX105 120 3 1 2 2 1 4 HWDP XT39 6 4 DP 14 00 Ib ft XD105 40 4 HWDP NC40 NC40 4 FH 4 DP 14 00 lb ft G 109 4 HWDP XT39 Operation Manual EPST Autotune 43 4 HWDP HT38 44 41 2 HWDP NC46 4 IF 48 5 1 2 HWDP 5 1 2 FH CB 49 51 2 HWDP 5 1 2 FH VAM CDS _ _____16 5 DP 19 50 lb ft G 105 50 51 2 HWDP XT54 51 5 1 2 HWDP HT55 55 65 8 HWDP 6 5 8 FH 5 1 2 DP XT54 26 73 p f 24 7p f IEU 4 1 2 DP 13 75 lb ft NC50 46 5 HWDP HT50 16 sC 5 7 8 DP 23 4lb ft S 125 VAM VX57 25 26 6 5 8 DP 40 lb ft GT Type6 Electroproject Soft Torque Auto Tun
11. controller continuously checks if the actual values of Kf and Cf are out of range The settings are out of range if one of the following conditions is true Cf 300 or Kf 300 Cf 15000 Kf 10 Jtd Where Utd is the inertia of the top drive Note Chapters 4 3 1 untill 4 3 2 3 are mentioned for Manually Input of Kf and Cf 4 3 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 Next 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 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 the Next Kf and Cf values 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 this sheet is provided by SHELL Q IMPORTANT ooft Torque may be in the on state while changing the Next Kf and Cf values Make sure when activating EPST by Activate EPST proper next Kf Cf values are filled in When manual input of the next Kf Cf values is desired switch off Auto Tune and or switch of the AT Auto transfer function on the settings screen Else the manual fi
12. 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 ooft 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 4 3 2 3 Procedure for Kf and Cf calculations with BHA an Drill pipe calculation See also paragraph 4 3 2 1 and 4 3 2 2 New configuration Select Home screen Switch EPST OFF Select BHA Entry screen Fill in BHA settings at the BHA entry See paragraph 4 3 2 1 Select Drill Pipe Entry screen Fill in existing Drill pipe settings at the Drill Pipe entry See paragraph 4 3 2 2 Press calculate button Press orange transfer button Select Home screen 0 Activate EPST 2 9 ete Xp e n de m Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 22 ElectroProject EI ES aandrijftechniek Connecting new stand Operation Manual EPST Autotune 1 Select Home screen 2 Switch EPST OFF 3 Select Drill Pipe Entry screen 4 If applicable a new drill pipe entry must be added by selecting a pipe name at the next not used drill pipe entry row n
13. 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 4 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 drive 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 drill string 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
14. units Length Diameter and Torque units can be changed independently Clean Screen Function The screen will be blanked for 30 seconds to make it possible to wipe the screen clean without accidentally 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 itself can then be made Be careful with the Exit to runtime function When the EPST control program is terminated EPST 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 6 Maintenance 6 1 Trouble shooting guide EPST system 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 Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 31 ElectroProject EI NS aandrijftechniek 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 conne
15. 24Vdc 300100 UT P10255 ElectroProject EBI Deciror red Som Torque EPST EfherCAT ProfiBUS MODULES Taran Er EEE aandrijftechniek 127 anne f gene pupos 30 0 2011 Fco pne A r she dh pie ki a a Business Lii of Cofely Ppers by b l 3 l l dH 3 50 see l extr pre et nl UTE EE AE Fi k Vp pla Rev JF LAE ET Tender Pe ee ee IH rih version 2 3 page 39 Operation Manual EPST AT Electroproject Soft Torque Auto Tune Operation Manual EPST Autotune 7 4 EPST connected in between the profibus communication cable install ElectroProject EI NOS aandrijftechniek AFL i Le Pel S m u CONNECTOR n ma SLO MALE GI m E A D OF MALE SI x B E Sae ME NS di 579 72 0 0 xa C SE EMEN ES 72 RII L2 ERAT n SITUATION 1 EPST CONTROL ON TOP DRIVE EXISTING INSTALLATION Prov ELES ABLE ProflBLES CABLE Lu pa MA 20m t2Mbps MAX rm OLD SITUATION TOP DRIVE VFD jl ProtBuis DP ProfiBL S DP NODE NODE Fajri a iar Caf i CONTROL CURRENT 24Vdc ect gems HectroProject Soft Torque EPST EherCAT ProfiBUS MODULES ElectroPra kei EE aandrijftechniek EST ours fer general purpose Fhectr prose Andr pin dink kin a Business Unit of Cofely Pperts by tal 411 40M S S wawalar md nl TEHERI ADI NA ils ALANE ETA le ET UIT ECCO BLUR EN a version 2 3 page 40 Operation Manual EPST AT Electroproject Soft Torque Auto Tune Operation Man
16. 4 ElectroProject EB N NOS aandrijftechniek Operation Manual EPST Autotune 2 Stick Slip mitigation 24 What is Stick Slip otick 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 itself 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 otick 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 The torque variations can be accompanied i by groaning noise Hl j j coming from the top iv aur j jf drive Characteristic for the slip stick
17. As oana BENI x TT NLN NOS Aaaa SUIS WALSAS Auv1ow anduoL os EN 2 2f0140 29213 ou Duwag uondameg LOTS NOILd2 LOTS NOLO G H0 8XX0 060 359 SNAWAIS 16 H0 79xX0 060 359 SNEWS ae MNEs JAINA SNITIDNG w d SITTdIJOJd HLM ONY YS d3HLO YO qoc wirts z9 T _ SADIOUaL SVIA J HACINIS JEBI 304 JTOulNCO SNIT YI qe NOLLO3NNO2 PT sdgarzr Alda BIAS avo NIYAH ACES o saaa l cobpao aa un Q z a s Sd 08412 HOSTIH Cy Idd Hal Sui IAYO 19 2048 EX VZ 0T GC 02 S499 SNANAIS zem Ten na QUIS OG S H2LI AS L3NHJ9 Xd 2ILVIAITS mm XV Eml OT 00 0699890 HOH gt D38 2d WIulSOCNwI Abet 11 Td AR 3570 sdqa00 SLvO QuvOg 3 ENOEZ JD LINYOd sdq J 0T SI YO 318v2 L3NuoJd 7 bO7X 39NV1V95 TTD SL aeos Q r O ooocc O 1S 2048 E Y2 OTPa2 bOTSHNOS SNZAZIS Gp zan Tesn SebeSucckSd Nyl HOLIMS LANYOdd DILYS TY DYADEZ 10 dav3 Hovis HONOL YOLINOW OXYS TOIL h99A79 SNHI BIS OT ZT 1 dH XON OT BNYd HOTIQL 2LEVIWIS T YOLINOW Lat WOO 1O3 LNOO Lud tad es zd3 version 2 3 page 37 Operation Manual EPST AT Electroproject Soft Torque Auto Tune Operation Manual EPST Autotune 7 2 EPST connected to the 2 profibus connection of the VFD ElectroProject EBI NS aandrijftechniek Wo Ap Lt Le Prodpus DP NODE r Saka EPST CONTROL CEST dav MENS E 529 7241 0 L2H0 XA Ji EXISTING IMSTALLATION C
18. Autotune aandrijftechniek 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 To open the warning screen press the button Warning if flashing An overview of warnings is shown Actual warnings are blinking red di 000999000000 w r di did w di di wi d d wi w oi di 8 wi oi o 5 i d di 0 0 eee RRR WARNING DISK PARTITIONS Warning from CALCULATION DRILL CONFIGURATION Fault Kf Cf SETTINGS OUT OF RANGE FAULT COMMUNICATION DISPLAY FAULT WATCHDOG EPST operating in limits Torque limit reached Power limit reached Speed limit reached Torque setpoint actual value deviation Home Drill Pipe EE a eS Z baxen ata E Figure 19 ST Warnings 1 Warning Disk Partitions Not applicable 2 Warning from Calculation Drill Configuration Calculation of drill string configuration can t be executed check BHA and drill string configuration Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 34 ElectroProject EB N NS aandrijftechniek 3 Operation Manual EPST Autotune Warning Kf Cf Settings out of range If Kf or Cf value is too high or too low an out of range error will be generated Check if Kf and or Cf values are correct inputted The EPST controller continuously checks if the actual values of Kf and Cf are out of range The settings are out of range if on
19. EINNIE T R AND CBP Profil EzDP ADAPTER ARE muon 3 SCOPE OF SUPPL EXISTING DRILLING CONTROL 2Mbp amp MAX 20m CONNECTDR SLB Ur MALE or EMEA EWIN TA EB L2 CA ProfBus DP NODE AE Heel NODE SEMEN WR UN 1H rs CIPA Pr GTILE DP ADAPTER SLAVE 2 Papi LI T T T 3 TT iact Sof FPST CONTROL CURRENT 24Vde 300100 P10247 ElectroProject BRE SOC Or reyes SOR kulk a k laka K EherCA TT Prof BU5 MODULE iania EREN aardirij techrikak MU conoser r eee 30 05 2011 LI ka j ni a TIT Ecopet Ay niri a nie ki n usines Unit of Ei fly Psperts by bil 40 LOT dH SO 50 www nl ectropro get nl VEL MALBD Ag Bod VE FLA Pre da UEPTUPETV ETNDARLPPNI II ICH ETI POT HI E version 2 3 page 38 Operation Manual EPST AT Electroproject Soft Torque Auto Tune Operation Manual EPST Autotune 7 3 EPST connected in between the profibus communication cable bypass ElectroProject EI ES aandrijftechniek Wo Ap Lt Le _ j j wi kv EB E44LL kEk d Bk LBLMk Z _ D kVjwkEkkk _ A S a S o iU LL k r i J _ Allai A140252 BECKHOFF EtherCAT ELG731 ProflBLE DP MASTER TE Pro iBUS DP V B Z Proteus a t WEE NODE ATTENTION SWITCHES OFF SITUATION 2 k NO EPST CONTROL AT ALL EXISTING INSTALLATION Profiles CABLE L Wi pa M x mimi TOP DRIVE VFD ProfBLs DP HODE Fl iect Soft EPST CONTROL CURRENT
20. EPST is activated Kf an CF start values must be calculated to begin EPST with If no other start values for EPST are present use this button When pressing on the Initialize AT button a pop up screen will appear Veta Me Me eco Ea L fe MEE ee eM lectroProject if flashingo MIMIC Home __ mE Ei aandriiftechniek Beek Initialize AT Activate EPST En a e 35 40 45 sp 9506 20 6 2570 F A 3 i 75 5506 wry 2570 E oe 4 Pop up window to Initialize EPST settings Fill in the actual measured depth to initialize auto tune Py m 120 90 60 30 0 BHA Drill Pipe Auto i Fill in the approximately actual depth of the drill bit and press enter After pressing Accept measured depth start values will be calculated and used as Next Kf and Cf values When EPST is activated these values will be used as actual Kf and Cf values Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 24 ElectroProject Operation Manual EPST Autotune aandrijftechniek The shorter the measured depth the higher the next Kf and Cf values will be If the entered depth is too low the calculated next values of Kf and Cf will be out of range A fault will be generated Kf Cf settings out of range after trying to activate EPST Because the maximum Kf value is top drive independent a minimum depth for the initialization button cannot be given Kf max is ten times the inertia of the top drive
21. ERE Electroproject Soft torque BHA Drill Pip Auto m E A Figure 18 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 the actual speed setpoint is less than the Auto switch off speed or when the TD is switched off EPST will be switched off automatically after the Auto switch of time This function can be disabled by entering 0 seconds EPST 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 EPST is switched OFF when there is no rotary drilling operation Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 30 ElectroProject EBI NOS aandrijftechniek EPST time out displa Operation Manual EPST Autotune If there is no communication between the HMI control panel and the EPST IPC EPST will be switched 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 EPST must be forced Q IMPORTANT Note This time should always be a minimum of 4 seconds Toggle system Units Change over between kNm meter and k Ibf ft ft
22. 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 7 Press Calculate button to calculate new Cf Kf and length values 8 Press Transfer button to make new calculated values active 9 Select Home screen 10 Switch EPST ON 4 3 8 Automatic calculation and activation by EPST Auto Tune algorithm EPST AT EPST AT is a new developed Soft Torque Auto Tune algorithm patented by Electroproject EPST AT differs from other auto tune algorithms because it really identifies the drill string and BHA while the drill string is rotating Although soft torque is mainly used to mitigate stick slip it is proven that soft torque has a positive effect on the drill process even if there is no stick slip EPST AT can be used when there is no stick slip in contrast to other soft torque auto tune algorithms EPST AT analyses high resolution measured top drive data torque speed while operating the top drive It provides automatically the tuning parameters Kf Cf for the EPST Soft Torque controller With EPST AT there is no need to manually enter these parameters or configure the drill string and bottom hole assembly at the EPST control panel The EPST AT function can be enabled or disabled If it s enabled it will analyse data while the top drive operates and EPST Soft Torque is activated The EPST AT algorithm analyses
23. Manual EPST AT version 2 3 page 42 ElectroProject EN NOS aandrijftechniek Operation Manual EPST Autotune 7 7 Quick Guide using EPST with Auto Tune ENABLED EP soft torque controller Quick guide EPST Auto Tune When starting a new hole or on a new depth only once you have to initialize EPST AT Press Initialize AT Fill in the actual Accept measured depth measured depth Press on the actual depth box to initialize auto tune Cancel Fill in actual depth of bit confirm with enter 4 m Press Accept measured depth Check on the Settings screen if Auto Tune and AT Auto Transfer are active green Press Home for home screen When drilling is started activate EPST AT by pressing Activate EPST Activate EPST will become green green is active When values are out of range a screen will popup Compare Kf and Cf with Shell Kf Cf calculation list if within or 20 press Accept otherwise cancel and fill in Kf and Cf manually See Operation Manual When adding a stand Switch off EPST before drilling will stop by pressing the green Activate EPST button Activate EPST will become gray gray is off When drilling is started activate EPST AT by pressing Activate EPST CHANGE of Kf and Cf While drilling with EPST activated and Auto Tune enabled new Next Kf and Cf values will show automatically on the home screen together with the green text
24. ain BHA configuration the entries on this BHA entry screen don t have to be adjusted anymore Note The units of diameter and length can individually changed on the settings screen m inch Toggle Toggle MESE e All Torque Units Unit inch MSS esa rre Linch Toggle Length Diameter Moyea e KN Unit Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 19 ElectroProject EI NOS aandrijftechniek Operation Manual EPST Autotune 4 3 2 2 Drill Pipe Entry screen Warning ectroProject Soft Torque time 11 56 t fashing MIMIC Drill Pipe Entries aandrijftechniek Pipe type Stand m T tal lul 100 00 i 1 t H 0 00 0 00 295 00 69 00 29 00 1896 00 Stand mua Length 2228 1 m Calculated values Next Kf Cf values Calculate kf 2750 Next Kf 1150 1146 EN CI 3400 BHA Drill Pipe ECHECHE EE EU Figure 14 Drill Pipe Entry screen mn um The drill pipe entry screen does have a total of five 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 3 4 and 5 will remain unused Pipe name and ID field There are 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 Pipe database will continuously be updated
25. ccessed at directly at the EPST IPC and only need to be modified by the EPST specialist while commissioning 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 120 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 Auto Tune Operation Manual EPST AT version 2 3 page 9 ElectroProject EBI NS aandrijftechniek Operation Manual EPST Autotune 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 200Hz sampling Depending on the size of the applied hard disk s log data can be hold for months i strs Plot E File Data menu plot Window Help jl x 0 ElectroProject EI Er Mon Sep Us 10 20 00 2013 REM aandrijftechniek VA008 Torque setpoint out kNm 11 18 36
26. creen Info Screen butto Alarm sign button Actual mimic screen IPC time Warning ElectroProject Soft Torque time 11 52 fashino MIMIC Home Figure 8 Upper section of the screen Alarm signal and button If a warning is active the button 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 Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 12 ElectroProject EBI NOS aandrijftechniek IPC time The actual time of the EPST industrial pc IPC is shown This is not the actual time of the HMI clock This time is used with the log data and messages of the EPST IPC Operation Manual EPST Autotune 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 4 2 CONTROL Activate EPST Switching EPST ON and OFF is done by the Activate EPST button toggle function on the Home screen The button is grey when EPST is not active and green when active Figure 9 Activate EPST button OFF state If pressed Activate EPST EPST will be switched ON and automatically the Next Kf Cf values will become act
27. ctivated with the activate EPST button When the next values differ more than the in the settings set percentage Max difference next and actual Kf Cf the next values will be coloured dark orange Then if the Activate EPST button is pressed a pop up window will show TORQUE A i00 Tmax kNm The next values for Kf and or Cf differs more than 10 0 Accept next values and activate EPST Do you want to accept the next Use current values and activate EPST values and activate EPST Cancel and don t activate EPST Trend BHA Drill Pipe Auto Entry Entry Tune Figure 12 Pop up when activating EPST Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 15 ElectroProject EI NOS aandrijftechniek Possible reasons for a certain difference between the old and new values Operation Manual EPST Autotune EPST AT has been switched off for a couple of stands In the meantime the calculated Auto Tuning values are changed more than the last actual ones EPST AT has not been able to produce next Kf and Cf values for a while A After re initializing the Next Kf Cf values with the Initialize AT button it is most likely that these next values are different than the actual ones Wrong manual input or first time manual input Skipped manual input of new Kf Cf values for a while Restart using EPST like starting a new hole Q IMPORTANT The EPST
28. ctors CAT5 Operation Manual EPST Autotune 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 There are 3 ways how to disconnect the EPST controller This depends on how the EPST system is connected to the original TD system The EPST controller can be connected 1 tothe 2 profibus connection of the VFD see also annex 7 2 2 in between the profibus communication cable see also annex 7 3 and 7 4 3 tothe TD system by controlling the analog I O signals see also annex 7 5 Follow the corresponding procedures below to fully disable the EPST system 1 EPST is connected to the 2 profibus connection of the VFD a Make sure EPST is switched off on the EPST control panel b Disconnect the purple cable profibus from the Beckhoff Master module in the EPST controller cabinet 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 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 g After power on the drive will operate normally with this alarm on e o o Electroproject Soft Torque Auto Tune Operation
29. d at TD n drill soeed 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 Settings screen A value of 0 5 seconds is recommended Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 27 ElectroProject a gP i Operation Manual EPST Autotune aandrijftechniek 5 3 BHA entry screen See paragraph 4 3 2 1 on page 18 5 4 Auto tune screen Auto Tune AT Auto Transfer Calculated Kf Nm rad If auto tune is switched on La EREN Calculated tuned values will be Calculated Cf Nms rad estimated while drilling with EPST 5 5 switched on Em If auto tranfer is switched on settings screen Next Kf Nm rad Calculated auto tune values will be Next Cf Nms rad automaticly copied to the Next EPST E tune values The next EPST Kf Cf values will be used by Kf actual Nm rad the EPST controller the next time it s Cf actual Nms rad enabled Drill Pipe Entry The Auto Tune screen is onl
30. d ones 220006 1 17 37 PM 9 4 2013 Connection to PLC strs controller strs is established 110001 1 17 37 PM 9 4 2013 Change to operating mode online 70041 1 17 37 PM 9 4 2013 Password list import aborted with error e E BHA Drill Pipe Home Trend E EAD Figure 17 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 Auto Tune Operation Manual EPST AT version 2 3 page 29 E lectroProject Operation Manual EPST Autotune aandrijftechniek 5 6 User Settings screen Warri ElectroProject Soft Torque time 15 42 Lu MIMIC Settings Filtertime signals for displaying signals sec Auto switch off STRS level rad sec Auto switch off STRS sec 0 2 no auto switch off STRS time out display sec O no auto switch off Max difference next and actual Kf Cf 0 Auto tune AT Auto tranfer Toggle Toggle Length Unit Torque Units Unit eT ea A Linch Toggle Toggle Length Diameter TELLE Unit Unit Version controller 1 037 Clean Screen Function Exit Run Time Version panel EPST 1 18 AT modbus LUD
31. downhole components including the bit itself Furthermore stick slip is known to decrease ROP by some 259 Also steering rotary drilling operation is very difficult under stick slip conditions The EPST system is designed to mitigate the stick slip behaviour 4 1 EPST HMI Control panel Controlling the EPST soft torque system is done on a HMI touch screen Buttons Buttons are operated by touching the displayed symbol on the screen Accidentally touching the screen could activate unwanted functions To wipe the screen clean see chapter 0 Clean screen function Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 11 ElectroProject EBI NOS aandrijftechniek Numeric input Operation Manual EPST Autotune Figure 6 Numeric key pad 0 9 numeric input values lt Backspace Enter ESC Escape 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 Bottom section of the screen Depending on the version of the EPST control software and the available options the below screen selection buttons will be present at the bottom section of each screen see figure 6 By selecting one of the screen selection buttons the selected screen will be activated The screens will be described in the next chapters Upper section of the s
32. e Operation Manual EPST AT version 2 3 page 21 ElectroProject EBI NOS aandrijftechniek Total length When switching ON the EPST system for the first time during a drilling process the existing pipe configuration needs 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 Operation Manual EPST Autotune 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 indicates that a calculation of the Kf and Cf values
33. e of the following conditions is true Cf 300 or Kf 300 Cf 15000 Kf 10 Jtd Where Jtd is the inertia of the top drive 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 6 or check wiring Fault watchdog No profibus communication between EPST IPC and VFD Check if VFD is powered up or check wiring Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 35 ElectroProject EI dre z Operation Manual EPST Autotune NS aandrijftechniek 7 Annex 7 1 Overview installation 37 7 2 EPST connected to the 2 profibus connection of the VFD 38 7 3 EPST connected in between the profibus communication cable bypass 39 7 4 EPST connected in between the profibus communication cable install 40 7 5 EPST connected to the TD system by controlling the analog I O signals 41 7 6 Quick Guide manual input Kf and Cf 42 7 7 Quick Guide using EPST with Auto Tune ENABLED 43 Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 36 Operation Manual EPST Autotune on tallat ect EBI J NS aandrijftechniek iew ins ElectroPro Overv 7 1 cul eiNasua At dizazyerpeloadizazhodiure valid Jr3 amp Coudo gnep A OG 26 9 89 0 T A q Sadka A jo7 jo Qu sseusng e si auaysts aang paloa 0 NOISIA3H 9w vm EE sures
34. e the Kf and Cf 4 3 2 1 BHA Bottom Hole Assembly Entry 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 4 3 2 2 Warning ElectroProject Soft Torque UCEUDUEUUUEPPDEPEUEEDUNUUEUEPTPTTETETTUETEETE if flashing ATRATI r Outer inch Inner inch Length m Diameter Diameter No item 0 00000 2 50000 114 000 Bim 75000 Normal 4 69016 2 00000 14 800 Figure 13 BHA Entry screen The BHA entry screen has a maximum of 5 items to enter Obviously in practice a BHA will have more components The most significant components in the BHA in terms of weight 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 the first four items four parameters should be entered Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 18 ElectroProject EI NOS aandrijftechniek 1 Material gt No Item Normal or Non magnetic 2 Outer diameter 3 Inner diameter 4 Length Operation Manual EPST Autotune The o
35. en AT and EPST is activated and the AT algorithm is estimating Kf an Cf values The green AT NV Auto Tune New Value indicator will show up when the EPST AT algorithm has found a the first new value after activating EPST Auto Tune button The Auto Tune button enables the EPST auto tune algorithm When EPST is activated Kf and Cf values will automatically estimated for the current drill string Initialize button Next Kf an Cf values will be calculated by input of measured depth Use only when starting EPST with auto tune enabled for de first time of a new hole 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 5 2 The time scale x axis is fixed The graph shows the last 120 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 5 2 Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 26 ElectroProject ES NS aandrijftechniek 5 2 Trend screen Operation Manual EPST Autotune ElectroProject Soft Torque time 14 19 MIMIC Trend Graph Actual ipe F m M Ni i Ji l I I ii il Il j Sec BHA Drill Pipe Auto aie Figure 16 Trend screen The trend graph shows three magnitudes 1 Actual Drill spee
36. ive Figure 10 Activate EPST button ON state If pressed Activate EPST EPST will be switched OFF Switching ON the EPST controller can be done bump less 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 Next values of Kf and C have been set This can be done manually by calculation with BHA and drill pip entries or automatically by EPST AutoTuning EPST AT EPST will be switched OFF automatically or cannot be switched on when e acommunication error occurs between IPC and VFD e communication timeout between touch panel and IPC has been exceeded See chapter 5 7 EPST time out display e the VFD speed setpoint is less than the Auto switch off speed See chapter 5 7 Auto switch off e the VFD is switched off e The Kf Cf settings are out of range 4 3 Kfand Cf tuning parameters The EPST controller is a speed controller tuned with the Kf drive stiffness in Nm rad and Cf drive damping in Nms rad values Depending on the drill string and BHA configuration the tuning parameters Kfand Cfare calculated Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 13 ElectroProject EBI NOS aandrijftechniek 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
37. lled in values will be overwritten by the auto tune function 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 Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 16 ElectroProject EI NS aandrijftechniek Example part of Kf and Cf sheet as provided by Shell Operation Manual EPST Autotune Total Measured Depth along hole Tuned values Total MD Kf Cf om Nira Nms rad 1800 2523 046 508 493 776 478 464 449 435 422 408 395 4965 382 4863 2369 This table is unique for each top drive drill string and BHA configuration Procedure manual input Kf and Cf Check if correct Kf and Cf table is available for the current configuration Select Home screen Select Next Kf input field press at the Next Kf numeric field Numeric keypad will appear 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 Enter the new Next Cf value same procedure as Next Kf step 3 to 8 S f 0 iu ge SY e EPST controller is now ready to be re activated Note If the EPST controller was still activated while changing the next Kf Cf values EPST mu
38. measured drill data in blocks of ten minutes If the first block contains usable information in the data it can calculate directly the tuned values of Kf and Cf If there is not enough information in the data it takes another block or more to identify the Kf and Cf values When EPST is switched off and on again add stand the actual Kf an Cf values of the EPST controller will be updated with the calculated values from the EPST AT algorithm Note Keep in mind that if stick slip is present the EPST AT algorithm is not capable to produce Kf and Cf auto tune values at a regular basis If no new Kf and Cf are estimated the drilling conditions must be changed rpm WOB so new values can be estimated 4 3 3 1 CONTROL Auto tune and Initialize button ence Initialize AT The Auto tune button enables the EPST auto tune algorithm when EPST is enabled switched on When Auto Tune is enabled next Kf Cf values will be estimated automatically when drilling and EPST is enabled When EPST is re enabled the new Next values will become active Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 23 ElectroProject EI NOS aandrijftechniek If EPST is activated with EPST AT enabled it takes a while before the system can estimate the first calculated next Cf Kf values Operation Manual EPST Autotune The AT algorithm is only active while EPST is enabled When starting to use AT the Kf Cf values must fir
39. nnected to the 2 profibus connection of the VFD e 38 7 9 EPST connected in between the profibus communication cable bypass 39 7 4 EPST connected in between the profibus communication cable install 40 7 5 EPST connected to the TD system by controlling the analog I O signals 41 7 6 Quick Guide mantal inp t Kf and UI iy y yi nie nel aykka nakan buk n k d di Sewala r k ae wa D H uk dessen 42 7 7 Quick Guide using EPST with Auto Tune ENABLED c c ceeesssssssssssssesssseeeseseeseeens 43 Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 3 ElectroProject EI NS aandrijftechniek Operation Manual EPST Autotune 1 Preface 1 1 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 This manual has been derivated from the standard EPST operation manual and supplemented with operation instructions for the use of EPST Auto Tune EPST AT functionality 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 sho
40. re 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 Auto Tune Operation Manual EPST AT version 2 3 page 2 ElectroProject EB N NOS aandrijftechniek Operation Manual EPST Autotune Content 1 L O lA E
41. re 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 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 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 Auto Tune Operation Manual EPST AT version 2 3 page
42. roproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 7 ElectroProject EBI Operation Manual EPST Autotune ENS aandrijftechniek Another most common implementation example ST control panel monio or IPC Ethernet PNE RT ket 2 g ooo E oo oo o P Ja 0000 ooooo o 2 Q M yy ge E o A C e RP e rikin ooo q e 8 G gt lt gt lt an Ld kul Lat ni CN BECKHOFF Kil PLC Controller Actual speed digital encoder feedback Drill string And bottom hole assembly to eS i lt 9 Figure 4b EPST System overview in between original profibus example 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 owitching Soft Torque Auto Tune AT ON and OFF Entering the right settings for the tuning parameters Kf and Cf Alternatively calculation of Kf and Cf depending on BHA and Drill pipe specifications pe es Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 8 ElectroProject EN NOS aandrijftechniek Operation Manual EPST Autotune 3 3 Settings The user settings can be found at the Settings screen on the EPST HMI control panel System settings can be a
43. st be first deactivated and activated again to make the new Kf Cf values active 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 2 5290 and Cf 2422 Enter these values in the corresponding input fields at the Home screen Before activating EPST again check if values on the touch panel are correctly entered Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 17 ElectroProject ES NS aandrijftechniek 4 3 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 4 3 2 1 and 0 Operation Manual EPST Autotune The drill pipe entry screen does have a total of three different drill pipe parts to configure Item one is 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 recalculat
44. st be initialized see paragraph 4 3 4 Press the Initialize button when start using EPST AT before activating EPST 4 3 3 2 Procedure for using EPST with auto tune function enabled 1 Check on the settings screen if Auto Tune and AT Auto Transfer are enabled 2 EPST AT must be initialized with the Initialize AT button on the home screen when starting a new hole or start using it after a different depth the last time it was used 3 otart using EPST by activating it with the Activate EPST button on the home screen After a short time the AT Active indicator will appear meaning that the EPST AT algorithm is working in the background 4 After minimal 10 minutes drilling with EPST AT the first estimated values will appear in the Next Kf Cf fields on the home and auto tune screen If this happens also the green AT NV will be appear on the home screen 5 Disable or let EPST switch off automatically when adding a new stand 6 After adding a stand start normal drilling again and activate EPST again When the next values of Kf and Cf were in range of the actual ones set on the settings screen with the Max difference next and actual Kf Cf setting the next values estimated while drilling the previous stand will be used automatically as actual values 7 Go to step 4 4 3 4 Initializing EPST AT Use the Initialize AT button to calculate new start values for the EPST AT Because EPST AT can only produce EPST tuning values when
45. ual EPST Autotune 7 5 EPST connected to the TD system by controlling the analog I O signals ElectroProject BS NOS aandrijftechniek EXISTING MODIFIED CABINET XP2 BY PASS PLUG API LOS MEELEVEREN CONNECTOR WORDT OP LOCATIE AAN DE KABEL GEMONTEERD DOOR EP NEXCOM LOGO DOWN Al XSi DIN RAIL MOUNTING SOCKET TO BE WIRED BY CLIENT SUPPORT CABLE v AT THIS POINT Xam HEP L 10m i i Fi NU IPA 2314 i _l6r gt version 2 3 page 41 Operation Manual EPST AT Electroproject Soft Torque Auto Tune ElectroProject EN NOS aandrijftechniek Operation Manual EPST Autotune 7 6 Quick Guide manual input Kf and Cf EP soft torque controller Quick guide manually 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 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 Auto Tune Operation
46. uter inner diameter and length can be entered by selecting it s numeric input field Because of the huge variety of BHA components there is only a standard drill pipe database implemented in the EPST system HWDP or normal DP s can be selected in item 5 The rest of the BHA components must be configured at items 1 till 4 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 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 The fifth item is meant for selecting a standard heavy drill pipe from the predefined database Select the use heavy drill pipe used in the BHA Add all used lengths of the BHA HWDP s and fill it in the length field of item five 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 cert
47. values Also drill speed needs to be above a threshold value Compared to normal operation EPST is not activated the threshold speed value above which stick slip cannot exist is lower when soft torque is on Q IMPORTANT Operation Manual EPST Autotune When Auto Tune with auto transfer is not used Kf and Cf must be adjusted each time the drill string configuration changes e g adding a stand The EPST system has Actual and Next Kf Cf settings for the EPST controller Figure 11 Kf Cf values on the Home Screen Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 14 ElectroProject EI NOS aandrijftechniek The Kf and Cf values with the black background are the actual used values when EPST is active These values cannot be changed directly Each time EPST is activated by pressing on the Activate EPST button the Next values will be copied to the actual values directly except when the next values differs to much with the actual ones Operation Manual EPST Autotune There are four ways to specify the next Kf and Cf settings 1 Manually input of Kf and Cf Home screen 2 Calculation with integrated BHA and drill string configuration BHA and Drill pipe entry screen 3 Automatic calculation and activation by EPST Auto Tune algorithm EPST AT 4 By the Initialize AT function on the Home Sreen If correct settings are available in the next Kf and Cf values EPST can be a
48. y a status screen At the top of the screen there are three indicators EPST EPST soft torque controller is active when green Switching EPST on and off can be done on the home screen Note EPST is also switched off automatically when the drilling speed setpoint drops below the setting Auto switch off EPST level on the settings screen Auto Tune EPST AT is enabled This means that when EPST is enabled the auto tune algorithm tries to estimate automatically values for Kf and Cf If a new values are calculated it will be showed in the Calculated Kf and Cf fields Electroproject Soft Torque Auto Tune Operation Manual EPST AT version 2 3 page 28 ElectroProject Operation Manual EPST Autotune aandrijftechniek AT Auto Transfer EPST AT Auto transfer is enabled When new values for Kf and Cf are calculated these values will not only be shown in the Calculated Kf and Cf fields but will also be used as Next Kf Cf settings The Next Kf Cf settings will be used as actual Kf Cf settings the next time EPST is activated or reactivated If Auto Tune and AT Auto Transfer are enabled the driller only has to switch EPST on and off Tuned settings for the EPST controller are automatically estimated end used 5 5 Messages screen ElectroProject Soft Torque MIMIC Messages 1 19 26 PM 9 4 2013 New Kf Cf values differs much from old ones 7 1 19 22 PM 9 4 2013 New Kf Cf values differs much from ol
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