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First Slide of Presentation

GeoBalance MPD Control


Neal Skinner

February 18, 2009 Carrollton, TX


Level 2 Skid

Retrofitted system (Siemens PLC)


Pressure control during circulating and drill ahead only
Two pressure transmitters upstream choke with wire cut and short sensing
Level 3 Skid

Pressure control during circulating and drill ahead


New build skids with flow meter downstream choke, meant for US market
Two pressure transmitters upstream choke with wire cut and short sensing
Combined hydraulic panel for chokes and ESD valve
Level 4 Skid with Backpressure Pump Skid

Remote operated block valves (air)


Same choke panel as for Level 3 skid
Third choke for tie-in of Backpressure pump for use during connections
Backpressure pump with soft start
Open loop control system

No feed back
Relying on good knowledge
about process
Using RT Hydraulics without
feedback from BHP can be
defined as an open loop
control system
Components in a closed loop system

Closed loop means that there is feedback Process


(shower)
Reference,
Controller Disturbance:
(brain) Air temp.,
Temp of hot
water, etc
Actuator
(hand on valve) Measuring
device
(hand)
Time delay

Time delay in the control system


require slower control to avoid
instability
Time delay in MPD system:
Delay in communication lines
Delay in physical system:
Hydraulic valves
Hydraulic lines
Choke valves
For BHP control there is time delay
due to pressure propagation from
choke
Not all events down hole can be
controlled using choke on surface
Turning the valve at
same speed as
before gives too hot
or cold water
PID components

P Proportional
I Integral
D Derivative

1 t de
U (t ) K p e(t )
Ti 0 e( ) d Td dt
PID components; Proportional component

General about the Most important value.


P-value Should always be greater than zero.
The P-component is part of I-component and D-component as well, and changing
the value will also affect those components.

Increase P-value Gives faster control.


Can be unstable (oscillating) if value is too high.

Decrease P-value Gives slower control.

P-value = 0 Turns off the PID controller. (not only the P-component)

1 t de
U (t ) K p e(t )
Ti 0 e( ) d Td dt
PID components; Integral component

General about Purpose of the I-component is to avoid static deviation.


the I-value During step changes of set point the I-component will make the pressure
overshoot the set point.
Increase I-value Makes the controller converge slower to the set point.
Gives less overshoot during set point changes.
Decrease I-value Makes the controller converge faster to the set point.
Gives more overshoot during set point changes.
I-value = 0 WARNING: Never put the I-value to zero!! Putting this to zero gives unstable
system.
Very high I- Turns off the effect of the I-component. However it is NOT switched off and will
value increase I-component over time if there is deviation between set point and
pressure reading.
Put I-value to zero by swapping between Position and Pressure control.

Integral wind-up Wind-up is that the I-component increase to very high value.
This can happen if e.g. the air to the choke panel is off while the pressure control
is on. Then the control output from the I-component will increase without
being able to influence the pressure.
The system should be swapped between position and pressure control to reset
(put to zero) the output from the I-component.

1 t de
U (t ) K p e(t )
Ti 0 e( ) d Td dt
PID components; Derivative component

General about The D-component is calculated by taking the derivative of the difference
the D-value between the set point and the pressure reading and multiplying it by the D-
value.
This value is therefore sensitive to measurement noise.
The D-component is a damping component that helps to suppress pressure
variations.

Increase D-value Increase the sensitivity to measurement noise.


Increase the damping of pressure variations.

Decrease P-value Decrease the damping of the pressure variations.


Decrease oscillations caused by measurement noise.
D-value = 0 Turns off the D-component.

1 t de
U (t ) K p e(t )
Ti 0 e( ) d Td dt
Overview of MPD control system

Closed loop control system


Cascade control system when system is in BHP control mode
MPD Control modes

The Control modes are:

Standby
Standby
No
Noremote
remotecontrol
controlactions,
actions,data
dataacquisition
acquisitiononly
only

Manual
Manualcontrol
control
Remote
Remotecontrol
controlof
ofchoke
chokeand
andBackpressure
Backpressurepump
pump

Surface
Surfacepressure
pressurecontrol
control
Automatic
Automaticpressure
pressurecontrol
controlto
tohold
holddesired
desiredupstream
upstreamchoke
choke
pressure. Hydraulic model is not in control loop.
pressure. Hydraulic model is not in control loop.

BHP
BHPpressure
pressurecontrol
control
Automatic
Automaticpressure
pressurecontrol
controlto
tohold
holddesired
desiredBHP.
BHP.Control
Control
depend on hydraulic models output.
depend on hydraulic models output.
Control Modes

ChkP
BHP Stand-By
ManualControl
Control
ControlMode
Mode
Mode

Pos.
Pos set point
control

Setpoint
In HMI

Position control
Mechanical components in control loop

We are controlling the speed of


opening/closing
(not directly the position)
Speed adjustment valve has
significant influence of the
control performance
Hydraulic pressure influence the
control

Choke trim and choke


characteristic
Overview of Process

Oh, we also have a well!


Operational window for choke trim

PU / S PD / S
Qchoke Cv
SG

Limits high flow


@ low pressure
Flow characteristic, 3 trim
Cv, Flow coefficient
Operational window for choke trim

Limits high flow


@ low pressure
Flow characteristic, 2 trim
Operational window for choke trim

Depend on flow rate, surface pressure and mud density


Is only defined for single phase fluid

Limits low flow


@ high pressure
Operational window for choke trim

Higher mud density gives more


controllability at lower flow rate
Operational window for choke trim

2 trim can be used at lower


flow @ higher pressure

2 trim has
limitation at
high flow
rate @ low
pressure
Operational window for choke trim

Limits high flow


@ low pressure
Operational window for choke trim

Limits high flow


@ low pressure
Operational window for choke trim

Limits high flow


@ low pressure
Calculate PID settings

Use excel sheet to get a starting point:

Microsoft Excel
Worksheet

Pay strict attention to units!

Bulk modulus = 1 / compressibility


Work flow

Check Smiley
charts

Default is for
3trim
Settings are for
To be able to calculate Gain scheduling
starting points for PID controller
settings.
25 s is recommended
Use excel sheet

Test of system Adjust if first time with


choke panel
Check that control signals
are as expected
Test and adjust PID settings (from Guidance to tuning)
1. Keep system in Manual on choke panel (or in Automatic and do Position control in
HMI).
2. Establish the desired flow rate and pressure upstream choke while controlling using
manual control on Choke panel (or by using Position control in HMI)..
control3. When the flow rate and pressure is stable input the pressure as setpoint in HMI.
in HMI).
ng using manual control on Choke panel (or by using Position control in HMI)..
HMI. 4. Switch system to Automatic on Choke panel and in Pressure Control in HMI.
n HMI. 5. Wait to see that the system is stable.

6. Input 75 psi lower pressure setting.


hen converge to desired pressure. The figure below shows some result from flow testing. As we can see there is a difference in response when the press
7. Watch response: it should start reacting, it should overshoot a little bit and then
converge to desired pressure. The figure below shows some result from flow testing. As
we can see there is a difference in response when the pressure is increased. The important
thing is that the does not become unstable.
8. Do approx 100 psi steps in pressure
around the expected pressure when assure
that the system is stable. Do some rate
changes and ensure that system still is stable
and capable of keeping pressure at desired
pressure. Adjust the PID parameters until the
response is good.
Thanks for your attention!

QUESTIONS?

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