Energy-saving control system and control method of frequency conversion direct drive winch of petroleum electric drilling rig

Abstract

The application discloses a kind of petroleum electric drilling rig variable frequency direct drive winch energy-saving control system, including upper integrated monitoring system, upper integrated monitoring system is connected in turn switch A, lower PLC automation execution system PLC master station by Ethernet communication, switch B, switch B is also connected with direct drive winch A frequency converter and direct drive winch B frequency converter respectively by Ethernet communication, lower PLC automation execution system PLC slave station connects each parameter module, the switch A is also connected with winch drum encoder by PN / DP converter.The application also discloses a kind of control method of petroleum electric drilling rig variable frequency direct drive winch energy-saving control system.The application solves the problem of large no-load current and high energy consumption of direct drive winch in the prior art.

Description

Technical Field

[0001] This invention belongs to the field of electrical equipment technology, specifically relating to an energy-saving control system for a variable frequency direct drive winch of an oil electric drilling rig, and also to a control method for the energy-saving control system of the variable frequency direct drive winch of an oil electric drilling rig. Background Technology

[0002] As high-power direct-drive motor-driven winches are increasingly used in AC variable frequency electric drive drilling rigs, they have shown remarkable advantages over conventional chain gearbox-driven winches in terms of smaller mechanical size, lighter weight, higher transmission efficiency, and simpler maintenance. However, they have also revealed shortcomings such as larger no-load current and higher energy consumption.

[0003] To compensate for and solve the above-mentioned shortcomings, an energy-saving control method for the frequency conversion direct drive winch of an oil electric drilling rig was designed by optimizing the software of the AC frequency conversion direct drive winch control system. Summary of the Invention

[0004] The purpose of this invention is to provide an energy-saving control system for a variable frequency direct drive winch of an oil electric drilling rig, which solves the problems of large no-load current and high energy consumption of the existing direct drive winch.

[0005] Another objective of this invention is to provide a control method for an energy-saving control system of a variable frequency direct drive winch for an oilfield electric drilling rig.

[0006] The first technical solution adopted in this invention is an energy-saving control system for a variable frequency direct-drive winch of an oilfield electric drilling rig, comprising an upper-level integrated monitoring system. The upper-level integrated monitoring system is sequentially connected to switch A, a lower-level PLC automation execution system PLC master station, and switch B via Ethernet communication. Switch B is also connected to the frequency converters of direct-drive winch A and direct-drive winch B via Ethernet communication. The frequency converter of direct-drive winch A is connected to the motor of direct-drive winch A, and the frequency converter of direct-drive winch B is connected to the motor of direct-drive winch B. The motors of direct-drive winch A and direct-drive winch B are also connected to the PLC slave station of the lower-level PLC automation execution system. The PLC slave station of the lower-level PLC automation execution system is connected to various parameter modules. Switch A is also connected to the winch drum encoder via a PN / DP converter.

[0007] The first technical solution of the present invention is further characterized in that,

[0008] The various parameter modules include: direct drive winch auxiliary power distribution module, disc brake hydraulic station module, and winch sensor module.

[0009] The data from the disc brake hydraulic station includes: disc brake parking brake solenoid valve, disc brake emergency brake solenoid valve, disc brake left working caliper pressure, disc brake right working caliper pressure, disc brake safety caliper pressure, disc brake system pressure, disc brake high oil temperature alarm, and oil level alarm data.

[0010] The data from the winch sensor module includes: crane anti-collision, over-ring anti-collision, riser pressure, and hook suspension weight.

[0011] The direct-drive winch auxiliary power distribution module is connected to disc brake hydraulic station motor A, disc brake hydraulic station motor B, direct-drive winch B motor fan, and direct-drive winch A motor fan. The direct-drive winch B motor fan and direct-drive winch A motor fan are also connected to the lower-level PLC automation execution system PLC slave station.

[0012] The second technical solution adopted in this invention is a control method for an energy-saving control system of a variable frequency direct drive winch for an oilfield electric drilling rig, which is implemented according to the following steps:

[0013] Step 1: The upper-level integrated monitoring system sends the operating mode command to the lower-level PLC automation execution system PLC master station via Ethernet communication through switch A. Definition 0: Normal mode, energy-saving command is invalid; Definition 1: Energy-saving mode, energy-saving command is valid.

[0014] Step 2: The lower-level PLC automation execution system PLC master station determines whether the energy-saving command is valid. If the energy-saving command is valid, continue to step 3; if the energy-saving command is invalid, jump to step 9.

[0015] Step 3: The PLC master station of the lower-level PLC automation execution system determines whether the winch is in a stopped state. If the winch is in a stopped state, continue to step 4; if the winch is in a running state, jump to step 10.

[0016] Step 4: The lower-level PLC automation execution system PLC master station adopts the energy-saving mode motor data group to realize energy-saving mode calculation;

[0017] Step 5: The PLC master station of the lower-level PLC automation execution system sends an energy-saving mode command to the direct drive winch A frequency converter and / or the direct drive winch B frequency converter via Ethernet communication through switch B, and the frequency converter switches to energy-saving operation mode.

[0018] Step 6: The lower-level PLC automation execution system PLC master station reads the operating data of the winch frequency converter through Ethernet communication via switch B, and performs calculations, displays and stores the data.

[0019] Step 7: The lower-level PLC automation execution system PLC master station receives other control commands from the winch via Ethernet communication through switch A, realizing the automatic control functions of the winch such as starting, stopping, speed adjustment, braking, and collision prevention.

[0020] Step 8: End;

[0021] Step 9: The lower-level PLC automation execution system PLC master station adopts the normal mode motor data group to realize normal mode calculation;

[0022] Step 10: The lower-level PLC automation execution system PLC master station sends a normal mode command to the direct drive winch A frequency converter and / or the direct drive winch B frequency converter via Ethernet communication through switch B. The frequency converter switches to normal operation mode and then jumps to step 6.

[0023] The beneficial effects of this invention are as follows: An energy-saving control system for a direct-drive winch of an oilfield electric drilling rig includes: 1. A main drive winch power control system: using an ABB ACS880 fully digital AC variable frequency speed control device as the power drive source for the main motor of the direct-drive winch. 2. An auxiliary power control system for the direct-drive winch: an MCC power distribution system providing power to various auxiliary equipment of the direct-drive winch (main motor cooling fan motor, lubricating oil pump motor, hydraulic station, disc brake, etc.). 3. A PLC automated monitoring system for the direct-drive winch: consisting of an upper-level integrated monitoring system (including an HMI touchscreen) located in the centralized monitoring room where the electric drilling rig operator is located, a lower-level PLC automated system master station located in the electric drilling rig electrical control system room, and a lower-level PLC automated system remote slave station located in the local control box of the direct-drive winch, as well as control switches, buttons, indicator lights, power supply circuits, etc., of the direct-drive winch auxiliary power control system. The direct-drive winch PLC automated monitoring system monitors the main drive winch power control system and the auxiliary power control system of the direct-drive winch through industrial Ethernet communication and displays their operating status on the HMI touchscreen. Control method of energy-saving control system for variable frequency direct drive winch of oil electric drilling rig: Based on PLC automatic monitoring system hardware, the relevant data of the main power control system and auxiliary power control system of the direct drive winch are collected through Ethernet intelligent DAQ data acquisition system. The working condition of the winch is predicted. The dual DDS parameter group switching technology is applied and various safety protection functions are integrated to design a variable frequency direct drive winch for oil electric drilling rig with two operating modes: economic energy saving mode and normal mode. Attached Figure Description

[0024] Figure 1 This is a control block diagram of the energy-saving control system for the variable frequency direct drive winch of the petroleum electric drilling rig of the present invention;

[0025] Figure 2 This invention provides a control flowchart for the energy-saving control method of variable frequency direct drive winch for petroleum electric drilling rigs. Detailed Implementation

[0026] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0027] This invention provides an energy-saving control scheme for a variable frequency direct-drive winch on an oilfield electric drilling rig. The winch is controlled by two completely independent ABB ACS880 frequency converters driving the two main variable frequency motors of the winch in a one-to-one manner. The system is designed so that the direct-drive winch energy-saving control system can select to control either winch motor individually, or select both winch motors to operate synchronously using master / slave control.

[0028] Data from each inverter group is accessed via Siemens PROFINENT industrial Ethernet and Ethernet switches to the main communication network of the variable frequency drive winch energy-saving control system. The PLC monitors the inverter's operating status in real time, collecting key data such as the winch's hook load, hook speed, hydraulic station fluid pressure, disc brake control solenoid valve, main motor cooling fan status, and winch lubricating oil pressure. This data helps determine the winch's operating condition. Combined with optimized and upgraded control algorithms in the PLC software, the system implements two operating modes for the variable frequency drive winch: economical and energy-saving, and standard power-efficient. Simultaneously, it aggregates various fault protection functions related to the winch, ensuring that in the event of any fault, the PLC software-designed safety protection measures and process control mechanisms execute corresponding protective actions, protecting the variable frequency drive winch energy-saving control system for safe, reliable, and efficient operation. See [link / details omitted]. Figure 1 and Figure 2 .

[0029] This invention discloses an energy-saving control system for a variable frequency direct-drive winch of an oilfield electric drilling rig, such as... Figure 1 As shown, the system includes a supervisory control and monitoring system (HMI), which is connected sequentially to switch A, the lower-level PLC automation execution system PLC master station, and switch B via Ethernet communication. Switch B is also connected to the direct-drive winch A frequency converter and the direct-drive winch B frequency converter via Ethernet communication. The direct-drive winch A frequency converter is connected to the direct-drive winch A motor, and the direct-drive winch B frequency converter is connected to the direct-drive winch B motor. The direct-drive winch A motor and the direct-drive winch B motor are also connected to the lower-level PLC automation execution system PLC slave station. The lower-level PLC automation execution system PLC slave station is connected to various parameter modules. Switch A is also connected to the winch drum encoder via a PN / DP converter.

[0030] The various parameter modules include: direct drive winch auxiliary power distribution module, disc brake hydraulic station module, and winch sensor module.

[0031] The data from the disc brake hydraulic station includes: disc brake parking brake solenoid valve, disc brake emergency brake solenoid valve, disc brake left working caliper pressure, disc brake right working caliper pressure, disc brake safety caliper pressure, disc brake system pressure, disc brake high oil temperature alarm, and oil level alarm data.

[0032] The data from the winch sensor module includes: crane anti-collision, over-ring anti-collision, riser pressure, and hook suspension weight.

[0033] The direct-drive winch auxiliary power distribution module is connected to disc brake hydraulic station motor A, disc brake hydraulic station motor B, direct-drive winch B motor fan, and direct-drive winch A motor fan. The direct-drive winch B motor fan and direct-drive winch A motor fan are also connected to the lower-level PLC automation execution system PLC slave station.

[0034] A control method for an energy-saving control system of a variable frequency direct drive winch for an oilfield electric drilling rig is implemented according to the following steps:

[0035] Step 1: The upper-level integrated monitoring system (HMI) sends the operating mode command to the lower-level PLC automation execution system PLC master station via Ethernet communication through switch A. Definition 0: Normal mode, energy-saving command is invalid; Definition 1: Energy-saving mode, energy-saving command is valid.

[0036] Step 2: The lower-level PLC automation execution system PLC master station determines whether the energy-saving command is valid. If the energy-saving command is valid, continue to step 3; if the energy-saving command is invalid, jump to step 9.

[0037] Step 3: The PLC master station of the lower-level PLC automation execution system determines whether the winch is in a stopped state. If the winch is in a stopped state, continue to step 4; if the winch is in a running state, jump to step 10.

[0038] Step 4: The lower-level PLC automation execution system PLC master station adopts the energy-saving mode motor data group to realize energy-saving mode calculation;

[0039] Step 5: The lower-level PLC automation execution system PLC master station sends an energy-saving mode command to the direct-drive winch A frequency converter and / or the direct-drive winch B frequency converter via Ethernet communication through switch B (based on the winch motor selection command received from the upper-level integrated monitoring system (HMI)). The frequency converter switches to energy-saving operation mode.

[0040] Step 6: The lower-level PLC automation execution system PLC master station reads the operating data of the winch frequency converter through Ethernet communication via switch B, and performs calculations, displays and stores the data.

[0041] Step 7: The lower-level PLC automation execution system PLC master station receives other control commands from the winch via Ethernet communication through switch A, realizing the automatic control functions of the winch such as starting, stopping, speed adjustment, braking, and collision prevention.

[0042] Step 8: End;

[0043] Step 9: The lower-level PLC automation execution system PLC master station adopts the normal mode motor data group to realize normal mode calculation;

[0044] Step 10: The lower-level PLC automation execution system PLC master station sends a normal mode command to the direct drive winch A frequency converter and / or direct drive winch B frequency converter via Ethernet communication through switch B (based on the winch motor selection command received from the upper-level integrated monitoring system (HMI)). The frequency converter switches to normal operation mode and then jumps to step 6.

[0045] This invention has two operating modes for the direct-drive winch: an economical and energy-saving mode and a normal power-energy mode. It reduces the high current and energy consumption of the direct-drive winch when it is unloaded or lightly loaded, achieving good energy-saving indicators, while also ensuring the power-energy indicators of the direct-drive winch when it is heavily loaded, thus better leveraging the high transmission efficiency of the direct-drive winch.

[0046] 1. Application of two different motor operating modes in variable frequency direct drive winches.

[0047] The direct-drive winch variable frequency speed control system is designed with two operating modes: an economical and energy-saving mode for when the motor is unloaded or lightly loaded, and a normal power-energy mode for when the motor is heavily loaded. To improve the safety performance of the control system, the two operating modes can only be switched in standby mode.

[0048] 2. Application of dual DDS parameter group switching technology in variable frequency direct drive winches.

[0049] In the direct-drive winch variable frequency speed control system, two sets of motor operating parameter sets (DDS) are designed and stored. One set of DDS parameters is used when the motor is running under no-load or light-load conditions, while the other set is used when the motor is running under heavy load conditions. To improve the safety performance of the control system, the two sets of parameters can only be switched in standby mode.

Claims

1. A control method for an energy-saving control system of a variable frequency direct drive winch for an oilfield electric drilling rig, characterized in that, Based on the energy-saving control system of the variable frequency direct drive winch of the oil electric drilling rig, the specific implementation steps are as follows: Step 1: The upper-level integrated monitoring system sends the operating mode command to the lower-level PLC automation execution system PLC master station via Ethernet communication through switch A. Definition 0: Normal mode, energy-saving command is invalid; Definition 1: Energy-saving mode, energy-saving command is valid. Step 2: The lower-level PLC automation execution system PLC master station determines whether the energy-saving command is valid. If the energy-saving command is valid, continue to step 3; if the energy-saving command is invalid, jump to step 9. Step 3: The PLC master station of the lower-level PLC automation execution system determines whether the winch is in a stopped state. If the winch is in a stopped state, continue to step 4; if the winch is in a running state, jump to step 10. Step 4: The lower-level PLC automation execution system PLC master station adopts the energy-saving mode motor data group to realize energy-saving mode calculation; Step 5: The PLC master station of the lower-level PLC automation execution system sends an energy-saving mode command to the direct drive winch A frequency converter and / or the direct drive winch B frequency converter via Ethernet communication through switch B, and the frequency converter switches to energy-saving operation mode. Step 6: The lower-level PLC automation execution system PLC master station reads the operating data of the winch frequency converter through Ethernet communication via switch B, and performs calculations, displays and stores the data. Step 7: The lower-level PLC automation execution system PLC master station receives other control commands from the winch via Ethernet communication through switch A, realizing the automatic control functions of the winch's start, stop, speed adjustment, braking, and anti-collision. Step 8: End; Step 9: The lower-level PLC automation execution system PLC master station adopts the normal mode motor data group to realize normal mode calculation; Step 10: The lower-level PLC automation execution system PLC master station sends a normal mode command to the direct drive winch A frequency converter and / or the direct drive winch B frequency converter via Ethernet communication through switch B. The frequency converter switches to normal operation mode and then jumps to step 6.

2. The control method of the variable frequency direct drive winch energy-saving control system for an oilfield electric drilling rig according to claim 1, characterized in that, The energy-saving control system for the variable frequency direct-drive winch of the oilfield electric drilling rig includes a host integrated monitoring system. The host integrated monitoring system is connected to switch A, the PLC master station of the lower-level PLC automation execution system, and switch B via Ethernet communication. Switch B is connected to the frequency converters of direct-drive winch A and direct-drive winch B via Ethernet communication. The frequency converter of direct-drive winch A is connected to the motor of direct-drive winch A, and the frequency converter of direct-drive winch B is connected to the motor of direct-drive winch B. The motors of direct-drive winch A and direct-drive winch B are connected to the PLC slave station of the lower-level PLC automation execution system. The PLC slave station of the lower-level PLC automation execution system is connected to various parameter modules. Switch A is also connected to the winch drum encoder via a PN / DP converter.

3. The control method of the variable frequency direct drive winch energy-saving control system for an oilfield electric drilling rig according to claim 2, characterized in that, The various parameter modules include: direct drive winch auxiliary power distribution module, disc brake hydraulic station module, and winch sensor module.

4. The control method of the variable frequency direct drive winch energy-saving control system for an oilfield electric drilling rig according to claim 3, characterized in that, The data from the disc brake hydraulic station includes: disc brake parking brake solenoid valve, disc brake emergency brake solenoid valve, disc brake left working caliper pressure, disc brake right working caliper pressure, disc brake safety caliper pressure, disc brake system pressure, disc brake high oil temperature alarm, and oil level alarm data.

5. The control method of the variable frequency direct drive winch energy-saving control system for an oilfield electric drilling rig according to claim 3, characterized in that, The data from the winch sensor module includes: crane anti-collision, over-ring anti-collision, riser pressure, and hook suspension weight.

6. The control method of the variable frequency direct drive winch energy-saving control system for an oilfield electric drilling rig according to claim 3, characterized in that, The direct-drive winch auxiliary power distribution module is connected to disc brake hydraulic station motor A, disc brake hydraulic station motor B, direct-drive winch B motor fan, and direct-drive winch A motor fan. The direct-drive winch B motor fan and direct-drive winch A motor fan are also connected to the lower-level PLC automation execution system PLC slave station.

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