CH 2 - Theory of Operation

Training Solutions
Theory of Operation
One Company … Unlimited Solutions 1

Objectives
Upon completion of this chapter, the students will be able to:

List Amphion’s design objectives for:
Training Solutions
Overall control of rig tools
Tripping
Drilling
Identify, interpret and use common screen elements
Describe Amphion’s methods for stopping motion in both normal

and abnormal conditions
Describe the Zone Management System and explain its operation
Interpret alarm color coding and severity of alarm conditions

General Description
Distributed processing:
Each tool is controlled by its own computer.
Training Solutions
Consistent web-based interface:
Every tool is accessed via Internet Explorer.
The same task (e.g. adjusting a setpoint) is always done

the same way.
Controls that look alike typically work alike on every tool.
Alarms and information are reported in a consistent and

color coded manner.

Screen Controls I
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Alarm Display I
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Tripping Design Objectives
Maximum SAFE speed of block movement
Crown and floor protection
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Prevention of “birds-nesting”
Minimal tripping time

Tripping I
Maximum SAFE speed of block movement calculated from:

Hook load
Training Solutions
Block position
Block direction
Block velocity
Block acceleration
Available braking torque

Tripping II
Low
Acceleration Signal
Select
Velocity Maximum
Training Solutions
Safe
Position & Speed
Direction
Available
Braking Torque
Desired
Hook Load Speed

Tripping III
Training Solutions
Drilling
Design objective:
Maintain consistent preset pressure on the bit
Training Solutions
Four parameters:
Rate of penetration (ROP)
Weight on bit (WOB)
Top drive/rotary table torque output (torque)
Differential standpipe pressure (Delta-P)

Drilling – ROP
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Drilling – WOB
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Drilling – Torque
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Drilling – Delta P
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Drilling – Lower Setpoint
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Drilling – Raise Setpoint
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Safety
When Amphion was designed safety was a primary

consideration. Although there are many safety features
within the Amphion system, two require special attention:
Training Solutions
Stopping the block
Zone Management System

Stopping
IEC60204-1 defines three categories of stop functions:

Category 0
Training Solutions
Stopping by immediate removal of power to the machine
actuators (i.e. an uncontrolled stop)
Category 1 (This is not used)
A controlled stop with power available to the machine actuators
to achieve the stop and then a removal of power once the stop is
achieved.
Category 2
A controlled stop with power left available to the machine
actuators.

Stopping
Category 0 Stop:
Dumps all air/hydraulic fluid from
brake cylinders (brakes are
spring-applied/pneumatic or
Training Solutions
hydraulic- released)
Sends “Drive Off” commands to
VFDs, as well as zero speed and
minimum torque commands
Category 0 is an uncontrolled
stop! (a screeching halt)
Does not follow the deceleration
profile and carries significant risk
of “bird’s-nesting.”
Category 0 is invoked only when
stopping the block outweighs all
other considerations.

Stopping
Category 0 stop is invoked when:

The driller’s emergency stop button is pressed
Training Solutions
The Automatic Drawworks System (ADS) controller fails
The Crown-o-Matic switch is activated
The block lowers when held by the motors and zero-

speed is commanded
The block moves up or down while parked
Communication is lost with the remote I/O block

controlling the brake solenoid valves

Stopping
Category 2 stop:
Normal operation stops are technically category 2 stops.
Training Solutions
However, the term category 2 is only used for stops under
abnormal or emergency conditions.
Category 2 stops follow the deceleration profile just like
normal operational stops. The difference is that category
2 stops are initiated automatically by Amphion in
response to a fault or emergency condition.

Stopping
A category 2 stop will occur when:

Two drawworks rotary encoders have failed (and all of the encoders
are enabled)
Training Solutions
Two hook load sensors have failed (and all of the sensors are
enabled)
Communication is lost with the remote I/O (except the brake I/O)
Brake air or hydraulic pressure is low
Torque transfer from motor to brake has failed
An enabled autodrill parameter (ROP, WOB, Torque, Delta-P)

exceeds its setpoint by a specified margin for more than 5 seconds

Stopping
A category 2 stop also occurs when:

The velocity profile is not being followed
Training Solutions
Block movement in the hoisting direction is detected
when there is a stopping command
Communication is lost with a VFD
A VFD, chopper or resistor fails

Special Note On the Emergency Stop
Training Solutions
What will happen if you press Emergency Stop now?

Soft Trip
In addition to the IEC specified Category 0 and Category 2

stops, Amphion incorporates one other emergency action:
Training Solutions
The soft trip – A soft trip neither stops nor slows the block
but it does prevent the block velocity from being raised
above 25% of its maximum and prevents un-parking if the
block is parked.

Soft Trip
If a soft trip occurs while the block is traveling at 25% or less of

maximum velocity, it cannot be run faster than 25% except by
pressing the override button.
Training Solutions
If a soft trip occurs while the block is traveling at a velocity greater
than 25% of maximum, it will continue at its present velocity until
slowed either by the driller or by the normal deceleration process
when approaching a travel stop or limit. Once slowed below 25% of
maximum, it cannot be run faster than 25% except by pressing the
override.
If a soft trip occurs while the block is parked, the parking brake
cannot be released except by pressing the override.

Soft Trip
A soft trip will occur when:

Actuation energy is low for either brake
Training Solutions
Gearbox lubrication pressure is low to either brake
Cooling water outlet temperature from either brake is high (water

cooled only)
Cooling water inlet temperature to either brake is high (water cooled
only)
Cooling water temperature rise is excessive in either brake (water
cooled only)
Cooling water flow is low to either brake (water cooled only)
High temperature occurs on any phase of any motor

Safety – ZMS
Training Solutions
Safety – ZMS
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Safety – ZMS
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Safety – ZMS
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Safety – ZMS
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Safety – ZMS
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Safety – ZMS
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Safety – ZMS
Training Solutions

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Training Solutions

One Company … Unlimited Solutions 1

Upon completion of this chapter, the students will be able to:

Describe Amphion’s methods for stopping motion in both normal

Interpret alarm color coding and severity of alarm conditions

One Company … Unlimited Solutions 2

The same task (e.g. adjusting a setpoint) is always done

Alarms and information are reported in a consistent and

One Company … Unlimited Solutions 3

Maximum SAFE speed of block movement

Crown and floor protection

Minimal tripping time

One Company … Unlimited Solutions 6

Maximum SAFE speed of block movement calculated from:

Available braking torque

One Company … Unlimited Solutions 7

One Company … Unlimited Solutions 8

Weight on bit (WOB)

Top drive/rotary table torque output (torque)

Differential standpipe pressure (Delta-P)

One Company … Unlimited Solutions 10

When Amphion was designed safety was a primary

Zone Management System

One Company … Unlimited Solutions 17

IEC60204-1 defines three categories of stop functions:

One Company … Unlimited Solutions 18

One Company … Unlimited Solutions 19

Category 0 stop is invoked when:

The Crown-o-Matic switch is activated

The block lowers when held by the motors and zero-

Communication is lost with the remote I/O block

One Company … Unlimited Solutions 20

One Company … Unlimited Solutions 21

A category 2 stop will occur when:

Brake air or hydraulic pressure is low

Torque transfer from motor to brake has failed

An enabled autodrill parameter (ROP, WOB, Torque, Delta-P)

One Company … Unlimited Solutions 22

A category 2 stop also occurs when:

A VFD, chopper or resistor fails

One Company … Unlimited Solutions 23

One Company … Unlimited Solutions 24

In addition to the IEC specified Category 0 and Category 2

One Company … Unlimited Solutions 25

If a soft trip occurs while the block is traveling at 25% or less of

One Company … Unlimited Solutions 26

A soft trip will occur when:

Cooling water outlet temperature from either brake is high (water

High temperature occurs on any phase of any motor

One Company … Unlimited Solutions 27

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