Testing The Pressure Limiting Controller

Testing the Pressure Limiting Controller
The follows field tests are to be carried out on the pressure limiting controller at Savanna.
Speed Test:
Set the pump speed or throttle (strokes per minute) to a fixed value and adjust the choke to set the
standpipe pressure below the pressure limit set-point. Now introduce a step change in the pump speed by
increasing it. You should see the controller taking action by preventing the speed from increasing further
after the pressure reaches the pressure limit set-point
For example, run the pump at 60 spm (it can be either single or both the pumps). Set the pressure limit
set-point at 2500 psi. Now slowly close the choke to raise standpipe pressure to say 1500 psi. Hold the
choke at this position. Now introduce a step change in speed by setting the pump throttle to 70 spm. Note,
if the system pressure is still below the pressure limit set-point at 70 spm, then increase to 80 spm. You
should see the controller taking action to keep the system pressure at 2500 psi.
Repeat the test for a different combination of speed, pressure and pressure limit set-point. Please do fill
the table below while doing this test.
Table 1 - Speed Test Data
Initial pump New pump New pump

Initial standpipe Pressure limit
Date Time speed Pv speed Sp speed Pv
pressure (psi) set-point (psi)
(spm) (spm) (spm)
7/23/201 12:0
60 2520 2800 70 63
1 1
12:0
41 1200 1500 50 45
5
12:0
41 1200 1500 60 45
7
12:0
40 1200 2000 70 52
9
Pressure Limit Set-Point Test:
In this test, step changes are introduced in the pressure limit set-point. Initially set the pump speed at a
certain value and adjust the choke to produce a pressure that is below the pressure limit set-point. Then,
introduce a step change in pressure limit set-point by setting its value less than the standpipe pressure.
You will see the controller taking action and reduce the pump speed in order to bring the system pressure
below the new pressure limit set-point. After this, reset the pressure limit set-point to its original value
and you will see the pump speed rise.
For example, let the pump speed be at 60 spm and the system pressure is at 1500 psi. The pressure limit
set-point is at 2500 psi. Now, change the pressure limit set-point to 1000 psi. You will see the controller
taking action by reducing the pump speed to bring the system pressure to 1000 psi. After the system
pressure settles at 1000 psi, increase the pressure limit set-point to 2500 psi. You will see the pump speed
rising again to 60 spm and the system pressure climb back to 1500 psi.
Repeat this test for different combinations of pressure, speed and pressure limit set-point.
Note, this test is very important since the problem encountered during the previous test was during a
similar operation. Definitely repeat that same test – drastically reduce the pressure limiting set-point from
3600 psi to 380 psi while the pump speed is at 60 spm and the system pressure is just below 3600 psi.
After the controller takes action and the system settles at 380 psi, then reset the pressure limiting set-point
to 3600 psi. You will see the pump speed rise back again to 60 spm.
Please do fill the table below while doing this test.
Table 2 – Pressure Limit Set-Point Test Data
New
Initial Initial Initial New
New pump standpip
pump standpipe pressure limit pressure
Date Time speed Pv e
speed Pv pressure set-point limit set-
(spm) pressure
(spm) (psi) (psi) point (psi)
(psi)
7/23/201 12:1
75 3760 4200 1500 45 1500
1 8
12:2
50 1780 3000 500 26 499
2
12:2
60 2515 3200 1500 45 1495
9
12:3
70 3320 4000 1250 41 1246
3
Percentage Choke Closer Test:
In this test we are trying to mimic a sudden blockage in the drill bit by suddenly closing the choke.
First ensure that the pumps are not running. Now experimentally find the amount of time it takes to fully
close the choke. For example, while doing this test in the H&P rig up yard we found that it took 15
seconds to fully close the pneumatically activated choke. Assuming that the choke closer is linear in time,
the pressure limiting controller is tested for various degrees of closure. The time it will take the pump to
close 30%, 50% and 70% can be estimated based this linear assumption.
Now open the choke fully. Set the pump throttle at 50 spm and the pressure limit set-point is set at 1000
psi. Calculate the time it takes to close the choke to 30%. Going back to the H&P case, if it took 15 secs
to close the choke fully, then by closing them for 5 secs you will achieve roughly 30% blockage. Now
close the choke suddenly for 5 secs and see the response of the controller. Fully open the choke again and
repeat the tests for 50% and 70% blockage. In each case, the controller will reduce the speed if the
pressure increases more than the pressure limit set-point.
You can repeat the above test for pump throttle set at 70 spm and pressure limit set point set at 2000 psi.
Table 3 – Time Taken for Choke Closure
Time taken for fully closing the choke X seconds
30 % closer of choke X * 30/100 seconds

Table 4 – Percentage Choke Closer Test Data
New
Initial pump Initial New pump standpip
Dat Tim Pressure limit Percentage
speed Pv standpipe speed Pv e
e e set-point (psi) blockage
(spm) pressure (psi) (spm) pressure
(psi)

Testing The Pressure Limiting Controller - With Savanna Data

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Table 1 - Speed Test Data

Initial pump New pump New pump

Pressure Limit Set-Point Test:

Please do fill the table below while doing this test.

Table 2 – Pressure Limit Set-Point Test Data

Percentage Choke Closer Test:

Table 3 – Time Taken for Choke Closure

Time taken for fully closing the choke X seconds

30 % closer of choke X * 30/100 seconds

70 % closer of choke X * 70/100 seconds

Table 4 – Percentage Choke Closer Test Data

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