Digital Oil Drilling Control System

Technical Specifications

The table below covers our standard SJ‑DCS configurations. Custom I/O counts and screen sizes are available.

Applications

The digital oil drilling control system from SJ is deployed on a wide range of drilling and workover rigs:

1. Land Drilling Rigs (Conventional & AC)

Upgrading older mechanical rigs with a digital control system is one of the highest‑ROI investments. Our SJ‑DCS can be retrofitted to existing drawworks, top drives, and mud pumps – typically for less than $150,000 – and delivers 10–20% faster drilling, reduced downtime, and lower fuel consumption.

2. Offshore Jack‑Up & Semi‑Submersible Rigs

Offshore rigs have more complex systems (BOP, riser tensioners, dynamic positioning) and stricter safety requirements. Our offshore‑grade system integrates all of them, with redundant hardware and ABS/DNV certification. Real‑time data streaming to shore allows onshore drilling engineers to support the offshore driller.

3. Automated Pad Drilling (Shale)

Shale pads have identical well profiles. Our system stores drilling parameter "templates” – the optimal settings from the first well can be automatically applied to the second, third, and fourth wells. This standardizes performance and reduces driller‑to‑driller variability by 70%.

4. Workover & Snubbing Rigs

Even smaller workover rigs benefit from digital control. Our SJ‑DCS‑Basic can be installed on a snubbing unit to automate jack sequencing, monitor snubbing loads, and integrate with BOP control. Simple, rugged, and cost‑effective.

5. Remote & Harsh Environment Operations (Arctic, Desert)

When your drilling location is a 12‑hour helicopter ride from the nearest town, you need a control system that doesn’t break. Our hardware is rated for -30°C to +60°C, with sealed enclosures that keep out dust and sand. Remote diagnostics let our engineers log in and troubleshoot without flying to site.

6. Geothermal & Mining Drilling

Geothermal wells share HPHT challenges with oil drilling. Our system has been adapted for superheated brine environments (special sensor conditioning). For mining (water wells, exploration), we offer a lower‑cost "Lite” version.

Product Types & Models

We offer several variants of the digital oil drilling control system to match rig type and complexity:

OEM & Private Label:

• We can integrate the SJ‑DCS into your rig design as the standard control system

• White‑label with your logo, part numbers, and documentation

• Custom software modifications for unique drilling techniques

Why Choose SJ Petroleum Machinery?

1. Sinopec‑Owned – Built by Drillers, for Drillers

SJ is a wholly owned manufacturing subsidiary of Sinopec – one of the world’s largest drilling contractors. Our control system is the result of thousands of wells drilled by Sinopec rigs, not a generic automation package from a software company that has never seen a rig. We know what breaks, what frustrates drillers, and what actually speeds up drilling.

2. 80+ Years of Rig Equipment Expertise

Since 1941, we’ve built drawworks, top drives, mud pumps, and BOP stacks. That means we understand not just control software but the physics and mechanics of every component our system controls. When we write a motor control algorithm, we know the thermal limits of the drawworks brake.

3. Open Architecture – No Vendor Lock‑In

Many control system vendors use proprietary hardware and software, making it expensive to add third‑party sensors or upgrade. The SJ‑DCS runs on standard industrial PCs and PLCs (Siemens, Beckhoff, or Rockwell – you choose). The HMI software is based on standard SCADA packages (Ignition, WinCC, etc.). You own the code; no recurring license fees.

4. Ruggedized for the Rig Floor – Not the Office

Our hardware is not repurposed office equipment. Vibration resistance, temperature extremes, dust and hose‑down protection, and explosion‑proof ratings are standard. We offer ATEX Zone 1 and Zone 2 certified components for the control cabin and hazardous areas.

5. Proven Performance in Major Oilfields

SJ‑DCS systems are currently operating on over 150 rigs worldwide – including Sinopec’s own fleet in the Sichuan Basin (deep gas), Saudi Arabia (land rigs), and offshore Vietnam. Case studies available on request.

6. Short Lead Times & Competitive Pricing

A complete SJ‑DCS‑Advanced system for a land rig can be delivered in 8–12 weeks from order (including engineering, panel build, software configuration). Western competitors often quote 20–30 weeks. Pricing is typically 30–40% lower for equivalent functionality.

7. Remote Support & Training

Our engineers can commission the system remotely via VPN (saving travel costs). We provide 3 days of on‑site training for your drillers and maintenance crew. After commissioning, we offer 24/7 phone/email support and optional annual service contracts.

8. Future‑Proof – Ready for Autonomous Drilling

The SJ‑DCS platform is designed to integrate with higher‑level autonomous drilling systems. We’ve already built interfaces for automated pipe handling, remote rig control from shore, and AI‑based ROP optimization. When you’re ready for the next step, the hardware is already capable.

Frequently Asked Questions (FAQ)

Q1: Can you retrofit a digital control system to my 20‑year‑old mechanical rig?

Yes – and that’s a common project. We add sensors (drawworks encoder, weight indicator transducer, pump pressure transmitters, etc.) and interface with your existing pneumatic or hydraulic controls via electric‑over‑pneumatic (E/P) converters. You keep your drawworks, but gain digital control. The retrofit typically costs $100k–$200k (hardware + engineering) and pays for itself in 4–8 months through faster drilling and fewer downhole tool failures.

Q2: Does the system require internet connection to function?

No. The core control functions (auto‑driller, HMI, data logging) work fully offline. Internet is only needed for remote monitoring, data offload, or software updates. You can configure the system to use a cellular modem or satellite only when you want.

Q3: How does the anti‑jam algorithm work? Will it falsely stop the drill when not needed?

The algorithm monitors torque oscillations at 100 Hz. When a stick‑slip pattern is detected (torque swinging between 0% and 200% of average), the system gradually reduces the setpoint for weight on bit (WOB) until torque stabilizes. This typically takes 2–5 seconds. If torque is already stable, the system does not interfere. In field trials, false triggers occurred less than once per 50 drilling hours and were always due to a genuine downhole vibration event.

Q4: What happens if the control system crashes while drilling?

The system is designed with a "watchdog” timer and failsafe relays. If the industrial PC or PLC stops responding for more than 1 second, the watchdog automatically:

• Releases the drawworks brake (stops lowering)

• Sets top drive RPM to zero

• Sounds an alarm
  The driller can then take manual control using the backup joysticks and hardwired buttons. We have never had a complete control system failure that required pulling the bit, but the failsafe is there.

Q5: Can your system integrate with existing BOP control panels?

Yes. We have standard interface modules that read BOP position switches and pressure transducers and can send open/close commands. We also integrate with the choke manifold for automated well control during kicks. If your BOP control system is from a different brand (Cameron, NOV), we’ve almost certainly done it before.

Q6: How much training do my drillers need?

Most drillers become comfortable with the basic HMI within one shift (8 hours). The advanced features (auto‑driller setup, parameter tuning) require an additional 8‑hour classroom session. We include 3 days of on‑site training with every system. For large fleets, we can train‑the‑trainer.

Q7: Do you offer a cloud‑based remote monitoring service?

Yes. For an additional monthly fee, we host a secure cloud platform where you can view real‑time and historical data from any SJ‑DCS‑equipped rig. The platform includes multi‑rig comparison charts, KPI dashboards (ROP, connection time, downtime), and automated daily drilling reports emailed to your engineering team. Onshore engineers can also change parameter setpoints (with driller approval) remotely.

Q8: What’s the warranty on the SJ‑DCS?

Standard: 18 months from shipment or 12 months from commissioning, whichever comes first. Extended warranties up to 5 years are available. We also offer a "next‑day” replacement for critical hardware (touchscreens, PLCs) – we ship a spare unit the next business day.

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