Synchronous drilling system

Technical Specifications – Synchronous Drilling System

System Component	Specification
Control Architecture	Distributed: local drive controls + central PLC coordination
Central PLC	Redundant hot‑standby (optional), scan cycle ≤20 ms
PLC I/O	Up to 512 digital inputs, 256 digital outputs, 128 analog I/O (expandable)
Drive Interfaces	Profibus DP, Profinet, EtherNet/IP, or Modbus TCP (customer selectable)
Network Topology	Dual‑ring redundant Ethernet (copper or fiber optic)
Network Failover Time	<200 ms (automatic, no data loss)
Driller Stations	1 (standard) or 2 (redundant/co‑pilot)
Station Failover Time	≤1 second (heartbeat detection)
HMI Displays	2× 24” industrial touchscreens per station, sunlight‑readable (1000 nits)
Safety Interlocks	9 independent (6 hardware + 3 software cross‑checked)
Master‑Follower Load Imbalance	<±5% steady state
Soft Pump Ramp	Programmable S‑curve, 0–60 seconds, synchronized with block movement
Skidding Sync (option)	±2 mm accuracy over 20 m, electro‑hydraulic proportional control
Data Logging	30‑day historian at 1 Hz; export CSV via USB or Modbus TCP
Remote Access	Secure VPN (customer‑controlled) for diagnostics only
Operating Temp (electronics)	-20°C to +55°C; cold‑hardened option to -40°C
Power Input	480 VAC or 600 VAC, 50/60 Hz, 3‑phase (custom voltages available)
Certifications	API 4F, 7K, 8C, Q1, RP500; CE; GOST 12.2.141‑99 (optional)
Typical Cabinet Dimensions	2200(H) x 800(W) x 600(D) mm per cabinet, 2–4 cabinets depending on I/O count

Product Types – Which System Configuration Do You Need?

We offer three standard system packages, plus full customization:

1. Single‑Station Land Rig System (Base Package)

• One driller station, non‑redundant PLC (single CPU)

• Redundant network (dual‑ring) and power supplies

• 6 safety interlocks

• Data logging and USB export

• Best for: standard land rigs, workover rigs, budget‑conscious projects

2. Dual‑Station Redundant System (Most Popular)

• Two driller stations with seamless failover

• Redundant PLC (hot‑standby CPUs)

• 9 safety interlocks

• Skidding synchronization ready (add cylinders and valves separately)

• Best for: offshore rigs, multi‑well pads, high‑cost daily rate operations

3. Remote+Automation Ready System (Advanced)

• All features of Dual‑Station Redundant

• Additional OPC‑UA server for third‑party automation integration

• Remote driller station (control van or onshore center) over fiber or satellite link

• Predictive maintenance data logging (trend analysis on motor currents, pump pressures)

• Best for: automated drilling projects, remote Arctic/desert operations, operators moving toward reduced crews

4. Retrofit Kit (For Existing Rigs)

• Same control cabinets and software, but with adapter plates and harnesses for non‑SJ Petro drives

• We survey your existing drives and sensors, then build interface cables and custom PLC logic

• On‑site commissioning by our engineers included

Application Fields

🏗️ Multi‑Well Pad Drilling (Shale, Tight Gas)

The combination of fast connections (synchronized drawworks + top drive) and precision skidding (electro‑hydraulic sync) reduces total pad time by 10–15%. The dual‑station redundant system keeps you running even if one display fails.

🌊 Offshore Platform & Jack‑Up Rigs

Our system is built with marine-grade enclosures, redundant everything (PLC, network, power supplies), and hot‑standby CPUs. Remote operation capability allows onshore engineers to monitor and assist without flying offshore.

⛽ Extended‑Reach and Horizontal Drilling

Smooth, coordinated control reduces stick‑slip and bit bounce, letting you drill longer laterals with fewer twist‑offs. The data historian helps identify harmful vibration patterns.

🔧 Workover and Well Intervention

Lightweight dual‑station system for XJ workover rigs. One driller handles hoisting/rotation, the second manages pipe handling and BOP testing – or a single driller runs everything. Speeds up tubing runs by 20–30% compared to conventional control.

🧪 Remote & Automated Drilling Campaigns

Our advanced system includes OPC‑UA for integration with automated drill floor robots, pipe handling systems, and remote operation centers. Used in several Arctic and desert projects where on‑site crew size is minimized.

Why Choose SJ Petro for Your Synchronous Drilling System?

🏭 We Manufacture Both the System and the Rig

Unlike pure automation suppliers, we make the mechanical rig too. That means our control engineers have full access to the drawworks gearbox ratios, mast natural frequencies, pump inertia data, etc. We tune the system’s master‑follower gains and soft ramp profiles to your specific rig’s characteristics, not generic settings.

✅ Over 50 Systems in the Field – Continuous Improvement

We delivered our first synchronous system in 2015. Today, more than 50 AC‑VFD rigs use our control architecture. Every field service report and customer suggestion goes back to our engineering team. You are not buying version 1.0.

🔧 Pre‑tested, Plug‑and‑Play Delivery

We do not ship loose components and a schematic. We pre‑wire every cabinet, load the PLC code, connect to a test simulator, and run a full FAT in your presence (or via live video stream). You watch the system control simulated drawworks, pumps, and interlocks before we pack it.

🌍 Global Support with Local Spares

We stock spare PLC modules, power supplies, network switches, touchscreens, and joysticks in our regional warehouses (Americas, Middle East, Asia‑Pacific, Russia/CIS). 24/7 remote diagnostic support via secure VPN. On‑site commissioning and training included in the system price.

📋 Transparent, Fixed‑Price Package

Our quote includes:

• All hardware (cabinets, PLC, drives, HMI, sensors, cables)

• Software (PLC code, HMI application, data historian)

• Factory acceptance testing (FAT) with your witness

• Crating, shipping documents, export packing

• On‑site commissioning (1 engineer, 2 weeks)

• 12‑month warranty and 24/7 support hotline

Frequently Asked Questions (FAQ)

Q1: Can I use your synchronous drilling system on a rig that is not from SJ Petro?

A: Yes. We have retrofit kits for most major rig brands (National Oilwell Varco, Honghua, Lanzhou LS, etc.) as long as the drives support a standard fieldbus (Profinet, Profibus, EtherNet/IP, or Modbus TCP). We will survey your existing equipment and provide a fixed‑price quote for the retrofit package, including interface cables and on‑site commissioning.

Q2: How long does commissioning take for a new system?

A: For a new rig build with our factory‑pre‑tested system, commissioning typically takes 10–14 days on site. This includes mounting cabinets, pulling network/fiber cables, connecting field sensors, power‑up, and driller training. For a retrofit, allow 3–4 weeks due to survey and custom harness fabrication.

Q3: What happens if the central PLC fails? Does the rig stop?

A: With our redundant (hot‑standby) PLC option, the system has two CPUs. The standby CPU mirrors the primary’s program and data. If the primary fails, the standby takes over in <50 milliseconds. The driller may not even notice. If you choose the non‑redundant single PLC, the rig will stop safely (all drives go to safe state) – but you can switch to local manual backup controls (we include hardwired joysticks for emergency operation).

Q4: Can I connect your system to my existing SCADA or remote operations center?

A: Yes. We provide an OPC‑UA server (standard on the Advanced package, optional on others). Your SCADA can read any real‑time data point and historical trends. We also support Modbus TCP for simpler integrations. We do not allow write access from external systems for safety reasons – but you can send setpoint changes (e.g., target pump pressure) through a secure, audited interface.

Q5: What training do you provide for drillers and maintenance technicians?

A: Our standard package includes:

• 2 days classroom on system architecture, safety interlocks, and normal operation

• 2 days hands‑on at the actual rig or our simulator (drillers practice connections, failover scenarios, emergency stops)

• 1 day for maintenance – how to read diagnostic LEDs, swap modules, use the HMI’s diagnostic screens

We can also provide remote refresher training via video conference. All training materials (manuals, video recordings, checklists) are included.

Q6: How do you handle software updates or bug fixes?

A: All software updates are released through our secure customer portal. You download the update to a USB drive and install it via the HMI’s service menu. Critical security or safety updates are communicated by email and phone. We do not perform over‑the‑air updates without your explicit request.

Q7: Is the system certified for use in explosive atmospheres (hazardous area)?

A: Our standard control cabinets are IP54, suitable for non‑hazardous areas (driller’s cabin, control room). For Zone 2 or Class I Division 2 installations, we offer purge/pressurized cabinets or remote mounting of electronics away from the hazardous area. Sensors and junction boxes are available with ATEX/IECEx certification. Please specify your required hazardous area classification for a custom quote.

Q8: What is the typical lead time for a synchronous drilling system?

A: For a standard Base or Dual‑Station system (non‑retrofit), lead time is 14–16 weeks from order to FOB port shipment. This includes engineering, cabinet fabrication, wiring, PLC programming, and FAT. Add 4 weeks for the Advanced system with OPC‑UA and remote station. Add 6–8 weeks for a retrofit kit (survey, custom harness fabrication, on‑site commissioning slot).