Mud Pump Synchronizer

Functional Description
18 September 2007

System Control Architecture

The LTI mud pump synchronizer is one sub-system of the rig automation system. The
control program runs on a Siemens S7 PLC which connects via a Profibus network to
various input and output modules, as well as a touch screen human-machine interface
(HMI) to provide control and monitoring functions. The relationship of the various
system components is illustrated by the following diagram.

Rig Inputs DRILLER CONTROLS AND DISPLAY Rig Control

Outputs
Sensors and Control HMI Status Control
Aux Inputs Inputs Outputs Outputs
Profibus DP Inputs Ethernet 10/100 Profibus DP Outputs

PLC Control Program running on Siemens S7 PLC

Mud Pump Synchronizer

System Purpose
The purpose of the mud pump synchronizer is to allow multiple mud pumps to operate
simultaneously while preventing pressure transients as much as possible. The speed of
each mud pump is adjusted to prevent simultaneous strokes from multiple pistons.

Safety
The control system should take all reasonable precautions to ensure personal safety and
to prevent damage to the environment, equipment, or the well. However no man-made
system is perfect and the ultimate responsibility for proper safe operation lies with the
equipment operator.

Overview
The mud pump synchronizer works in conjunction with the regular mud pump control
system and is capable of controlling two or more mud pumps. The driller may control the
individual speed of one or more mud pumps either individually or in synchronized mode.
It is also possible for the system to automatically maintain standpipe pressure at a
specified level. Standpipe pressure control is described in a separate document.

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 Mud Pump Synchronizer
Functional Description
18 September 2007

Inputs
The following inputs are required for proper operation of the synchronizer.

Sensors - Electrical
Sensors are devices which convert a physical characteristic to an electrical signal. The
mud pump synchronizer system requires uses the following sensors:
Mud Pump proximity switches – provide a discrete (on/off) signal which indicates the
pump has rotated past a reference position. A prox switch must be installed at the same
reference position on each mud pump in order to synchronize the pumps.

Operator Control Inputs

Operator controls connected directly to the control system hardware:
Speed Control (Throttle, one speed control for each mud pump) An analog signal, usually
0 to 10VDC. The speed control is included in the normal mud pump control system
Mud Pump On/Off switch
Master On/Off switch
Bypass On/Off switch

Outputs
Drillers Console Outputs
These status outputs are located on the drillers console:
Pump Speed in SPM
Synchronizer Status
Stroke Counters
Hours Counters

Control Outputs
The Mud Pump synchronizer outputs consist of speed correction signals sent to the
individual mud pumps. No additional wiring or electrical signals are required.

Synchronizer Operation
Synchronizing mud pumps involves designating one pump as the master, and then
automatically adjusting the speed of each slave pump to maintain a constant phase
relationship between pumps. If no pump is selected as master, then no synchronization
can take place.

You can designate a mud pump to be the master by setting its Master Select switch to the
“on” position. Only one pump should be designated as master. In the event that more
than one pump is selected as master, the pump with the highest speed control input will
obtain control as master. If any pump is switched on but not selected as the master, then
it may operate either as a slave (Bypass off) or independently (Bypass on). The switch
labeled “Bypass” determines whether the mud pump is synchronized with the others or

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 Mud Pump Synchronizer
Functional Description
18 September 2007

else operates independently. When the Bypass switch is on, the associated mud pump
will not be synchronized.

Figure 1 Mud Pump Synchronizer Controls

In order to synchronize mud pumps, the speed of the pumps is automatically adjusted
slightly so that the pressure pulses from each piston are spread equally throughout the
cycle. Actual phase lag is continuously measured and corrected by the control system.
The actual desired phase lag will be set to 360 degrees divided by the total number of
pistons. For example if there are two pumps with three pistons each, the phase lag will be
360 / 6 or 60 degrees. With three pumps and nine pistons, the lag will be 360 / 9 or 40
degrees.

The speed of the master pump is set either by the normal speed control input for that
pump, or by the automatic standpipe pressure control described in a separate document.
The speed of the slave pumps will follow the speed of the master pump. Bypassed pumps
are controlled by their individual speed control inputs.

The control system will not synchronize a mud pump until it has been running at a speed
greater than 20 SPM for at least two seconds.

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