Beijing Petroleum Machinery Factory (BPM) is a state-owned Size-two Medium-Sized enterprise with a history of nearly 50 years. It’s one of the earliest enterprises that have passed the ISO9000 quality system authentication in China’s oil industry. Now it has evolved into a professional oil drilling equipments manufacturer integrating development and research, design, production, sales and service. It’s also the developer of China’s first AC frequency conversion top drive device. In merely 4 and half years, it has designed and sold 100 top drives. BPM is aware of the major task of maintaining international standards in techniques while creating unique competitive advantages. As early as in 2003 when the key project of industrialization of the first domestic top drives was initiated, BPM has started long-term cooperation with Siemens, the first rank automation system solution supplier. The far-sighted strategic decision has secured it to seize the top position in the top drive industry in China.
As the researcher and developer of China’s first AC frequency conversion top drive device, BPM is prepared to undertake every important mission from time to time. On the one hand, it has to face increasingly fierce international competition, ensuring a better quality of domestic top drives than international brands. On the other hand, due to the rapid development of private, state-owned and foreign oil drilling equipments manufacturers, it has to cope with the growing price pressures. BPM has to safeguard international standards in techniques and widen the competitive advantage among domestic counterparts.
This state-owned Size-two Medium-Sized enterprise with a history of nearly 50 years is one of the earliest enterprises that have passed the ISO9000 quality system authentication in China’s oil industry. It has acquired certificate permits like API SPEC 16D and so on from American Petroleum Institute. In possession of helicoid hydraulic motor series, land blowout preventer control device, down hole single-screw oil pump, bumper jars and top drive oil drilling device, it has reached a gross industrial output value of 1.2 billion Yuan and sales revenue of 882 million, being a professional oil drilling equipments manufacturer integrating development and research, design, production, sales and service. The self-developed AC frequency conversion top drive oil drilling device is copyrighted with CNPC and has filled the blank domestically with its registered national technical patents.
To grasp the opportunity for oil drilling
In recent years, the growth of oil resource exploitation and export of oil drilling equipments have given rise to the increasing boost of oil drilling equipment manufacturing industry. Authentic national data shows, from January to October 2006, the oil drilling equipment manufacture industry has reached a sales revenue totaling 24.424 billion Yuan, increased by 75.12% year-on-year and 33.25% faster than last year and a profit of 2.417 billion Yuan, increased 115.80% year-on-year, 40.82% faster than last year. At present, China is one of the few countries that could produce 1000
Graph 2: 2005-2007 the sales venue and profit increase tendency of domestic oil drilling equipments manufacturing industry
Dr. Zou Lianyang, VP and Chief Engineer of BPM is very optimistic about the domestic oil drilling market. ‘Because of the promising perspective of oil industry, the production value and profit of BPM is rising by times. The fine atmosphere of our oil industry has promoted the development of relative industries including the upstream and downstream products mainly centering on oil drilling and oil refining respectively. Our products covering land oil and gas field to which China National Petroleum Corporation and China Petroleum & Chemical Corporation belong and offshore oilfield to which China National Offshore Oil Corporation belongs have been exported to more than 40 countries and areas. ‘北石’ and ‘BPM’ are now widely recognized brands both home and abroad. In the eleventh five-year plan period, the government attaches great importance to the development of energy quality, safety in production and the development of large-size machinery manufacturing industry. It presents a new opportunity for us.
Graph 3: Professor Zou Lianyang, VP and Chief Engineer of BPM
For supplier of large-size equipment products like us, it’s important to secure development through quality, creditability and competitive strength while withstanding the price pressure. To meet the basic needs of our customers such as 24 hrs non-stop oil drilling, we try to ensure the quality and performance by checking the machine halt hours every month. The reason why our facilities are widely adopted in many countries all over the world is also through years of accumulation of techniques, performances and creditability reputation.
‘Under the guideline of scientificationization, digitalization and internationalization, as digitization demonstration enterprise, we are deeply concerned with the areas of automation and information. With a staff totaling over 600 and 300 computers, every two persons are in possession of a computer which is leading in the field’, adds Engineer Shen Ke from the Chief engineer office of BPM, proudly of the achievements.
Qualitative change from the first top drive to the output of hundred
Top drive, shot for top drive oil drilling device, is an important leading technology in the oil drilling industry, dubbed one of the three technical fruits of modern oil drilling equipments. The device used to be only produced in advanced countries such as the US and Canada. In order to acquire top drive products of independent intellectual rights, BPM has started research on AC frequency conversion top drive oil drilling device since 2003 and succeeded in industrialization.
Professor Zou Lianyang introduced, ‘Top drive was initiated in January 2003 with the objective of promoting the standards of both design means and design ideals because we hope to produce the best products by the most advanced means’. In the beginning of implementing home-made top drive industry key project, BPM has established long-term cooperation relationship with Siemens, a top-rank international automation system solution supplier, to jointly develop AC frequency conversion top drive device for oil drilling and to provide BPM with Siemens top drive electronic controlling system solution. At present, Siemens has successfully delivered hundred sets of DQ70BS, DQ90BSC and DQ40BSC AC top drive device electronic controlling system.
Graph 4: AC frequency conversion top drive oil drilling device and its application on oil drilling site
Xie Haihuan, Electric engineer from the Top drive center explains in detail the structure and performance of top drive products. ‘Top drive oil drilling device is the pioneering technology in oil drilling. It saves time for oil drilling by 20% to 25% and prevents wedging of drill tool. The outstanding economic effect that off-angle drilling and skillful direction well brought indicates it will represent the tendency in oil drilling machinery. The BPM top drive drilling systems including hoisting system, rotary power drive system, drill string automatic proceeding device, drill string blowout preventer and intelligent control system, is a comprehensive system with high-power, high automation level and electro-hydraulic technology. Top drive system moves along with the vehicle, providing circulating path, drill string blowout preventer and proceeding functions such as control, connect, teardown and rotary power for drill strings. We adopt many advanced technologies such as Siemens S7 300 PLC Programmable Logic Controller, PROFIBUS-DP Fieldbus Control System, Communications by fiber optic networks, Remote Monitoring and HMI to exert general intellectual control over the system, to enhance vividly the intelligentized level and creditability of the whole system’.
|
Items |
BPM |
|
Canadian |
|
Namely total depth |
|
|
|
|
Maximum load |
4500KN |
4500KN |
4500KN |
|
System output |
12t |
12.25t |
3.3t |
|
Mains voltage |
600VAC 50Hz |
600VAC 50Hz |
600VAC 50Hz |
|
Rated power |
400HP×2 |
400HP×2 |
450hp×2 |
|
Ambient temperature |
－ |
－ |
－ |
|
Range of speeds of rotation |
0～220r/min |
0～228r/min |
0～195r/min |
|
Operating torque |
50KN.m (continued) |
50KN.m (continued) |
50KN.m (continued) |
|
Maximum torque |
75KN.m (interrupted) |
73KN.m (interrupted) |
74KN.m (interrupted) |
|
Ratio of speed |
10.5:1 double reduction |
10.5:1 double reduction |
18.61:1 double reduction |
|
Data Transmission |
(PROFIBUS) and fiber |
(PROFIBUS) |
(PROFIBUS) |
Chart 1: Comparisons of the main technical index of three typical 500 ton top drive devices
By contrast in main performance and technical index (reference to Chart 1), BPM top drive can satisfy the needs of the drilling of ultra deep well and bad hole. The comprehensive capability involving the integration of back-up tong, two-load channel technology and electro-hydraulic technology has contributed to the more advanced performance, more stable quality and safer operation, in all a better product than foreign counterparts. It merely takes 4 and half years for BPM to finish the design and sales of 100 top drive devices, building China into one of the few countries in the world that the production of top drive device is possible in large scale following US, Canada and Norway.
To equip the refined machinery with automation
The slogan on the entrance of BPM which reads to produce refined equipments with science and technology is in everyone’s mind. During the eleventh five-year period, BPM will continue take part in the major research project of China National Petroleum Corporation, namely DQ120BSC Top Drive device project to enhance the standard of our top drive products. Xie Haihuan also mentions the latest development of the project. She says, ‘a(chǎn)t present DQ120BSC top drive device has been checked and accepted. The mainly adopted automation equipments include Siemens S7 300 PLC, S120 drive system, wireless transmission and HMI. In technical sense, the next step is to broaden the industrial torque, increase the capacity as the drilling deepens, make possible more stable functions, reduce design volume and realize high efficiency and stability. In addition, the application of explosion proof is also a key point. We’ll strengthen the explosion proof function based on the needs of our clients for better performance.’
‘The products adopted in BPM top drive electronic controlling system are all from Siemens, designed and produced by Siemens Factory Automation Engineering Co. (SFAE)’. Mr. Liu Liwei, Supervisor of oil drilling business of Engineering Department of SFAE, partner of Siemens in system integration says, ‘Top drive electronic controlling system fulfills intelligent communication between electric control room and driller’s console and among host control stations. It provides convenience for drill maintenance staff and digger centralized monitoring and has good visibility and readability. Meanwhile, it largely simplifies the system structure to enlarge the development room for follow-up functions. In terms of design, installation, running, maintenance and efficiency, it has shown great advantage and laid foundation for the integrated automation of the system.’
What’s worth mention is that, top drive network system is using PROFIBUS-DP structure including all the remote station and frequency conversion drive system. All the subsidiary stations, rectifiers and inverters communicate with CPU through PROFIBUS agreement. In addition to CPU and host station, all the communication cables are shielded twisted pins. The communication between CPU and host station is through cable. The signal modules shared by CPU rack are 5 DI, 2 DO and 1 AO. The digital input is to input the various power station status variables into PLC, for displaying in WINCC SCADA system. The SIMATIC S7-300 PLC used in this project is the control core of Siemens integrated automation TIA system, a key display of its integrity and openness.
While researching and developing the top drive, BPM has established testing apparatus with complete functions, loads and power at international advanced level. It has formed modern manufacturing facilities with international standards and a set of pioneering design and development methods. The oil drilling technology and skills developed by BPM include over 10 national patents. The yearly manufacturing capability has reached over 100 sets of top drive. In addition, it has cultivated a high-level team of technical servicemen.
Professor Zou adds, ‘our cooperation with Siemens focuses on large-size products at higher levels. It’s quite different from single project cooperation. Our top drive products are produced continuously in subsequent periods, which presents a challenge for both sides to overcome difficulties, share succeed and help each other on the same boat. Siemens shows full support for BPM and provides the finest solutions for electronic controlling system. We’re delighted to pursue the dream of Top drive with Siemens!’
（轉(zhuǎn)載）
