http://www.sdrg.com/ SDRG Controls Uses Automation Direct Equipment to Implement New Friction Drillpipe Processing Line

1. A Success Story
SDRG Controls Uses Automation Direct Equipment
to Implement New Friction Drillpipe Processing Line
SDRG Controls (www.SDRG.com) is a control systems integrator in Houston, Texas that
recently helped Superior Drillpipe implement a new drillpipe processing line that friction
welds tool joints to drillpipe and conditions the pipe to meet tough drilling customer
requirements. The line is controlled by an Automation Direct DirectLogic 405 PLC and C-
more touch panel HMI.
Superior Drillpipe needed to tie a wide variety of equipment stations and functions into a
seamlessly flowing system that kept costs low while efficiently delivering the functionality
necessary to produce high quality drilling pipe products. SDRG Controls first worked with
Superior to define the items necessary to control and the operating sequence that best met
their needs. SDRG Controls selected Automation Direct equipment to serve as the heart
of the system due to their high performance, cost effective products. The DL405 PLC was
selected due to its modular flexibility, wide I/O support, low costs, and familiar, but powerful
programming and operating capabilities.
Each station on the line was configured somewhat independently, with many pushbutton
stations that allowed the operator flexible control and the ability to control the line pace at
a rate that allowed proper attention to special detail when appropriate. Pushbutton stations
were tied to PLC control to allow easy adjustment of conveying and operating functions.
The C-more HMI allowed configuration of parameter entries to adjust operator and batch
preferences, such as timing and position settings.
The line began with a friction welding station, where tool joints were loaded into a rotating
spindle, which was then moved by carriage to contact a section of drill pipe held by a vise.
Parameters such as spindle speed and weld pressure are adjusted by the operator at the
station for best results for each pipe type. After welding, the pipe is kicked along conveying
equipment to additional stations.
Following welding, pipe is moved to a shear station. Here, an operator loads the pipe,
reheats the weld joint using induction heating, and performs various shearing patterns by
pushbutton selection. Various timing parameters are user adjustable through the HMI. The
shear removes the rough edges around the weld joint. The operator turns the pipe and
repeats the shear process until the pipe meets requirements. The pipe is then moved
further down the line.
A key station follows where the pipe is austenitized and quenched to strengthen the
sections. The austenitizing station is composed of several components and is automated
to ensure positioning of components and timing of treatments is optimal and consistent.
The pipe with welded tool joint are first loaded on to a pair of slides that allow precision
positioning of the pipe along its length. The slides are operated by motors controlled by
Automation Direct 2HP GS2 drives. The drives allow position and speed to be controlled
by the PLC, as well as adjustment of acceleration and deceleration patterns. The drives

2. also worked well at interfacing to a somewhat atypical 380V motor that was provided by
the slide manufacturer.
By pressing a start pushbutton on the austenitizing station, and prior entry of key operating
parameters for the pipe treatment through the HMI, the station ran through an automated
procedure. First clamps closed to hold the pipe on the slides. Next, the pipe moved to a
pre-configured position, moving through a stationary induction heater coil. Positioning was
controlled by encoder feedback to a CTRIO card in the PLC. This interface allowed the
pipe to move quickly towards the set position, then slow as it approached the setpoint, and
stop at the exact position desired. The quadrature encoder provided a high resolution count
for precision location, and indicated the direction of movement to track forward and reverse
positioning over the course of the procedure.
Once at position, the pipe was further clamped and then heated by starting a program in
a standalone ramp/soak controller. Near the end of the heat cycle, quench motors are
started to ready a quench bath located behind the heater coils. At the completion of
heating, holding clamps are released, and the pipe end with tool joint is inserted into the
quench bath. Positioning and timing for each quench is configured through HMI parameters
to meet the quality needs of each batch. At the conclusion of the quench, each pipe is
drawn back by the slides, out of the quench, back past the induction heating, and returns
to a clear retract position where it can be then conveyed to the next station.
Following austenitizing, the pipe is moved to a tempering station. Here, multiple pipes are
positioned along the conveying line before induction heater coils. Unlike the austenitizing
station, here the pipes remain fixed, and the heater coils move forward to a user set
distance. Position is again controlled by encoder feedback, with the coils moving to a
preset position with an operator procedure start pushbutton. Heating of the weld joint is
again accomplished using a standalone ramp/soak controller, although the temperatures
are lower and the duration usually shorter than austentizing. Heat levels are adjusted
through the controller, by observing pipe temperature with a two color infrared
thermometer, and adjusting the power level of the induction heater power unit as
appropriate. After the heat cycle completes, the controller signals the PLC, and the heater
coils retract. The pipe air cools to strengthen the joint, and the pipe is ready for conveying
to the next station.
Finally, the pipe is conveyed to an automated grinding station. At this station, the operator
pushes a start button to start the pipe rotating in place, and begin a grinder positioning
sequence. Through a series of position and timer settings, the grinder oscillates back and
forth along the pipe as it rotates, smoothing any remaining rough spots.
The line is just one of many at the Superior Drillpipe plant dedicated to producing quality
drillpipe. By utilizing Automation Direct’s readily available equipment, SDRG Controls was
able to quickly tie together the control needs for the production line. With the flexibility and
spare capacity the design incorporated, it was possible to make a number of small changes
during startup to greatly enhance the quality and ease of use of the system. SDRG
Controls continues to support the system and other equipment at the plant, and offers a
wide range of design, construction, programming, startup, and documentation services to

3. its customers.