Revolutionizing High-Pressure Testing

In the realm of drilling equipment manufacturing, testing isn’t just a routine; it’s a critical process ensuring secure and efficient operations beneath the Earth’s surface. Halliburton, a pioneer in the industry, confronted the challenge of upgrading their manual high-pressure simulation process to enable operators to conduct tests remotely, safely, and more efficiently.

Enter Optimation, equipped with NI LabVIEW software and CompactRIO hardware, to engineer a groundbreaking turnkey solution that would revolutionize Halliburton’s testing approach.

The Need for Transformation

In the harsh environment beneath the Earth’s crust, drilling tools and electronics endure extreme pressures. To avert costly accidents and guarantee equipment reliability, manufacturers must rigorously test their products under these conditions before deployment. Halliburton’s existing approach involved manual high-pressure simulations, jeopardizing technicians due to the absence of a barrier between them and the high-pressure sources. Recognizing the necessity for a safer and more efficient method, Halliburton embarked on a journey to overhaul their control system.

The Optimation Solution

Optimation’s response to Halliburton’s challenge was nothing short of revolutionary. They embarked on the creation of an all-inclusive turnkey solution, encompassing the development of a new valve, panel, and control system, all enclosed within a specially designed cargo container. This containerized strategy offered unparalleled flexibility, permitting the system’s assembly and commissioning at Optimation’s facility in Rochester, New York, before its deployment at Halliburton’s site.

At the core of this pioneering solution resided the NI CompactRIO controller. Operating as an Ethernet-based system, it facilitated seamless connectivity between the test consoles and controllers through the building’s network. This architectural choice empowered operators by facilitating resource check-in and checkout via LabVIEW software, providing multiple test consoles access to the CompactRIO controller. The CompactRIO’s FPGA capability was a game-changer, enabling high-speed signal acquisition, processing, and control. This real-time processing was instrumental in preventing the mixing of diverse test substances and maintaining control even in the event of a Windows OS shutdown.

The system offered both manual and automatic operational modes. In manual mode, operators were presented with an intuitive interface, enabling them to interact with valves and set pump parameters to create specific test conditions. On the other hand, the automatic mode executed preprogrammed recipes — sequences of pressure and valve states — crafted by Optimation engineers. Safety was of paramount importance, and a unique simulation feature allowed engineers to validate recipes before actual testing, ensuring precision and security.

Data acquisition was a crucial element of the testing process, and the Optimation solution excelled in this aspect. The system could acquire data at varying rates, and operators had the flexibility to visualize this data either digitally or graphically. A noteworthy aspect of the system was its integration of NI’s FPGA code, which aided in noise reduction for accurate pressure signal analysis.

High-pressure testing inherently involves risks, and Optimation’s solution left no room for compromise in safety. The control room was effectively isolated from the test area, safeguarding technicians from high-pressure exposure. Real-time monitoring through IP cameras ensured that technicians could observe the test conditions without endangering themselves. Moreover, the system’s control and data acquisition were conducted through Ethernet, further minimizing any risks associated with high-pressure environments.

A Blueprint for Success

The success of this collaboration between Optimation and Halliburton underscored the power of NI hardware and software. The seamless integration of FPGA capabilities, real-time processing, and Windows OS compatibility positioned NI as a frontrunner in the development of comprehensive testing solutions. This approach proved significantly more streamlined and effective than previous multi-subcontractor projects, showcasing NI’s prowess in bridging gaps and delivering cohesive solutions.

Halliburton’s adoption of this innovative system design marked a significant leap towards standardization across its sites. This integrated architectural design not only ensured safety and precision but also opened avenues for cross-training technicians across different systems. With NI’s tools, possibilities were vast — signal refinement, real-time safety checks, and user-friendly interfaces — all contributing to enhanced operational efficiency.

In a world where precision and safety are paramount, Optimation’s turnkey solution powered by NI technology had set a new benchmark in high-pressure testing. Through the synergy of innovative engineering and cutting-edge tools, this collaboration stood as a testament to the transformative potential of engineering excellence.

The original case study discussed in this post was authored by Dan Purvis from Optimation.