Eci Training Cooling

TESCO TRAINING
DEPARTMENT
ECI (S)
TOP DRIVE TRAINING
Copyright 2011 Tesco Corporation

COOLING
SYSTEM

COOLING SYSTEM TOP DRIVE
TRAINING
 AT THE COMPLETION OF THIS SECTION YOU WILL

BE ABLE TO :
 IDENTIFY COMPONENTS
 UNDERSTAND A BASIC REFRIGERATION CIRCUIT
 IDENTIFY COOLING SYSTEM FLOW PATHS
 IDENTIFY AND TROUBLESHOOT PROBLEMS

COOLING SYSTEM
 TOP DRIVE PUMP: supplies coolant to the top drive for

cooling gearbox and motors.
 DRIVE PUMP: supplies coolant to the power module cold

plates.
 CHILLER BYPASS PUMP: is used to bypass the chiller

circuit when the chiller is out of service for repair, coolant is
run through the modine instead.
 CIRCULATION PUMP: moves the coolant from the chiller

tank up to the chiller condenser coils. (High ambient and
1350)

 MODINE / AKG: radiators.
 COLD PLATES: used for transferring heat away from

electronic components.
 PA44 MOTOR STATORS: have coolant passing through

them to transfer heat away from the motors, and into the
coolant lines, through the heat exchanger then returning
back to the mechanical module.
 HEAT PUMP: maintains the ambient temperature in the

power module within a range of 65 F to 75 F.
 DEHUMIDIFIER: removes moisture from the air in the

power module.
CHILLER
 COMPRESSOR: brings (low pressure gas in) and
pumps (high pressure gas out) to condenser.(R22
refrigerant)
 CONDENSER: (high pressure gas in) turns back to

(high pressure liquid out) when it cools, going
through condenser (air cooled).
 TX VALVE: controls the flow of liquid through the

evaporator,(temperature controlled)
 EVAPORATOR: (low pressure liquid in) changed

back to (low pressure vapor out), when heated by
power module coolant.
COOLING SYSTEM DATA
MD-500 AND CHILLER
 1 TON =12,000 BTU/HR (HEAT REMOVAL RATE)
 THE ECI-900, (2) MD-500 DRIVE REQUIRE A 10 TON CHILLER.
 THE ECI-1350, (3) MD-500 DRIVE AND HIGH AMBIENT UNITS REQUIRE A
25 TON CHILLER.
 EACH MD-500 REQUIRES 15 GPM (57 LPM) AND A HEAT REMOVAL RATE
OF 34,130 BTU /HR.(10kW)
 THE ECI-900 MD-500 DRIVE COOLANT PUMP IS DRIVEN BY A 5 HP MOTOR

COOLING SYSTEM DATA
 THE ECI-1350 MD-500 DRIVE AND HIGH AMBIENT UNITS COOLANT

PUMP IS DRIVEN BY A 10 HP MOTOR
 THE ECI-900 DRIVE USE 2 CHILLER COMPRESSORS WITH THE WATER

TEMPERATURE THERMOSTAT (WTT) SET AT COMP#1 @68 DEG.F
(21.1DEG.C) COMP#2 : 5 DEG. APART (AUTOMATIC)
 ECI-1350 DRIVES AND HIGH AMBIENT UNITS USE 4 CHILLER

COMPRESSORS WITH THE WATER TEMPERATURE THERMOSTATS (WTT)
SET AT : COMP#1 @70DEG.F (21.1DEG.C) COMP#2 @70DEG.F
(21.1DEG.C) COMP#3 @72DEG.F (22.2DEG.C) COMP#4 @74DEG.F
(23.3DEG.C) (MULTI STAGE SYSTEM)

COOLING SYSTEM DATA
CHILLER BYPASS
 THE ECI-900 MD-500 DRIVE CHILLER BYPASS PUMP IS DRIVEN BY A
5 HP MOTOR
 THE ECI-1350 MD-500 DRIVE AND HIGH AMBIENT UNITS CHILLER
BYPASS PUMP IS DRIVEN BY A 10 HP MOTOR
T0P DRIVE
 EACH PA44 MOTOR REQUIRES 7 GPM(26.6 LPM) OR 3.5 GPM (13.3
LPM) PER STATOR.
 THE 450 TOP DRIVE AND THE ECI-900 TOP DRIVE COOLANT PUMP IS
DRIVEN BY A 5 HP MOTOR
 THE ECI-1350 TOP DRIVE AND HIGH AMBIENT UNITS COOLANT
PUMP IS DRIVEN BY A 10 HP MOTOR
FLOW SWITCHES
 THE TOP DRIVES AND MD-500 COOLANT RETURN LINES CONTAIN
FLOW SWITCHES, IF THERE IS NO FLOW THE TOP DRIVE WILL NOT
RUN (NO FLOW NO GO)
COOLING SYSTEM DATA
GOULDS PUMP MODEL AND APPLICATIONS
 1SVC1J6LO: 450 HP TOP DRIVE AND DRIVE PUMPS, 900 HP TOP

DRIVE AND CHILLER BYPASS PUMPS.
 2SVC1L6NO: 1350 HP AND 900 HP HIGH AMBIENT PACKAGE TOP

DRIVE AND CHILLER BYPASS PUMPS.
 3SVB1J6DO: 900 HP DRIVE PUMP.
 4SVB1L6DO: 1350 HP AND 900 HP HIGH AMBIENT PACKAGE

DRIVE PUMP.

TEMPERATURE LIMITS
 2 STATOR THERMISTOR/MOTOR:
YELLOW WARNING 266 °F (130 C)
RED SHUTDOWN 284 °F (140C) (TOP DRIVE)
 CCB SENSOR:
YELLOW WARNING 122 °F (50C)
RED SHUTDOWN 131 °F (55 C) (HEAT PUMP)
 PRE REGULATOR SENSOR:
RED SHUTDOWN 131 °F (55 C) (CHILLER)
 INVERTER SENSOR:
RED SHUTDOWN 131 °F (55 C) (CHILLER)

COOLING SYSTEM ECI 900

TOP DRIVE COOLING
SYSTEM
3SV
1SV
1SV

TOP DRIVE COOLING
SYSTEM

COOLING SYSTEM
ECI 900 HIGH AMBIENT
4SV
2SV
2SV

COOLING SYSTEM ECI 1350
4SV
2SV
2SV

COOLING SYSTEM
ECI 1350 HIGH AMBIENT
4SV
2SV
2SV

CHILLER TOP DRIVE
COOLANT TANK COOLANT TANK
145 GAL/548L 145 GAL/548L
COOLANT (UCARTHERM)
50/50 GLYCOL MIX
TOP DRIVE COOLANT PUMP CHILLER BYPASS PUMP
AND MOTOR AND MOTOR
PUMP OUTLETS
PUMP INLETS Copyright 2011 Tesco Corporation

DRIVE PUMP AND MOTOR

CHILLER CIRCULATION PUMP INLET FROM RESERVOIR
CHILLER CIRCULATION PUMP

COOLANT PUMPS

SERVICE LOOP (HOSE REEL)

TOP DRIVE HYDRAULIC QUICK COUPLERS
INLET
INLET
TOP DRIVE COOLANT QUICK COUPLERS

MALE COUPLER
FEMALE COUPLER
TOP DRIVE COOLANT PLUMBING

COOLANT PASSAGES IN PA44 MOTOR
ECI 1350
COOLING LINES OUT FROM MOTOR STATORS
CAUTION** FITTINGS OUT OF MOTOR MAY HIT QUILL IF NOT THE

CORRECT ONES
COOLING LINES INTO MOTOR STATORS
MINIMUM FLOW
3.5GPM(13.2L) /STATOR.
7GPM(26.5L) /MOTOR
THIRD MOTOR INTLET COOLING LINES ECI 1350
THIRD MOTOR OUTLET COOLING LINES

ECI 1350
MOTOR INLET COOLING LINES

HEAT EXCHANGER INLET FROM KAMAN MOTORS
GEARBOX OIL AND TOP DRIVE COOLANT HEAT EXCHANGER
HEAT EXCHANGER OUTLET BACK TO MECHANICAL MODULE

TO PA44 MOTORS FROM MECHANICAL MODULE
FROM PA44 MOTORS BACK

TO TANK
OUTLET TO MECHANICAL MODULE

FLOW SWITCH
OUTLET TO POWER MODULE
OUTLET TO TOP DRIVE
RETURN FROM TOP DRIVE

RETURN FROM POWER MODULE
COOLANT FILTERS
(10 MICRON)

DRIVE COOLING SYSTEM
The cooling system is designed to cool down the DRS drive(s) electronic
components and circuit boards by circulating a glycol-based antifreeze
coolant through the Drive cold plates.
Its main components are located in Mechanical and Power module:
• Heat Pump and
• Standard 10 Ton or High Ambient 25 Ton Chiller

CHILLER
HEAT PUMP


POWER MODULE COOLING LINES TO COLD PLATES
MINIMUM FLOW
5 GPM(19L) /COLD PLATE.
15 GPM(57L) /MD500
FROM HEAT
PUMP
TO HEAT
PUMP

CHILLER AND HEAT PUMP
It is critical for the electronic components to maintain certain ambient

temperature and humidity levels within the building and inside the drive
cabinets to prevent condensation.
The power module has a dedicated, self-contained cooling system,

called Heat Pump, which is basically an AC unit that controls both
temperature and humidity according to preset levels.
The Heat Pump is installed inside the Power Module.

HEAT PUMP

HEAT PUMP REFRIGERANT CAPACITY
(3.5lbs-5lbs)
FILL CONNECTIONS (HEAT PUMP)
HEAT PUMP LOCATION

WHEN MAKING REPAIRS TO CHILLER CIRCUIT
BASIC REFRIGERATION USE DRY N2 TO
CYCLE
PREVENT COPPER OXIDE FROM FORMING IN PIPING (BLACK)
HEATING REFRIGERANT
COOLING REFRIGERANT
HIGH PRESSURE VAPOR, HIGH PRESSURE LIQUID, LOW PRESSURE LIQUID/ VAPOUR, LOW PRESSURE VAPOUR.
CHILLER CIRCUIT
LOW PRESSURE LIQUID/

VAPOUR, TURNS TO A
LOW PRESSURE VAPOUR
WHEN HEATED IN THE
EVAPORATOR WITH THE
POWER MODULE COOLANT
(LIQUID HEATED)
HIGH PRESSURE
VAPOR, TURNS TO A
HIGH PRESSURE
LIQUID WHEN COOLED
BY THE CONDENSOR
(AIR COOLED)
CPR
CPR
HIGH PRESSURE VAPOR, HOT GAS BYPASS HIGH PRESSURE LIQUID, LOW PRESSURE LIQUID/ VAPOUR, LOW PRESSURE VAPOUR,
DISCHARGE LINE
(GAS) (HIGH PRESSURE)
(HIGH PRESSURE CUT OUT SWITCH)

CONDENSER
CONDENSER REFRIGERANT IN
CONDENSER REFRIGERANT OUT

(LIQUID) (HIGH PRESSURE)
HOT GAS BYPASS VALVE
LINE TO EVAPORATOR
EQUALIZER LINE
HOT GAS BYPASS SOLENOID
PROVIDES A MEANS TO BYPASS HIGH PRESSURE REFRIDGERANT TO THE SYSTEMS LOW

PRESSURE SIDE IN ORDER TO MAINTAIN A GIVEN MINIMUM SUCTION PRESSURE, AND TO
BALANCE THE SYSTEM CAPACITY TO THE LOAD DEMAND Copyright 2011 Tesco Corporation
LINE TO EVAPORATOR FROM HOT GAS BYPASS VALVE
COMPRESSOR HEATER
CHILLER REFRIDGERANT LEVEL GAUGE

(HIGH PRESSURE LIQUID) (R22)

TX VALVE
TX VALVE BULB
OUT (B) IN
REMOTE BULB
EQUALIZER LINE
(A)
THE THERMO EXPANSION VALVE REGULATES THE FLOW OF LIQUID REFRIGERANT

INTO THE EVAPORATOR IN EXACT PROPORTION TO THE RATE OF EVAPORATION OF
THE LIQUID REFRIGERANT. THE TX VALVE RESPONDS TO (A) THE TEMPERATURE OF
THE GAS REFRIGERANT LEAVING THE EVAPORATOR AND (B) THE PRESSURE AND THE
SPRING IN THE EVAPORATOR. THIS CONTROLLED FLOW PREVENTS LIQUID
REFRIGERANT FROM RETURNING TO THE COMPRESSOR. Copyright 2011 Tesco Corporation
P1
AS TEMPERATURE AT
BULB INCREASES THE
PRESSURE INCREASES
BULB
AT P1 AND OPENS
P2 EXPANSION VALVE.
WORKING AGAINST
OUTLET PRESSURE P2
AND SPRING P3
P3 P1 = P2 + P3
VALVE IS EQUALIZED
P1 GREATER THAN P2 + P3
VALVE WILL OPEN
P1 LESS THAN P2 + P3
VALVE WILL CLOSE
OR REFRIGERANT IN
(LOW PRESSURE)
EVAPORATOR
REFRIGERANT OUT
OW PRESSURE)

LOW PRESSURE CUT OUT LINE TO ADJUSTABLE SWITCHES
DISCHARGE LINES
SUCTION LINES
(GAS) (LOW PRESSURE)

CHILLER COMPRESSORS AND EVAPORATORS LOCATION
COOLER
WARMER
CHILLER REFRIGERANT CAPACITY ECI 1350 OR HIGH

AMBIENT PACKAGE (30lbs) Copyright 2011 Tesco Corporation
CHILLER EVAPORATOR LOCATION
EVAPORATOR REFRIGERANT OUT

(GAS)
EVAPORATOR REFRIGERANT IN
(LIQUID)
TX VALVES

ECI 900 CHILLER COMPRESSORS LOCATION
CPR VALVES PROTECT COMPRESSORS FROM OVERLOAD
WARMER
COOLER
LIQUID LINE DRIERS MAX. 1-2 DEG.BETWEEN INLET AND OUTLET

ECI 900 HIGH AMBIENT, ECI 1350
OVERHEAD CHILLER CONDENSER COILS
LIQUID LINE DRIER MAX. 1-2 DEG.BETWEEN INLET AND OUTLET

900 CHILLER
SUCTION PRESSURE SHOULD BE 60-80 PSI
DISCHARGE PRESSURE SHOULD BE 250-300 PSI (NORMAL)

In Summary…
• The Top Drive system has three separate sources for
cooling.
1. Top Drive cooling fan
2. Drive Module Chiller
3. Power Module Heat Pump
• Through correct maintenance, operation, and

inspection of these components we can ensure no
damage is done to the equipment due to
condensation or overheating.
• By ensuring the chiller coolant is maintained at least 4
to 5 degrees above the ambient temperature of the
power module and the PA44 motors do not achieve
130 degrees C, we can expect full utilization of all the
components for extended durations.

Eci Training Cooling

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Eci Training Cooling

Загружено:

Авторское право:

Доступные форматы

TESCO TRAINING

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 AT THE COMPLETION OF THIS SECTION YOU WILL

Copyright 2011 Tesco Corporation

 TOP DRIVE PUMP: supplies coolant to the top drive for

 DRIVE PUMP: supplies coolant to the power module cold

 CHILLER BYPASS PUMP: is used to bypass the chiller

 CIRCULATION PUMP: moves the coolant from the chiller

Copyright 2011 Tesco Corporation

 COLD PLATES: used for transferring heat away from

 PA44 MOTOR STATORS: have coolant passing through

 HEAT PUMP: maintains the ambient temperature in the

 DEHUMIDIFIER: removes moisture from the air in the

 CONDENSER: (high pressure gas in) turns back to

 TX VALVE: controls the flow of liquid through the

 EVAPORATOR: (low pressure liquid in) changed

MD-500 AND CHILLER

 1 TON =12,000 BTU/HR (HEAT REMOVAL RATE)

 THE ECI-900, (2) MD-500 DRIVE REQUIRE A 10 TON CHILLER.

 THE ECI-900 MD-500 DRIVE COOLANT PUMP IS DRIVEN BY A 5 HP MOTOR

Copyright 2011 Tesco Corporation

 THE ECI-1350 MD-500 DRIVE AND HIGH AMBIENT UNITS COOLANT

 THE ECI-900 DRIVE USE 2 CHILLER COMPRESSORS WITH THE WATER

 ECI-1350 DRIVES AND HIGH AMBIENT UNITS USE 4 CHILLER

Copyright 2011 Tesco Corporation

 1SVC1J6LO: 450 HP TOP DRIVE AND DRIVE PUMPS, 900 HP TOP

 2SVC1L6NO: 1350 HP AND 900 HP HIGH AMBIENT PACKAGE TOP

 3SVB1J6DO: 900 HP DRIVE PUMP.

 4SVB1L6DO: 1350 HP AND 900 HP HIGH AMBIENT PACKAGE

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

PUMP INLETS Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

CHILLER CIRCULATION PUMP

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

TOP DRIVE COOLANT QUICK COUPLERS

TOP DRIVE COOLANT PLUMBING

COOLING LINES OUT FROM MOTOR STATORS

CAUTION** FITTINGS OUT OF MOTOR MAY HIT QUILL IF NOT THE

THIRD MOTOR OUTLET COOLING LINES

Copyright 2011 Tesco Corporation

MOTOR INLET COOLING LINES

Copyright 2011 Tesco Corporation

GEARBOX OIL AND TOP DRIVE COOLANT HEAT EXCHANGER

HEAT EXCHANGER OUTLET BACK TO MECHANICAL MODULE

FROM PA44 MOTORS BACK

OUTLET TO MECHANICAL MODULE

OUTLET TO POWER MODULE

OUTLET TO TOP DRIVE

RETURN FROM TOP DRIVE

Copyright 2011 Tesco Corporation

Its main components are located in Mechanical and Power module:

• Heat Pump and

• Standard 10 Ton or High Ambient 25 Ton Chiller

Copyright 2011 Tesco Corporation