Rosshill

Technical Manual
60 Hz SCR Drive System
RIG/PLANT REFERENCE REFERENCE DESCRIPTION
ADDITIONAL CODE SDRL CODE TOTAL PGS

This document contains proprietary and confidential information National-Oilwell, L.P.
which belongs to National Oilwell; it is loaned for limited purposes 1530 W. Sam Houston Pkwy. N
REMARKS only and remains the property of National Oilwell. Reproduction, in
whole or in part; or use of this design or distribution of this Houston, TX 77043
MAIN TAG NUMBER DISCIPLINE information to others is not permitted without the express written USA
consent of National Oilwell. This document is to be returned to Phone +1 713-935-8000
National Oilwell upon request and in any event upon completion of
CLIENT PO NUMBER the use for which it was loaned. Fax +1 713-935-8382
 National Oilwell
CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV
Client Document Number 20605-45 L
www.natoil.com
Document number 20605-45
Revision L
Page 2
REVISION HISTORY
L 16.03.2005 Updated to New Template BKF

Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved
CHANGE DESCRIPTION
Revision Change Description

A Initial Release
B Added Revision History page and drawing number in footer. Revised figures 1-10, 1-13, and 1-
14. Formatting corrections.
C Corrected text and figure item callouts items in figures 1-4, 1-5, and 1-6.
D Make formatting correction.
E Remove references to ARH and Ansaldo Ross Hill on pages 1-1, 1-2, and 1-25.
F Update figures.
G Update (2) photos (Figure 1-5, Figure 1-9); add photo numbers; update figure number style.
H Revise Figure 1-1 to reduce printing time and printer memory problems.
J Convert to Word 97 format.
K Add Table of Contents codes. Correct Level 5 and Level 6 styles and errors.
L Updated to New Template.
www.natoil.com 24 HOUR SERVICE (713) 935-8000

Revision L
Page 3
TABLE OF CONTENTS
1 SYSTEM INFORMATION ................................................................................................. 5

1.1 Description.............................................................................................................. 5
1.2 Specifications.......................................................................................................... 5
1.3 Functional Description ............................................................................................ 8
2 OPERATING PROCEDURE FOR GENERATOR SYSTEM MODELS 1201 THROUGH
1650 9
2.1 Starting an Engine .................................................................................................. 9
2.2 Bringing the First Generator On Line ...................................................................... 9
2.3 Synchronizing Generators .................................................................................... 10
2.4 Remove Generator from Line and Stop Engine .................................................... 17
2.5 Turning on an SCR Unit........................................................................................ 17
2.6 Switch on Auxiliaries............................................................................................. 18
2.7 Normal Operation ................................................................................................. 18
2.8 Crisis Operation .................................................................................................... 19
2.9 Shut Down Instructions......................................................................................... 20
2.10 Capabilities ........................................................................................................... 21
3 MAINTENANCE.............................................................................................................. 23
3.1 Receiving & Handling ........................................................................................... 23
3.2 Installation ............................................................................................................ 26
3.3 Cubicles................................................................................................................ 28
3.4 Testing.................................................................................................................. 29
3.5 Servicing ............................................................................................................... 31
3.6 Quality .................................................................................................................. 31
3.7 Harsh Operation ................................................................................................... 32
3.8 Environment.......................................................................................................... 32
3.9 Storing an SCR Drive System............................................................................... 34
4 TROUBLESHOOTING.................................................................................................... 36
4.1 Overview............................................................................................................... 36
4.2 Malfunction Analysis ............................................................................................. 36

Revision L
Page 4
4.3 Analysis of Front Panel Indicators ........................................................................ 36

4.4 Systems Analysis.................................................................................................. 37
4.5 Special Tools And Equipment............................................................................... 39
5 REMOVAL & REPAIR .................................................................................................... 40
5.1 Cubicle Removal................................................................................................... 40
5.2 Cubicle Repair ...................................................................................................... 40
5.3 AC Control Module ............................................................................................... 40

Revision L
Page 5
1 SYSTEM INFORMATION
1.1 Description
The SCR Drive System provides electrical power conversion and control for the DC motors
on a drilling rig. The system regulates AC power from engine-generator sets and delivers
continuously variable DC power to traction motors which are coupled to functions such as
Drawworks, Rotary Table, Top Drive, Cement Pumps and Mud Pumps (see Figure 1-1).
A typical drive system consists of the following units:
• Generator Units for control of engine-generator sets.

• SCR Units for AC to DC rectification for traction motor power and control.
• Transformer Feeder Unit - AC feeder breakers to feed step-down transformers that
deliver low voltage power for AC auxiliaries such as motor blowers, water pumping,
lighting and living accommodations.
• DW Dynamic Brake - electrical resistance or regenerative brake for Drawworks
motors.
• Field Supply Unit for DC field supply to shunt wound, separately excited DC traction
motors.
• Driller's Console for control of all drilling functions from the drill floor.
• Mud Pump/Cement Pump Console for local control of the pumps during
maintenance.
• Motor Control Center containing starters for AC auxiliary motors and feeder breakers
for lighting panels and smaller distribution transformers.
1.2 Specifications
The drive system conforms to IEEE-45 standards for electrical switchgear. For offshore
systems, certification can be obtained from American Bureau of Shipping (ABS), United
States Coast Guard (USCG), and Det Norske Veritas. See Table 1-1 for system
specifications.

Revision L
Page 6
Table 1-1. System Specifications
ELECTRICAL
AC Input Three phase, 60 Hz, 600 VAC
Prime Power Usable KW depends on

horsepower of prime mover.
Engine Governor 0.5 Hz steady-state regulation

with one Second response time
at 5% load unbalance of rated
load
Generator Voltage Regulator

±3% regulation one second
response time with ±10% load
unbalance of rated KVAR’s.
DC Output Zero to 750 VDC at zero through

maximum current
Current Rating (Continuous Duty)

SCR bridge output is usually
zero to 1,800 ADC (this can vary
depending on model).
MECHANICAL
Temperature Range -22°F to 105°F
(-30°C to 40°C)
Cubicle Construction Fabricated from 12 gauge

cold-rolled steel with welded
construction and expanded
metal ventilation openings.
The cubicle bus is solid
copper with a 0.0005 Inch
(0.0013 cM) electroplating of
silver.
Console Construction Fabricated from 12-gauge

#304 stainless steel plate
with welded construction.

Revision L
Page 7
Figure 1-1. SCR Drive System

Revision L
Page 8
1.3 Functional Description
Figure 1-2 shows a typical one-line diagram. Observe that power from the engine-
generator sets is collected on a common AC bus.
AC to DC rectification occurs in SCR bridges. The output of the SCR bridge is applied to
the DC traction motors via contactors. Contactor logic is set at the Control Console being
used. Note that circuit breakers isolate each generator set and SCR Unit from the Main AC
Bus.

Revision L
Page 9
2 OPERATING PROCEDURE FOR GENERATOR SYSTEM MODELS 1201 THROUGH

1650
During the following procedures, refer to Figures 1-3 through 1-6.
2.1 Starting an Engine
1. Place the ENGINE CONTROL switch to IDLE.
2. Start the engine and run it at idle speed until it is warmed up.
3. Place the ENGINE CONTROL switch to RUN.
2.2 Bringing the First Generator On Line
1. Turn the SYNC switch to the number of generator about to be brought on line. The
PUSH TO CLOSE pushbutton on the appropriate generator cubicle door should
illuminate.
2. Set the SPEED ADJUST control knob so the FREQUENCY meter indicates 60 Hz.
3. Adjust the VOLTAGE ADJUST control knob so the VOLTS meter indicates 600
Volts.
4. Charge the circuit breaker (if necessary) by pushing the CHARGE pushbutton for
electrically charged circuit breakers, or by cranking the circuit breaker handle for
manually charged breakers.
5. Close the circuit breaker by pushing the illuminated PUSH TO CLOSE pushbutton
on the appropriate generator cubicle door.
6. Turn the SYNC switch to the OFF position.

Revision L
Page 10
2.3 Synchronizing Generators
2.3.1 To Bring an Additional Generator On Line
1. (Models 1200, 1201, 1500) Turn the SYNCHRONIZING switch (Item 9 on Figure 1-
3, Item 11 on Figure 1-4) to SYNC.
OR
1. (Model 1400) Turn the SYNCRONIZING switch (Item 15 on Figure 1-5) to the
number of generator about to be brought on line.
OR
1. (Model 1600) turn the SYNCHRONIZING SWITCH (Item 20 on Figure 1-6) to

AUTO.
2. Position the VOLTS ADJUST knob (Item 13 on Figure 1-3 and 1-4, Item 10 on
Figure 1-5, Item 17 on Figure 1-6) so the AC VOLTMETER (Item 5 on Figures 1-3
and 1-4, Item 18 on Figure 1-5, Item 7 on Figure 1-6) indicates 600 Volts.

Revision L
Page 11
Figure 1-2. Typical One Line Diagram

Revision L
Page 12
3. Adjust the SPEED ADJUST knob (Item 12 on Figures 1-3 and 1-4, Item 9 on Figure
1-5, Item 18 on Figure 1-6) until the SYNCROSCOPE needle (Item 20 on Figures 1-
3 and 1-4, Item 17 on Figure 1-5, Item 22 on Figure 1-6) moves clockwise (the
engine/generator speed is faster than desired) and the two SYNCHRONIZING
LIGHTS (Items 21 on Figure 1-3, Items 19 on Figures 1-4 and 1-5, Items 23 on
Figure 1-6) brighten/dim.

Revision L
Page 13
Item Description
1. GEN Circuit Breaker
2. AC Kilowatts Meter
3. AC Kilovars Meter
4. AC Ammeter
5. AC Voltmeter
6. Generator Run Light
7. Generator On Line Light
8. Engine Control Switch
9. Synchronizing Switch
10. Ammeter Select Switch
11. Voltmeter Select Switch
12. Speed Adjust Knob
13. Volts Adjust Knob
14. % AC Ground Ammeter
15. % DC Ground Ammeter
16. Ground Fault Indicator Lamps
17. Ground Detector Test Button
18. Power Limit Light
19. Hertz (Frequency) Meter
20. Synchroscope
21. Synchronizing Lights
Figure 1-3. Controls and Indicators for Models 1200 and 1500

Revision L
Page 14
Item Description
3. AC Ammeter
4. AC Kilovars Meter
5. AC Voltmeter
6. Generator Run Light
7. Generator On Line Light
8. Ammeter Select Switch
9. Voltmeter Select Switch
10. Engine Control Switch
11. Synchronizing Switch
14. % AC Ground Ammeter
15. % DC Ground Ammeter
16. Ground Fault Indicator Lights
17. Ground Detector Test Push Button
20. Synchroscope
21. Hertz (Frequency) Meter
Figure 1-4. Controls and Indicators for Models 1201

Revision L
Page 15
Item Description
3. Kilovars Meter
4. AC Ammeter
5. Engine Control Run/Off/Idle Switch
6. GEN Run Light
7. GEN On Line Light
8. Push to Close Lighted Pushbutton
11. % AC Ground Fault
12. % DC Ground Fault
13. Ground Fault Indicator Lights
14. Ground Detector Test Push Button
15. Generator Synchronization
Select Switch
16. Frequency (Hertz) Meter
17. Synchroscope
18. AC Voltmeter
21. Hour Meter
Figure 1-5. Controls and Indicators for Model 1400

Revision L
Page 16
Item Description Item Description

1. AC Kilowatt Meter 13. Ammeter Select Switch
2. Temperature Meter 14. Engine Governor Switch
3. Kilovars Meter 15. Circuit Breaker Switch
4. AC Ammeter 16. Voltmeter Select Switch
5. % DC Ground Meter 17. Volts Adjust Knob
6. % AC Ground Meter 18. Speed Adjust Knob
7. AC Voltmeter 19. Temperature Select Switch
8. Generator Run Light 20. Synchronizing Switch
9. Circuit Breaker Push to Charge 21. Frequency (Hertz) Meter
Push Button 22. Synchroscope
10. Ground Fault Indicator Lights 23. Synchronizing Lights
11. Ground Detector Test Push Button 24. GEN Circuit Breaker
12 Circuit Breaker Indicator Lights
Figure 1-6. Controls and Indicators for Model 1600

Revision L
Page 17
4. Crank the handle of the GEN CIRCUIT BREAKER (Item 1 on Figures 1-3, 1-4, and
1-5, Item 24 on Figure 1-6) once to charge the GEN CIRCUIT BREAKER.
5. Close the GEN CIRCUIT BREAKER when the needle of the SYNCROSCOPE
points straight up, the SYNCHRONIZING LIGHTS go out, and the PUSH TO
CLOSE pushbutton on the GEN CIRCUIT BREAKER is illuminated.
6. Position the VOLTAGE ADJUST knob so the KVAR meter gives the same reading
as the other generator(s) on line.
7. Turn the SYNCHRONIZING SWITCH to the OFF position.
2.4 Remove Generator from Line and Stop Engine
1. Open the circuit breaker by pushing the circuit breaker OFF pushbutton.
2. Place the ENGINE CONTROL switch in the IDLE position.
3. If the GOVERNOR CONTROL switch has an OFF position, go to the OFF position
only after engine has cooled down.
4. If system equipped with a GOVERNOR CONTROL pushbutton switch, the engine

must be shut down at the engine.
2.5 Turning on an SCR Unit
1. Check the Driller's Console to insure assignment for this SCR is turned off (the 12
o'clock position de-assigns all SCRs).
2. Charge the circuit breaker (if necessary), by pushing the CHARGE pushbutton (for
electrically-charged circuit breakers) (refer to Figures 1-3 through 1-6) or by cranking
the circuit breaker handle (for manually-charged circuit breakers). Some systems
have molded-case circuit breakers. These do not require charging.
3. Close the SCR circuit breaker by pushing the PUSH TO CLOSE pushbutton (this
may be mounted remotely or directly on the circuit breaker). Crank the circuit
breaker handle once to close molded-case circuit breakers.

Revision L
Page 18
2.6 Switch on Auxiliaries
1. Close the feeder circuit breaker to feed AC supply to the distribution transformers
and the MCC.
2. Close the circuit breakers corresponding to each of the blowers and auxiliaries. Set
the HAND/OFF/AUTO switch to AUTO (if applicable).
3. If the motors are shunt wound, switch on the appropriate field power supplies. Each
motor's field current should be ≈50 Amps (or per the motor nameplate rating).
2.7 Normal Operation
2.7.1 KVAR Sharing
Adjust the VOLTS ADJUST knobs so all generator units KVAR meters are the same.
2.7.2 KW Sharing
A master/slave circuit automatically balances the Kilowatts (Horsepower) among all on-line
engines (the load is shared equally).
The master generator is the lowest- numbered unit connected to the Main AC Bus. The
remaining generators are slaved to the master. For example, if Generator 1, 2, and 4 are
connected to the Main AC Bus, Generator 1 is the master.
In systems using Auto Share (Auto Sync) AC Control Modules, master/slave floats. No AC
Control Module can be the dedicated master in an Auto Share system.
The magnetic coupling that exists between paralleled generators insures that all engine
generator sets connected to the Main AC Bus at the same time will run at the same speed.
The SPEED ADJUST knob on the master generator has total control of the Main AC Bus
frequency. The slave units SPEED ADJUST controls are disabled.
The combination of KW (Real Power) and KVAR (Reactive Power) sharing between engine
generator sets should cause all generator AMMETERS to read about the same value. Any
imbalance in the readings of the various KVAR meters can be adjusted by using the
VOLTAGE ADJUST knob of the generator that has the lowest KVAR meter reading.

Revision L
Page 19
2.7.3 Power Distribution
Distribution of the total power is governed by the following equation:
DCPower Demand = Power Used (Total - AC)
Bring additional generators on line to increase the total power available. To increase the
total DC power available, increase the total power by putting more generators on line. AC
power is usually a small fraction of the DC power. To increase power for a specific DC
function, it also helps to reduce the power consumed by the other DC functions.
Due to the Main AC Bus feature and the Power Limit circuit, it is possible to connect as few
generators to the Main AC Bus as are necessary to do the work. For economy and
efficiency, match the total available power to the total load.
2.8 Crisis Operation
2.8.1 Unit Malfunction
The GEN ON LINE and SCR ON lights will illuminate when the respective units are
connected to the Main AC Bus. The lights go out when that unit is tripped off-line
(disconnected from the Main AC Bus). If a generator\SCR unit becomes inoperative,
continue the system operation on other units.
2.8.2 Sync Malfunction
If the SYNCHROSCOPE is inoperative, use the SYNC lights to parallel the generators. If
both the SYNCHROSCOPE and the SYNC lights fail, use a Multimeter.
Switch the Multimeter to a 600 VAC scale. Connect it across the generator circuit breaker
from the top to the bottom of any one phase. The voltage will swing from minimum to 600
VAC just as the SYNC lights should change from dim to bright. Adjust the SPEED ADJUST
knob for the oncoming generator until the swing slows. Close the circuit breaker when the
Multimeter voltage reading is minimum.
2.8.3 Transient AC Surge
The green SURGE SUPPRESSION light will extinguish if a problem blows the Surge
Suppression Circuit incoming line fuses.

Revision L
Page 20
2.8.4 Sprocket Slip
The SPROCKET SLIP light illuminates when Mud Pump assignment contactors trip. This is
caused by a sprocket slip, chain failure, or belt slippage on a dual motor mud pump. After
the chain drive is repaired, push the SPROCKET SLIP RESET button to extinguish the
SPROCKET SLIP light and to allow the contactors to close.
2.8.5 Ground Fault
The three GROUND DETECTOR lights and the % AC GROUND and % DC GROUND
meters indicate ground faults.
These are only indicators and the fault must be located and corrected.
AC ground faults can occur anywhere along the AC power network (generator to AC bus
cables, feeder distribution to the AC motors, and the generator control bus in the cubicle
itself). The GROUND DETECTOR lights will isolate the fault to one of the phases, and the
% AC GROUND meter will indicate the degree of the fault.
DC ground faults may occur anywhere along the DC network from the DC (+) and DC (-)
buses in the SCR cubicles to the motor cables. Isolate the fault to one motor by observing
the % DC GROUND meter. The % DC GROUND meter needle will fluctuate as the faulty
motor speed is changed.
2.9 Shut Down Instructions
1. Turn off the SCR unit by tripping the SCR circuit breaker. The SCR ON light will
extinguish.
2. Disconnect the generator from the Main AC Bus by tripping the Generator circuit
breaker. The GEN ON LINE light will extinguish.
3. Push the engine IDLE pushbutton. Cool the engine per the engine manufacturer.
4. After the engine cool-down period is over, turn the Generator Control cubicle
OFF/IDLE/RUN switch to OFF to stop the engine. Shut down the fuel rack if there is
no OFF button.

Revision L
Page 21
2.10 Capabilities
Figure 1-7 shows an SCR bridge Current versus Voltage response curve. Figure 1-8
shows DC series and shunt motors Speed versus Torque curves. These are for a specific
brand and model motor. Other brands and models will be different.
Figure 1-7. SCR Bridge Current versus Voltage Curve
Figure 1-8. Speed versus Torque Curve

Revision L
Page 22
Figure 1-9. Typical SCR House

Revision L
Page 23
3 MAINTENANCE
This chapter contains information to assure proper operation of the system through periodic
functional tests and preventive maintenance.
If the system fails to perform as indicated in the functional test instructions, consult the
troubleshooting guidelines listed in this manual.
3.1 Receiving & Handling
SCR switchgear is normally installed in a truckload-sized house (see Figure 1-9), a

self-contained, structural steel building mounted on skids. Cabling to external devices such
as generators, motors and control consoles is terminated at weatherproof plug panels (see
Figure 1-10).
If the house is not ordered, the equipment should be handled with care to prevent
excessive mechanical shock, and protected from possible damage due to moisture and dirt
during rig-up. See Figures 1-11 and 1-12 for cubicle lifting procedure.
Figure 1-10. Plug Panel of One SCR House

Revision L
Page 24
Figure 1-11. Cubicle Lifting Procedure

Revision L
Page 25
Figure 1-12. Cubicle Lifting Procedure

Revision L
Page 26
3.2 Installation
See Figure 1-13 for a typical SCR switchgear layout in a house.
Figure 1-13. SCR House Layout

Revision L
Page 27
If an SCR house was not ordered, refer to the following instructions for installation of the
SCR Cubicles. Figure 1-14 shows a typical SCR Drive Cubicle lineup.
Figure 1-14. SCR Drive System Typical Cubicle Lineup

Revision L
Page 28
3.3 Cubicles
3.3.1 Preliminary Considerations
Door Clearance
The SCR room must be large enough to allow the doors to be opened 90 degrees. The
doors cover the full height of the cubicles. The height of the room must have clearance for
the cable tray, piping, and ducting.
Ventilation and Ducting
The room air must be changed twice per minute when the cubicles are enclosed in a room.
Ducting in the front and rear of the room should force the air to flow the full length of room.
Heat Loss
Heat loss for a SCR system housed in a room fully insulated on walls, floor and ceiling, and
containing no distribution transformers, is approximately 2.5 tons for each 1,000 HP of DC
load.
Vibration Pads
If the cubicles are mounted in a high vibration area, such as the region close to the engine
skid, the cubicles should be mounted on vibration insulating pads. The vibration frequency
should be within 30 Hz, and the amplitude should not exceed 0.02 cM. Korfund spring-type
vibration isolators are recommended.
Location
Lift the cubicle with a crane into the general installation area. Use four lifting points per
cubicle. Refer to Figures 1-11 and 1-12 for the lifting procedure.
Use hydraulic hand trolleys (Rol-A-Lift or equivalent) to move the cubicles into the exact
location. Two trolleys may be required for wide cubicles such as the Motor Control Center.
Cover the vertical rest beams of the trolleys with carpeting to protect the finish of the
cubicle panels.
Slide the trolley horizontal forks all the way underneath the cubicle.
Jack up the cubicle approximately 6" (15 cm) above the floor.
Push the cubicle carefully into the location, jack down, and remove the trolley horizontal
forks.

Revision L
Page 29
Mounting
Butt the sides of the cubicles tightly together.
Bolt the cubicles together at the top and bottom using 3/8" bolts.
Install the AC bus splices to connect the bus together from cubicle to cubicle.
Cable Installation
Refer to the cabling diagrams in the SCR job book. Cables between the cubicles are
furnished by the customer unless the SCR drive system is installed in a Power Control
Building.
All power terminations are made through the cubicle top unless otherwise designed.
If the SCR system is supplied inside a Power Control Building, power and control cable
terminations are at one end of the building.
The terminations are copper stubs with a one-inch diameter bolt hole. The customer
should furnish plated-copper, crimp-type lugs. Avoid screw-type pressure connectors.
If multiple single conductor cables are used to feed the system, transposing of the cables
must be considered to ensure current sharing between conductors.
Control Consoles
The Driller's Console is typically mounted on top of the Drawworks pneumatic control
console. The Mud Pump and Cement Pump consoles are provided with tabs. Each tab has
a bolt hole for wall installation. Refer to the respective console drawings for detailed
installation instructions.
Control cable terminations are made from the bottom with plug-in-type Pyle National
connectors or screw-type terminal blocks fed through stuffing tubes.
3.4 Testing
This section contains information to test the proper functioning of the SCR Drive System.
Perform the test daily. If the system fails any part of the test, use the Troubleshooting
section to locate the malfunction.

Revision L
Page 30
3.4.1 Safety Precautions
IF CARELESSLY HANDLED, THE SCR DRIVE SYSTEM CAN INFLICT

GRAVE INJURY. SAFETY PRECAUTIONS MUST BE OBSERVED AT ALL
TIMES TO PREVENT ELECTRIC SHOCK.
Team Work
Maintenance work should preferably be performed by a team of two electricians. This

assures help in an emergency situation.
Personal Wear
Do not wear metallic watch straps, rings, or bracelets.
Live Circuit
Consider all circuits to be energized unless known to be dead.
Tools
All electric tools should be grounded. Handles on the tools should be insulated. Do not
leave tools in the cubicles after the work is completed.
Fuses
Close a fuse by pushing on the plastic cover. Do not place a finger underneath the cover.
Fire
Remove power to the unit under fire. Read the label on the fire extinguisher to be sure it
can put out an electrical fire. Water may be used, but be very certain that all power is
removed including the power on the main bus.
3.4.2 Daily Test
Perform the following checks to assure the proper functioning of the drive system.
1. Check lights and meters on cubicles and control consoles.

Revision L
Page 31
2. Check Ground Detector indicators. All three lamps should glow a dim orange. The
Ground Fault Percentage meters should read close to Zero.
3. Check field current supply of all shunt motors.
4. Ensure that KWs and KVARs are shared between all the generators on line.
5. During tripping, listen for switching action of the DW Dynamic Brake contactor.
6. Ensure that all SCR blowers are running.
3.4.3 Monthly Test
Perform the "Mechanical Overspeed Trip" and "Reverse Power Trip" Functional tests,
located in Table 2-4 (see Section 2).
1. Check waveshape of SCR Amps at the test pins on the DC Control Module. See the
SCR Unit section for further details.
2. Inspect the cooling inlet filters and clean/replace as necessary.
When working in conditions of low humidity, wipe off meter lenses with a
damp cloth or use anti-static spray.
3.5 Servicing
Servicing consists of cleaning the system components and replacing those which have
become defective or worn out. Periodic servicing will make the SCR Drive System more
reliable and last longer. A reliable system is less likely to suffer sudden failures or
deteriorate below the performance specifications.
The system components are vulnerable to three factors: inferior quality, harsh operation
and severe environment.
3.6 Quality
Efforts to eliminate this source of failure are made at our manufacturing and testing facility.
The system is rigorously tested through every phase of operation. The electronic modules
are placed in ovens at 165°F (75°C) for 96 hours to simulate numerous hours of operation
at normal temperature. Thus, components which are likely to fail during the first hours of
operation are replaced before shipment.

Revision L
Page 32
3.7 Harsh Operation
The drive system should be operated within its capabilities. Operation above the ratings
subjects the system to severe strains. The controls should be handled with care. A harsh
switching action can generate a damaging transient overload.
3.8 Environment
3.8.1 Heat
Components can fail suddenly due to overheating. Even though the drive system is rated
between -22°F (-30°C) through 104°F (40°C), the sys tem operation is more reliable at
normal temperatures. Components age faster at temperature extremes.
The blowers in each SCR cubicle remove the heat from the electrical assemblies. As a
further precaution, vital units such as the SCR bridges and electronic modules have heat
sinks for faster cooling. Inspect the assemblies frequently for indications of overheating
such as charring or burned insulation due to loose connections. Replace the damaged
components even thought they may not have failed completely.
3.8.2 Vibration
The drive system units do not generate vibrations. However, vibrations from rotating
machinery such as the generator set cause mechanical stress that can loosen connections
and crack insulation.
3.8.3 Dust
Dust is attracted to high voltage switchgear surfaces because of the static electricity
charge. As a result, circuit discontinuities, or even shorts can occur.
3.8.4 Moisture
Moisture aggravates problems caused by dust. The contaminants cake on the components
and conductivity is increased. Further, corrosion can occur.
Servicing consists of three operations: cleaning, inspection, and replacement.

Revision L
Page 33
3.8.5 Cleaning
Wipe clean the cubicle and component surfaces with a lint-free cloth moistened with a mild
cleaning solvent. Be sure to leave the surfaces dry.
TURN OFF THE MAIN POWER TO THE SYSTEM BEFORE CLEANING. TEST
THE CLEANING SOLVENT ON A SMALL SURFACE TO MAKE SURE IT
DOES NOT DAMAGE THE PLASTIC PARTS OR INSULATION, OR REMOVE
PAINT.
3.8.6 Inspection
Check all components for overheating and corrosion. Replace damaged components even
if not completely failed. Inspect cables and wires for broken or burned insulation. Tighten
all connections and check switches, knobs, and buttons for easy movement.
CARELESS INSPECTION ITSELF CAN CAUSE MALFUNCTIONS. DO NOT

TUG CABLES AND WIRE HARNESSES, SHAKE THE ELECTRONIC
ASSEMBLIES OR FIDDLE WITH THE KNOBS. EMPLOY VISUAL
INSPECTION AS FAR AS POSSIBLE.
Operating conditions dictate the servicing period. Adhere to the following schedule during
the initial period and adjust it according to need.
3.8.7 Connections
Experience has shown that many problems with electrical equipment are the result of loose
connections. Periodic checks for tightness can be helpful.
3.8.8 Weekly Servicing
1. Clean all cubicle and air conditioning filters.
2. Check Driller's console and Foot Throttle for air pressure. If there is moisture inside
the compartments, the dryer in the air line may be clogged.
3. Check assignment contactors. Inspect the coils for signs of overheating such as
discoloration or charred insulation. Check contacts for corrosion or pitting. Inspect
the freewheeling diodes; also inspect auctioneering diodes in the system.

Revision L
Page 34
4. Clean tachometer pickup plugs. Do not screw pick up in too far. Flywheel will
damage coil upon starting diesel.
5. Check AC leakage for every SCR bridge.
3.8.9 Quarterly Servicing
Clean and inspect the system components as indicated in Weekly Servicing. In addition,
tighten the bus bar bolts.
3.9 Storing an SCR Drive System
1. Disconnect HOC batteries at the battery terminals.
2. It is important to keep the SCR house interior dry while stacked. Install covers on all
external connectors on the plug panels. Place corrosion inhibitors in consoles and
cabinets.
3. Seal any openings to keep varmints out.
4. Lift the brushes on traction motors.
5. Apply power to generator and traction motor heaters if possible. Heaters in electrical
equipment areas are helpful.
6. Cover traction motor blower openings.
3.9.1 Removing an SCR Drive from Storage and Placing it in Service
1. Inspect bus bars for debris. Inspect and clean throughout cubicles, consoles, MCC
cans and underneath the main and switchgear line-ups.
2. Physically rotate the SCR blowers.
3. Manually operate all motor starters and contactors before powering up.
4. Open and inspect all modules.
5. Open and inspect all generator and traction motor covers.

Revision L
Page 35
6. Open all fuses in the system and high-resistance check the main three phase bus
bars before applying power.
7. Remove covers and inspect SCR bridges. Clean as necessary.
8. Reconnect HOC batteries. If good, they will fully recharge within 24 hours.
9. Clean all potentiometer windings (speed adjust, voltage adjust, hand throttles, foot
throttle).
10. Tighten all bus bar bolts and screw connections.
11. Manually phase-up each SCR bridge as soon as possible.
12. Inspect all power resisters for cracks.
13. Check AC leakage on all SCR bridges.
14. Check knob settings on EGB-10P or 13P actuators.
15. Check resistance of all magnetic pickup circuits and all actuator circuits.
16. Check compatibility of all modules.
17. Check outputs of hand and foot throttles.
18. Check current and voltage feedback for all SCR bridges.
19. Perform emergency-off and reverse power trip tests for all engines.
20. Verify sync circuits with a VOM.
21. If equipment has been idle for more than one year, all electrolytic capacitors should
be replaced.

Revision L
Page 36
4 TROUBLESHOOTING
4.1 Overview
Troubleshooting allows the isolation of a malfunctioning SCR Drive System unit.
It consists of first looking at the broad possibilities of failure, and then breaking down the
likely possibility into successively smaller trouble spots.
Examine the whole system as it is situated between the generators and the loads. Then
narrow the search to a cubicle or console, then to an internal assembly, and finally to a
component. The malfunction can be quickly located by seeking out signs of trouble, such
as extreme readings on the meters, tripped circuit breakers, and smoking components.
A step-by-step troubleshooting approach should consist of the following items: malfunction

analysis, analysis of front panel indicators, systems analysis, and signal tracing.
4.2 Malfunction Analysis
Troubleshooting is easier and faster if the nature of the malfunction is pinned down.
Sometimes, the faulty behavior of the system may be caused by operator error. For
example, the Driller may forget to turn on the lockout switch, open the throttle, and assume
that the SCR unit is defective.
The faulty behavior of a motor or generator may be blamed on the SCR system. Make
sure the fault is not outside the system before making extensive repairs such as replacing a
SCR cell.
If the malfunction occurs off and on, it may be useful to keep a log of the system
parameters with a strip chart recorder.
4.3 Analysis of Front Panel Indicators
Many malfunctions can be located by analyzing the meters and lights on the front panel.
Warning lights on the cubicle panels flag ground faults, AC surge, sprocket slip, and
reverse power conditions. Operational lights indicate whether a SCR or a Generator is on
the bus. Even voltmeters and ammeters provide valuable troubleshooting information. For
example, a stalled motor is indicated by high current, and low voltage. Low current and
high voltage is an indication of an unloaded motor.

Revision L
Page 37
4.4 Systems Analysis
Think of the system as being made up of interrelated blocks or units. Ignore the contents of
the unit, and simply consider the inputs and outputs. Refer to Figure 1-15.
DRILLER'S
GENERATOR
CONSOLE
DC
CIRCUIT
ELECTRONIC
BREAKER
MODULE
GATE FIRING
AC SUPPLY
PULSES
SCR BRIDGE
0 - 750 VDC SUPPLY
POWER
CONTROL
Figure 1-15. System Block Diagram
A malfunctioning unit does not provide the correct outputs. The fault may be due to
incorrect inputs. If not, some of the assemblies within the unit may be defective.
To troubleshoot, the system, first isolate the faulty unit by examining the outputs of the
suspected units. Then examine the inputs to the faulty unit. If one of the inputs is
incorrect, trace the signal from the incorrect input to its source unit. If, however, the inputs
are correct and the outputs are incorrect, troubleshoot the defective unit. Isolate the fault to
any one of the unit assemblies by a similar system analysis.
Inputs to many of the SCR Drive System units are of two forms: power and control. For
example, a SCR cell must receive the AC supply and the control firing pulse at the gate. If
both the inputs to the SCR cell are correct and the output of the SCR cell is incorrect, the
cell is defective.
The defective unit can be easily located by tracing signals associated with the malfunction.

Revision L
Page 38
GENERATOR 1 CIRCUIT SCR 1 CONTACTOR

BREAKER
GENERATOR 2 CIRCUIT SCR 2 CONTACTOR MOTOR

BREAKER
Figure 1-16. A Parallel Circuit
The motor can be operated on any one of the two power lines (refer to Figure 1-16). If it
fails to run, the fault can be in the motor, the assignment switch, or the power lines.
The power line can be checked out by simply switching the motor to one of the other lines.
If the motor runs, then obviously, the first power line is defective.
Each power line is made up of components in series. If the power line circuit is defective,
all the components and the wiring must be suspected. The defective component can be
located by tracing the power supply from the motor back to the generator.
Begin the signal tracing at the motor. If power is present at the motor and the motor is not
running, the motor is defective.
If power is absent at the motor, check for its presence on both sides of the contactor. If
power exists on the SCR side, but not on the motor side, the contactor is open.
Signal tracing should continue back toward the Generator until the defective component is
located. In extremely long series circuits, it may be convenient to divide the circuit in half.
Begin the probe in the middle. If the signal is missing, trace back toward the generator until
the signal is regained. If the signal is present, trace away from the generator until the signal
is lost.

Revision L
Page 39
4.5 Special Tools And Equipment
The following instruments are needed to troubleshoot the SCR Drive System.
4.5.1 Multimeter
The Simpson Model 250 (or equivalent) is recommended to measure voltage and
resistance values. The meter should be insulated, rugged and possess:
DC/AC Volts: Zero through 1,000 Volts in several ranges.

Accuracy: 3% of full scale.
Ohms: Zero through 10 MΩ in several ranges.
Accuracy: 2% of arc length.
It is recommended that digital-type meters not be used for measurements in

power circuits. It has been found that, in some cases, reading inaccuracies
may be induced by digital-type meter usage.
Digital multimeters may be used to measure voltage and current signals in the SCR drive
but you should be aware that some digital meters are overly sensitive to the high electrical
noise typical of that found in any switching high power supply. Digital meters that are not
designed with proper filtering and measuring techniques and can give inaccurate readings.
4.5.2 AC/DC Clamp-On Ammeter
This meter is used to safely measure high currents. The Columbia Model 1000A is
recommended.
4.5.3 Oscilloscope
The oscilloscope is used to check the SCR gate pulses and ripple on various DC voltages.
The Tektronix Model 305 (or equivalent) is recommended. The unit chosen should have >3
Inch diagonal viewing screen and two channels for comparing two signals.

Revision L
Page 40
5 REMOVAL & REPAIR
5.1 Cubicle Removal
If a cubicle is damaged beyond repair, perform the following steps:
1. Disconnect power cables from the bus stubs located at the top of the cubicle.
2. Remove bus links which connect the AC bus from cubicle to cubicle.
3. Remove the bolts which join the cubicles at the top and bottom.
4. Slide the fork of a hydraulic hand trolley underneath the cubicle and jack it up
approximately 6" above the floor.
5. Pull out the cubicle carefully, taking care not to bump the adjoining cubicles.
5.2 Cubicle Repair
Repair of the SCR Drive System normally consists of repairing an assembly within a
system unit. A system unit is not replaced unless it is damaged beyond repair. When a unit
is replaced, perform a functional test on it before operating the system. Refer to the
respective unit manual for test instructions.
5.3 AC Control Module
If an AC Control Module is malfunctioning, replace it with the spare AC Control Module and
return the faulty unit to us.
To remove and replace the AC Control Module perform the following steps.

Revision L
Page 41
1. Unscrew the Deutsch fastener at the top of the module and swing open the cover.
2. Release the wiring harness by removing each wire from the terminal board.
3. Unscrew the four Deutsch fasteners which hold the module to the cubicle wall.

Revision L
Page 42
4. During new module installation, ensure you match the wire number to pin number.
5. Reconnect the module to the cubicle wall with the four Deutsch fasteners.
6. Reconnect the wiring harness by replacing each wire on the terminal board. Ensure
that each wire is correctly placed and that the retaining screw is tightened.

Revision L
Page 43
7. Swing the cover closed and fasten it in place with the Deutsch fastener on top.

Revision L
Page 44
THIS PAGE INTENTIONALLY LEFT BLANK

Rosshill

Загружено:

Сведения о документе

Исходное описание:

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

Rosshill

Загружено:

Авторское право:

Доступные форматы

Technical Manual

60 Hz SCR Drive System

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

ADDITIONAL CODE SDRL CODE TOTAL PGS

Client Document Number 20605-45 L

L 16.03.2005 Updated to New Template BKF

Revision Change Description

www.natoil.com 24 HOUR SERVICE (713) 935-8000

1 SYSTEM INFORMATION ................................................................................................. 5

www.natoil.com 24 HOUR SERVICE (713) 935-8000

4.3 Analysis of Front Panel Indicators ........................................................................ 36

www.natoil.com 24 HOUR SERVICE (713) 935-8000

A typical drive system consists of the following units:

• Generator Units for control of engine-generator sets.

www.natoil.com 24 HOUR SERVICE (713) 935-8000

Table 1-1. System Specifications

Prime Power Usable KW depends on

Engine Governor 0.5 Hz steady-state regulation

Generator Voltage Regulator

DC Output Zero to 750 VDC at zero through

Current Rating (Continuous Duty)

Cubicle Construction Fabricated from 12 gauge

Console Construction Fabricated from 12-gauge

www.natoil.com 24 HOUR SERVICE (713) 935-8000

Figure 1-1. SCR Drive System

www.natoil.com 24 HOUR SERVICE (713) 935-8000

1.3 Functional Description

www.natoil.com 24 HOUR SERVICE (713) 935-8000

2 OPERATING PROCEDURE FOR GENERATOR SYSTEM MODELS 1201 THROUGH

During the following procedures, refer to Figures 1-3 through 1-6.

2.1 Starting an Engine

1. Place the ENGINE CONTROL switch to IDLE.

3. Place the ENGINE CONTROL switch to RUN.

2.2 Bringing the First Generator On Line

6. Turn the SYNC switch to the OFF position.

www.natoil.com 24 HOUR SERVICE (713) 935-8000

2.3 Synchronizing Generators

2.3.1 To Bring an Additional Generator On Line

1. (Model 1600) turn the SYNCHRONIZING SWITCH (Item 20 on Figure 1-6) to

www.natoil.com 24 HOUR SERVICE (713) 935-8000

Figure 1-2. Typical One Line Diagram

www.natoil.com 24 HOUR SERVICE (713) 935-8000

www.natoil.com 24 HOUR SERVICE (713) 935-8000

www.natoil.com 24 HOUR SERVICE (713) 935-8000

Figure 1-4. Controls and Indicators for Models 1201

www.natoil.com 24 HOUR SERVICE (713) 935-8000

Figure 1-5. Controls and Indicators for Model 1400

www.natoil.com 24 HOUR SERVICE (713) 935-8000

Item Description Item Description

Figure 1-6. Controls and Indicators for Model 1600

www.natoil.com 24 HOUR SERVICE (713) 935-8000

7. Turn the SYNCHRONIZING SWITCH to the OFF position.

2.4 Remove Generator from Line and Stop Engine

2. Place the ENGINE CONTROL switch in the IDLE position.

4. If system equipped with a GOVERNOR CONTROL pushbutton switch, the engine

2.5 Turning on an SCR Unit

www.natoil.com 24 HOUR SERVICE (713) 935-8000

2.6 Switch on Auxiliaries

2.7 Normal Operation

2.7.1 KVAR Sharing

www.natoil.com 24 HOUR SERVICE (713) 935-8000

2.7.3 Power Distribution