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2. Description of Machine
Power supply----------------------------------------------------------------------------------------------------6
Rolling system --------------------------------------------------------------------------------------------------6
Rotating system ------------------------------------------------------------------------------------------------7
Circulation System ---------------------------------------------------------------------------------------------8
Two type of drives for drill ------------------------------------------------------------------------------------8
Typical power range---------------------------------------------------------------------------------------------9
Typical Load Analysis -----------------------------------------------------------------------------------------9
Application 1 (DC)----------------------------------------------------------------------------------------------22
Application 2 (AC)----------------------------------------------------------------------------------------------24
1
1. Relevant Documents ----------------------------------------------------------------------------------25
1. Application Background
Overview of Oil Industry
In the past century, as the most important resource, oil greatly promoted the development of
human being. In addition, with the development of oil chemistry, oil is closely connected with
almost every part of our ordinary lives, like food, cloth, housing. Figure 1 shows the profile of
oil industry:
At the beginning of 1980s, electrical drill started to enter china market. All of those were directly
imported. In 1998, XPEIC and ROSS HILL signed a contract to develop SCR drill market. After
that point, electric drill market changes from a potential market to a booming market. Also, the
competition becomes more and more fierce.
Procedure of Drill
As showed in Figure 1, Drill is the first node of the oil industry chain. But exploring a applicable
oil well is by no means an easy job. Figure 2 shows the general processing of drilling an oil
well.
Machine Installation
Location Choose Drill Complete
Oil Well Point Shot
Connect Rod : Change Rod : Change Drill Consolidate Turn to Production if Oil Well
According to drive:
• Mechanic drive
• Electric drive
• Hydraulic
According to depth:
• Small oil drill <2000m
• Middle oil drill 2000 4500m
• Deep oil drill 4500 6000m
• Deeper oil drill 6000 9000m
• Deepest oil drill 9000 15000m
According to environment:
• Ordinary land oil drill
• Desert oil drill
• Polar area oil drill
• Sea (includes offshore) oil drill
2. Description of Machine
Power supply
The power ranges form 800kw to 4000kw, which is ordinarily provided by diesel machine and diesel generator.
Rolling system
Functions:
To hoist up and lay down the rod and drill head
When drill a deep well, the rolling system has to undertake weight of 300 tons. Figure 5 shows the profile of rolling
system.
Rotating system
Functions:
Cut the earth
Circulation System
Functions:
Clear the drill hole
Help break rocks
Cool drill head
Take out the rock crumbs
The mud builds the wall of drill hole
Phase 1: Hoisting up
1400A
500-1000A
The function of Auxiliary brake is to slow down the rod when it falls. Auxiliary brake is better to
be canceled because of its cost and inconvenience.
Because the drill machine normally operates in distant area, a special standard should be
implemented. In China, JB/T 7845-1995 specifies the requirement of land drill.
Ordinarily, drill machine works in distant areas where have no power networks. So the separate
diesel generator supplies the power of drill. There are two problems: first, the power is limited;
second, the power cannot be regenerated.
Solutions:
• Constant power control (Serial field DC motor, Constant power control for AC and DC
drives)
• Power limitation
• Current limitation
• Harmonic elimination
• Power factor compensation
• Choose special diesel generator (Power factor 0.7-0.8)
Volume limitation:
Because the drill machine frequently moves around, even more, the drive system, MCC and
diesel generator controller are loaded in a single control house, the volume of each part should
be limited as much as possible.
Solutions:
• Reduce the SCR angel: α (DC)
• Special motor (e.g. GE-752)
• Enlarge the content of single cubicle
• Simplify the system, e.g. no speed sensor
• Common bus
Reliability
Since the cost of drilling is quite high, it is very important to reduce the failure time. Even worse,
if the failure time during drilling exceeds 40 minutes, the well will possibly be abolished. For the
advanced drill machine, the fault rate may be only 0.01%. The reliability means: first, longer
MTBF; second, easy to maintain; third, the machine may still works even part of it fail.
Solutions:
• Robust mechanic parts
• Reliable electrical parts
• Simplify the system
• The control parts are identical (the rolling system and the mud pump)
• Redundant system
• Better protection against environment
Special Motor
• Better protection
GE company can supply special motor for drill, such as GE-752. Now, in China, some
manufacturers (e.g. Yongji motor factory) can produce similar motor. Siemens can also provide
compact motor, which has been used in Daqing oil field.
Drive system
40 -- 50 m
Drill Platform
Generator
MCC
Controller
Door Door
! Note: Because diesel generator can not absorb energy, only single phase drive system can
be implemented for drill machine. Though, in some places, drill machine is supplied by power
networks, it is possible to use rectifier/regenerator system configuration.
Transformer
Generator
Motor
DW /R T Mud Pump
Charictor:
• Single phase
Power supply:
• Power networks or Generator
Advantages:
• Can work anywhere
• Most economical
• Simple topology
Department: BD 11 Only for internal use
Author: Gan Chuan F:\Application for Drilling Drive System.doc
© Siemens Electrical Drives Ltd.
Siemens Electrical Drives Ltd. Application Manual for Land Drill
Disadvantages:
• Can not regenerate
Comment:
• A comptitive solution
Generator Transformer
Rectifier (1
phase)
Charictor:
• Single phase
• With a brake resistor
Power supply:
• Power networks or generator
Advantage:
• Can work anywhere
• Economical
• Brake resistor can absorb energy when rod deccelerates
Disadvantage:
• The system reliability is reduced by the contactor.
Comment:
• This configuration is widely used by ROSS HILL company. The benefit of this solution is
that the rolling system can deccelerate faster.
Generator
Transformer
Rectifier Motor
Inverter
Charictor:
• Single phase
• SCR Rectifier
Power supply:
• Power networks or Generator
Advantage:
• Can work anywhere
• Simple topology
Disadvantage:
• Can not regenerate
• Slightly more original investment than DC solution
Comment:
• Comparing with the following AC solution, it is not promising.
Generator
Rectifier Motor
Charictor:
• Single phase
• SCR Rectifier
• With a brake resistor
Power supply:
• Power networks or Generator
Advantage:
• Can work anywhere
• Brake resistor can absorb energy when rod deccelerates
Disadvantage:
• Slightly more original investment than DC solution
Comment:
A promising AC solution
Some data need to be transferred from control house to drill platform. (About 50m) It is better to
use communication than use directs signal transfer.
I/O
PLC S7-300
Drives MCC
PROFIBUS
Fiber optic
Operator
PLC S7-300 Devices
Disadvantage:
• Expensive
Comment:
• This solution is implemented by ROSS HILL company, but it is expensive
Note: Shield cable is also applicable, but should abide by EMC specification
I/O
PLC S7-300
Drives MCC
Remote I/O
Fiber optic
Operator
Adapter Devices
Figure 20: Communication Configuration 2 (Remote I/O)
Advantage:
• Reliable
• Easy to maintain
Department: BD 15 Only for internal use
Author: Gan Chuan F:\Application for Drilling Drive System.doc
© Siemens Electrical Drives Ltd.
Siemens Electrical Drives Ltd. Application Manual for Land Drill
• Completed EMC
• Less signal attenuation
• Wire elimination
• Cheaper
Disadvantage:
• Special protocal
Comment:
• This solution is a more appropriate solution for drill machine, because it is not necessary
to put a PLC in drill platform.
Note: Shield cable is also applicable, but should abide by EMC specification
Pedal Switch:
Discription:
To increase productivity, when the rod is arising, the operator may add an abrupt speed value.
That is carried out by a pedal switch, internally is realized by an auxiliary set point.
Solution:
ADD
Abrupt Set Point
Pedal Switch
Discription:
Winch (rolling system) and rotating tray (rotating system) are normally driven by a single drive
system and mechanically switched. To protect rod, when two motors are mechanically coupled,
rotating tray can only be driven by single motor.
Solution:
Enable
Enable AND
Description:
The speed set of rolling system is given by a potentiometer in drill platform. Due to the
technology requirement, the potentiometer can only make sense when it rotates from zero.
That is, an abrupt set point cannot be given at beginning. When the potentiometer is at zero, a
switch signal will be activated.
Meanwhile, when the winch motor is running, the motor cannot stop if the motor fan stops.
However, only the fan is on, the motor can restart.
Solution:
Fan On
Potentiometer at Zero
Enable
AND AND
SET (Q=D)
Enable
D Q
STORE
NOT Q
RESET
Power On
OR
Current Limitation
Description:
When the rotating tray is running,operator many change the current limitation
Solution:
Current Set
Load Distribution
Description:
According to standard of drill machine, when two motors are electrically coupled, load
imbalance should be less than 10%.
Solution:
To conform to the configuration without sensor, 6SE70-Application Manual (Page 200)
introduces a load distribution solution. This solution has been successfully realized by SEDL,
and the static load imbalance is less than 1%.
f* +
_ m
fact
Drive 1
fact m
+
_
Power Limitation
Description:
Generally speaking, for example, a 4000m drill needs three diesel generators. To save energy,
not all of those diesel generators are simultaneously running, and the generator is manually
switched. That is, it is possible the drives may need more power than the currently running
generators can provide. At that moment, the diesel generator has to be reliably protected. Even
more strictly, the drives can still run automatically without exceeding the power currently
Department: BD 18 Only for internal use
Author: Gan Chuan F:\Application for Drilling Drive System.doc
© Siemens Electrical Drives Ltd.
Siemens Electrical Drives Ltd. Application Manual for Land Drill
provided. Though the generator can protect itself, but it cannot satisfy the latter requirement.
So, the drives have to automatically limit their power required.
The drive system of ROSS HILL has such function, but using analog circuit to realize that.
SEDL provides a novel solution. Basically speaking, it is better than ROSS HILL s.
Generator controller can output a signal ranged from 0.8 to 0.6 when the power output
changes more. The factor 0 means that the generator reaches it s power limitation point,
though it can still run in short time while the factor is 0.2 or 0.3.
Solution:
A(0)
1
Generator Factor
A<B
A ( 0.3 )
Speed Set Value
A*B
Explanation:
When the generator overloads, i.e. Generator Factor>0, a smaller speed set point will be
valid. Then, the power absorbed by convert will sharply cut back. Afterward, the Generator
Factor will recover (<0). In that way, generator and converter will be dynamically balanced to
retain Generator Factor to Zero without obvious speed fluctuation. As a result, the power is
limited and converter can still run.
ROSS HILL reduced the power by cutting back the current, so the system response is much
slower. That means the power factor will exceed 0 at some moment.
Since drill machine works in extremely rigorous environment, AC motor is more competitive.
According to the report oversea, for AC drives, it is possible to eliminate auxiliary brake. Thanks
to that, AC drives will probably replace DC drives, because the auxiliary brake is expensive and
fragile.
A typical rolling system is 1000KW, so it is possible to drive it with single motor or double
motors. Both are used in China.
Motor
Mechinc
Motor Motor
Mechinc
Though the left solution is slightly expensive, it is self-redundant. In that way, the system
structure can be simplified.
System Redundancy
To increase of the system reliability, ROSS HILL realizes system redundancy by using
contactor.
According to the well depth to drill, different motor combination will be used. Due to those
contactors, operator can easily change the combination by simply rotating a switch.
However, the system configuration becomes complicated. Since the device become more
reliable, it is better to adopt simpler configuration.
In the common bus system configuration, since large numbers of capacitor are paralleled, it is
possible that the energy stored in the DC link capacitor cannot be neglected.
So, for every braking of drill machine, 229 KWs power can be saved. Since the drill machine
start and stop frequently, that can slightly save energy.
Customer Benefits
• In the past years, many new technologies have been implemented to enhance productivity
and shorten time, such as horizontal drill, deep well and automatic drill. Horizontal drill, for
example, can increase the well productivity with six times. But such kind of technology needs
electric drives.
Department: BD 21 Only for internal use
Author: Gan Chuan F:\Application for Drilling Drive System.doc
© Siemens Electrical Drives Ltd.
Siemens Electrical Drives Ltd. Application Manual for Land Drill
• The efficiency of electric drill can be up to 90%. Especially, AC drive can have power factor
more than 0.9. Meanwhile, the drill time can be greatly shortened by electric drill. That is,
energy can be saved. Furthermore, field drilling is very money consuming, saving time means
saving.
• Electric parts have longer MTBF than mechanic parts.
• The motor and the involved mechanical parts of the system are protected by the drive thanks
to its the controlled soft-start.
• Thanks to electric drive, the drill structure is greatly simplified. The installation time can be
shortened to half. Meantime, the transportation fee can be reduced.
• For the international projects, it is necessary to use electric drill. That is very important for
China, because China is very competitive for international project bid thanks to her low price
human resource. In fact, half of the electric drills in China are drilling overseas.
• Fewer operators are needed for a drill team.
• The drives of SIEMENS have flexible communication ability, so they can seamlessly integrate
with automation system. That is, the drill can be better controlled and the Man Machine
Interface can be friendly.
• Thanks to the free logic blocks of drives, some technology can be fulfilled by drives
themselves. In that way, the area control unit is well packaged. Then the system is simple and
the interface can be neat.
• The parameterization of several drives of the same size is easily done with the use of the
OP1S or the PC-based SIMOVIS software.
• The drill time for a certain well. For example, a 4000m well, how many days were cost by
mechanic drill and by electric drill.
• How much diesel oil was consumed by drilling certain well?
9. Successful Projects
Application 1 (DC)
System configuration
1000KW×2 AC 600V
Generator
Generator: 1000KW, 600V
800KW×2 AC 600V
Rectifiers
M RT DW
p
Rectifier Motor
Inverter Generator
Basic data
Motor:
• Type: YZ02
• Voltage: 750V Current: 1150A
• Rated speed: 1060r/m
Rectifier: 6RM2487-3KS10-1 and SITOR
No speed sensor
Application 2 (AC)
1000KW×3 AC 600V
System configuration Generator
800KW×3 AC 600V
Rectifiers
DC-bus
A B C D E F Inverters
Mp1 RT
Mp2
DW
Rectifier Motor
Inverter Brake
Basic data
Introduction:
No speed sensor
plex
Department: BD 24 Only for internal use
Author: Gan Chuan F:\Application for Drilling Drive System.doc
© Siemens Electrical Drives Ltd.
Siemens Electrical Drives Ltd. Application Manual for Land Drill
10. Reference
Electric and Automation Engineering Manual
Chinese
www.cpc.com.cn
www.natoil.com
12. Consultant
Gan Chuan or Gao Chenghai
174#, Jintang Rd
Hedong District,
Tianjin, 300180
P.R. China
Tel: 0086-022-24979797-251(252)
Fax:0086-022-24977210
Email: c.gan@sedl.siemens.com.cn
ch.gao@sedl.siemens.com.cn