A Training Course for Rig Electricians

Basic SCRs

Section 4
Basic SCRs

1 Equipment Overview ................................................ 2

2 How Does It Work .................................................. 11
3 How Do I Operate It ............................................... 18
4 Inspection ............................................................ 24
5 Maintenance.......................................................... 28
6 Spare Parts ........................................................... 29
7 Troubleshooting..................................................... 30
8 Questions ............................................................. 31
9 Reference Material ................................................. 33
10 Work Place Assignments ......................................... 34
11 Glossary ............................................................... 35

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1 Equipment Overview
1.1 SCR Systems

1.1.1 History
Diesel electric rigs using diesel engines to power DC
generators, which in turn power DC motors much like the
diesel electric railway systems from manufacturers such as
EMD, were the first on the scene.

In the late 1960s, when transistors and other solid-state

electronic devices were introduced, rig designers and
manufacturers began to develop other ways to transmit and
control electric drilling power. They began using diesel
engines to turn AC generators, converting or rectifying the
AC to DC and using the DC to power motors on the
equipment.

1.1.2 System Information

The SCR drive system provides electrical power conversion
and control for DC motors on a drilling rig. The system
regulates AC power from engine-generator set 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.

Figure 1 General Rig Power Distribution System

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A typical system consists of the following units:

• Generator Units for AC Power generation to SCR’s.

• SCR Units for AC to DC rectification for traction

motor power and control.

• Transformer Feeder Unit for 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 accommodation.

• DW Dynamic brake for electrical resistance or

regenerative brake for Drawworks motors.

• Field Supply Unit for DC field supply to shunt

wound, separately excited DC traction Motors.

• Drillers Console for control of all drilling functions

on drill floor and mud pump room.

• Mud Pump/Cement Pump Console for local

control of the pumps during maintenance.

• Motor Control Centres containing starters for AC

auxiliary motors and feeder breakers for lighting
panels and smaller distribution transformers.

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1.2 Silicon Controlled Rectifiers

An SCR rectifies AC to DC utilizing the same principle as a

standard diode. However, unlike the diode an SCR will not
conduct electricity until it receives a ”trigger pulse” to its
gate circuit.

Figure 2 SCR Operation

A Silicon Controlled Rectifier (SCR) is a semiconductor

rectifier that has the added feature of controllability. The SCR
is capable of conducting OR blocking current in the forward
direction, depending upon the gate signal. The SCR, like the
diode, will always block current flow in the negative or
reverse direction. The act of controlling or turning on an SCR,
(i.e. telling it to conduct current) is also known as gating or
firing the SCR. If only one SCR in an AC circuit is fired, only
one – half of the AC current waveform is conducted.
Current flows only when the device is gated. The device will
only turn off when the gate is turned off and the applied
voltage reaches zero. The device will only conduct current in
the positive, forward direction, if it is gated.

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Current flows when the device is gated. The device will

only turn off when the gate is turned off and the voltage
reaches zero.

Figure 3 SCR On/Off Cycles

When the gate is not energized, the current is blocked in

both directions. The SCR and its controlling voltage can
operate very rapidly, up to hundreds of times per second.
Thus, the SCR gate opens and closes rapidly to allow and
stop the voltage/current flow. This rapid opening and closing
allows the Driller to control the power going to the DC
Traction Motors controlling the Drilling Equipments’ various
functions.

Figure 3 Various Types of SCR’s

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For example, once the Driller selects a function on the

Drillers Console, and operates the associated hand throttle,
the control signals are received at the corresponding DC
Module. This in turn controls the SCRs in the selected
cubicles. This applies to all the drives such as the
Drawworks, Rotary Table, Top Drive, Mud Pumps, Cement
Pumps and propulsion drives for Marine units using the same
system.

Figure 4 General Rig Power Distribution System

Controlling Power

AC power or voltage is pulsating in nature. A technician can

measure the AC voltage by displaying it on an oscilloscope,
which is somewhat like a small TV set. An oscilloscope
projects a picture of AC voltage in the shape of a wavy line,
which looks similar to an ocean wave. Called a sine wave, the
line pulses above and below the base line. If the driller
makes the SCR conduct electricity all the time, the SCR
conducts full current in only one direction, thus converting
AC to DC at maximum power capacity.

Figure 5 DC Voltage Shown as a Sine Wave

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The sine wave diagram in Figure 5 indicates maximum power

if DC flows the entire time the wave is above the base line,
only one phase is shown in this diagram. If three phases
were to be shown, overlapping the above sine wave equally
spaced, one then gets a continuous series of half waves
above the base line producing power.

If, however, the driller makes the SCR conduct during only
one part of each sine wave, the SCR converts and transmits
only a part of the current at reduced power. By using a
special controller, the driller can govern the point of the
single wave when the SCR starts to conduct, and thus vary
from zero to maximum amount of rectified power relayed to
the motor. To satisfactorily control the gate voltage, the
manufacturer has to combine several input signals. For
example, the driller has to be able to control a motor's power
input, so the manufacturer includes a throttle signal.

As explained before the throttle is used to accurately control

the gate pulse firing angle. Using the Figure 5 diagram
imagine the gate being fired on the ascending side of the
wave for a brief time, then fired again on the descending side
of the wave at the exact point relative to the firing on the
ascending side. The DC voltage produced would be the same
and repeating this action on all wave forms would give you a
constant series of pulses at the same voltage, as far as the
DC motor is concerned these pulse are so rapid that it sees
basically a DC voltage.

Now, if we change the gate pulse firing to a moment either

slightly before or slightly after the previous occasion, we will
see a lower or higher voltage appearing at the DC motor. As
speed is directly proportional to voltage in DC motors we can
see that the speed of the motor actually varies. This is the
principle of speed control using the hand throttle to vary the
gate pulse timing via the DC module which in turn is
controlling the output of the SCR Bridge DC voltage and
current to the assigned DC traction motor.

Other signals fed to the gate control system are:

• Current Limit Signal to limit the maximum amount

of current conducted.

• Rate Limit Signal to control the rate of current

turn-on, to limit the electrical surges.

• Paralleling Signal to allow the rig operator to run

more than one SCR in parallel (paralleling SCRs may be
required to power a large motor)

• Motor Speed Limit Signals to prevent the motor

from being run too fast.

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1.3 Assignment Contactors

The DC output of the main SCR bridge is connected to the DC

motors via assignment contactors. If the bridge is dedicated
to a single motor only, one contactor in the positive
connection is needed. However, if the bridge is assignable to
more than one motor, positive and negative contactors are
necessary.

Figure 6 SCR Cubicle & Power contactor

1.4 AC Bus And Control Units

In the SCR (AC-DC) system, three-phase alternators

generate AC power, which is rectified to DC power via the
SCR Cubicle. Figure 7 below shows a combined Cubicle
containing both the SCR Bridge and the Generator control
systems.

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The size and type of the rig determine the size and number
of the alternators required. Heavy-duty cables feed the
power from the alternators to common conductors. This set
of conductors is called the AC bus or the common bus. The
common bus is made up of larger copper bars, usually called
bus bars. Power from the bus bars then flows to special units
or cabinets, where the SCRs rectify the AC and other controls
are located.

Figure 7 Rig SCR System ( AC to DC )

1.5 Meeting Power Demands

In the operation of the SCR rig, the system has to generate

just enough power to meet the total DC motor demands at
any particular time. In addition to the DC motor demands the
rig has to generate what is commonly called “Hotel” loads,
which is basically the loading that is always present
regardless of the rigs operational state. This includes, but is
not limited to Cooking facilities, Accommodation, Sewage,
Potable water supplies, Sea water pumps and Lighting small
Power.
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Good practice however calls for keeping a little surplus AC

capacity. Indeed, proper planning and consultation with the
driller and Toolpusher regarding the operation will allow you
to have suitable power available for all expected loads. This
avoids having frantic telephone and P.A. calls for more
power. It will also be seen by the clients representative as
good management, reflecting on the whole operation.

The rig might need this extra capacity when some operation
suddenly requires more DC power. For instance, more friction
in the hole creates more torque for the rotary or Top Drive
and increases the power demand. As a result, rig owners do
not have to run all the AC generators when they know that a
particular operation requires less power than the system at
full capacity; for instance, during logging and wire line
operations the demand will be much smaller.

This economy, along with the ease and flexibility of control,

is the real advantage of the SCR system.

1.6 The Most Common Manufacturers

Power Systems, Baylor, Bautiel Ross Hill/Hill Graham,

GE, Tech-Power, Integrated, Westinghouse, CEGELEC,
Alstrom, Haier Haisi Control Technologies,(HHCT) and
ASEA.

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2 How Does It Work

2.1 General Explanation

An SCR puck or thyristor is used to provide controlled

rectification of a fixed voltage AC supply. The main SCR
Bridge is made up of six SCR pucks. Each incoming AC phase
connects to two SCR pucks; one connects to the positive DC
busbar, and the other to the negative DC bus bar. An SCR
puck can only carry current if it has been triggered by the
firing pulses from the electronic module. By changing the
moment in time during each cycle of AC waveform that the
firing pulse is applied to the device, the amount of voltage
passed to the DC motor can be varied from zero to full
output. The standard SCR cubicle contains one six pulse
bridge capable of carrying between 1000 and 2300 amps
depending on model type.

Each Cubicle contains an incoming AC circuit breaker, blower

fan for the SCR Bridge, outgoing contactors, electronic
control module, and in some cases the field supply cubicles if
the drive motors are Shunt wound.

2.2 AC Control Module

Included in the SCR system is the AC control module which is

designed to maintain the speed of the engine driving the
generator under all conditions during drilling operations.

Figure 8 AC Control Module

The AC module is designed to control the speed of the engine
driving the generator at all times. It does this by sensing the
engine speed from the flywheel teeth and converting this to a
signal.

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This is converted into an output by the AC Modules

electronics. Finally this output drives the actuator which
controls the fuel rack on the generators diesel engine. This
in turn controls the amount of fuel supplied to the engine,
resulting in a constant speed under varies load conditions.

Figure 9 Bank of SCR Modules

Once the controls are set on the main switchboard and the
generator is on line, the AC module will be left to control that
engine/generator speed and reaction to the changes in load
and conditions. It has to maintain constant speed and
voltage in company with the other generators on the
switchboard running in parallel.

The AC module contains the electronic circuits for the running

and control of the associated Generator units. These can be
grouped into assemblies.

1. Engine governor control

2. Voltage regulator

3. Protection circuits

4. Master/Slave circuits

2.2.1 Engine Governor

The engine governor controls the engine speed, and thereby,
the generator frequency. The controlling electronics are
located inside the AC module and are a feed back type
control circuit. The governor output is connected to a throttle
actuator which controls the engine fuel rack. The actuator
opens the rack in direct proportion to the current applied by
the governor though its coil.

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2.2.2 Voltage Regulator

The voltage regulator controls the generator field current
though the exciter, to regulate the generator voltage. The
regulator employs two feedback loops. The voltage control
loop provides overall regulation by matching the generators
voltage to the voltage reference. The exciter current control
loop regulates the exciter field supply.

2.2.3 Protection Circuits

This circuit compares the generator supply parameters
against there respective preset limits. It consists of a
protection switch, controlled by the reverse power
under/over frequency and the under/over voltage detectors.

Also included in this protection circuitry is the “No Pulse”

pickup detector. The protection switch is made up solid state
components which control the trip relay. This in turn de-
energizes the under voltage coil which causes the Generator
circuit breaker to open. In some systems a shunt trip coil
rather than a UV coil is the method used to trip the circuit
breaker. The later method is not considered fail safe.

The power limit circuit can also be considered part of the

protection circuits; however it has no control over the
generators main circuit breaker. Its purpose is preventing the
load from exceeding the capacity of the engines that are
synchronized onto the main bus system. This circuit monitors
the kWs and kVAs of all of the generators on line. If the
preset limits are exceeded a signal is sent to all of the SCRs
to phase down. This action distributes the available power
equally among the SCR Bridges. This setting is normally set
at 95% of the engine horse power rating.

2.2.4 Master/Slave Circuits

This explanation applies to a Ross Hill SCR System and may
differ if your system is from another manufacturer.

The master/slave circuit is to prevent generators fighting

each other for control and it basically allows one module to
control all of the others. A master slave circuit automatically
balances the kW’s. This action results in an equal load for all
engines. The master generator has the lowest number
among the ones on the bus. The remaining generators are
slaves. For example if Gen 1, Gen 2, and Gen 4 are on the
bus, then Gen 1 is the master. The master/slave circuit also
matches the slave unit frequencies to that of the master. The
speed adjust knobs on the slave units become disabled.

The combination of kW and kVAR sharing should cause all

generators to read an equal value.

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2.3 DC Control Module

Included in the SCR system is the DC control module which is

designed to control the output of an SCR bridge rectifier,
which in turn converts the incoming 3 phase 600 VAC into a
variable 0-750 VDC output. This module lives in the
associated SCR cubicle and is designed to generate the firing
pulses for the SCR Bridge after all of its input parameters
have been satisfied. The module processes these feedback
and reference signals and fires the six SCR’s in the bridge to
supply the assigned DC motor with enough power to match
the corresponding throttle setting.

Figure 9 DC Control Module

The DC module contains the electronic circuits for the SCR
unit. These can be grouped into three assemblies.

1. DC Regulator

2. SCR Firing circuits

3. DW Dynamic Brake

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2.3.1 DC Regulator
The regulator is a feedback control circuit which
automatically matches the motor speed and torque to the
throttle command from the control console. The regulator
output is a firing reference to the SCR firing circuits. Inputs
to the circuit consist primarily of the speed reference, speed
feed back and current feed back. The regulator consists of
two control loops, a voltage (speed) and a current (torque)
loop. Speed reference from the control console is summed
with the speed feedback signal to derive a current command
which in turn, is summed with the current feedback signal to
derive the firing reference.

2.3.2 SCR Firing Circuits

There are six identical circuits one for each SCR. The wave
form actually consists of two pulses, a main pulse followed by
a backup pulse. The backup pulse is essential for firing the
SCR at low DC output.

2.3.3 DW Dynamic Brake

This phenomenon is called regeneration. The motor can be
effectively braked by dissipating the regenerated power into
a resistor bank. Another form of regenerative braking
converts this waste energy via an inverter, and injects this
back into the AC power system. The dynamic brake slows
the drawworks motors to the hand throttle speed setting
after the foot throttle is released. The brake is designed to
function during hoisting mode. It is not a substitute for or to
be confused with the Eddy current brake commonly know as
the Elmagco or Baylor brake. The circuitry that triggers this
function resides inside the DC module.

The dynamic brake is automatically applied four seconds

after the foot throttle is released, provided the motor speed
exceeds the hand throttle setting. Typically the motors
require 30 to 40 sec to coast from full speed to cathead
speed. But with dynamic braking, the time is reduced to 10
to 15 seconds.

2.4 DC Module Feedback and Reference Signals

2.4.1 Speed Reference

This signal originates in the control consoles. The consoles
are equipped with hand wheels which the operator rotates
clockwise to control the traction motors. Each hand wheel is
linked to a rheostat which outputs 0 to +8 VDC speed
reference signal for 0 to maximum throttle.

Note. This speed reference signal can come from more than
one location. For example, the drawworks which has a hand
wheel and a foot throttle. Also the Mud pumps can be
controlled from either the drillers console or locally at the
mud pump itself.
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2.4.2 Speed Feedback

This is an analogue signal of the motor speed. It is 0 to
+10VDC for maximum speed.

2.4.3 For Shunt Motors

The speed is directly proportional to the armature voltage.

Field Loss Relay Shunt motors have a safety device

incorporated into the control system which will effectively
shut the motor down if the field supply to the motor is lost.
This prevents a dangerous runaway situation occurring, as
the loss of the field to a shunt motor will cause an unloaded
motor to speed up.

2.4.4 For Series Motor

The speed is a function of the armature voltage divided by
the magnetic flux. The flux, in turn, is a function of the
armature current. Therefore speed for a series motor is
derived by dividing the voltage feed back signal with the
shaped current feedback signal.

Sprocket Slip Relay Series motors will also over speed if

the load suddenly becomes disconnected, for example a
broken chain on mud pump, or the sudden disconnection of a
drive hub on the DC motor. This safety device also shuts
down the DC motor.

2.4.5 Current Feedback

This is analogue signal of the motor torque, since torque is
directly proportional to the armature current. It is derived by
taking the output signal from current transformers (CT’s)
which are placed around the 3 phase AC input to the bridge.

2.4.6 Voltage feedback

The DC (+) and DC (-) buses are tapped to develop a 15:1
analog of the SCR bridge volts. Signals from the bus are
dropped through a set of 3.9 K ohm resistors used to drive
the front panel SCR voltmeter. The other differential signal
Vbr+ and Vbr- which is applied to the DC control module for
use in the DC regulator circuit. When the bridge voltage is at
max 750 VDC the signal voltage is 50 VDC when measured
at Vbr+ and Vbr-.

2.4.7 Current Limit

This signal prevents the speed reference from demanding
excessive current. Each function has its own current limit
setting. The module automatically sets the current limit by
what function it is assigned to.

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2.4.8 Zero Throttle Interlock

This circuit protects the SCR Bridge and the traction motors
from sudden starts, if the selection switch is switched with
the throttle in the advanced position or if power is restored
after it has been lost, as in the case of a blackout. It forces
the module into gate suppression; the throttle signal is only
present when the contactor logic signal arrives at the DC
module. The driller must set the throttle to fully off before
the motor can be selected and run.

Figure 10 Zero Throttle Interlock

2.4.9 Speed Limit

This signal prevents the speed reference from demanding
excess speed. It is particularly useful for series motors.

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3 How Do I Operate It
3.1 Driller’s Console Operation

The Driller's Console is the primary control centre for the rig
DC functions. It is installed on the drill floor near the
Drawworks and contains an Assignment switch to apply
power to various combinations of functions suitable for
tripping or drilling. In addition, the Driller's Console houses a
lockout switch and throttle for each function. Lights on the
Driller's Console indicate the on-line status of the generators,
SCR units, and auxiliary AC devices such as blowers, chain
oilers, etc.

Figure 11 Drillers Console

3.2 Single Assignment Switch

The main drilling assignment switch allows the driller to

assign each of the SCR Bridge’s he has for drilling to any one
of the pre-arranged programs shown on the console
engraving plate. (a typical 4 SCR, 8 program switch is shown
below). For convenience the program positions are identified
as the hours on a clock defining vertically up as the 12
o’clock position, the other positions following respectively.

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ASSIGNMENT Switch positions on the left side (positions 8

through 11) are designed for tripping and those on the right
side (positions 1 through 4) are intended for drilling. The
Driller, however, is free to choose whichever is needed at
anytime. For each of these positions of the ASSIGNMENT
Switch the number in the blocks refer to the SCR units, while
the function it drives is listed below the number in the box.

Figure 12 Single Switch Assignments

In each position (except “off” when no SCR’s are assigned)

the numbers above the squares refer to the SCR Bridge
number 1 through 4, and the motor driven by that SCR
Bridge is shown in the box. For example in the 11 o’clock
position SCR Bridge No. 1 is assigned to drive Mum Pump 1
(MP1), SCR No. 2 is assigned to DWA, SCR 3 to DWB and
SCR 4 to RT. These are all assigned simultaneously when
the main switch is in the 11 o’clock position and all of the
motors listed may be controlled independently at the same
time.

If SCR 1 was faulty and tripped itself off line then the
capability to drive MP1 would be lost in the 11 o’clock
position, but the other 3 SCR’s could still be used for their
respective functions. In that case if it was essential to
operate MP1 then the driller would change his assignment to
say the 10 o’clock position allowing him to control MP 1 from
SCR 2. In that case DWB becomes assigned to SCR 1 and
hence would not be available.

The positions 1-4 intended for drilling operations while 8-11

are intended for tripping, though the driller is free to choose
whichever he needs at any time. Positions 1 & 2 make
maximum use of the available SCR’s by connecting in series
the two drawworks motors (DWS), thus giving full lifting
torque capability but only half hoisting speed. Positions 3 &
4 give half lift capability up to full speed. During drilling the
need to lift full load at full speed is limited.

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Note that typically only DWA will run in reverse and

drawworks dynamic braking (if fitted) normally only applies
to DWA.

3.3 Multiple Assignment Switches

On certain systems, usually where the assignments program

would be too complex for a single switch, several switches
are used. A typical layout of such a system is shown in
Figure 22.

Figure 13 Multiple Switch Assignments

A separate switch is provided for each function, allowing

assignment of each function to one of several SCR’s. For
example MP1 may be assigned to SCR 1, 2 or 5 and MP2 to
SCR 5, 4 or 3. Indicator lamps are provided on the Driller’s
console to show which SCR’s are already assigned, should
the operator attempt to assign a function to an SCR Bridge
that is already in use, the control logic is interlocked such
that the SCR will maintain its original duty until it is de-
assigned.

Figure 14 Drillers Console with Drawworks Controls

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3.4 Drawworks Assignments

In DRILLING positions, DWA and DWB motors are connected

in series (DWS). This provides full lifting capability, but only
half the hoisting speed, with only one SCR bridge utilised.

In TRIPPING positions, the motors are connected to separate

SCR bridges, giving full hoisting speed.

3.5 Drawworks Foot throttle

The Drawworks Foot Throttle pedal is pressed to operate the

Drawworks once the DW Hand Throttle is rotated out of the
OFF position. The RT ammeter will indicate the current
drawn by the Rotary Table motor, and this is an indication of
developed torque, which will be calculated through a formula
that considers the gear ratios in the drive system.

Figure 15 Drillers Console and Foot Throttle Assembly.

In some systems the Drawworks and Rotary Table motors

are fitted with Magnahellic Pressure switches. If the blower is
not switched on the normally-closed air pressure switch stays
closed to trigger the alarm. This alarm can also be triggered
if the normally closed contacts in the blower starter MCC fails
to open. This would indicate that the contactor has not closed
because of a fault in the control circuit.

But in most systems the auxiliaries required for the operation

to run must start before the main motors can be started, and
this is called interlocking. Where all the auxiliaries motor
starters have normally open contacts in them that are
connected in series, and must all be closed before the start
signal can reach the main drive motor start system. These
main DC drive motors cannot be started without the AC
auxiliaries being started first, and this must always be
considered when fault finding as a reason why a particular
DC motor will not run. There is always the possibility of dirty
or damaged auxiliary contacts in a starter, or a wiring fault,
or simply a bad connection in this system. The DC motor
lockout switches on the motors can also be in this system.

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3.6 Mud Pump Assignments

These are generally assigned and controlled by the driller at

the drillers console, however the local mud pump console
located in the mud pump room or area is used to operate the
mud pumps for maintenance such as changing out liners etc.
This console is not designed for normal operation of the
pumps because throttle range is restricted to half the range
available from the Driller’s Console. In addition, rod oilers,
chain oilers and charging pumps are not switched on
automatically.

3.7 Rotary Table And Top Drive Assignments

Like the Drawworks motors these are assigned and controlled

by the driller from the drillers console. A selection switch on
this panel will assign the appropriate assigned SCR to provide
power to either the rotary table or the top drive.

3.8 Driller's Console Indicators And Controls

The blower status lights are associated with auxiliary AC

devices of the corresponding DC functions. For example, the
DW blower light illuminates when all auxiliary devices of both
the drawworks motors such as blowers and chain oilers are
switched on.

Figure 16 Indication Lights

The GEN and SCR Status Lights illuminate when the

corresponding units are connected to the Main AC Bus.

If the positive pressurization within the Driller's Console is

lost a normally-closed air pressure switch will close to trigger
the alarm if the pressure drops below two inches of water,
which should be the difference between the pressure inside
the Driller's Console and outside pressure.

There are lockout switches for each DC motor function. Once

turned on, the corresponding hand throttle wheel (there are
four) is rotated clockwise to turn it from zero to maximum
speed.

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Figure 17 Drillers Control console with Foot Throttle

The Driller's Console is pressurized so as to meet the

requirements of equipment in hazardous areas, to the
equivalent of 2 inches of water from an air regulator. The
customer should provide a dry air bleed at 75 to 150 PSI to
the regulator.

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4 Inspection
The doors should be opened on the SCR equipment and an
inspection made for dust and dirt and if any is found it should
be removed with a vacuum cleaner while the equipment is
switched off. To avoid blowing the dust around the cabinets,
an air line should not be used.

It is necessary to keep the internal equipment clean to avoid

the chance of flash over during operations, and the filters on
the cubicles doors should be clean and dry to stop as much
dust as possible before it gets into the units. Once it has
entered the SCR cubicles the cooling blowers for the SCRs
will blow the dirt up through the heat sinks where it will be
very difficult to remove afterwards.

Figure 18 Front View of an SCR Bay

The SCR blower unit should be inspected on a regular basis

to make sure there is not a build up of dirt on the squirrel
cage blower blades in the SCR blowers, as this will reduce
the efficiency of the blowers and the air flow.

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These units are normally very noisy and bearing noise can be
hard to hear so a check of slack in the bearings should be
made now and then to check their condition when they are
shut down. Loss of any of the SCR blowers can lead very
rapidly to overheating of the SCRs. With this in mind the
blower loss alarm is to be checked. If one is not fitted
consideration should be given to the fitting of such a device
at the earliest opportunity.

If the system is shut down, it is always a good idea to go

over the system to check for loose connections, while one
has a chance. Also make a visual check for hot spots. The
system can also be checked while it is operating with heat
sensing equipment. Repairs can then be made to correct any
problems found, when the system can be shut down.

Figure 19 SCR Puck Exposed with the Heat Sink Split

The Drillers console should be opened on a regular basis to

make sure there is not a build up of water inside if the Drill
Crew has been washing down, or a build up of oil if the air
filter/drier has not stopped the oil getting through from the
Rig Air System which has lubricators.

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The spindles for the throttles should be greased to keep them

free, and to also help stop water migrating down the shafts
when the panel is hosed down. Normally there will be a
grease nipple on the inside of the panel for each throttle
spindle. The brushes on the throttles can also be checked at
the same time to make sure that they are in good contact
with the rheostat coils, and that the wiper spring tension is
correct. It is also a good time to check the micro-switches on
the throttles to make sure they are in good condition.

Figure 20 Drillers Console with Door Open

The mechanical stop fitted to the throttles also has the
function of activating a micro switch at the zero position. This
initiates what is known as “Zero throttle interlock”. It is not
unknown for this mechanical stop device to “fall off” and this
can lead to two potential problems within the system.

1. Zero Throttle Interlock Problem. That the zero throttle

interlock is never activated, which means no
adjustments or assignments for the SCR system can
be achieved. The system needs to know the hand
throttle is at zero before initiating any actions. This is
to stop any equipment suddenly starting when it is
switched on with all the associated safety concerns.

2. Throttle Problem. Or that when the driller rotates the

throttle back to zero the throttle may overrun and go
directly to maximum speed. This action can cause
severe SCR problems, the least of which may be
blowing the fuses.
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The door gasket on the Driller Console should be inspected to

make sure it is in good condition. This gasket will prevent
water from getting into the electrics if the front is washed
down on a regular basis. It is also a good idea to spray
around the switches on the front of the panel with WD40,
and to make sure that all of the seals are in good condition.

The foot throttle should be checked regularly to make sure

the operation of it has not been effected by mud and water,
and that it returns normally to the off position under its own
spring pressure. In very cold climatic conditions the throttle
has been known to freeze if there has been water inside the
enclosure.

In the SCR room it should be part of a normal daily routine to

check that the room is cold and dry, the air conditioning is
working well and that any filters in the air flow system are
clean and dry. This keeps the supply of clean cold air
constant for the cooling of the SCRs as they can produce a
lot of heat when operating and can be damaged by heat due
to the lack of cooling.

On some rigs the blowers for the SCR room air conditioning
units are driven by V belts and these belts need to be
checked regularly to make sure they are in good condition to
prevent failure while the system is operating.

The tips of the main DC contactors in the bottom of the SCR

cubicles should be checked to see if they have been damaged
by constant use, and the tips changed if there is too much
arcing while the system is operating. A stock of spare tips
should be kept in the store. Particular attention should be
paid to the Reversing Contactor, which can receive more
damage than the other contactors. These tips are copper
with a tin coating, and arcing will increase when the tin
coating is lost.

Most contactors have arc shields, which need to be kept in

good condition. Also many contactors have separate contacts
which are connected by a woven strap to the main contacts,
and these are used to quench the arc as the breaker closes
before the main contacts make contact, to prevent arc
damage to the main contacts. These contacts are replaceable
as a sacrificial assembly.

On some rigs there are contactors and resistor banks for the
Dynamic Braking System and these will need to be checked
to make sure the contactors are in good condition, and that
the resistor banks are in good condition and well ventilated.
They can get very hot while tripping and can become a fire
hazard if something has been stored on top of the cover
preventing air flow or if they have not been used for some
time and there is a build up of dust and dirt.

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5 Maintenance
This is an excerpt from the Ross Hill Maintenance Manual.

5.1 Servicing

5.1.1 Console
• Examine the internal assemblies periodically for signs of
corrosion. Corrosion is possible if the front panel door is
not properly sealed or if the air or purge air is bringing in
a large quantity of moisture.

• Rotate the hand wheels and the switches and examine

the switch and rheostat assemblies behind the Driller's
Console door panel. Check the switch contacts and
rheostat wiper arms carefully. Test the rheostat linkage
for tightness.

5.1.2 Drawworks Foot Throttle

Perform the following service on the Foot Throttle every
three months under normal conditions.

• Remove the Foot Throttle and open the rear dust

cover.

• Check and re-tighten the set screws. Ensure that the Foot
Throttle potentiometer returns to zero.

• Check that the rheostat wiper does not rub the wires
entering the Foot Throttle.

• Grease the bearing surfaces.

• Reassemble carefully to ensure that the Foot Throttle box

is watertight.

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6 Spare Parts
The spare parts required will depend on the system in use,
but in most systems it will be a case of keeping a stock of
crucial printed circuit boards and modules such as the Ross
Hill AC and DC control modules. This enables repairs to be
made very quickly in the event of down time by pulling out
one item and replacing it with a known good spare.

The damaged item can then be repaired and put back into
stock as a spare for the next time, as these items can be
very expensive to replace. It must be noted though that
these items must be repaired to the original specification to
perform as the original and not downgraded during the repair
with sub standard components. They should always be tested
after repairs are completed before being put in stock as a
good spare.

A rig should always have in stock the items that will stop it
operating or create down time and items it cannot operate
without while drilling. Depending on the rig in question, in
the SCR system this comes down to some of the major
components of the system. Some of these items are, the
Foot Throttle of which there should be at least one spare, a
hand throttle for the SCR control panel, again at least one
spare, complete with the micro-switch and operating handle
in case the original cannot be salvaged due to corrosion.
Complete spare switches for the switches on the Drillers
Console, spare resistors and diodes for inside the Drillers
Console along with spare terminal blocks.

Spares required for the SCR equipment room should include.

a spare breaker for an SCR cubicle, a spare blower assembly
for an SCR cubicle, spare DC contactors with the parts to
repair them, such as spare contactor tips, spare coils, and a
reversing contactor. Spare SCR Pucks normally in packs of
ten should be available in case one or more gets shorted, or
in the case of other types of systems spare SCR brick type
assemblies which are not repairable.

Fuses for the SCRs bridges, various breakers and contactors

for the ancillaries that run off the main AC system, and
various small control transformers. There is always a
recommended spare parts list provided with each system.
However, review the records to evaluate which parts were
the most frequently consumed and order accordingly.

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7 Troubleshooting
7.1 What If It Breaks Down

It is very rare that you will experience the loss of the whole
SCR system, unless there is a power failure, or the drill
console emergency stop switch is activated. In most cases a
break down will result in the failure of only one SCR bridge.

Generally most SCR systems contain a multiple assignment

selection matrix, which will allow you to change the SCR
which is assigned to a particular DC drive motor. This
function will allow you to immediately see if the SCR is the
cause of your problem.

7.2 Fault Finding

Troubleshooting consists of first looking at the broad

possibilities of failure, and then breaking down the likely
possibility into successively smaller trouble spots. This
consists of examining the whole system as it is situated
between the in-coming feeders and the loads, and then
narrowing the search to a cubicle or console, then to the
internal assembly, and finally to a component.

A step-by-step troubleshooting approach should consist of

the following items: malfunction analysis, analysis of front
panel indicators, system analysis, and signal tracing.

7.3 Malfunction Analysis

Malfunction analysis is easier and faster if the nature of the

malfunction is pinned down. Sometimes, the faulty behaviour
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 the SCR unit is defective.

The faulty behaviour of a motor may be blamed on the SCR

system. Make sure the fault is not outside the system before
making extensive repairs such as changing out an SCR cell.

7.4 Testing
Perform a functional test after repairing or replacing any of
the console assemblies. If the unit fails to perform as
required refer to Troubleshooting later in this section to
locate the malfunction. To test the Driller's Console, simply
observe the operating instructions to run the motors in each
Assignment switch position. Make sure the Blower lights turn
on as indicated and the motor performance follows the
throttle command.

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8 Questions
Related to the AC side of an SCR System

1. The electronic controls for the operation and control of

the AC Generators is located in what module or
component:

a) DC Module. b) AC Module. c) Control Module d)

Drilling Module.

2. The engine governor is responsible for controlling

what function of the AC Generator:

a) Speed. b) Voltage. c) Current. d) Shutdown.

3. Where does the control of the voltage regulator

originate from:

a) The exciter. b) Generator output voltage. c)

Speed sensor. d) Switchboard.

4. Name three of the protection circuits that will trip the

generator main circuit breaker off line:

a) Over speed. b) Over voltage. c) Under voltage.

d) Over frequency. e) Under frequency. f) Under
speed. g) Over current. h) Under current. i) Reverse
Current.

5. Describe how the master slave circuit works on a Ross

Hill system:

a) Selects high denomination generator as leader. b)

Selects the lowest denomination generator as the
leader. c) The generators decide amongst them
selves who will be the leader. d) The first generator
put on line will be the leader. e) The last generator
on line will be the leader.

6. What is the purpose of the current transformer

located in the SCR cubicles:

a) Sense the circuit voltage. b) Sense the circuit

current. c) Sense the circuit frequency. d) Monitor
the output of the SCR.

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7. What is the purpose of an under voltage trip coil on a

SCR main circuit breaker:

a) To trip the breaker on over current. b) To trip the

breaker on under frequency. c) To trip the breaker
when the output voltage drops below the required
level.

8. If the driller accidentally hits the emergency off

button on the drillers console what will occur:

a) The lights will go out. b) The generators will shut

down. c) The SCR cubicle breakers will trip off line.
d) The rig will shut down.

9. What does it mean when the power limit light is on at

the drillers console:

a) That you cannot have any more power. b) That

you have to shut something down to conserve power.
c) That you need to start another generator to provide
more power. d) That the rig will shut its self down if
more power is not supplied.

Related to the DC side of an SCR System

10. What does the abbreviation “SCR” mean:

a) Semi controlled rig. b) Slow construction rig c)

Silicon controlled rectifier. d) Special controller rig

11. What is the difference between an SCR and a diode:

a) The ______ will allow current to flow one way only,

and the ______ will not allow current to flow until it is
switched or gated, and then it will allow current to
flow until the flow stops or reverses its direction.

12. Explain the main function of an SCR:

a) To control the flow of current. b) To control the

direction of current flow. c) To control the rate of flow
and prevent reversal of current flow as a rectifier.

13. The electronic controls for the SCR Bridge are located
in what module or component:

a) SCR control module. b) AC control module. c)

DC control module. d) Switchboard. e) MCC
unit.

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9 Reference Material
The best reference material for any SCR system is the
manufacturer’s service manuals that are usually supplied
with the system when it is new.

These manuals cover everything from commissioning the

system when it is newly installed to trouble shooting and
fault finding when the system is in normal operation.

In most cases there are people employed with the

manufacturers who can assist in time of need by email or by
telephone who can talk over a problem with you on the
company technical support line.

The service manuals and drawings will supply the information

required to replace any damaged components and wiring
diagrams showing the circuitry and test points required for
fault finding if you have a problem or breakdown.

5.2 Web Sites

http://www.iadc.org/dcpi/dc-marapr01/m-techpower.pdf

http://www.legacypower.net/

http://en.wikipedia.org/wiki/Silicon_controlled_rectifier

http://www.allaboutcircuits.com/vol_3/chpt_7/5.html

http://www.kilowattclassroom.com/Archive/SCRArticle.pdf

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10 Work Place Assignments

Note.

This assignment is to make you aware of all the SCRs and DC

traction motors that are driven by this equipment. It will lead
to the SCR cubicles, which together with the motors and
auxiliaries makes up your system.

1. Locate the SCR FER (field equipment room) this will

generally be close to the main power generating
source. Which in the case of offshore rigs is the
engine room, and for land rigs they will be skid-
mounted modules or enclosures.

2. Note the number of SCR Bays that makes up your

system and the general layout. Look at the
accompanying meters indication lights and location of
the SCR Main circuit breakers.

3. Find the SCR selection identification plate. Somewhere

on your SCR panels will be a selection matrix plate
that will show the drillers assignment switch positions
and the associated DC motor that will be assigned to
which SCR. Take note of the flexibility that this
switching plan allows for your system when drilling or
tripping. When viewed with the one line schematic for
the DC power path it will familiarise you with your
systems capabilities.

4. Look for the location of the AC & DC control modules

or PCB’s (printed circuit boards). Generally the DC
modules are housed inside the SCR control cubicles
and conversely the AC modules live inside the
generating cubicles or are panel mounted.

5. Now approach the driller’s control panel and take note

of where the driller assigns these SCR’s to there
respective DC drive motor. Also look for the SCR
Emergency shutdown button which will open all the
SCR main circuit breakers back at your switch room.

6. Check out the mud pump room or area and locate the
remote mud pump control panel. Note the local
controls and indication setup that apply to your
system.

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11 Glossary
Anode The positive power terminal of an SCR or Diode.

Cathode The negative power terminal of a SCR or Diode.

Current Limiting A means to limit the maximum amount of

current applied to the load.

Command Signal An input variable applied to an SCR

power controller to adjust it's output.

Conductance The ability of a material to conduct electricity.

Conductance is the inverse of resistance.

Current Feedback A means to maintain the applied current

to the load. The applied current is maintained as a linear
function of the command signal regardless of line voltage and
load changes.

CT Current Transformer A device used for sensing

current. It's output is an electrically isolated signal
proportional to the measured current.

DI/DT The rate of rise of applied current to an SCR as the

unit turns on.

DIODE A semiconductor which allows current to pass in

one direction only.

Distributive Control A means of controlling the on/off time

of the SCR's to obtain a desired power output to the load.

DV/DT Refers to the maximum rate of rise of applied

voltage across an SCR that will NOT cause a false turn-on.
Usually stated as volts/second.

Forward Drop The voltage drop across a semiconductor

when that device is conducting current in it's normal forward
direction.

Gate The signal terminal of an SCR. The terminal used to

turn on an SCR.

Heatsink Device used to transfer heat away from either

an SCR or Diode.

SCR (silicon controlled rectifier) Typically used in a

controlled back-to-back configuration in order to rectify both
the positive and negative half cycles of an AC line.

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