ross hill scr mud pump drive factory

ENSCO 71 is a Jack-Up drilling rig which was originally constructed at the Hitachi Zosen shipyard in 1982.  The original GE motor controls comprised five 1163 KVA generators and four 1800 ADC SCR units with associated auxiliary transformer feeders and jacking units. The SCRs were assignable to two 1600 HP twin-motor Mud Pumps, a twin motor 2000 HP Drawworks and a 1000 HP Rotary Table. A separate feeder drives a 1110 HP Top Drive. A fifth SCR was added by Hill Graham Controls in 1985 to power a third 1600 HP Mud Pump, which was cabled to the main busbars.

In early 2012, a decision was made to add a fifth 2500 KVA generator and an additional auxiliary transformer, to close-couple these to the main switchboard via a bus tie circuit breaker, and to include a dedicated feeder for the fifth SCR. A sixth SCR was also included in the switchboard extension to provide an alternative drive source for the third Mud Pump, effectively removing this load from the main switchboard. The switchboard extension, including full integration with the existing GE and Hill Graham equipment, was engineered and built by Zeefax.

It is an unfortunate characteristic of SCR systems that the Power Factor (the relationship between real and reactive power) is poor – often down as low as 0.4 – which maeans that the KW capacity of the engines is under-utilised. This often leads to frustration because the rig runs out of power, yet the engines may be only delivering half of their full-load capacity. This article explains how the Power Limit system works and what can be done to ensure it is working at its optimal level.

In general terms, the KW the system consumes is provided by the engine. The other limitation on power delivery is the current capacity of the generator, which is often expressed as a VA or KVA value. SCR systems are designed with something like a 0.7 Power Factor rating; in other words, the KW of the engine will be 0.7 x the KVA rating of the generator. This goes some way to compensating for the poor Power Factor, but often is insufficient during operations where where the Mud Pumps are heavily loaded. However, measures are still available to ensure that the system is delivering what it can within these physical limitations, one one thing to ensure is that the Power Limit system is working optimally.

The purpose of the Power Limit is to prevent rig blackouts in the event of sudden increases in load. The original philosophy also was to allow the minimum number of engines to be run and maximise efficiency but most drilling operators prefer not to run up against these limits and demand as much power as is available. The Power Limit system measures the KW load of the highest loaded engine, and the current load of the highest loaded generator and compares this to a pre-set reference to determine if Power Limiting of the SCRs should occur. Furthermore, some systems have an initial 60% KW limit, which then opens up to 100% once this threshold has been reached under ramped control. This is to allow the engine turbo-chargers to spin up. Once above this threshold only the 100% limit is in operation, unless the load dips below 60% in which the ramp is re-set.

We design, deliver and support electrical engineering projects, from simple machine controls to large scale production and process line systems. Our key skills include:Hill Graham and Ross Hill Type SCR Drives andGenerator Controls

We have particular expertise with power systems and DC or AC variable speed drives. We have highly specialised knowledge about drive systems for Oil Rigs, and have unrivalled experience in design, modification, repair and testing of Ross Hill and Hill Graham type SCR systems.

Using sophisticated software we are able to model power systems and calculate short circuit levels to ANSI and IEC standards. From the same on-line drawing we can generate time/current co-ordination curves and a comprehensive schedule of device settings. Our Harmonic Analysis tool is able to accurately predict expected levels of total harmonic distortion introduced by variable speed drives, UPS’s and other harmonic sources, and analyse the effect of adding filters to the system.

JOTON has forged relationships with many of the worlds leading industrial equipment suppliers and, together with it’s own technical and manufacturing capabilities, can source or manufacture a wide range of spare parts for Westinghouse, GE, Ross Hill and Hill Graham SCRsystems.

We are able to identify Ross Hill or Hill Graham parts from the original part number, and can provide exact equivalents where these are available. Where an exact replacement is not available, either due to limited supply or obsolescence, Zeefax can engineer an alternative or recommend a near equivalent.

DSL can provide you with exact replacements for your Hill Graham or Ross Hill systems. We have built a unique database of these specifications, and this, combined with the experience and expertise of our technicians (former employees of Hill Graham in the UK) enables us to re-engineer, and even improve on, the original specification.

We believe we are the only company in the world able to provide replacement AutoSync modules for Ross Hill and Hill Graham systems. In order to improve on the original design, this product is fully digital, but is an exact replacement, occupying the same footprint and having the same pin configuration.

DSL are today developing improved specification products as pin-for-pin replacements for legacy Ross Hill and Hill Graham technology. We can provide many of the printed circuit boards used on these systems, and even improve on some of the design features of the original product to improve reliability, robustness or functionality.

Advancements in technology mean that many of the power semiconductors which were built in SCR systems 10 years ago have been superseded by devices with better specifications. Specifying replacement or equivalent devices is a skilled task, but our engineers are able to ensure that, when the original component is not available, a suitable replacement can be found. If the replacement is not an exact fit we can engineer an adaptation to ensure continued serviceability of legacy equipment.

DSL has designed and built a new type of AC and DC Module simulator, both provide a better testing platform for standard Ross Hill and Hill Graham type AC and DC modules. In particular, the AC module simulator provides a much improved engine control and start-up simulation.

In addition we are able to repair and re-calibrate most Ross Hill and Hill Graham printed circuit boards (PCBs), including Power Limit, Field Supply Regulator, Sprocket Slip, Drillers Console, DC Auxiliary, SCR Auxiliary and Generator Exciter PCBs.

All these over-voltage refer to peak voltage, but SCR elements are damaged, which are usually eliminated by using varistor, namely the surge suppression circuit.

When SCR positive and negative busbar outputted by cabinet is shortly earthed directly or indirectly, the indication light will be more bright (dark bright under normal condition) and DC ground percentage meter indicates positive or negative end earthing, which indicates ground degree.

Modern Drilling practices demand additional mud pumping capabilities which was not envisioned in older systems. JOTON can revitalise a rig by adding a third Mud Pump and add-on mini console.

Our goal is to provide quality services to the drilling and completions industry. We offer premier AC and DC rig construction as well as service and support and our technicians are trained on Ross Hill, IPS (Integrated Power System), tech power SCR, and the increasingly prominent ABB Variable Frequency Drives. We give our clients the one on one attention that they deserve our team of young professionals strive for excellence in every area both on and off the job. There are no jobs to big or to small.

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IDM is a full service manufacturer of new land drilling systems and remanufactured land rig packages. The company’s extensive capabilities include rigs, drilling equipment, electric power systems, SCR or AC variable speed systems, and advanced instrumentation.

The National Oilwell Varco (NOV) Ross Hill RHC-1400 is their most popular SCR drive system. Several thousand RHC-1400 SCR bridges are powering drilling equipment around the world. These bridges are on large and small land rigs and numerous drilling platforms. SCR systems usually consist of three, four or five of these bridges depending on the size of the rig.

We have an ever changing supply of Ross Hill SCR components, though typically we have a fullSCR of both AC and DC control modules, usually in all flavors. You can buy one outright, exchange a bad component for a good one, or just send us your bad component for repair.

The electricity and control system by ZPEC can be used for 3000 to 9000 meters rigs, rig123.net’ target=’_blank’>VFD andSCR systems for client option.

The SCR drive system can be used for controlling SCR element, rectifying the constant voltage and frequency AC power into continuous adjustable SCR power, which makes it possible to control the drawworks of drilling rig, mud pump, rotary table, or the speed and torque of top drive, and it can realize stepless speed regulation, and meets the drive requirement.

Three mud tanks, 42’ x 10’ x 8’6”, 1500 barrel capacity with mud lines, two Brandt King Cobra shale shakers, Pioneer T12E4 desilter and Pioneer T6E6 desander.

Power Control Technology has forged relationships with many of the worlds leading industrial equipment suppliers and, together with it"s own technical and manufacturing capabilities, can source or manufacture a wide range of spare parts for Westinghouse, GE, Ross Hill and Hill Graham rig123.net" target="_blank">SCR systems.

We are able to identify Ross Hill or Hill Graham parts from the original part number, and can provide exact equivalents where these are available. Where an exact replacement is not available, either due to limited supply or obsolescence, Joton can engineer an alternative or recommend a near equivalent.

Joton can provide you with exact replacements for your Hill Graham or Ross Hill systems. We have built a unique database of these specifications, and this, combined with the experience and expertise of our technicians (former employees of Hill Graham in the UK) enables us to re-engineer, and even improve on, the original specification. We believe we are the only company in the world able to provide replacement AutoSync modules for Ross Hill and Hill Graham systems. In order to improve on the original design, this product is fully digital, but is an exact replacement, occupying the same footprint and having the same pin configuration.

Joton are today developing improved specification products as pin-for-pin replacements for legacy Ross Hill and Hill Graham technology. We can provide many of the printed circuit boards used on these systems, and even improve on some of the design features of the original product to improve reliability, robustness or functionality.

Advancements in technology mean that many of the power semiconductors which were built in SCR systems 6 years ago have been superseded by devices with better specifications. Specifying replacement or equivalent devices is a skilled task, but our engineers are able to ensure that, when the original component is not available, a suitable replacement can be found. If the replacement is not an exact fit we can engineer an adaptation to ensure continued serviceability of legacy equipment.

Joton has designed and built a new type of AC and DC Module simulator, both provide a better testing platform for standard Ross Hill and Hill Graham type AC and DC modules. In particular, the AC module simulator provides a much improved engine control and start-up simulation.

In addition we are able to repair and re-calibrate most Ross Hill and Hill Graham printed circuit boards (PCBs), including Power Limit, Field Supply Regulator, Sprocket Slip, Drillers Console, DC Auxiliary, SCR Auxiliary and Generator Exciter PCBs.