ross hill scr mud pump drive supplier

The Zeefax Total Rig Auditavoids downtime and ensures rig systems remain operational and reliable. Many Drilling Companies will invest in a completeRig Auditin the knowledge that it offers a comprehensive overview of the state of their rig, which can also be submitted for compliance and due diligence purposes.SCR Training Simulator

Every Drilling Rig must have a Power Control Room – sometimes also known as an SCR (standing for Silicon Controlled Rectifier) System – which forms the functional heart of the power control of the drilling operations. Typically, SCR systems comprise a large steel room, inside of which will be a range of Motor Control Centres, Engine & Generator Controls, SCR Control cubicles, and other instruments and systems used for drilling purposes.

SCR Systems usually operate at 600V, and clearly, these systems can be extremely dangerous if not operated correctly and carefully by suitably trained operators. It is therefore vital that drilling engineers and operators are well trained using a combination of class room tuition and on-the-job training.

In response to this need, Zeefax have created the world’s first full size SCR Training Simulator, which accurately mimics the a real SCR; it looks and feels like the real thing, providing a realistic experience of live field operations – but without the dangerous high voltage. This system was created specifically for Naftogaz – for more details, click here.

A key feature of the simulator is the addition of the on-board computer system, which mimics all of the signals that would normally come into this SCR system from the live engines and generators, including the motors running the mud pumps, the rotary table or the Drawworks, etc. and can also simulate a wide range of known faults, allowing trainees to experience first hand problem solving in the safety of the simulator, before they experience the live system.GE Legacy Drive Systems

Used the same type SCR bridge as the Generation III, but rated at only 1200-1500 amp since the heat sink assembly is of a slightly different design. This system uses the GE generator GEM modules controls.

1980’s, 900amp. SCR bridges using the GE GEM Generator Control. As the bridges are small it requires two SCR bays to run a two-motor Mud Pump or Drawworks.

If you are interested in applying for this position, then please send us your latest CV and a covering letter toTest and Calibration Engineer – SCR products

Zeefax is the value source for parts and services for your legacy GE Drive and Generator Control Systems. We hold an inventory of critical spare parts and can provide comprehensive service solutions including Repair and Return of Modules and PCBs.

Zeefax operates a comprehensive repair and return service for all legacy GE Drive and Generator Control Systems. which includes cleaning, testing, repairing or replacement of defective components and a full system load test. This service includes a 6-month limited warranty.

Zeefax understands that replacement of a complete SCR Control System is often not viable due to the large cost and loss of production due to system downtime. At Zeefax we can offer a comprehensive service to support your legacy GE Drives and give it a renewed lease of life. That not only includes supply of spare parts and a repair/calibration service; qualified service engineers with years of experience with these Drives are available for regular Health Checks, fault-finding and general support purposes.Careers

In response to many customer requests, we have designed our own version of the legacy Ross Hill Controls AutoSync AC generator control module; the new module has been completely re-designed and incorporates all new digital circuitry as well as optional expansion capability to future proof the module.

Advancements in technology mean that many of the power semiconductors which were built into SCR systems 30 or more years ago have been superseded by new devices, often with improved specifications.

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.Hill Graham Controls (HGC)

Following our acquisition of Hill Graham Controls (HGC), Zeefaxis in a unique position to offer total support for all legacy Hill Graham and Ross Hill Controls (RHC) systems both in the UK and throughout the world.

Zeefax’s unique experience and expertise has allowed the company to design, manufacture, supply, repair and calibrate many of the control modules used within older Hill Graham installations, as well as other manufacturer’s systems, including Ross Hill Controls (RHC) type systems.

In recent times,Zeefax has developed and brought to market a new digital AutoSync module, with an improved contemporary design and operation. This advanced module occupies the exact same footprint and has pin-for-pin connection compatibility with the now obsolete Ross Hill module, thereby providing a simple and cost effective upgrade path for existing users of the AutoSync module.

As part of our maintenance and service offerings for SCR systems, Zeefax is able to mobilise support and engineers to provide technical assistance during emergency shutdowns and downtime periods.

Given our years of experience and unique position to offer total support for all legacy Hill Graham Controls (HGC), and other manufacturer’s systems including Ross Hill Controls (RHC), IPS, and GE Micro Drill SCR systems, Zeefax can provide a full range of technical services for installation, commissioning, and ongoing operational support.SCR System Health Checks

The time to find out if your system is reliable is when operations are quiet – not during critical well operations – so the Zeefax SCR System Health Check is designed to identify potential weaknesses and either repair or replace immediately, or mitigate against these until a repair or replacement can be effected – usually at a quite time.

For reliable operation, the contact between the SCR devices and the heatsinks must be as good as possible but over time, and especially in offshore installations, corrosion may attack the interface between the SCR device plating and the aluminium heatsink. If corrosion is present it takes an expert to decide if refurbishment is required because as long as the damage is minimal and the two elements remain undisturbed, the mutual corrosion may still maintain a good contact.

Since our acquisition of Hill Graham Controls (HGC), our module repair facility and engineers, have been able to test and calibrate modules sent to us for repair within a quick turnaround period. In an important development, Zeefax has designed and built a new AC and DC Module simulator, to provide an improved testing platform for Hill Graham and Ross Hill type AC and DC modules. In particular, the AC module simulator is much improved over the older unit, and provides a greatly enhanced engine control and start-up simulation.

In addition, we are able to repair and re-calibrate most Hill Graham and Ross Hill type printed circuit boards (PCBs), including Power Limit, Field Supply Regulator, Sprocket Slip, Drillers Console, DC Auxiliary, SCR Auxiliary and Generator Exciter PCBs. Furthermore if following evaluation, repair is not possible, in many cases we can supply new manufactured boards using the original designs, but enhanced by us using modern components and manufacturing techniques. In this way, we can help to ensure that legacy systems remain operational and continue to provide reliable and trouble free service beyond their expected life.Motors & Generators

Even given the relatively controlled working environment of typical SCR pods, the conditions can often cause deterioration to both electrical and mechanical performance, requiring removal of the unit from the system, followed by refurbishment and renovation.

The heat sinks are inspected and if required, will be re-machined to ensure excellent electrical contact is maintained. Importantly, the SCR Thyristor ‘puck’ is replaced, and very special attention is given to the clamping torque and orientation.

If you would like to know more about the range of available Driller’s Foot Throttles, please call or email us, and we will be pleased to assist.SCR Blower Assemblies

An important part of every system is the forced air cooling, which is vital to ensure continuity and reliability of operation of the SCR stacks. It is essential that the heat generated during operation is reliably carried away, and Zeefax now produce a series of SCR Blower Assemblies which are compatible with the those used in legacy Hill Graham and Ross Hill type systems.

The Zeefax SCR Blowers are designed to operate with voltages up to 600 V @ 50 or 60 Hz; the operating voltage needs to be specified at the time of purchase (see the details and specification form below) and the blower may be configured with either Single or Duplex impellers and with or without base frames.

In order to aid potential users with the selection of replacement blowers, we have created a simple form which can be used to provide the few technical details we require. In this way, we can ensure that any SCR Blower supplied by us is fully compatible with existing assemblies, and will then install directly into the available location with minimal re-work required. You can download this form from this site; please fill it in and return it to us to receive a quotation.

Through our in-house R&D, we are developing improved specification products as replacements for legacy Hill Graham Controls or Ross Hill Controls boards; we can provide original replacements for many of the PCBs used on these systems, and by using modern techniques and components, we can even improve on some of the design features of the original products to enhance reliability and functionality.

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.

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.

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.

MUD SYSTEM:  Shakers 2each Derrick, Construction Crimp Wall Tanks  Active Mud System 1,500 BBL (Can add 2x 500 BBL Reserve mud tanks available if needed for an additional cost)

The first-generation Drilling rig driving system uses the DC module in the ROSHILL 1400 system to control the conduction angle of the SCR element, and rectify the constant voltage and constant frequency AC power supply into a continuously adjustable DC power supply. The output of the rectifier bridge supplies power to the DC motor through the assigned contactor, realizes the speed and torque control of the rig drawworks, mud pump, turntable or top drive, and implements infinitely variable speeds. This system is compatible with offshore drilling platforms and land drilling systems.