Section 8 - Electric Torque 8-1

SECTION 8

ELECTRIC TORQUE
8-2 GEONEXT - Sensors

Red dot facing

current flow for a
positive signal

Safe Area

SNR_ELT1.jpg

Signal strength increased

Safe Area

SNR_ELT2.jpg

2
Figure 8-1 -- Hall Effect Sensor Installation
Section 8 - Electric Torque 8-3

SECTION 8 -- ELECTRIC TORQUE

8.1. General

Torque is measured to limit the maximum stress on the drill string, and to obtain an idea of the
hole and bit conditions.

On most rigs, the drill string is turned by the rotary table and kelly combination; however, the
rigs have a Top Drive installed. A Top Drive is a motor (almost always an electric motor) which
drives a shaft directly connected to the drill string.

Regardless of the type of drive, the current, and therefore the torque, can be measured by a
Hall Effect sensor. When a top drive is in use, a torque signal can usually be obtained from the
Top Drive control module as well. This is useful if the rig has both a rotary table and Top Drive
and so, 2 Torque signals need to be measured.

8.2. Hall Effect Sensor

8.2.1. Description
Electrically-driven rotary tables are virtually always driven by DC motors. The relation between
current supplied and torque produced is linear for a DC motor.

An energised DC supply cable creates an electromagnetic field around itself proportional to the
current that flows through it. A Hall effect sensor can measure this magnetic field.

The Hall effect is based on the principle that semi-conductor crystals connected to a current
(the excitation current) generate a voltage when influenced by an electro-magnetic field (as
generated around the rotary table motor supply cable). The generated voltage is proportional
to the electromagnetic field and hence to the current supplied to the motor.

Note that, the Hall effect transducer is not a current transformer as used around AC supply
cables. The current transformer principle only works with AC.
8-4 GEONEXT - Sensors

Fig. 8.2 Hall effect sensor Electrical Connection

Hall effect sensor

434.AC.220

4 Wires cable
1- Red
2- White
3- Black
4- Green
Earth
connected on
junction box

1-Brown
2-Red
3-Orange
4-Yellow
Junction box Connected
312.AK.100 on GNX-01

Warning !!:
This sensor can be connected only
on the Concentrator GNX-110 and
not on the Field Box

Concentrator GNX-110
Section 8 - Electric Torque 8-5

8.2.2. Positioning
In principle the sensor can be clamped anywhere around the rotary engine supply cable.
Safety regulations and ease of access usually decide its location.

If the driller's control room (more commonly called dog house) is pressurised and the cables
pass through the control room, this would be a good location.

It would be useful to know the + and - supply cables, so that the sensor can be
installed the correct way around without guessing. The polarity of the current is
easiest to verify at the electric control room end.

8.2.2.1. Mechanical Safety

Caution : The Hall effect transducer is neither explosion-proof nor intrinsically safe. It should be
installed in a safe zone or protected environment.

The easiest place in a safe zone to install the sensor is usually the electric control room (SCR
room). This room is often next to the generator room. Follow instructions on hearing
protection whenever signs indicate the requirement.

Do not enter an electric control room without permission.

Never touch any breakers or switches when in the control room.

8.2.3. Installation
1. Before installation, note the calibration coefficients as indicated on the sensor. Most
sensors have two labels giving calibration information. One from the manufacturer is
listed on the top (50 mV = X Amp). On the side, another label lists the calibration for an
excitation current of 100 mA (X mV=1000 A, X is generally between 25 and 37 mVolt).
2. Open the sensor.
3. Clamp the sensor around a supply cable, so that the red spot on the sensor faces the
positive supply. See Figure 8-1 1
4. If cable thickness and slack permits, wind the cable twice through the sensor. This will
double the response (Figure 8-1 2). In practice this is rarely possible, because of limited
length and large diameter of the cable.
5. Close the sensor.

Note: The sensor will not be damaged if it is mounted the wrong way around, it will, however, produce
a negative signal when the supply cable is energised.

8.2.4. Electrical Connection

The sensor cannot be connected through a Zener barrier, because its supply current is too
high.

All electrical connections are shown in Figure 8-2.

8-6 GEONEXT - Sensors

8.2.5. Ordering Information

ITEM ORDER CODE DESCRIPTION

1 434.AC.230 Transducer, Hall Effect Complet 1000A
2 304.AL.040 Cord 4x0,75UL - L = 100 m - Connection junction box/GNX-110
3 312.AK.100 Junction Box 5 terminals Exproof
Section 8 - Electric Torque 8-7

8.3. Torque Measurement From a Top Drive Control Module

8.3.1. Description
The Top Drive motor has an integrated Torque sensor from which the signal is fed into the
motor control module.
The control module uses the signal to control supply to the motor, and for display on the
driller's console. The control module is usually situated in the SCR or Power control room.
Usually "auxiliary" contacts for take off of torque and RPM are available. Often both 0-10 Volt
and 0-20 mA (sometimes 4-20 mA) signals are available.
Because the control module is expensive and of vital importance to the rig, the rig electrician
will usually insist that a signal isolator is used between the rig’s signal and Geoservices
measurement equipment. A signal isolator will ensure that anything going wrong, including
short circuit of the signal, will not affect the control module.

8.3.2. Location
The Top Drive control is either installed in the SCR or power control room, or in an explosion
proof box or safe area (pressurised) on the drill floor.

8.3.3. Installation
In most cases, the rig electrician will prefer to do any work on the rig's electrical system
himself. Even though Varco makes most Top Drive installations, actual installations vary; if
you make the installation yourself keep the following in mind:
• Do not offer to do the job yourself if you are not familiar with the type of work.

• Do not enter the control room without permission.

• Do not work on the control module yourself without permission.

• Even if the torque signal is not obtained from the control module, run a four-core cable.

• While it is in all cases important to make wiring work neat, it is especially so when
working on or near complex installations like a Top Drive control. Any rig technician
working in the Top Drive controller cabinet is fully justified tearing out unidentified cables
or cables that are not professionally installed:

◊ Use the same method of entry into the cabinet or box as used for all other cables
(cable gland, MCT frame).
◊ Ensure cables are run neatly.
◊ Ensure that any unused wires are clearly distinguishable from a wire that might have
been cut or broken (double up the end, and cover it with a piece of tape).
◊ Ensure cable is properly marked "Geoservices Mudlogging RPM and Torque".
◊ Ensure that wires are properly labelled TRQ+, TRQ-.
◊ Fix the signal isolator properly if it is used; it should not roll around in the
cabinet.
8.3.4. Electrical Connection
The connections on the side of the Top Drive vary. Contacts are often labelled "Auxiliary
Torque". Often both 0-10 Volt and 0-20 mA (Sometimes 4-20 mA) signals are available. The
0-10 Volt signal is the easiest to deal with.

The signal can be connected to any configurable input able to measure 0-10 Volt.
8-8 GEONEXT - Sensors

WARNING !!! Connection only on the CONCENTRATOR (GNX-110) with isolator

configured according with the signal coming from driller’s control room.

DRILLERS CONTROL ROOM

Dip switches to be
adjusted (see below)

CONCENTRATOR
GNX-110

Connection
depending of the
Signal conditioner signal coming from
Weidmuller housed control room
on din rail
Section 8 - Electric Torque 8-9

Connection on CONCENTRATOR for 0-10V signal input/output

2- Signal +
3- Signal -
0-10V
Signal
from
drillers

Connection on CONCENTRATOR for 0-20 mA Signal input /output

1- Power Supply
2- Signal +
3- Ground
4- Signal –
(not connected

Resistor 49.9 Ω
Between 2 and 3

Connection on CONCENTRATOR for 4-20 mA Signal input /output

1-Signal +
2- Signal -
8-10 GEONEXT - Sensors

Configuration switches setting . Click on the image below for automatic setting
and check on the tables below !
Note: Bandwidth must be at 10hz
Section 8 - Electric Torque 8-11
8-12 GEONEXT - Sensors

Technical data for DC/DC Signal Conditioner

Input (adjustable)
Voltage uni-/bipolar adjustable 20 mV…200 V
Voltage calibrated ranges 0 +-60mV, 0…±100 mV, 0…±150 mV, 0…±300 mV,
0…±500 mV, 0…±1V, 0…±5V, 0…±10 V, 0…±100 V
Current uni-/bipolar adjustable 0.1 mA…100 mA
0…±0.3mA, 0…±1 mA, 0…±5 mA, 0…±16 mA,
Current calibrated ranges 0…±0.3,0…20 mA, 0…50 mA

Input resistance
at current input range < 5 mA/>5 mA approx. 100 Ω/approx. 5 Ω
at voltage input approx. 1 MΩ
Input capacity at current input approx. 1 nF
Voltage input range < 500 mV/> 500 mV approx. 1 nF/approx. 500 pF
Overload capacity at current input range < 5 mA/> 5 mA < 75 mA/< 300 mA
Voltage input range < 500 mV/> 500 mV max. < 20 mA/< 3 mA continuous current
Output (adjustable)
Voltage uni-/bipolar adjustable 0…10 V
Voltage calibrated ranges 0…±10V, 2…10 V, 0…±5 V, 1…5 V
Current uni-/bipolar adjustable 0…20 mV
Current calibrated ranges 0…±20 mA, 4…20 mA
-100%, -50%, 0%, 50%, 100% of measuring span of the
Offset Chosen output range

Load
at output current < 12 V (600 Ωat 20 mA)
at output voltage < 10 mA (1 KΩ at 10 V)
Offset 20 µA and. 10 mV
Residual ripple < 10 mVeff
Adjustment zero pot. +25% measuring span of the chosen output range
Adjustment span pot. 0.33…3.30 xend value of chosen input range
Gain error < 0.1% of FS
Temperature coefficient < 60 ppm/K of FS
Cut-off frequency > 10 kHz, < 10 Hz switch
General
Voltage supply 20…230 V AC/DC +1
Power consumption approx. 1W
Frequency range 48…62 Hz
Operating temperature -10°C…+70° C
Storage temperature -40°C…+85°C
Factory setting 0,,,10V/0,,,10V 10Hz
Dimensions W/L/H mm 12/5/92
Weight approx 100g
Approvals CE,UL,GL
Coordination of insulation according to EN 50178 04/96

Rated voltage 600V

Rated suege voltage 5kv 1,2/50us acc, to IEC 255-4
Overvoltage category III
Contamination class 2
Section 8 - Electric Torque 8-13

Test voltage 4KV eff, input against output against auxiliary power
Standard/specifications EN 50178
EMC standard DIN EN 61326

8.3.5. Electrical Safety

The SCR or power control room is often next to the rig generator room. Follow posted
instructions on hearing protection. If you are not familiar with cabling work, leave any work in
the power control room to the rig electrician or other qualified personnel. Do not touch any
switches or wiring in the control room. Always advise rig electrician about any intervention.

8.3.6. Technical Specifications

Sensitivity < 1mV

Repeatability ± 1 mV
Accuracy ± 1% of full scale
Resolution ± 0.5 mV
Operating current 100 mA
Operating voltage 15 VDC
Output signal 0-75 mV
Installation location Clamped around power cable to drive motor
Current Rating 2000 amps

8.3.7. Trouble Shooting

The signal route from the Electric Torque (Hall effect) to GNA is as follows:

SENSOR GNX-110 GNA

Standard Module GNX-01

In the following order check:

Sensor 100mV max. between pins 2 and 4
2 to 3 V between pins 1 and 3
+75 mA through pin 1
20 to 25Ω between pins 2 and 4 sensor disconnected.
20 to 25Ω between pins 1 and 3 sensor disconnected

Sensor to GNX-110 304.AL.040