WEATHERFORD DRILLING

Technical Guide
For
RIG ELECTRICIAN– PART I

© 2014 Weatherford. All rights reserved. 1

 A Training Course for Rig Electricians
Basic Eddy Current Brake

Section 1
Eddy Current Brake

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

2 How Does It Work .................................................... 4
3 How Do I Operate It ............................................... 10
3 Inspection............................................................. 12
5 Maintenance.......................................................... 15
6 Spare Parts ........................................................... 19
4 Trouble Shooting ................................................... 20
5 Questions ............................................................. 21
6 Reference Material ................................................. 22
7 Work Place Assignments ......................................... 22
8 Glossary ............................................................... 25

1
A Training Course For Rig Electricians
Basic Eddy Current Brake

1 Equipment Overview
1.1 Dynamic Brakes

The Eddy Current, or “Elmagco”, brake is an AUXILIARY

BRAKING DEVICE for drilling rig drawworks and other rotating
equipment requiring high braking torque at speeds from near
zero up to 500 RPM. This braking is produced entirely
electrically without the aid of friction braking devices, slip rings,
or other wearing elements. The brake is water cooled.

The Eddy Current brake, when used in conjunction with the

main drawworks brake, (Friction brake bands or Disc brakes)
maximises drilling efficiency whilst minimising maintenance and
critical downtime of the main drawworks braking system.

1.2 History

When the drilling industry moved offshore into waters requiring

subsea blowout preventers (BOP) and marine risers, it was no
longer considered safe to use hydromatic brakes to control the
huge weights involved. F. P. "Red" Gribbin and William B.
Baylor had acquired the rights to build dynamic brakes for rigs
in 1946. The eddy-current braking system does not depend
upon water pressure to work and is not at risk in the case of
burst connections. Moreover, the dynamic brake can handle the
cyclic overloads often encountered when floating vessels heave
in ocean swells. In 1954, they formed the Baylor Company to
build and install "Elmagco" Brakes. They were assisted by H.L.
"Duke" Zinkgraf who modified and improved the design, adding
a new control system.

So effective was their product that it can be said that almost

every offshore rig is equipped with the Baylor-Dynamic
Elmagco Brake. The same can be said for land rigs which use
the more modern SCR Drilling control system as opposed to the
smaller truck based drilling rigs, which are suited to the more
compact and less powerful hydromatic type brakes. However
with the event of new designs and changes in technology a
company called ETN is producing a large capacity hydromatic
brake. These brakes are occasionally being used as an
alternative to eddy current brakes on large drilling rigs.

2
 A Training Course for Rig Electricians
Basic Eddy Current Brake

These brakes are manufactured in a variety of sizes to suit the

size and capacity of the drawworks on which the brake is to be
installed. Therefore the larger the drawworks, the higher the
load capacity rating of the Eddy Current Brake.

Figure 1 Typical “Elmagco” Brake

The brake selected will be required to be able to control the

weight of the drill string or casing string being lowered into the
well.

Figure 2 Baylor Brake & Drawworks Package

3
A Training Course For Rig Electricians
Basic Eddy Current Brake

2 How Does It Work

2.1 Eddy Current Brake General Theory

When the iron rotor, rotates through a stationary magnetic

field, currents are induced in the rotor. These currents,
commonly called “eddy currents”, produce a magnetic field
which interacts with the stationary field. This field interaction
produces a force which opposes rotor rotation and provides the
braking torque for the eddy current brake.

The eddy current brake provides high braking torque at low

rotor speeds. This is a distinct advantage over other types of
braking systems such as water brakes i.e. hydromatic brakes.
The braking torque is dependent upon the strength of the
stationary magnetic field, rotor speed and rotor temperature.
Torque increases with magnetic field strength and rotor speed.
Torque decreases as the rotor temperature rises. The strength
of the stationary magnetic field is controlled by the electronic
brake controller. The driller can vary the electric power supplied
to the field coils in proportion to the braking requirements.

Figure 3 Construction of Eddy Current Brake

The eddy currents induced in the rotor produce heat. The

rotor’s temperature must be maintained within acceptable
limits or the braking torque will be reduced.

4
 A Training Course for Rig Electricians
Basic Eddy Current Brake

To maintain the rotor temperature within acceptable limits, a

cooling system is required. A steady flow of water is directed
into the area containing the rotor (see Figure 3). The
movement of the rotor through this water as it turns provides
uniform cooling of the rotor surface. If the flow of cooling water
fails while the brake is in operation the rotor will become
overheated and distorted. In this state the rotor, and possibly
the coils, will be damaged. Proper cooling techniques and
procedures are absolutely essential to maintain efficient braking
performance

Figure 4 Cooling Water Flow

Because of the tendency of eddy currents to oppose, eddy

currents cause energy to be lost. More accurately, eddy
currents transform more useful forms of energy such as kinetic
energy (rotation) into heat, which is generally much less useful.
In many applications the loss of useful energy is not
particularly desirable, but there are some practical applications.
One is in the brakes of some trains.

During braking, the metal wheels are exposed to a magnetic

field from an electromagnet, thereby generating eddy currents
in the wheels. The magnetic interaction between the applied
field and the eddy currents acts to slow the wheels down. The
faster the wheels are spinning, the stronger the effect, meaning
that as the train slows the braking force is reduced, producing
a smooth stopping motion. This example demonstrates the
same principle of operation for the Elmagco Brake.

In an eddy current brake a rotor is introduced into an

electromagnetic field which generates a counter EMF in the
rotor, and the faster the rotor is spinning the greater the effect.
This results in smooth braking but will not cause the load to be
stopped as the brake requires rotation to create the eddy
currents in the first place.

5
A Training Course For Rig Electricians
Basic Eddy Current Brake

The braking force is reduced proportionately as the speed of

the rotor through the magnetic fields is reduced. It will however
cause the load to slow depending on the current supplied to the
magnets and the actual weight of the load.

Figure 5 Cross Section of an Eddy Current Brake

2.2 Air Gaps

As previously mentioned the further the rotor is away from the

stationary magnetic field the weaker the counter EMF will be.
Consequently the bigger the air gap between the rotor and the
magnets, the less braking power available.

Figure 6 Air Gap Measurement

6
 A Training Course for Rig Electricians
Basic Eddy Current Brake

The total air gap will increase if the metal is lost from the rotor
due to corrosion. For this reason it is imperative to maintain
adequate concentration levels of coolant inhibitor in the
drawworks and Elmagco brake cooling water.

Figure 7 Signs of Severe Corrosion

Below is a table of recommended air gaps for various models of

brake;

Brake Model Air Gap / inches

15050 0.040 – 0.050

7838 0.055 – 0.065
7040 0.055 – 0.065
6032 0.040 – 0.045
5032 0.040 – 0.045
19RD130 0.040 – 0.045
9RD130 0.040 – 0.050
7RD150 0.040 – 0.050
9650 0.040 – 0.050

Table 1 – Recommended air gaps

When the Elmagco brake air gaps reach the manufacturer’s

maximum allowable limits, the performance of the brake is
seriously reduced. At this point the brake should be overhauled
at an OEM approved facility or replaced. As previously
mentioned the useful life of the Elmagco brake is highly
dependant upon the quality of the coolant and the inhibitor
used in the coolant to reduce the rate of material loss due to
corrosion, which in turn will prevent the air gap increasing.

7
A Training Course For Rig Electricians
Basic Eddy Current Brake

2.3 Brake Formula for Power Reduction

The formula used for checking brake power reduction with an

increase in air gap is as follows:

Equation 1 - Brake Power Reduction

Where;

T1 = Original Torque

T2 = Torque at present

A1= Original Air Gap

A2 = Air Gap at present

If we apply this formula to the 6032 Baylor brake with a

measured air gap of 0.110 the reduction in braking capacity is
drastic.

45000/T2 = (0.110)2 /(0.050)2

T2 = 9297 (ratio of almost 1 to 5 loss of braking capacity)

2.4 Brake Cooling

The energy absorbed by the brake, is converted into heat,

which is carried away by the cooling water. The cooling water
inlet is near the bottom of the housing. Therefore when the
rotor is stopped, or turning very slowly, the top of the rotor and
the top of the coils are not cooled at all. The upper part of the
brake will only be cooled if the rotor turns sufficiently fast
enough to carry the water up and disperse it around the top of
the brake. Applying continuous full power to the brake, while
drilling will generate heat in the top of the coils, this will not be
carried away by the cooling water. Without cooling water being
dispersed over the coils, they will overheat.

The maximum allowable temperature is only 165°F or 74°C. If

suddenly the brake is rotated (to make a connection) cold
water will flow over the hot parts and cause them to contract
rapidly. Repeated heating and cooling will cause rapid
expansion and contraction which can cause the welded joints of
the coils to fail. For this reason drilling with the brake applied
full on is prohibited.

8
 A Training Course for Rig Electricians
Basic Eddy Current Brake

2.5 Summary

In general, the brake may be used while drilling provided the

maximum current is limited to 50% or less. There are a
number of different controllers in use in the industry. Early
model controllers have a three-position switch to enable the
selection of High, Medium or Low braking power levels.

Figure 8 Brake Cooling Diagram

More recently “smart” controllers have been made available

to monitor and automatically control braking levels
depending on the operation being carried out at the time.
Some controllers have a selectable output that can be set to
“Tripping” or “Drilling” mode to ensure that the correct
current limit is applied. Other models monitor the maximum
current and automatically reduce it by 50% after a preset
time has elapsed.

9
A Training Course For Rig Electricians
Basic Eddy Current Brake

3 How Do I Operate It
As a result of various studies, experience, and discussions
with manufacturers, the following recommendations for the
operation of the Elmagco brakes are advised:

3.1 Voltage setting

Under normal tripping conditions the brake can be operated

with the full output of the controller, 240 volts DC. During
tripping the brake is operated only intermittently and the
rotor is constantly in motion. However the coils of the
Elmagco brake should only be energized to a maximum of
120 volts DC during normal drilling operations as the speed
of the rotor is greatly reduced, or practically at a standstill
for long periods of time. Constant high voltage levels result
in thermal loads that are too high, which will decrease the
life expectancy of the coils considerably.

3.2 Brake Control Systems

There are normally three different types of Elmagco brake

circuit controllers in operation, which have different
influences on the control arrangement and therefore also on
the working temperature of the coils, these are as follows:

• SCR Control (Silicon controlled rectifier)

The SCR control system is fitted with a three position

switch with Minimum, Medium and Maximum positions.
From these switches the brake coils receive different
voltage values (80V, 120V, 240 V). Units which have
these controllers in operation should only use the control
switch in "Minimum" or "Medium" positions during drilling
operations.

• PWM Control (Pulse Width Modulation)

The PWM controller does not have a selectable power

output switch, which means the coils receive the full 240
volts all the time that the driller’s control handle is at the
maximum position. The drillers control handle should not
be used at all during drilling operations.

PWM CL Control (Pulse Width Modulation with timer)

The PWM CL controller works in the same manner as the

PWM, but has the added feature that if maximum voltage
is applied for 10 minutes the controller output is
automatically reduced to 120 volts.

10
 A Training Course for Rig Electricians
Basic Eddy Current Brake

If the brake is used for “drill assist” where the speed of

rotation is very limited, it is recommended that no more
than half of full voltage is applied to the coils
continuously.

When the shaft is rotating at moderate speed, the rotor

picks up water and drops it on the top side of the
magnets, which helps to remove the heat from the coils.
However, when the speed is reduced, this cooling method
is no longer effective. The brake magnet coils are
sensitive to heat in the same way as a transformer or
motor windings, the hotter they operate, the shorter their
operational life.

Figure 9 Baylor Brake Drillers Control

Operation of the brake coils at half the rated voltage

causes only a slight loss of torque at low speeds.
However, the reduction of heat dissipation is significant;
only 25% as much coil heat is generated. Continuous
operation at full voltage will considerably shorten the
operational life of the magnets.

11
A Training Course For Rig Electricians
Basic Eddy Current Brake

4 Inspection
Routine inspections are absolutely necessary to ensure
proper trouble free operation of the Elmagco Brake.

4.1 Daily Inspection

• Observe brake water overflow vents while lowering drill

string into the hole. If constant flow is observed
coming from the vents, slowly begin to reduce the
inlet flow rate until discharge from the overflow vents
ceases.

• If reducing the inlet flow rate results in too high a

temperature of the discharged cooling water (above
165°F or 74°C), check the brake cooling water return
line to see if it has become restricted. Discharge flow
from the brake back to the reservoir or brake cooling
tank should be unrestricted.

• To maintain the lubricant volume add two ounces of

lithium-based ball and roller bearing grease to each
bearing cavity every 24-hour period, or before every
tripping operation. Note: It requires 43 strokes of a
typical hand grease gun or 21 strokes of an air-
operated grease gun to produce two ounces of grease.

4.2 Weekly Inspections

• Check DC voltage to the brake under full load

conditions (electrical full load, driller’s control in full
on position). Full voltage should be 240 volts DC +/-
10 volts DC at the brake.

4.3 Monthly Inspections

• Remove the brake magnet coil cavity explosion-proof

drain/breathers (four in total, two on each side of the
brake) and the brake junction box vent (if fitted).
Clean with kerosene. These drain/breathers should be
open for the passage of air or liquid. Replace all
breathers correctly before returning the brake to
operation.

IMPORTANT: To ensure the full operational life of

the coils the condensation that may form in the coil
cavities must be drained.

To ensure the free flow of air, these breathers must

be inspected every month and cleaned if necessary.

12
 A Training Course for Rig Electricians
Basic Eddy Current Brake

NOTE: Disengage the brake shaft from the drum

shaft by using the disconnect clutch to disconnect the
brake from the drawworks, before taking any air gap
measurements so that the brake can not be rotated
while being measured.

Figure 10 Taking Air Gap Measurement

Figure 11 Coil Cavity Breathers

• Inspect and record the brake air gaps. Remove the

1¼” NPT pipe plugs in the brake end plates (three
each side). Using feeler gauges (minimum length 6
inches), insert the gauges into the air gap between
the brake magnet and the rotor.

13
A Training Course For Rig Electricians
Basic Eddy Current Brake

4.4 Quarterly Inspections

Quarterly inspections consist of voltage, coil resistance and

insulation resistance value checks at the brake junction box
as described in OEM manual. After voltage checks are
complete turn off the main supply to the brake control
system, including the battery back up system if installed.
Disconnect each coil from their installed position in the brake
junction box. Remove only one set of leads at a time, for
example F1 & F2. Mark their position carefully; check the coil
resistance and insulation resistance then return the leads to
their correct position. Failure to do this will compromise the
operation of the brake. Log the readings that you have
taken and compare them with earlier readings and the OEM
specifications.

Figure 12 Measuring Coil Insulation Resistance

Test across Coil Resistance Insulation Resistance

Coil Ohm Meter 500 VAC

F1 & F2 14.1 ohm > 340

F1 & F2 13.9 ohm > 500

F1 & F2 13.8 ohm > 550

F1 & F2 14.0 ohm > 350

Table 2 Insulation Measurements

Insulation resistance should be 5 Megohms or higher when

checked with a 500 Volt DC insulation resistance tester
(Megger).

14
 A Training Course for Rig Electricians
Basic Eddy Current Brake

5 Maintenance
5.1 Corrosion Inhibitors

Find below a section of a report done on a platform rig that

was regularly mothballed and might have a work over or
drilling program for one or two months each year.

Moduspec Survey Report

“In February 2001, the Elmagco brake was fully refurbished.

New bearings were installed and the rotor and the two
magnets were built up so that the correct rotor gap could be
re-machined. The existing coils were then still found in
acceptable condition and were reinstalled upon reassembly of
the Elmagco brake.

During this present ModuSpec survey, we megger tested and

measured the resistance of the four coils; they were found to
be in good condition. When measuring the gap between rotor
and magnets, heavy corrosion was noted. Gap values
measured were between 0.010” and 0.020”. When last
measured in December 2001 the gaps were between 0,035”
and 0.040”. These gap measurements when new (or
refurbished) would be 0.055”.

The Elmagco brake is regularly (every two weeks) turned

over by the maintenance crew, but this does not slow down
the corrosion in the cooling water spaces when not in use.
The cooling water treatment that was in use can not take
effect during the long inactive periods of the brake. The
brake cooling system must be kept inhibited with a
recommended corrosion inhibitor like Nalfleet 2000 or
equivalent. Other corrosion inhibitors may be used providing
they are compatible with the materials used for pumps,
valves, heat exchangers and brakes.

Follow the chemical manufacturer's recommendations for

maintaining adequate corrosion protection and ensure
suitable test kits and test chemicals are on hand to routinely
evaluate the degree of corrosion protection. Homebrews,
using soluble oil for example are not recommended since
they leave an oily film on the heat transfer surfaces causing
a degradation of the cooling system. Additionally they can be
subject to the cultivation of hydrocarbon utilizing microbes
that form an acid sludge if not inhibited with an appropriate
biocide”. Protection of the equipment from corrosion and
scale formation is best done using a mixture of clean water
with the specified proven inhibitor concentration and
constant rotation of the brake.

15
A Training Course For Rig Electricians
Basic Eddy Current Brake

5.2 Instrumentation

A minimum amount of instrumentation is essential to permit

continuous monitoring of the brake under operational
conditions, and the Elmagco is often fitted with a self
contained alarm panel mounted above the main junction box
that will monitor water flow, and over temperature;

• There are water flow sensors in the cooling water pipes

to the Elmagco Brake to provide a signal warning the
driller on the rig floor of failure of the cooling water
flow.

• There is a water temperature thermocouple switch

fitted on the outlet of the cooling water system of the
Elmagco Brake which should close to activate an
alarm from the Elmagco alarm panel if the
temperature rises above the alarm set point of 165°F
74°C, to warn of over temperature.

• If any of these switches close, they will latch a relay

which will ring a bell, and bring up a red light to warn
the driller of the problem. There is a push button to
silence the bell, but the red light will remain on until
the offending switch is open again to cancel the
alarm.

Figure 11 Water Flow Instrumentation

Most new Baylor brakes have a plate mounted on the

housing warning that the Elmagco brake is not to be
operated in any conditions without flow and temperature
monitoring devices installed.

16
 A Training Course for Rig Electricians
Basic Eddy Current Brake

5.3 Brake Cooling Water Flow Rate Requirements

The following information was supplied by National Oilwell.

Table 3 is listing of nominal cooling water flow rate
requirement for various Eddy Current Brake models in typical
applications. Flow rate requirements are also indicated on
each Eddy Current Brake nameplate.

Brake Model Required Flow Rate

15050 230 GPM
7838 150 GPM
9650 150 GPM
7040 140 GPM
8350 140 GPM
6032 75 GPM
5250 75 GPM
5250 75 GPM
5032 50 GPM
3550 50 GPM
19RD-130 30 GPM
3630 40 GPM
19RD-130 30 GPM
7RD-150 40 GPM

Table 2-Brake cooling water flow rate requirements

The piping from the brake cooling water pump to the Eddy
Current Brake inlets must be of adequate size and no less
than recommended for the particular brake. The piping
should be routed in the straightest possible way, with no
more elbows and fittings than absolutely necessary.

The point at which the main supply line splits to feed both
sides of the Eddy Current Brake should be located so that the
distance to each inlet is about the same distance from the
“T” in the main supply, and the number of elbows, etc., in
each branch should be equal in both legs of the installation
from the “T” to each side of the brake casing to maintain
equal flow to both sides of the brake.

17
A Training Course For Rig Electricians
Basic Eddy Current Brake

5.4 Battery Backup Systems

Most rigs have a set of batteries installed which will supply

emergency power to the Elmagco Brake System in case of a
power failure, should it occur, to maintain control of the drill
string or casing string long enough for the driller to safely
secure (hang-off) the string.

The batteries are connected to a battery charger to maintain

them in a fully charged state.

Figure 12 Baylor Brake Battery Back Up System

18
 A Training Course for Rig Electricians
Basic Eddy Current Brake

6 Spare Parts
These units are normally returned to the manufacturer for
bearing replacement or repair, and the most common spares
kept on hand are flow switches and temperature sensors for
the alarm system on the brake, and spares for the alarm
system control box such as relays and lamps.

Figure 12 Spare Parts Store

19
A Training Course For Rig Electricians
Basic Eddy Current Brake

7 Trouble Shooting
7.1 What If It Breaks Down

The Elmagco (Baylor brake) is a critical piece of drilling

equipment. If this unit breaks down the first indication will be
the automatic activation of the back-up battery system if this
is fitted. This will allow time for the driller to control the rate
of decent of the drill string and bring the load to a safe stop.
Before the drilling operation can commence the fault will
have to be diagnosed and rectified as soon as possible.

7.2 Fault Finding Procedure

Always utilize the manual and the wiring schematics, they

will show you all of the main power and backup feeds to this
system. Verify that these are healthy. The next step is to
confirm that all control voltages are present. Normally in the
case of brake failure it can be traced to the hand controller,
or cabling between the hand controller and the control box,
this will usually be cable damage or bad plug and receptacle
connections, sometimes due to corrosion if they have been
installed for a long time where moisture has entered the plug
and receptacle connection creating a poor connection.

Figure 13 Drillers Baylor Brake Control

The driller’s hand control receives a control voltage from the

brake controller unit. As the Driller operates the hand control
the variable voltage is then returned to the controller, which
in turn controls the DC output, normally between 0 and 240
volts, to the brake. There are various voltages used on the
hand controller, and these can fail if a low voltage unit is
used on a higher voltage system. The serial numbers for the
controller assembly and hand control should be checked to
make sure they are compatible for the installed brake control
system.

20
 A Training Course for Rig Electricians
Basic Eddy Current Brake

8 Questions
1. What is a counter EMF?
It is the voltage, or electromotive force, that pushes
against the current which induces it and is caused by
a changing ________ field.

2. What provides the braking force of an Elmagco brake.

(a) Electro magnetic radiation. (b) Disc brakes.
(c) Electromagnetic attraction.

3. Mention the three items which have an influence on

the braking force of an Elmagco brake.
(a) Voltage & current (b) Speed of rotor.
(c) Temperature. (d) a, b,& c.

4. Explain why an Elmagco brake cannot bring the

drawworks to a complete halt.
The braking effect of an electromagnetic brake will
only work when the ______is turning.

5. What is the maximum outlet temperature of the

cooling water of an Elmagco brake?
(a) 80° C (b) 100 ° F (c) 180° C (d) 270° F

6. Why is drilling with a fully applied Elmagco brake

prohibited?
Damage to the Brake will occur because of______.

7. What will happen to the brake force if the speed of

the drawworks increases but doesn’t exceed the Max.
(a) Increase braking force (b) Decrease braking force
(c) Fading braking force (c) loss of braking force

8. Is there a maximum speed of the drawworks for the

Elmagco brake force to be most efficient?
(a) No (b) Yes (c) Maybe

9. Mention the required cooling-water flow rate of the

Baylor 7838 Elmagco brake and the smaller 6032
model.
(a) 150 & 75 GPM (b) 230 & 40 GPM
(c) 140 & 50 GPM (d) 150 & 30 GPM

21
A Training Course For Rig Electricians
Basic Eddy Current Brake

9 Reference Material
The service manual supplied by Baylor/Elmagco, with a new
brake assembly, contains the installation and service
information for that brake. The manual also contains
information on the alignment requirements for the coupling
during the initial installation and the flow requirements for
the proper cooling of the particular model of brake installed
on that rig.
There are other items apart from the brake that must be
considered, particularly with regards to the cooling system,
and the route the cooling water takes to return to the brake
cooling water tank.
There should be reference material on the rig for the brake
cooling water pump sizing to ensure the pumps are of
sufficient size to maintain the pressure required at all times
for the cooling of the brake.
There should also be reference material there for the type of
cooling installed, and this will come from the manufacturer of
the condenser or radiator system used to cool the water,
giving the flow and cooling data of those units.

2.6 Web Sites

http://www.physlink.com/Education/AskExperts/ae527.cfm

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

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

http://rimes.com.ve/Service2.htm

http://www.oceanstaroec.com/fame/1999/brakes.htm

22
 A Training Course for Rig Electricians
Basic Eddy Current Brake

10 Work Place Assignments

Note. Please refer to your equipment documentation for
specific voltages & test point locations.

1. Check the input voltage to the Elmagco Brake

Transformer to be sure it is getting the correct supply.

2. Check the output voltage from the Elmagco Brake

Transformer to be sure the correct supply is going to
the Elmagco Control Box.

3. Check the supply voltage at the Elmagco Control Box

to be sure the required voltage is present at the
supply terminals.

4. Check the Control Voltage at the output terminals of

the Elmagco Control Box to the Hand Controller at the
Drillers Console.

5. Check the input terminals of the Hand Controller at

the Drillers Console to confirm supply from the
Elmagco Control Box, which will be a constant
voltage.

6. Check the output terminals of the Hand Controller,

which will be a variable signal, adjustable by the
Driller on demand according to the load on the blocks
at any one time.

7. Check the Control Voltage input terminals of the

Elmagco Control Box for the variable volts from the
Hand Controller at the Drillers Console.

8. Check the DC output voltage and current from the

Elmagco Control Box to the Elmagco Brake, which
again will be variable, depending on the demands of
the Driller and the Drill String.

9. Open the explosion-proof junction box on the Elmagco

Brake, by removing the ring of stainless-steel bolts,
and inspect the flame path which will have been
machined to a polished finish. The matching faces
may have been protected from corrosion with a thin
film of non drying grease, but must still be a clean
polished surface to be accepted as explosion-proof.
When closed up again the surfaces must be clean and
dry. The surfaces of the flame path may be very thinly
coated with non drying grease, or a product called
“Senson” to prevent corrosion.

23
A Training Course For Rig Electricians
Basic Eddy Current Brake

10. Check the terminations inside the Elmagco junction

box and make sure all the cables are marked to
identify them, and if they are not marked, then they
should be, to make sure they will be returned to the
same terminals as they were removed from when
testing for resistance, and continuity, during routine
inspections

11. The Elmagco Brake connection cables should be

disconnected in the brake junction box, and tested
with a good quality multimeter for continuity and
resistance measured at the ends of each coil to find
out the resistance value of each coil, and the
resistance reading will to some degree depend on
temperature, but should all be about the same value,
then each coil should be measured with a Megger set
to 500 volt range, between the core and ground to
determine the value of the insulation of that coil to
make sure that they are above 2 Megohms.

12. The Flow Switches on the Cooling Water Pipes into the
Brake can be tested with Alarm Power off and the
cover of the switch removed, so that the probes of a
Multimeter can be placed across the switch terminals
to determine if the switch is open or closed, with the
Brake Cooling Water Pumps on and off to see if the
mechanism is working, the contacts are normally
closed, and opened by flowing water, so if the water
stops flowing the contacts will close and ring the bell.

13. The Thermocouple which is placed in the water outlet

from the brake is more difficult to test, as it is usually
difficult to reach, and requires to be immersed in
water of the correct temperature to close the contacts
to operate the alarm system. The test temperature
should be 165 degrees F (74 degrees C).

14. The plugs need to be removed from three positions on

each side of the Brake so that long feeler gauges can
be inserted between the rotor and the coil faces to
determine the Air Gap Clearance. The ideal gap
measurement is 0.055 to 0.065 inches (1.39mm to
1.65mm). Ensure that corrosion scale is removed
before attempting to conduct gap measurements.

15. The explosion-proof vents (breathers) for the coil

chambers need to be inspected for corrosion and to
ensure that the non-return device is operational. They
should be shaken to make sure the internal valve
components are still free to move and that the
“check” function is satisfactory. If, after cleaning, the
device’s non-return ability is in doubt replace the
breathers. When these units are reinstalled, thread
lubricant should be used on the thread to make it
easier to remove them next time.
24
 A Training Course for Rig Electricians
Basic Eddy Current Brake

11 Glossary
Dynamic Braking A method that produces
electromagnetic braking forces in the motor by dissipating
generated power from armature/shunt field reaction into a
resistive load. Braking force is determined by the field
strength, armature voltage, and thermal capacity of the
resistors. The result is a logarithmic braking characteristic
(curve) that diminishes with motor speed.

Regenerative Braking A method that produces

electromagnetic braking forces in the motor by electronically
controlling the return of generated power to the AC supply.
The result is a controllable linear braking characteristic
(ramp) that does not diminish with motor speed.

Bridge rectifier A diode bridge rectifier is a non-

controlled full-wave rectifier that produces a constant
rectified DC voltage.
An SCR bridge rectifier is a full-wave
rectifier with an output that can be controlled by the
switching of the gate control element.

Drive Controller Also called variable speed drive, or drive.

An electronic device that can control the speed, torque,
horsepower, and direction of an AC or DC motor.
• PWM drive is a motor drive using pulse-width
modulation techniques to control power to the motor. A
high-efficiency drive used for high-response applications.

• SCR drive is a motor drive that uses SCRs as the

power control elements. Usually used for low-bandwidth
high-power applications.

Direct Current Type of power supply available from

batteries, generators or a rectified source used for special-
purpose applications.

Eddy Current Currents induced in motor components and

transformers from the movement of magnetic fields.
Eddy currents produce waste heat and are minimized by
lamination of the motor poles and armature. Transformer
cores are also laminated to minimize induced currents.

Efficiency The ratio between useful work performed and

the energy expended in producing it. It is the ratio of output
power divided by the input power.

Insulation Non-conducting materials separating the

current-carrying components of an electric machine from

25
A Training Course For Rig Electricians
Basic Eddy Current Brake

each other or from adjacent conducting material at a

different potential.

Insulation Class A letter or number that designates the

temperature rating of an insulation material or system with
respect to thermal endurance.

Megohmmeter (Megger) An instrument for measuring

insulation resistance.

Rated Temperature Rise The permissible rise in

temperature above ambient for an electric machine operating
under load.

Trending Analysis of the change in measured data over at

least three data measurement intervals.

26
 A Training Course for Rig Electricians
Basic Generators

Section 2
Generators

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

2 How Does It Work .................................................... 3
3 How Do I Operate It ............................................... 28
4 Inspection............................................................. 32
5 Maintenance.......................................................... 34
6 Spare Parts ........................................................... 36
7 Trouble Shooting ................................................... 37
8 Questions ............................................................. 40
9 Reference Material ................................................. 41
10 Work Place Assignments....................................... 42
11 Glossary ............................................................ 43
12 Power Factor ...................................................... 44

1
A Training Course for Rig Electricians
Basic Generators

1 Equipment Overview
1.1 History

Before the SCR system became the normal method of control

of Drilling Power, a DC system was used where a DC
generator was the power source for a DC motor using
basically the same system as was used in Diesel Electric
Railway systems and Diesel Electric Mining Vehicles.

An 8, 12, or 16 Cylinder Diesel Engine was used to drive a

DC Generator, and the output was used to drive a DC motor
controlled by systems such as the Ward Leonard system of
control to vary the speed and output of the motor.

1.2 AC Supplying SCR Drives

With the development of the SCR system the Generators

became AC Generators/Alternators being driven by the same
diesel engines with the AC Current being converted to DC
current via an SCR System. This through a DC control
module also controls the speed of the DC motors by
controlling the output of the SCR system. The engines are
controlled by the AC modules in the same SCR system to
match the engine output with the DC Traction Motor demand
on the Drilling Equipment by maintaining the speed of the
engines regardless of the load placed on them.

1.3 AC Supplying VFD Drives

On the latest systems the AC Generators are now used to

drive AC Traction Motors using frequency control to achieve
the same level of control over these motors and removing DC
motors and their high maintenance from the Drilling System.

With these systems the AC output from the generators is still

rectified to DC and smoothed to remove the AC ripple. It is
then fed into the inverter section of the system to be
switched by insulated gate bipolar transistor in order to
simulate AC voltage and current. This is then supplied to an
AC traction motor. The time the transistors are switched on
and off will determine the voltage and frequency supplied to
the motor to control the motor speed.

1.4 Generator Manufacturers

Kato, Caterpillar, Stamford, Westinghouse, General

Electric etc.

2
 A Training Course for Rig Electricians
Basic Generators

2 How Does It Work

2.1 Magnetic Field Generators

The most important source of electricity is the magnetic field

generator, which converts the mechanical energy supplied by
a diesel engine into electrical energy. Even the storage
battery, which is the second-most important source of
electricity, gets its energy from a magnetic field generator
via a battery charging system.

As the name suggests, the magnetic field generator is based

on the relationship between electricity and magnetism. The
power generated can be used either near the site where it is
generated or it can be transmitted over vast distances. The
power generated is either direct current (DC), where the
current flows continuously in the same direction or
alternating current (AC) where the current is flowing in one
direction the first half of the cycle and in the opposite
direction during the second half of the cycle.

Whether the electric current is AC or DC is determined by the

way it is brought to the external circuits from the generator.
Until recently DC motors were preferred to AC motors
because DC motors develop the most torque at low speeds,
with excellent controllability which is required for drawworks,
rotary tables, Top Drives, mud pumps, propulsion motors
and large marine anchor winches.

This was previously not possible with AC motors,

consequently DC generators were used to power the DC
motors being utilized. Some older oil rigs still have DC
generators, but the majority of the modern rigs use AC
generators. Particularly since the advent of reliable SCR
control systems for use with the DC motors, which have been
used to drive the drilling equipment on oil rigs until recent
times.

2.2 AC/DC Generator Comparison

Since most of today's rigs still have DC motors, it might

seem strange to generate AC power and rectify it to DC,
compared to generating straight DC power.

Rig equipment needs a lot of raw power to operate, and

because of the AC generator design, manufacturers can build
AC generators bigger, cheaper and more powerful than DC
generators. In addition as modern AC generators are
“brushless”, maintenance of modern AC Generators is less
labour intensive than DC Generators which have brushes.

3
A Training Course for Rig Electricians
Basic Generators

As a result, rig owners can use more powerful diesel engines

to drive large AC generators, leading to a reduction of the
amount of engines and generators required to power a
standard rig. Power and maintenance costs are thus reduced.
The rigs operation requires a variety of different size auxiliary
AC motors along with lighting and small power panels. Step
down transformers are used to reduce the voltage from the
main generating plant to supply power to the Motor control
cubicles and small power and lighting distribution panels.

When using AC generators to supply power to the drilling

SCR units and all other AC requirements, no auxiliary
generators are necessary, except for emergency or stand by
generators to give power to the operation in the event of
total power failure. These are normally self contained units,
independent of the main system. As the AC generators do
not use commutators, AC generators require less
maintenance than the DC generators from a brush point of
view. Even if the generator has slip rings for excitation, these
rings are continuous and do not suffer the same amount of
brush wear that would be expected on a DC generators
commutator.

Commutators on DC Generators or Motors have a rotating

segmented surface, that tends to wear out the brushes that
are in contact with them. But the current that is transferred
between the brushes and the commutator while the motor is
running is the main cause of brush wear and sparking, as
current is transferred from coil to coil in the armature to
allow rotation.

Figure 1. Induced Voltage in a Magnetic Field

2.3 Induced Voltage

The basic principles to produce electricity are explained in the

next sections. When a conductor is moved through a
magnetic field, an electromotive force (emf) or voltage is
induced in the conductor. This induced voltage is proportional
to the rate at which the magnetic lines are cut by the
conductor passing through it (speed).
4
 A Training Course for Rig Electricians
Basic Generators

There are many lines of force in a strong magnetic field.

Consequently, a conductor moving through a strong field will
have a strong voltage induced by it.

A conductor which is moved fast will cut more lines of force

in a given time than one that is moved slowly. Therefore, the
speeds of the conductor as well as the strength of the
magnetic field affect the strength of the induced voltage.

2.3.1 Direction of the induced voltage

Left-hand rule for generators. See figure 2.

The direction in which the induced voltage will attempt to

move the electrons depends on the direction of the field
which the conductor is cutting and the direction in which the
conductor moves through it.

Figure 2 Left - Hand Rule for Generators

The relationship between the conductor motion, the direction

of the flux and the direction of the induced voltage can be
remembered through the use of the left-hand rule for
generators:

• Extend the thumb, the forefinger and the middle finger of

the left hand at right angles (90°) to each other.

• Point the thumb in the direction of the conductor motion

and the forefinger in the direction of the magnetic flux
from north to south.

• The middle finger will then point in the direction of the

induced voltage as shown in Figure 2.

5
A Training Course for Rig Electricians
Basic Generators

2.3.2 Direction of the magnetic flux

Left - hand rule for conductors. See figure 3.

If the direction of the current is known, the direction of the

magnetic flux around a conductor can be found by using the
left-hand rule for conductors if the conductor is grasped in
the left hand. With the thumb pointing in the direction of the
flow, the fingers will curve around the conductor in the same
direction taken by the lines of the force of the magnetic field,
as shown in the figure below.

Figure 3 Left - Hand Rule For Conductors

2.4 DC Generators

Since some older rigs still use DC-to-DC systems we will

explain these generators as well as the AC generators.

The standard operation is explained by following the

schematic in drawings Figures 4, 5, & 6

Figure 4 DC Generator Simplified Drawing

A rectangular loop of stiff copper wire rotates between the

north and south poles of an electromagnet that creates lines
of force called magnetic flux. These lines of force flow from
the magnet's North Pole on the right to the South Pole on the
left. The parallel dashed arrows show the magnetic flux
flowing between the two poles.

6
 A Training Course for Rig Electricians
Basic Generators

At Figure 4 the black side of the loop is moving up, while the
white side is moving down. Current flows clockwise through
the loop. The current goes to the commutator segment on
the right, through the brush and to the meter. The pointer at
the meter is showing that the current is flowing.

As the loop rotates through the magnetic flux, it generates

an electric current. Each end of the loop is connected to a
commutator segment. The simple commutator in the
schematic diagram is composed of two segments of copper,
but in the actual generator commutators are composed of
dozens of these segments.

Each half of the commutator segments rotates against a

brush (a small block of carbon with a concave face to match
the curvature of the commutator and a flexible copper cable)
that conducts electricity, from the rotating parts to the
stationary parts of the generator. The brushes conduct
electricity to a circuit outside the generator. The meter on
the schematic drawings deflects to the right to show the DC
flow.

Figure 5 DC Generator with Windings Perpendicular

In Figure 5 the loop has rotated 90 degrees so that it is

perpendicular to the magnetic flux lines. No current flows at
this particular moment. The commutator segments are NOT
touching the brushes, so the meter shows that no current is
flowing.

Figure 6 DC Generator with the Winding at 180°

7
A Training Course for Rig Electricians
Basic Generators

Figure 6. shows that the loop has turned 180 degrees

compared to figure 4. The current however still flows
clockwise through the loop. Consequently, the meter's
pointer still deflects to the right as it did in drawing 4. This
simple generator therefore generates direct current.

A practical result of the brushes touching/not touching the

commutator is that almost all DC generators show small
sparks between the commutator and the brushes resulting in
rapid wear of the brushes.

The contamination of carbon residue between the segments

of the commutator and around the insulators of the brush
holders and arms, has a bad influence on the insulation value
of the generator, the commutator operates as a rotating
switch, turning on and off coils in the armature as the
segments make contact with the brushes.

2.4.1 Construction of DC Generators

Figure 7 DC Motor Stator

Figure 8 DC Motor Armature

The DC generator consists of a steel frame or yoke

containing the field poles and the armature.

8
 A Training Course for Rig Electricians
Basic Generators

2.4.2 Field Construction

The pole pieces, supporting the field windings, are mounted
on the inside circumference of the yoke. These pole pieces
are usually built of sheet steel laminations riveted together
and have faces shaped to fit the curvature of the armature.
The electromagnets or field poles are arranged in the stator.
The electricity flows through the windings to create
electromagnets. This electricity comes from a small
generator, called an exciter, which the engines powers. This
power is converted into a magnetic field between the North
and South Poles of the field windings, and in turn induces a
voltage into the armature coils as they rotate through these
fields.

2.4.3 Armature Construction

An armature consists of a group of copper conductors
mounted in a slotted cylindrical core made up of thin steel
discs, called laminations. The commutator is designed for
maintaining the current flow in one direction through an
external circuit. This includes the brushes and brush holders
that carry the current from the commutator segments to the
external circuit. The outer surface of the cylindrical armature
core is slotted to provide means of securing the armature
coils, which on most generators are form-wound to the
correct size and shape.

2.4.4 Commutator
The free ends of the armature coils are connected to the
commutator segments so that commutation takes place as
shown in Figures a, b,& c. The current flows from the loop
into the external circuit through one brush and from the
external circuit back into the loop through the other brush.

2.4.5 Limitations DC generators

The DC generated is fed to the external circuits through the
commutator segments and brushes. These contact points
between the brushes and the commutator are subject to
wear. Making them potential trouble spots inside the
generator, these connections make up the biggest proportion
of the maintenance tasks assigned to this type of Generator.

When the generator is subjected to heavy load, excessive

sparking is likely to occur at the brushes unless the
commutator and brushes are continuously kept in good
condition. The generation of high voltages within the DC
generator would obviously be hazardous because of the
sparking tendency at the commutator and brushes. Sparking
also induces electrical noise, as modern rigs develop and
electronics and computer systems are introduced electrical
noise is definitely something to be avoided.

9
A Training Course for Rig Electricians
Basic Generators

2.5 AC Generators

Alternating current generators, also referred to as

alternators, are the most common means of electrical power
production. Like the DC generator, the alternator has an
electromagnet that generates magnetic flux from the North
to South Pole as indicated by the parallel arrows.

This example has a single copper-wire loop rotating clockwise

through the magnetic flux. Each end of the loop connects to
a slip ring, which is in contact with brushes. Unlike the
segmented commutator, the slip ring is a continuous ring. A
wire from each brush conducts current to a meter.

Figure 9 Simple AC Generator or Alternator

In Figure 9 the black side of the loop is rotating upward

through the flux. At the same time, the white side is rotating
downward. The current flows through the grey slip ring,
makes contact with the brush, and flows into the circuit and
meter. At this moment the current flows clockwise through
the circuit as indicated by the arrow and the meter pointer
will be deflecting to the right.

Figure 10 Simple AC Generator turned 180°

In Figure 10, the white side of the loop is rotating upward

through the flux, while the black side is going down. The
current flows now through the black slip ring, which touches
the brush and flows into the wire and meter.

10
 A Training Course for Rig Electricians
Basic Generators

At this moment, the current flows counter clockwise through

the wire and meter as indicated by the arrow and meter
pointer which is deflecting to the left. As the loop alternates
in contacting two separate slip rings, the current flow
changes from clockwise to counter clockwise on each rotation
of the loop.

2.5.1 Construction of AC Generators

All generators consist fundamentally of a field and an
armature, one of which must rotate. In the AC generator
shown in Figure 11, the armature or rotor is the rotating
member. Notice the DC exciter at the left, mounted on the
alternator shaft.

Figure 11 Cross section of a small AC generator.

Many small-size single-phase AC generators are designed

with the armature as the rotor, closely resembling the DC
generator, the significant difference being the slip rings that
bring the current out as an alternating current.

11
A Training Course for Rig Electricians
Basic Generators

The picture shown in Figure 12 shows a segment of the AC

generator with the slots in which the coil windings will be
placed. Better isolation of the coils is possible because of
their stationary position. In most large AC generators known
as alternators, the alternating windings are mounted on the
stator. In this way it is possible to supply the load current
directly to the external circuit without going through the
sliding contacts required in DC generators. Large AC
generators may have currents of several thousands amperes
per terminal, and sliding contacts would not stand such
heavy loads because they tend to spark, or arc over, and
sometimes even produce a short circuit.

Figure 12 Stator of an AC Generator

However, the voltage and current supplied as exciting

current to the rotating field are relatively small, and the slip
rings and brushes are adequate for such a circuit. The stator
of the revolving-field alternator is built up from steel
laminations, somewhat similar to the construction of the
armature core of a DC generator. The laminations of an
alternator stator, however, form a steel ring that is keyed or
bolted inside the circumference of a steel frame.

12
 A Training Course for Rig Electricians
Basic Generators

The rotor of the revolving-field alternator shown in Figure 13

consists of protruding poles on which the DC field windings
are mounted. The field windings are connected either in
series or in series groups connected in parallel.

Figure 13 Rotating-Field Unit on an AC Generator

The ends of the field windings connected to the slip rings are
mounted on the rotor shaft and separately excited by the DC
generator. This application is called the exciter and which is
often mounted on the alternator shaft. The excitation voltage
is usually 120 or 240 Volts

Figure 14 Detailed look at Coils of a Generator Rotor

The alternators used on DP vessels are large in size and they

generate 6,000 Volts. These alternators are large three-
phase generators as shown in Figure 14.

13
A Training Course for Rig Electricians
Basic Generators

Generator is the term used universally for both Alternators,

which produce Alternating Current AC and Generators, also
known as dynamos, producing Direct Current DC.
Generators will be used throughout too indicate both AC and
DC machines, when necessary any specific information to
each will be indicated.

Figure 15 Large Three Phase Generator.

To produce electricity a magnetic field must pass an electrical

conductor; this conductor has a voltage induced in it. This
voltage is the machines output. Simple machines have
permanent magnet rotating in the stator. As machines
increased in electrical output the permanent magnet became
too small to provide this output. Once this point was reached
the use of coils were introduced. With the coils came the
possibility of controlling the output voltage from external
sources. This control developed into the modern Automatic
Voltage Regulator (AVR).

In a throw back to older designs, modern generators are

being fitted with permanent magnets once again. The
reasoning behind this is simple, upon start up the Generator
relies on residual magnetism still being present to actually
begin the generation process. If left for some time without
use the residual magnetism simply dies away to a level
where little or no generation actually occurs on start up. The
fitting of a small permanent magnet ensures the generation
process can begin to a level where the AVR control can pick
up voltage and begin to operate and bring the generator
voltage up to the specified levels of output.

Without the permanent magnet installation the process of

“flashing” the generator had to be carried out by connecting
a battery momentarily to the field circuit in order to give the
generator enough residual magnetism to start to generate
voltage.
14
 A Training Course for Rig Electricians
Basic Generators

2.5.2 Generators Have Three Main Parts

1. The stator which contains the power coils which carry
the main current on a AC machine.

2. The rotor which located inside the stator is rotated by

the driving engine.

3. The exciter provides the power to the rotor coils which

produces the final output voltage of the generator.

2.5.3 The Stator

This is the main part of the generator it is large and heavy.
The output terminals carry the full current the generator can
produce. There are few maintainable parts on the stator. The
terminals need to be tight and secure to prevent arcing or
hot spots. Any filters on the alternator need to be kept clean,
if the air flow through the alternator is reduced, the
maximum safe temperature of the alternator will be reached
before the alternator has reached its maximum output.

2.5.4 The rotor

The rotor of a generator is made up of a set of coils fixed to
the rotors shaft. These coils on an Alternator are powered
from the excitation circuit, the Alternator has the magnetic
field fixed, relative to the shaft, and this means the whole
field rotates relative to the stator. On a DC generator it is the
stator which is supplied from the excitation circuit, a DC
generator has the field fixed in one place provided by the
stator, and the output is through the commentator and
brushes. In general terms the output of a DC generator is
from the rotor via a commutator. This is in contrast to the
output of an AC alternator, which is from the stator.

2.5.5 Exciter
Excitation is the system which provides the controlled small
electrical input current to the rotor, which then controls the
machines output power in the stator.

2.5.6 Excitation is Split into two Basic Types

1. Brushed Exciters which need a set of slip rings
mounted on the rotor shaft.

2. Brushless Exciters these have more equipment

mounted on the rotor shaft but do not have the
problems with carbon from the brushes and slip-rings.

15
A Training Course for Rig Electricians
Basic Generators

2.5.7 Brushed Machines

On a brushed machine the rotor coils are the same as those
on a brushless machine with the same electrical output. On
the main shaft a set of two slip-rings are fitted. The
associated brushes and brush gear mounted on the main
frame are supplied from the small DC generator driven by an
auxiliary drive shaft from the generators engine. The DC
exciter which is a small DC generator in its own right has its
output controlled by its own stator coils. In this system there
is maintenance required on the exciter commutator and
brush-gear. The carbon build up from these brushes is
required to be removed from insulators to remove possible
earth faults and the possibility electrical tracking or burning.

2.5.8 Brushed Exciters

These exciters are normally feed from a small DC generator
whose input is controlled by an Automatic Voltage Regulator
(AVR). A brushed exciter system has a set of slip rings
mounted on the rotor main drive shaft. These and their
associate slip-rings, supply the rotor with current to create
the revolving field, which creates the voltage in the stator of
the generator.

It is common to have a small DC generator to supply the

main rotor of the generator set. The output from this small
generator / exciter is controlled by the AVR circuit. The
disadvantage of this system is the quantity of equipment
needed and the additional maintenance of the brushgear,
that DC generator commutation and brushes require. In
certain applications the supply to the slip-rings is supplied
from a static converter. This is a small, relative to the output
of the generator, power supply used instead of the DC exciter
generator.

2.5.9 Brushless Machines

On a brushless Alternator, there are two sets of coils and a
diode bridge located on the main shaft.

Figure 16 Exciter Assembly on a Brushless Generator.

16
 A Training Course for Rig Electricians
Basic Generators

The main rotor coils which produce the magnetic field, which
is rotated within the stator coils, are the same size physically
and electrically no matter which method of excitation is used.

The exciter generator also known as the auxiliary generator

has its stator coils feed from the generators AVR system. The
excitation generator rotor coils supply the current to the
main coils. The Diode Bridge or revolving diode plate is used
to produce the DC for the rotor coils from the AC generated
in the exciter generator.

2.6 Generators Operating in Parallel

To understand how generators behave when in parallel, the

characteristics of load response of an individual machine
must be explained. The system frequency is fixed and
expected not to alter from the 60Hz when under steady state
conditions. The frequency is directly proportional to the
speed of the engine, and control of the frequency is achieved
controlling the speed of the engine. The system voltage is
also maintained at 600V under steady state conditions by the
AVR. In the drilling industry the continuous application of
varying high power loads means the system is rarely in a
steady state and the Automatic Voltage Regulator and Engine
Governor are continually working to keep the voltage and
frequency stable.

Several conditions need to balance within the

Engine/Generator control system to maintain the required
frequency and voltage. If any one of the parameters is
incorrect the control system will alter the signals to adjust
the Automatic Voltage Regulator (AVR) and or Governor to
bring the system back to 600V 60Hz.

Generally speaking the systems steady state conditions

(Voltage and Frequency) are as follows.

2.6.1 Governed by two Independent Factors.

1. System frequency is governed by the actual speed
of rotation of the generator; this is of course the
speed of the engine. So by adjusting the speed of
the engine the controller can keep the frequency
at the desired setting.

2. System voltage is controlled by the excitation

levels of the generator sent by the AVR. By
varying the excitation level the output voltage
levels of the Generator can be controlled.

17
A Training Course for Rig Electricians
Basic Generators

2.6.2 System Frequency

With the system running in stead state of 600 V and 60 Hz
the governor on the engine would be steady at a level
proportional to the load on the system and the number of
generators on line. When a load is applied to the system, by
starting a mixing pump, the system load would increase, and
each generator and engine load would increase. The control
system would increase the signal to the governor, and the
governor would move the fuel rack to increase the quantity
of fuel to the engine. The engine would speed up back to the
60Hz, and once back at or just over 60Hz the governor
control system would reduce the fuel, to ensure the systems
speed did not increase above the set point of 60Hz. The
system would once again return to the steady state.

2.6.3 System Voltage

At the same time when a load is applied to the steady
system the voltage on the system would drop, and the
voltage drops and the load amps increase because of this
voltage drop. This double drop places a larger load on the
generator engine, and the AVR responds in the same way as
the governor and increases, this time, the supply to the
excitation of the generator. As both these parts of the
system, governor control and AVR, operate automatically the
operator observing the system would find it difficult to
observe the drops in speed/frequency or voltage unless the
applied load was large. As you can see there are two distinct
parts to the load response on a generator.

Figure17 Mobile Generator Skids

18
 A Training Course for Rig Electricians
Basic Generators

2.7 Speed/Frequency & Voltage.

All generators in the system contain these two control loops,

with both of these loops containing several adjusting points,
for controlling response time and set points. To maintain any
system in a steady state the feedback of the signals need to
be controlled as well as amplified, damped and stabilised. If
one of these control points is incorrectly or even differently
set from another, the overall response to an equally applied
load will be different.

This different response causes the machines to react in a

different way and if exaggerated would lead to generator sets
fighting each other until the steady state was achieved. If
each machine responds the same way the system will react
to any changing load as a single unit. Once this has been
achieved it will be the aim to maintain the system in this
state at all times.

2.7.1 System Causes & Effects

To determine which machine is defective is a skill, which
needs thought and a logical approach. In a worse case
scenario you can get circulating currents between parallel
engine/generator sets where a generator is being driven by
the switchboard system, and the generator can and will act
as a motor and therefore the generator is trying to drive the
engine that is driving it against the engines rotation.

This is called reverse power and normally the Generator that

is being driven “backwards” will trip off line when the reverse
power levels exceed a preset figure. If no reverse power
protection is fitted or it is not functioning, in extreme cases
the engine could suffer severe damage in the transmission
train. For Generator sets to operate in parallel and balance
the system load between them, these main conditions must
be met.

• All engines must be running at the same speed.

• The voltage of the alternators must be the same.

• The response of the AVR & Governor control must be the

same.

To safely place an alternator on to the system, on line, the

speed and voltage must be the same. If either are out by any
significant degree the person carrying out the operation can
easily be in danger and the equipment can be seriously
damaged.

19
A Training Course for Rig Electricians
Basic Generators

There are well documented cases where engines have

received twisted crank shafts due to incorrect
synchronization or failure of an automatic synchronizing
system.

Figure 17 Main Generator

These statements may seem to be obvious to experienced

generator operators, but at many locations the balancing of
the system is automatic, and never clearly understood by the
operators. Synchronization is the act of bringing a generator
on line, and connecting it to the live electrical main bus
system. This may have one of more generators synchronised
to it and running together.

2.8 Speed

The speed of the system is called its frequency and is either

50Hz or 60Hz. This relates directly to the number of coils
built into the generator and the speed of the engine driving
the generator. Engine speed for a Caterpillar 399 is
1,200RPM on a 60Hz system. The exact speed needs to be
checked with your own system, if the speed is exactly the
same as the system the generator would just run on line
without generating power or taking power from the system.
To generate load the generator must be trying to move
faster.

2.9 Voltage

2.9.1 Preparing To Synchronize

To synchronize a generator, not only the speed but also each
generator must be producing the maximum voltage on the
same phase at the same time. If the voltage on the on red
phase, for example, reaches maximum at the same time on
both the system and the incoming generator the voltages are
running together and there will be no voltage difference
between the system and the incoming generator.

20
 A Training Course for Rig Electricians
Basic Generators

It is possible for the incoming generator and the system to

be running at exactly the same speed but the red phase of
the system is reaching its maximum at a different time to the
incoming generator. (Incoming generator is not in sync) This
situation produces a voltage between the system red phase
and the incoming machines red phase. The same voltage
difference can also be measured across the white and blue
phases. If the circuit breaker is closed at this time a very
large current will flow due to this voltage.

This very large current will cause damage to equipment and

danger to personnel. When the voltages are rising and falling
at the same time they are said to be in synchronism.
Therefore synchronization can be achieved by safely closing
the generators circuit breaker. Once on the line the machine
will be required to take load and supply power to the drilling
unit. For a machine to generate power the engine must be
trying to go faster. The faster it is trying to go the more
power it will generate. This may sound strange when the
speed is not allowed to increase, but examine the example of
a car going over a hill. Where to climb the hill the throttle
has to be increased, but on reaching the summit the amount
of throttle is reduced to prevent the car over speeding. The
relationship between the throttle pedal in a car and the
governor should make the generator control situation easier
to understand.

2.9.2 Governor Actuator

To control the engine the governor actuator is energised to
move the fuel rack which alters the amount of fuel delivered
to the engine. A governor actuator is the device mounted on
the engine and is commonly called just the governor. This
device, which is driven from the engine uses a small
hydraulic system within itself to change the small electrical
control signal to the mechanical force required to move the
fuel rack and hence the speed and power output of the
engine.

As can be seen in the Figure 17, this is a very poor electrical

installation, with terminal blocks and PVC insulating tape,
subject to high vibration on the engine. Termination is
normally achieved with a plug and receptacle or socket
connection, which has a threaded locking ring on the cord
grip receptacle to prevent loose connections due to vibration.
This type of connection allows for quick disconnection if
actuator replacement is required or to enable the actuator to
be tested on the engine for coil resistance.

21
A Training Course for Rig Electricians
Basic Generators

The control of the governor needs to react to the ever

changing loads during drilling operations and is therefore
reactionary. The speed of reaction is an amplification of any
signal difference and the damping of the response is all
adjustable. It is usual with modern equipment that they are
stable, reliable and very seldom need to be adjusted. Most
setting faults can be traced back to either initial set up, or
when some one has adjusted one machine with the best
intentions.

Figure 18 Governor Actuator on a Caterpillar 399

When setting up a system you must be able to put the full

dynamic loading onto the system to observe and adjust each
machine to balance reactions and responses. To try and do
this when in operation is fraught with difficulties, and not to
be contemplated unless you are fully conversant with the
system and have the support of the drilling management.
It is easy to cause a black out when adjusting a generator
governor even by experienced electricians, so you have been
warned. Once off line the off line machine should be checked
to see that it is running at 60Hz and 600V. This saves time
when putting the generator on line the next time. It may be
necessary to do it quickly and any reduction in the time
taken is beneficial.

22
 A Training Course for Rig Electricians
Basic Generators

2.10 Generator Protection

Earthing of the alternator is important, as some of the

protection circuit devices are dependant upon the faults
having a return path back to the point of supply.

Figure 19 Generator Control Switchboard.

The protection of generators is split into two sections.

2.10.1 Engine and Generator.

1. The engine protection is just the protection of the
engine, and is normally confined to overspeed,
lubricating oil pressure and temperature, and jacket
cooling water temperature to protect the engine from
mechanical failure.

2. The generator is protected against several failures or

conditions as is shown in the following table listing
protection, explanation, and possible causes.

23
A Training Course for Rig Electricians
Basic Generators

2.10.2 Causes and Explanations

Protection Explanation Possible causes

Reverse When the generator Engine slowed down

Power is taking load from or stopped.
the system like a
motor rather than Engine cannot
giving as a produce the required
generator. power, fuel
starvation.

Over The generator has The system load was

Frequency for some reason reduced very quickly
been going faster and the engine/s
than the specified could not react fast
frequency. enough,

governor actuator
problems.

Under The voltage Failure of the

Voltage generated by the excitation system
generator was below working in
what expected conjunction with
system. reverse power.
Depending upon the
two settings it may
be one trips before
the other.

Overload The generator load Too much load on

in Amps was above system or not
the maximum of the enough generators
system. on line for
operations.

Short A fault on the A fault on the

Circuit system that takes a system, which needs
very large current. to be investigated.

Table 1 Cause and Effect Chart

24
 A Training Course for Rig Electricians
Basic Generators

2.10.3 Secondary Protection Covers

• Preferential trips

• DC load control

• Alternator imbalance

• Earth fault detection

• Loading alarms.

These can again be split into two distinct types, one the
control and the other switching of system loads.

Figure 20 No Protection No Generator

2.10.4 Protection Controls.

The first group is the system protection controls. These are
used to protect the system from excessive load and the
possibility of blackout. A blackout on a drilling unit when in
operation can cause major “hole problems” and being stuck
in the hole is a likely outcome of a blackout.

To reduce the likelihood of a blackout, the generation system

is protected by load management systems. The complexity of
the load management can be a simple “Open circuit breakers
on certain non-essential loads” to remove those loads from
the system. To more complex systems, which will start, run
up, synchronize, and put on line the extra generators
required by the load.

25
A Training Course for Rig Electricians
Basic Generators

We will concentrate on the simpler types, and leave it to the

new recruit to furnish himself with the information on the
particular system employed on the drilling unit he is involved
with. As the load on the system increases the generator
circuit breaker protection system will be monitoring this. As
the load approaches a preset figure (normally 90-95% of the
individual generator load) the control system closes a relay.

2.10.5 Protection Relay Characteristics

The system design will dictate what these relay contacts do.

2.10.6 Executive Tripping

These relays can give “Open Circuit Breaker” signals to non-
essential loads, which have been defined at the design stage
of the unit. The contacts can also be used to “Ramp Down”
the DC load by reducing the SCR output to the DC motors.
The most dramatic is the opening of circuit breakers
supplying certain SCRs, which instantly reduces a major part
of the load but leaves the drilling department to manage the
available power to the best of their ability. This can lead to
dire consequences while drilling such as getting stuck in the
hole

2.10.7 SCR Phase-Back Signal

In one system the control point is an analogue signal, which
is used to control the maximum speeds of DC motors
connected to the system. The nearer the system gets to
100% load the further the DC motor outputs are ramped
down. Ramping down reduces the load and therefore the
system should be able to maintain the system running at
near full load by using this system, until another generator is
put on line to increase generating capacity.

Once the load reaches the 90-95% load figure, an overload

alarm is normally fitted to the drillers console to ensure he
knows the load is approaching a dangerously high level. This
alarm, which is normally in the form of a load limit light,
should initiate action from all departments to reduce the load
or place additional generators on line.

2.10.8 Generator Protection

The second group is dedicated to the protection of the
generator itself. It is difficult to provide protection against a
fault occurring within the generator. A short-circuit fault
within the generator would be fed from the generator itself
and all other generators on the system would feed this fault.
This causes a very large current to pass into the fault and
could result in major damage. The failed generator would be
tripped on either instantaneous short circuit protection or
reverse power trip dependant upon the severity of the fault.

26
 A Training Course for Rig Electricians
Basic Generators

To reduce this imbalance, protection is fitted within the

generator itself. With each of the phase coil groups being
monitored, protection circuits would open the circuit breaker
at a lower value than the short circuit value. Earth or Ground
fault monitoring of the power generation system on the main
switchboard will indicate a ground fault anywhere in the
supply system.

Figure 21 Engine Control Modules

Figure 22 Generator Synchronisation Panel

In many generators the temperature is monitored by placing

thermocouples in the stator windings to warn of high
operating temperatures. This can be a good tool in the
prevention of major problems, as all generators have a
maximum operating temperature, which should not be
exceeded if possible for long periods.

27
A Training Course for Rig Electricians
Basic Generators

3 How Do I Operate It

Figure 23 Generator Control Panel

3.1 Generator Parallel Operation

For Generator sets to operate in parallel and balance the

system load between them, these basic conditions must be
met.

• All engines must be running at the same speed.

• The voltage of the alternators must be the same.

• The response of the AVR & Governor control must be the

same.

When the voltages are rising and falling at the same time
they are said to be in synchronization and connections can be
made by safely closing the generators circuit breaker in this
state to put the generator on line.

28
 A Training Course for Rig Electricians
Basic Generators

3.1.1 Putting Generator on Line

The circuit breaker is made ready (Charged) by whatever
method it is designed for. Either by mechanical charging
using the lever, which will normally need to be operated
several times until the spring is charged. This action will
disengage automatically to prevent overcharging the spring.
Or it will be charged by an internal electric motor, in the
same way, ready for the circuit breaker to close at the push
of a button, or automatically by the system. To safely place a
generator on to the system, on line, the speed and voltage
must be the same. If either are out by any significant
degree, the person carrying out the operation can easily be
in danger, and the equipment can be seriously damaged.
There are well documented cases where engines have
received twisted crank shafts due to incorrect
synchronization, or failure of an automatic synchronizing
system. These statements may seem to be obvious to
experienced generator operators, but at many locations the
balancing of the system is automatic and never clearly
understood by the operators.

3.1.2 Synchronizing Procedure

Synchronization is the act of bringing a generator on line,
connecting it to the live electrical system.

The actual synchronizing procedure is the adjustment of the

generator frequency (speed) to match that of the generators
on the switchboard. The incoming generator’s speed pot, on
the switchboard, is used to adjust the frequency or speed of
that machine to the speed of the machines already on the
switchboard.

3.1.3 Synchroscope and Lamps

Before the incoming generator circuit breaker can be closed
the synchronization lamps and the synchroscope must
indicate the incoming generator and switchboard are exactly
in phase with each other. It is said that they are “In sync”,
when the lights will go out to indicate there are no potential
difference across the contacts of the breaker it is intended to
close. There should be only a small voltage flowing per
phase between the incoming generator and the switchboard,
and the breaker can be closed, to put the incoming machine
on line. This small voltage is there to prevent the
switchboard seeing the incoming generator as a motor.

3.1.4 Rule of Thumb

As a rule of thumb with the generator to be put on line, it
should be running slightly faster than the machines already
on line, and the breaker is closed at roughly the 5 to
12position, and by the time breaker closes the generator will
be exactly in sync with the system.

29
A Training Course for Rig Electricians
Basic Generators

To ensure the incoming generator will be generating a small

load when the circuit breaker is closed it should be running
slightly faster than the switchboard. By slightly faster it is a
common to have the synchroscope running in the faster
direction at about the speed of the second hand of a watch.

The reason for the system running faster is that if the

generator was running slower than the switchboard it could
be that generator would be taking load from the switchboard.
It would be in a Reverse Power situation and the generators
electrical protection could trip the machine off the board. This
tripping off can easily cause confusion to the operator and
start a fault-finding process which is not needed.

3.1.5 Balancing The Load

Once the circuit breaker has been closed and the generator is
on line, the generator needs to be balanced with the rest of
the machines on the switchboard. To balance the loads it
may just need a switch to be set to automatic or to adjust
the speed and voltage.

Balancing kW is controlled by using the speed of the

Engine.

Balancing kVAR is controlled by using the voltage

Regulator.

Once balance is achieved the system can be left to control

itself.

3.1.6 Master / Slave

It is common in offshore power systems, where a number of
generators are used in parallel, for one of them to be the
Master for speed control. This function is accomplished either
via a manual selector at the generators’ switchboard control
panels or designated within the control system by a software
command. Normally either the highest or lowest numbered
generator on line will be the master for speed control.
Adjusting this generator will cause all the generators on line
to react. This function will normally preclude the individual
adjustment of generators making it more important to get
the speed of any generator coming on line correct.

Once all generators are on line and settled the control

system only has to adjust one engine for speed control and
all the engines on line will follow it. The last thing to do is
switch off the synchroscope and lights. The log book or
switching records need to be completed with a time and
signature. The reason why the intended operation is put in
the book beforehand is that if an accident or incident occurs
the operator can show what was being done at the time.

30
 A Training Course for Rig Electricians
Basic Generators

3.1.7 Controls And Indicators

The basic controls and indicators available to the operator
are:

• Voltage control pot Control point

• Speed control pot Control point

• Circuit breaker close Direct control on or off

• Circuit breaker open Direct control on or off

• Generator load switch Generator load man/ auto

• Synchronization lamps Incandescent Lamps

• Synchroscope Indicator Meter

• Switchboard voltage Indicator

• Generator voltage Indicator

• Switchboard frequency Indicator

• Incoming generator frequency Indicator

• Generator load Ammeter (A) Indicator

• Generator load Watts (kW) Indicator

• Generator on line indication Indication lamp

As you can see there are only two controls, which are used to
adjust the frequency and voltage. The others are either
indicators or switches.

3.1.8 Taking Machine off Line

When taking a machine off line, it is recommended that the
load be reduced to a lower value, reducing the current on the
circuit breaker contacts. Once off line, the off line machine
should be checked to see that it is running at 60Hz and
600V. This saves time when putting the generator on line the
next time.

It may be necessary to do it quickly, and any reduction in the

time taken is beneficial. As you can see there are only two
controls, which are used to adjust the frequency and voltage.
The others are either indicators or switches.

31
A Training Course for Rig Electricians
Basic Generators

4 Inspection
4.1 Generator Inspection

Generators need to be inspected on a regular basis to

prevent problems occurring in the future. While the machine
is shut down, the covers should be removed, and the dust or
dirt should be blown out with dry air, or washed out with CRC
Electra clean to remove any grease or dirt from inside the
unit.

4.1.1 Brushed Type

If the unit is of the brushed type, the brushes and pig tails
should be checked for condition and replaced if the brushes
are too short, or the pig tails frayed or broken, and the brush
holder springs and arms inspected to make sure they are
able to move freely and are undamaged by corrosion, as they
are required to maintain a constant pressure on the carbon
brush.

4.1.2 Brushless Type

If the unit is of the brushless type, the pig tails on the diodes
should be checked to see if they are in good condition, and
not frayed or damaged by the centrifugal force exerted on
them by the rotor spinning, and the bolt connections checked
for tightness to make sure they are not lose.

4.1.3 General Checks

• All cable connections should be checked to make sure
they are tight and there are no hot spots.

• A visual check should be made of the mounting bolts to

make sure they are tight and the cooling fan and fan
covers to make sure they are secure and undamaged. On
Kato generators the cooling fan should be visually
checked for damage to make sure these have not been
used to bar the engine over/rotate the engine, causing
damage to the fan blades, as these can disintegrate at
speed if badly damaged.

• If the generator is not close coupled, the coupling should

be checked for damage or wear and greased if required,
and the coupling guard checked for damage and
reinstalled before the generator is run again to prevent
accidents.

32
 A Training Course for Rig Electricians
Basic Generators

• When greasing the coupling it should be observed that

the grease is leaving the coupling, or the pressure
relieved after greasing to be sure the coupling is not
under pressure. The same applies when greasing the
bearings on generators or motors. Always remove the
lower plug on the bearing housing to relieve pressure as
grease is pumped into the top grease nipple.

• The generator should then be run with the bottom plugs

out for about an hour to remove any excess grease, and
then the generator should be stopped and the bottom
plugs replaced, and the greasing operation is complete.

Figure 24 Generator with the Side Cover Removed

33
A Training Course for Rig Electricians
Basic Generators

5 Maintenance
5.1 Generator Maintenance

The Generators need to be opened on a regular basis and

blown out with dry air to remove dust and dirt, also washed
out with CRC Electra clean or an electrical cleaning solvent
that will not damage the insulation or brush gear, to remove
any foreign matter and grease from within.

Figure 25 Example of a Dirty Generator

5.1.1 Brushed type

If the Generator is of the brush type, the slip rings need to
be checked for any damage that may create brush wear, and
polished if required, but the skin on the surface of the slip
ring should not be broken unless absolutely necessary.

The brushes should be checked for condition to make sure

they are not cracked or too short, and the pig tails checked
to make sure they are not brittle or broken, and replaced if
required. The brush springs and arms should be checked to
make sure they are free and operating as they should to
exert the correct pressure on the brushes.

5.1.2 Brushless Type

With the brushless type Generator they to should be blown
out with dry air to remove dust and dirt, and washed out
with Electra clean or electrical cleaning solvent that will not
damage the insulation. The pig tails on the diodes of the
brushless exciter assembly should be checked to see if they
are brittle or damaged by the centrifugal force of the rotor
spinning during its operation.

34
 A Training Course for Rig Electricians
Basic Generators

These should be replaced as and all electrical connections

should be checked for tightness and signs of heat damage
from a hot joint between the diodes and plate/heat sink.

5.1.3 Bearings
The bearing should be only greased strictly according to
manufacturer’s recommendations and not over greased as
this will cause the bearings to overheat and the grease to
leak past the seals into the Generator interior throwing
grease everywhere in the windings.

It is normal during the bearing greasing procedure to remove

plugs at the bottom of each bearing, and then grease the
bearing. After this the Engine/Generator is run for a set
length of time (Nominally 1 hr) before being shut down and
the plugs replaced. This is to allow any excess grease to
purge through the plug vent and avoid being pushed through
the bearing lip seals.

If the Generator is not close coupled, the coupling should be

inspected to make sure it has been lubricated at regular
intervals, but should not be over lubricated as this will lead
to surplus grease being thrown off. Care should be taken to
ensure the coupling has not be pressured up if the seals do
not release the pressure, as this can lead to mechanical
damage.

5.1.4 Cooling Fan

The Generator cooling fan at the engine end should be
checked for damage, to make sure it has not been used to
rotate the engine with a crow bar, as this can in some cases
lead to failure where the fan can disintegrate when up to
speed.

In some generators, particularly General Electric, the bearing

housing cover will be insulated from the generator end cover,
and if the bearing housing is not insulated it has been known
for the bearing race to become pitted during operation by
arcing, leading to catastrophic bearing failure, which has
occurred in the past.

35
A Training Course for Rig Electricians
Basic Generators

6 Spare Parts
6.1 Brushed Type

Normally the only spares required for the brush type

Generators will be spare bearings front and rear, and spare
brushes if it is an older machine, with possibly a spare brush
arm assembly complete with springs.

6.2 Brushless Type

With the brushless type, again front and rear bearings, and
spare diodes positive and negative in case of failure.

6.3 Close Coupled Generators

In the case of close coupled Generators there may only be a

rear bearing as the front may be supported by the engine
rear bearing.

6.4 General

Where a governor system other than an SCR system is used,

for example the Woodward system, it would be wise to have
a spare engine control unit on hand with a spare actuator,
and at least one spare engine speed sensor for the flywheel.
It would be good policy to carry a spare Automatic Voltage
Regulator or AC Control Module in the case of an SCR
system.

Figure 26 Spare Parts Store

36
 A Training Course for Rig Electricians
Basic Generators

7 Trouble Shooting
7.1 What If It Breaks Down

Generally speaking the heart of the power system is the

generating plant. If for any reason this power supply is
interrupted it is essential to get the system up and running
as soon as possible. On plants that have an emergency
generator incorporated into their system, the power outage
will be less dramatic as this emergency unit will automatically
come on line after a short delay. However it must be noted
that this emergency backup is designed to only feed the
essential services because of its lower capacity.

7.2 Symptoms to Look For

Normally trouble shooting is confined to lack of excitation,

which will come back to the Automatic Voltage Regulator unit
or AC Control Module, which in turn determines the amount
of excitation, and output from the Generator.

This can be a component in the Generator control system, in

smaller units. Or in SCR systems part of the AC control
system, which in harmony with the DC control system, will
respond to the demands of the Drilling system. This is
achieved by ramping back the SCR output to protect the AC
system from overload.

Apart from a failure in the windings or a bearing failure, this

is normally where trouble will be located, and it will depend
on the size of the system as to where the Automatic Voltage
Regulator unit will be found, in larger systems such as SCR
systems it is replaced by changing out the AC Module.

If it is a case of component failure, changing the control unit

will in most cases solve the problem unless there is a
problem with the inputs and output to and from the system,
such as the wiring being open circuit or grounded, which may
have caused the component failure in the first place.

In the case of speed control problems, such as actuator

oscillations, one of the first places to look is the Engine
Speed Sensor at the flywheel, which being magnetic, may
have picked up steel filings from the flywheel, and in doing
so is no longer producing a clean signal.

37
A Training Course for Rig Electricians
Basic Generators

Another check should be done on the ball joints of the

actuator linkage system, as any slack will be chased by the
control unit. This will cause a hunting effect on the generator
and can be easily rectified by replacing the worn ball joints.
Attention should also be paid when setting up the actuators
on the diesel engines, to get the input current set to the
manufacturer’s specifications in milliamps, when the engine
is in the run mode. This can be achieved by adjusting the
linkage between the actuator and the fuel rack on the
engine, to get the angle of the actuator operating lever
correctly set.

If this actuator current is not the same on all the engines in

the system, this can affect the engine response, so that the
engines do not react in the same way to the throttle signal
when it is applied. The response should be the same with any
combination of engines in the system on the rig, to ensure
the engine response is consistent throughout all of the
engines, no matter which engines are in use at the time.

7.3 To Assist in Fault Finding

Always write down the details of the equipment and

operation the drilling unit is undertaking. This must include
all the machines on line and both individual and system
loads. From these any problem can over time be narrowed
down to a specific machine.

Below is a typical small generator termination panel, showing

the output connections from the bus-bar. The cable glands
for the outgoing cables are shown at the top. The terminal
strip at the bottom of the panel shows the control
connections required for the remote controls such as the
switchboard controls.

Figure 26 Generator Termination Housing.

38
 A Training Course for Rig Electricians
Basic Generators

7.4 Emergency Generator

This is the usual type of emergency generator arrangement

to be found on many offshore rig operations. Normally this
can be found in a compartment or room high up on the rig,
possibly near the accommodation or helideck. It will be
required to maintain emergency power, in the event of total
power failure of the main generators, in situations where the
main engine room may have been flooded. The aim with this
arrangement is that emergency equipment can still be
powered, such as fire fighting equipment, life boats, lighting,
cranes, and accommodation. These systems will receive
power until the rig is abandoned in the event of a serious
situation.

Figure 27 Emergency Generator

The emergency generator system has to be totally self

contained, and in many cases are self starting and able to
put themselves on line to provide for a reduced load when
the main power fails. This is to create a survival situation in
the event of an unforseen situation where the rig may have
to be abandoned.

These systems should be serviced regularly, and run once a

week, to make sure they are in good condition and ready for
use. The batteries need to be on trickle charge to ensure
immediate starting, and some have dual start facilities with
electric and air starters installed.

39
A Training Course for Rig Electricians
Basic Generators

8 Questions
General

1. Explain the left-hand rule for conductors:

a) The direction of the current in the conductor is

shown by the direction the _______ of the left hand is
pointing. b) The direction of magnetic flux in the
conductor is shown by the direction of the _______ of
the left hand. c) What will show the lines of force by
the use of the left hand rule for conductors?

2. Name the three main parts of an AC generator that

are required for it to operate:

a) The rotating assembly of the generator.

b) The stationary assembly of the generator.
c) The source of excitation in the generator.

3. Why is the earthing of the generator so important:

a) It will prevent personnel getting shocks. b) It is

the return path for the generated power. c) It is
critical to the safe operation of the system so that
fuses and breakers will open in cases of fault currents.

4. What is required for a generator to generate load?

a) For the generator to be rotating. b) To be trying to

go faster. c) To have an exciter assembly attached to
provide excitation.

5. What is the normal frequency (in Hz) of offshore

generators?

a) 50Hz. b) 60Hz c) 70Hz.

6. What can be the danger of a short circuit inside a

generator?

a) That it will burn out the generator. b) That the

windings will short to ground. c) That other
generators in the system will feed into that fault
causing a major melt down of that generator.

40
 A Training Course for Rig Electricians
Basic Generators

9 Reference Material
Reference material for a particular make of generator should
be available to the maintenance staff on the drilling rig and
should be kept in the maintenance office. It is in the interest
of the electrician to become familiar with these manuals for
the particular model used on the rig and also the manuals for
the engine control system such as Woodward or the AC
control modules of the SCR system used on the rig to control
the engines.

With the generators there are normally few problems once

the system is commissioned unless there is damage from an
external source, such as water or oil, a major mechanical
failure. The same can generally be said about the governor
control system with an SCR system once it has been
commissioned, but it is not always the case with systems
such as Woodward which have adjustments that can be
made to potentiometers on the front of the unit and are open
to abuse by the uninformed. It is always wise to consult the
manufacturer’s manuals before setting about making
adjustments where possible to governor systems. If the
generator is one of the smaller units, and it is possible to
make adjustments to the automatic voltage control unit, the
manual should be consulted before doing so to prevent
damage to equipment in the system from voltage spikes or
surges in the system.

In all cases the simple items should always be checked first,

such as the magnetic pick at the flywheel, or the linkage
between the actuator before any adjustments are made to
the system, because once the system has been disturbed it
may take some effort to synchronise everything back to
being in balance. It is always good practice to mark the
original position before changes are made, so that if it does
not work out, it can be returned to the original position.

9.1 Web Sites

http://ncert.nic.in/sites/learning%20basket/electricity/electri
city/machine/dc_generator.htm

http://www.physclips.unsw.edu.au/jw/electricmotors.html

http://www.tpub.com/neets/book5/15.htm

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

http://www.allaboutcircuits.com/vol_2/chpt_1/1.html

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

41
A Training Course for Rig Electricians
Basic Generators

10 Work Place Assignments

Note.

This assignment is designed to familiarise you with the main

& Emergency generating units that supply all the power to
your rig.

1. Locate the main generation and power path one line

electrical schematic, this will show the number of
main generators in your system. It will also allow you
to see the power path of the supply via the generators
main circuit breaker, which inturn feeds the main
switchboards bus system, then on to feeder circuit
breakers which will supply power to motor control
cubicles (MCC’s) and Light and small power
switchboards that will exist in the field.

2. Go and find the main engine room or generating skids

that is appropriate to your rig.

3. Ask the question of how many generators are

required to be run in parallel to supply the Drilling
load, for both drilling and tripping. Also, check to see
if your system has a load phase back ability built into
the system ( This generally is built into the SCR
system which monitors the available KVA and phases
back (reducers the load) on the SCR system by
slowing down the DC drilling motors.

4. Look to see the how many generators make up your

main power system.

5. Check out the name plate on each unit to ascertain

the kW output.

6. Look for the Generator control panel which houses all

of the generator controls and familiarise yourself with
the synchronization instrumentation and controls. Pay
particular attention to the generators main circuit
breaker and the means by which this is closed. Eg.
automatically or manually.

7. Go and find the Emergency generator if applicable to

your rig.

8. Check out the name plate and note the kW output.

9. Look for the Emergency Generators main circuit

breaker and control panel.

42
 A Training Course for Rig Electricians
Basic Generators

11 Glossary
Alternating Current (AC) Current which varies from zero
to a positive maximum to zero to a negative maximum to
zero, a number of times per second, the number being
expressed in cycles per second of Hertz (HZ)

Alternator A device for converting mechanical energy into

electrical energy.

Electro-Motive Force (EMF) The force which causes

current to flow in a conductor; in other words, the voltage
potential.

Generator A general name for a device that converts

mechanical energy into electrical energy. The electrical
energy may be direct current (DC) or alternating current
(AC).

Ground A connection, intentional or accidental, between an

electrical circuit and the earth or some conduction body
serving in the place of the earth.

Phase The uniform periodic change in amplitude or

magnitude of an alternating current. Three phase alternating
current consists of three different sine wave current consists
of three different sine wave current flows, different in phase
by 120 degrees from each other.

Rated Speed Revolutions per minute at which the set is

designed to operate.

Rated Voltage The rated voltage of an engine generator set

is the voltage at which it is designed to operate.

Stator The stationary part of a generator.

Voltage Regulator A component which automatically

maintains proper generator voltage by controlling the
amount of DC excitation to the rotor.

Watt Unit of electrical power. In DC equals volts times

amperes. In AC equals effective volts times effective amps
times power factor times a consistent dependent on the
number of phases. 1 kilowatt = 1,000 watts.

Winding All the coils of a generator. Stator winding consists

of a number stator coils and their interconnections. Rotor
windings consist of all windings and connections on the rotor
poles.

43
A Training Course for Rig Electricians
Basic Generators

12 Power Factor
12.1 Unity is Everything

A power factor of one or "unity power factor" is the goal of any

electric utility company since if the power factor is less than
one, they have to supply more current to the user for a given
amount of power use. In so doing, they incur more line losses.
They also must have larger capacity equipment in place than
would be otherwise necessary. As a result, an industrial facility
will be charged a penalty if its power factor is much different
from 1.

12.2 Power factor correction

Industrial facilities tend to have a "lagging power factor",

where the current lags the voltage (like an inductor). This is
primarily the result of having a lot of electric induction
motors - the windings of motors act as inductors as seen by
the power supply. Capacitors have the opposite effect and
can compensate for the inductive motor windings. Some
industrial sites will have large banks of capacitors strictly for
the purpose of correcting the power factor back toward one
to save on utility company charges. Most loads in modern
electrical systems are inductive, which means that they
require an electromotive field to operate. Example AC
motors, heater banks and transformers etc.

(Everything you need to know about KVAr but were afraid to

ask.)

It is also known as:

• Pf

• Cos Ǿ

• Impedance phase angle

Most loads in modern electrical systems are inductive, which

means that they require an electromotive field to
operate(i.e. Motors)

Remember the “flux” created by an EMF flowing in a

conductor

44
 A Training Course for Rig Electricians
Basic Generators

Inductive loads require two kinds of current:

• Working Power, which performs the actual work of

creating heat, light, motion, etc.

• Reactive Power, which sustains the electromagnetic

field.

• Working Power is measured in kilowatts (kW). It does

the “work” for the system –providing the motion, heat, or
whatever else is required.

• Reactive Power is measured in kilovolt-amperes-

reactive(KVAr). It doesn’t do useful “work”. It simply
sustains the electromagnetic field. For motors it is
inductive in nature. For power lines it is “capacitive” in
nature.

Power Factor
In a vector relationship, Working Power and Reactive
Power make up Apparent Power.

Working Power

Reactive Power Apparent Power

Apparent Power is measured in

kilovolt-amperes kVA.

Power Factor is the ratio of Working Power to Apparent

Power

45
A Training Course for Rig Electricians
Basic Generators

Working − Power
Power Factor =
Apparent − Power

Power Factor of 1 is best but practically unobtainable

without PF correction.

Example: 1200 kVA/900 kW generator

900
PF = = 0.75
1200

2000kW load, 4000kVA generated.

2000
PF= = 0.5
4000

Power factors of 0.6 are common on drilling rigs. And values

of 0.4 are known.

Power Factor Correction:

Power Factor Correction can be used to “correct” the

power factor and reduced the reactive load.

Ross Hill supply power factor correction units that “produce”

VAr of a “capacitive” nature which counteract up to 1600kVAr
of an inductive nature.

Power Factor
Capacitive load (PF Correction) counteracts
inductive load.
The vector diagram after PF correction:

• The aim should be to maintain the PF at approximately

0.8

• This can be done with PF correction

• PF<is a waste of generating capacity

46
 A Training Course for Rig Electricians
Basic Transformers

Section 3
Transformers

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

2 How Does it Work .................................................... 5
3 How Do I Operate It ................................................. 8
4 Inspection............................................................... 9
5 Maintenance.......................................................... 10
6 Spare Parts ........................................................... 12
7 Trouble Shooting ................................................... 13
8 Questions ............................................................. 14
9 Reference Material ................................................. 15
10 Work Place Assignments ......................................... 16
11 Glossary............................................................... 17

1
A Training Course for Rig Electricians
Basic Transformers

1 Equipment Overview
1.1 Transformers

A transformer is a static electrical device that transfers

electrical energy from one circuit to another by magnetic
coupling. It usually comprises two or more coupled windings,
and, in most cases, a core to concentrate magnetic flux. An
alternating voltage applied to one winding creates a varying
magnetic flux in the core, which induces a voltage in the
other windings. Varying the relative number of turns between
the primary (input) and secondary (output) windings
determines the ratio of the input and output voltages, thus
transforming the voltage by stepping it up or down between
circuits.

Figure 1, A Typical Dry Transformer Installation.

The primary voltage of a transformer can be anything from

110V for your portable radio to 400,000V (400kV) used to
distribute power over the long distances throughout the
country. Transformers come in several styles or types but it
is common practice for only dry types to be used within
drilling units. For this reason, only dry type transformers,
which are cooled by natural convection or “forced air” cooling
fans will be described in this section. Inside the enclosure,
the transformer coils are solidly secured to the frame of the
unit, which is then secured to the drilling unit’s main
structure, usually by welding or bolting.

2
 A Training Course for Rig Electricians
Basic Transformers

1.2 Drilling Transformers

Drilling transformers usually are 600V primary and 480V

secondary dry type transformers, where the rig generators’
output voltage is 600 VAC. But if the generating voltage is
higher, say 11,000 VAC, then there may be more than one
transformer to step the voltage down. The voltage will be
stepped down to 600 VAC for the SCRs, then down to 480
VAC for the three phase AC motors, then down again to
208/110 VAC for the lighting and utility power. These
voltages will depend on the geographical location from which
your rig originates.

It is important to note that transformers do not change

frequency under any circumstances. This is important to
consider when changing three phase electric motors. It may
not seem a very big change to substitute a 60 Hz motor with
a 50 Hz unit however the speed of an AC motor is
determined by frequency and the difference between 50Hz
and 60 Hz is 20 percent.

Using a motor designed for 50Hz operation at 60Hz means it

will run 20 percent faster than it should and the full load
current will exceed its specifications. The certification for that
motor becomes both invalid and unsuitable if run with a 20
percent speed differential. The motor will run but will rapidly
burn out under these conditions.

Figure 2 Transformer Enclosure on a Land Rig

In Figure 2 the transformers are clearly visible in this picture,
with the main transformers at the rear, and the smaller
lighting and utility power transformers at the front, as will be
found on land rigs everywhere.

3
A Training Course for Rig Electricians
Basic Transformers

There are many manufacturers of transformers in all the

industrial countries of the world, and these are produced to
meet the local demand wherever voltage reduction is
required, from the main power grid system of up to 400,000
volts down to 120/240 volts for the domestic market.

Figure 3 Basic Rig Power Distribution Layout

Figure 4 Drilling Transformer Skid

On oil exploration rigs, many of the transformers are

produced by the manufacturers of the power distribution
systems used, such as GE, Westinghouse, Ross Hill, Siemens,
Allen Bradley, to mention a few.

4
 A Training Course for Rig Electricians
Basic Transformers

2 How Does it Work

2.1 Distribution System

The power is generated and originates from the top of the

diagram to the various stages and voltages of the system as
shown in (Figure 3) above.

• From the generator to the 600V main switchboard,

from the 600V switchboard via a circuit breaker to the
600/480 volt main transformer, to the 480V
switchboard for three phase power for the rig three
phase motors. The secondary of the main transformer
is 480 volts.

• From the 480 volt switchboard a supply is taken via a

circuit breaker to the primary windings of a 480/208
volt three phase transformer to reduce the voltage to
208 volts three phase, which in turn can be changed
from three phase to single phase by the way in which
the transformer is wound.

• If the primary windings are wound in Delta to receive

the 480 volts from the switchboard, and the
secondary windings are wound in " Y " configuration
or Star, the 208 volts produced will have a neutral
connection to allow a phase to neutral voltage of 120
volts, with the neutral taken from the centre common
connection of the " Y ".

• The primary of the lighting & small power transformer

is 480V, so you cannot automatically assume the
highest voltage on a system is always the primary
voltage.

2.2 Transformer Construction

Transformers are formed by placing both primary and

secondary windings on a laminated steel core, which is
magnetised by the AC voltage. The magnetic effect in one coil
induces a voltage in the other coil in the simplest terms.

2.3 Transformer Temperature

A transformer or any coil or winding can only sustain a certain

temperature safely. This is the limiting value of most electrical
equipment. If they get too hot the insulation, which has a laid
down maximum working temperature, fails and the equipment
is destroyed. If an electrician can smell a hot transformer they
should endeavour to find out the cause and carry out actions
to reduce the transformer temperature by whatever method is
possible.

5
 A Training Course for Rig Electricians
Basic Transformers

The first line of defence with a hot transformer is to reduce the

electrical load on the transformer and reduce the current being
drawn from the transformer. The losses in a transformer are
given off as heat. This heat has to be dissipated in some way
or other. In a dry type transformer the windings are made
with gaps between each layer of the winding, which allows the
heated air to rise causing a cooling flow through the
transformer. This is called Air Natural ventilation (AN); a high
proportion of transformers of this type are used within the
drilling units. As the electrical size in kVA of the transformer
increases the size of the cooling air flow needs to increase as
well.

This can only go to a pre-determined level before external

devices are needed. At this point cooling fans are normally
fitted to make the air flow much higher and taking a much
larger quantity of heat from the transformer. This reduction in
heat allows the transformer to carry more current before the
temperature reaches the maximum allowable. Cooling of the
transformers is therefore an important point to observe.
Checking that the fans are running or that none of the vents
are blocked should be a regular practice. If temperature
detectors are fitted to the transformers the readings including
the current on primary and secondary should be recorded as
an indication of reduced cooling or of excessive loading.

Figure 5 Transformer Heat Exchanger

2.4 Transformer Characteristics

A transformer by definition does not produce power it just

changes the values.

In a transformer Power In = Power Out (neglecting losses

which are less than 1%.)

A transformer is used to change the system voltages to what

have become the normal voltages round the world.

6
 A Training Course for Rig Electricians
Basic Transformers

2.4.1 Why 600 Vac Is Used

DC was the most common type of motor introduced to the
drilling industry to drive drawworks and mud pumps. The
normal maximum voltage for DC motors is around 750V DC,
where 600VAC converts to 750 VDC through an SCR system
to drive the traction motors. Therefore the primary voltage
for main step down transformers on rigs with SCR systems is
600 Vac.

Figure 6 Dry Type Transformers

Transformers are used to change the voltage of the power

source in alternating current systems. This can be either by
stepping down the voltage or stepping up the voltage. In the
case of isolation transformers this voltage can be the same
on the primary and secondary windings. These are used to
isolate the power source from the load.

7
A Training Course for Rig Electricians
Transformers

3 How Do I Operate It
3.1 Energising

The transformer is normally operated, or energised, by

closing a breaker on the primary input side to supply it with
power, or put it on line, whereby a higher or lower output
can be drawn from the secondary side by closing a breaker
to connect it to the load it is required to drive.

Figure 7 Main Power Distribution Switchboard

The Transformer is normally an integral part of an electrical

system and is used to transform the voltage in one section of
the system to a different voltage for another section of that
system. The transformer is used to raise or lower the voltage
supplying various pieces of electrical equipment in the
system to the different voltages required.

8
 A Training Course for Rig Electricians
Basic Transformers

4 Inspection
4.1 Transformer Inspection

Transformers normally require little attention if they are in a

clean dry environment, away from areas where they may be
subject to water ingress, where people are washing down
areas or equipment. If they are outside, they are normally in
weatherproof enclosures which would only be subject to wind
and rain, and are designed for such conditions.

Figure 7 Transformer Earthing Leads

After the transformer has been electrically isolated a normal

inspection would be confined to removing the covers or doors
and looking for excess dust/dirt on the coils and signs of
water ingress into the enclosure. A more through inspection
would be to check for loose connections or signs of hot joints,
and possible cable damage or deterioration of insulation.

Figure 8 Panels Removed for Transformer inspection

If the unit is fan cooled the condition of the fan bearings,

fixtures and cable should be checked for damage or
deterioration. The fan control circuit should be checked to
make sure the thermal sensor, if installed, is operating to
start the cooling fan at the required temperature.

9
A Training Course for Rig Electricians
Transformers

5 Maintenance
5.1 Transformer Testing

The testing of transformers, for maintenance purposes, is

relatively straightforward. The correct isolation of the
transformer before work commences is of the utmost
importance. Depending upon the specific layout of the
system it is possible for the transformer to be live even
though the transformer primary circuit breaker has been
isolated. To ensure the transformer is isolated and dead,
both sides of the transformer needs to be Isolated.

Isolation needs to be fully effective and tested by a voltage

tester, which has been tested on a known source before and
after testing the primary and secondary transformer
terminals. It is advisable to test at the transformer to ensure
there cannot be any mistakes in identification. Testing of the
transformer for electrical maintenance reasons is normally
limited to an insulation resistance of the primary and
secondary windings to ground. An additional test of the
insulation, between the primary and secondary windings, is
also carried out.

Table 1 Test Procedure for a Transformer

When testing one winding the other winding is required to be

earthed, that is connecting the terminals to earth/or ground
temporarily. This is to ensure that any voltage applied, to the
one winding, for testing purposes is not capable of producing
a voltage on the other winding. This induction of voltage on
the terminals of the transformer if not earthed would create
a dangerous situation to personnel on other parts of the
installation who are unaware the isolated system is alive. In
addition the induced voltage, from the test equipment, may
expose the windings to voltage levels above the designed
test voltage of the windings.

10
 A Training Course for Rig Electricians
Basic Transformers

5.2 Transformer Checks

In general little maintenance is required for Dry Transformers

in that there are very few moving parts to be considered in
the system. They should be checked when isolated for loose
connections and cable damage, and any general appearance
of overheating to the windings, insulation, and terminations,
and to make sure they are clean and dry inside their
enclosure. If they have cooling fans, these should be heard
running while listening for bearing noise, and checked while
still for bearing end float or movement, damaged fan blades,
or fan guard.

Figure 9 Test Connections for a Transformer

The supply cable to the fan should be checked for damage or

wear, and any thermal sensors should be checked to make
sure they are operating and that the fan is starting when the
Transformer gets hot enough to require cooling. It is very
important to include all transformer connections when
carrying out a thermo graphic infrared survey. Even if you
cannot immediately do anything about it, it is vital any faults
found are corrected at the first opportunity.

Figure 10 Earthing of Transformer for Inspection

11
A Training Course for Rig Electricians
Transformers

6 Spare Parts
6.1 Spares

Very few spare parts are required for Dry Transformers due
to the lack of moving parts. The only parts that may be
required will be for the cooling fans, for which one might
wish to keep spare bearings, blades, and guards, and if
installed on your operation, a spare thermal switch for
controlling the fans, and any contactors or relays for the fan
starters or control systems.

Figure 10 Spare Parts Store

12
 A Training Course for Rig Electricians
Basic Transformers

7 Trouble Shooting
7.1 What If It Breaks Down

The loss of any transformer will obviously mean that all down
stream or secondary connected equipment will be without
power. Depending on what is connected to this transformer
will dictate the seriousness of the blackout. It can generally
be assumed that the loss of any of your facilities
transformers will cause flow on effects that must be rectified
ASAP.

7.2 Fault Finding

Troubleshooting is fairly straight forward as there are no

moving parts apart from the cooling fans, which are separate
items from the main units. If the main breaker for the
Transformer should trip on overload, it will normally be one
of two things, a short circuit, or a ground fault, both of which
can be checked with the aid of a Megger and Multi-Meter. If
Meggered between the windings and ground, and a zero or
very low reading is obtained, the insulation has probably
failed and the copper windings are touching the steel core
somewhere.

If it is shorted within the windings, this is much harder to

find as the normal resistance is very low anyway, and will
need instruments more sensitive than a Multi-meter to
measure the internal resistance of the windings. If the
reading to ground is good (above 1MegOhm), all the output
circuit breakers are open, and it still trips the supply circuit
breaker when switched on, there is a very good chance the
Transformer is shorted internally.

There will be an inrush of current when the unit is switched

on and this should be allowed for in the current settings of
the breaker during commissioning and should require no
further adjustment afterwards. If a cooling fan fails to
operate, it can well be a failed thermal sensor, which has
failed to bring on the fan starter, or in the case of bearing
failure where the rotor has locked up, the circuit breaker may
have tripped to protect the fan motor if that or something
else has prevented the motor rotating.

13
A Training Course for Rig Electricians
Transformers

8 Questions
1. What is the function of a transformer.

a) To change the frequency in a system. b) To

change the voltage in a system. c) To change the
current in the system.

2. What is the normal type of transformer used on rigs?

a) Oil cooled transformers. b) Oil filled fan cooled

transformers. c) Dry transformers.

3. What maintenance is required on transformers?

a) None. b) Blow out with dry air to remove dirt and

dust, and check the connections when isolated and
earthed. c) Test with Thermographic equipment.

4. What is the normal cause of failure of transformers?

a) High temperature due to overloading. b)

Insufficient loading of the transformer. c) Standing
out in the open in the weather.

6. During normal maintenance what should be looked

for:

a) A clean, dry, transformer. b) A build up of dirt,

dust, and moisture that may cause a fault to ground. c)
Damaged insulation or loose connections.

7. What precautions should be taken when doing

megger testing on a transformer?

a) Ensure the transformer is isolated. b) Open the

output breakers and ground the output side of the
transformer. c) Ensure that instrumentation will not
be damaged through current or potential
transformers.

8. What should always be on the outside of transformer

enclosures?

a) Space to remove the outside covers. b) A safe

working environment. c) Clear signs on all
approaches to the transformer of the danger inside
the transformer enclosure.

14
 A Training Course for Rig Electricians
Basic Transformers

9 Reference Material
The best reference material for any equipment is the
manufacturer’s service manuals that are usually supplied
with the equipment.

These manuals cover everything from installation to the

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

There have been many reference books written over the

years on the construction of transformers, where much of the
information related to coil winding, or motor rewinds will
have relevance to the construction of transformers, with the
sizing of the wire and the types of insulation used to wind
these coils.

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.

One of the most important pieces of information is the data

plates on the transformer which will give the winding
information, and the input and output current ratings of the
transformer. This will be the first reference point if the
transformer is getting too hot, so the input and output
current can be checked to find out if it is being overloaded.

9.1 Web Site

http://myweb.tiscali.co.uk/teslatutorial/TRANSFORMER_ANAL
YSIS.htm

http://en.wikipedia.org/wiki/Three-phase_electric_power

http://www.physclips.unsw.edu.au/jw/electricmotors.html#T
ransformers

http://www.circlec.com.au/

http://www.electricityforum.com/products/trans-s.htm

http://www.jeffersonelectric.com/cgi-bin/site.pl?

15
A Training Course for Rig Electricians
Transformers

10 Work Place Assignments

Note. To assist you with these checks first find the one line
schematic for power generation associated with your rig.
Take this with you so as to familiarise yourself with the main
power system.

1. Go and locate the position of the main 600 to 480 volt

Transformer/s, after getting hold of the one line diagram
of the Rigs main distribution power system.

2. Look at the specification label and note the type of

transformer and the max KVA. & Temp

3. Are any warning signs displayed near or at the

transformers.

4. Is a high temperature indication or alarm installed. Check

and record the transformer temperature for reference.
Value_________ deg. C.

5. Ask the question when was a thermal inspection of the

busbars and connections last carried out.

6. Check if there are any Ventilation cooling fans and

observe that they are functioning and not making any
unusual noises

7. Check for general cleanliness and make sure that there is

no obstruction with the storage of materials or objects
that could effect air flow.

8. Go and check the main switch board for the location of

the main transformer feeder breaker. This will be
connected to the 600 Volt bus system.

9. If there is more than one main power transformer, check

to see how these are connected to the switchboard and if
a bus tie breaker is incorporated in the bus system.

10. Go and locate all other Transformers in the system. The

power distribution diagram should also indicate what
other distribution transformers are connected to your
system. Eg. general lighting & small power transformers.

11. Carry out the same checks on these units. Of particular

importance is finding all of these transformers to
familiarise yourself as to there location.

16
 A Training Course for Rig Electricians
Basic Transformers

11 Glossary
Alternating Current (AC) An electrical current flow of
continuously changing polarity, which rises to a maximum
voltage in one direction, decreases to zero and then sinks to
the maximum voltage in the other direction before changing
polarity once again. This pattern is referred to as a sinusoidal
wave and the number of cycles per second is equal to the
frequency, which is measured in "Hertz"

Ambient Temperature The normal surrounding

temperature of the environment in which a transformer will
operate .

Auto Transformer A transformer used to step voltage up

or down. The primary and secondary windings share common
turns and thus provide no isolation.

Core The ferrous centre part of a transformer or inductor

used to increase the strength of the magnetic field.

Core Saturation Condition that occurs when an inductor or

transformer core has reached maximum magnetic strength.

Current Transformer (CT) A transformer used in

instrumentation to assist in measuring current. It utilizes the
strength of the magnetic field around the conductor to form
an induced current that can then be applied across a
resistance to form a proportional voltage.

Delta A standard three phase connection with the ends of

each phase winding connected in series to form a closed loop
with each phase 120 electrical degrees from the other.

Delta-Delta The connection between a delta source and a

delta load.

Delta-Wye The connection between a delta source and a

wye load.

Duty Cycle The percentage of time a transformer will be

supplying the Full Rated Power to the load. Percentage of
time a unit is expected to perform at Full Rated power versus
time spent in idle.

Efficiency The percentage of input power available for use

by the load.

Encapsulation A process in which a transformer or one of

its components is completely sealed with
epoxy or a similar material. This process is normally
performed when a unit might encounter harsh
environmental conditions such as moisture, salt spray, full-
water submersion or corrosive elements.
17
A Training Course for Rig Electricians
Transformers

Exciting Current The current drawn by a transformer at

nominal input voltage in its unloaded (open-circuit)
condition.

Filter A selective network of resistor, inductors, or

capacitors which offers comparatively little
opposition to certain frequencies or direct current, while
blocking or attenuating other frequencies.

Flux The lines of force of a magnetic field.

Forced Air A method of temperature regulation that

involves air from an external environment being
forcibly exchanged with a transformer's enclosed
environment.

Ground Fault Any undesirable current path from a current

carrying conductor to ground.

Impedance Forces, including resistance and capacitive or

inductive reactance, which resist current
flow in AC circuits.

Inductance The ability of a coil to store energy and

oppose changes in current flowing through it. A
function of the cross sectional area, number of turns of coil,
length of coil and core material.

Inductor A coiled conductor that opposes change in

current.

Inrush Current A brief and momentary surge of current

through the transformer, due to residual flux,
experienced at the instant the transformer is energized.

Isolation Transformer A transformer with primary and

secondary windings physically separated by
design to permit magnetic coupling between isolated circuits
while minimizing electrostatic coupling.

Nominal Voltage The normal or designed voltage level.

For three phase wye systems, nominal
voltages are 480/277 (600/346 Canada) and 208/120 where
the first number expresses phase to
phase (or line to line) voltages and the second number is the
phase to neutral voltage. The nominal
voltage for most single-phase systems is 240/120.

Nominal Voltage The normal or designed voltage level.

For three phase wye systems, nominal
voltages are 480/277 (600/346 Canada) and 208/120 where
the first number expresses phase to phase (or line to line)
voltages and the second number is the phase to neutral
voltage. The nominal voltage for most single-phase systems
is 240/120.
18
 A Training Course for Rig Electricians
Basic Transformers

Power Factor Watts divided by volt amps, kW divided by

kVA. Power factor: leading and lagging of voltage versus
current caused by inductive or capacitive loads, and
harmonic power factor: from nonlinear current.

Primary Winding The coil winding that is directly

connected to the input power.

Rated Power The total output power available from all

secondary windings, expressed in
Voltamperes (VA) or Kilovoltamperes (kVA).

Reactance Opposition to changes in flow of alternating

current. Capacitive reactance is opposition
in change from a capacitor, and inductive reactance is the
opposition in change from a coil or other
inductor.

Regulation The percentage difference between a

secondary winding's output voltage when operating under
no-load or open-circuit and full load conditions.

Secondary Winding(s) The coil winding(s) supplying the

output voltage to the load(s).

Shielding Imposing a metallic barrier to reduce the

coupling of undesirable electromagnetic signals.

Taps or Voltage Taps Additional connections to a winding

allowing different voltages to be obtained from the same
winding. Often used on the primary winding to allow the
transformer to be used in different countries having different
line voltages available.

Temperature Rise(DT) The additional maximum heat

above ambient temperature that the transformer itself will
generate in the normal course of operation.

Test Potential A voltage applied to a winding to insure

adequate insulation performance. Normally applied between
a winding and all other windings, and between a winding and
ground. Also known as the Dielectric Withstanding Voltage
and the Hipot Voltage.

Three Phase Power Three separate outputs from a single

source with a phase differential of 120 electrical degrees
between any two adjacent voltages or currents.

Transformer A static electrical device, which, by

electromagnetic induction, regenerates AC power from one
circuit into another. Transformers are also used to change
voltage from one level to another. This is accomplished by
the ratio of turns on the primary, to the ratio of turns on the
secondary.

19
A Training Course for Rig Electricians
Transformers

Transient A high amplitude, short duration pulse

superimposed on the normal voltage wave form or ground
line.

Voltage Regulation Maintaining stability of output voltage

under conditions of fluctuating input voltage.

Working Voltage The voltage that a winding will operate

at, but not necessarily the output voltage of the winding.

Wye A wye connection refers to a polyphase electrical

supply where the source transformer has the conductors
connected to the terminals in a physical arrangement
resembling a Y. Each point of the Y represents the connection
of a hot conductor. The angular displacement between each
point of the Y is 120 degrees. The centre point is the
common return point for the neutral conductor.

20