Bharat Heavy Electricals Limited, Bhopal

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 AC Power Control Room ( AC-PCR)

 

 

 

 

Purpose:AC-PCR is used to provide centralized control for auxiliary Ac loads and utilities consisting of starters & feeders for 415 VAC 3 phase motors and 415 VAC 3 phase & 230 VAC single phase motors and feeders. 

AC-PCR shall consist of:

Heat Insulated Steel Housing coated with Weather Proof Paints.
600 KVA Transformers
MCC (Motor Control Center)
Lighting & 60 KVA Lighting Transformer
Plug & Socket Arrangement

Specification of AC-PCR:

Input: 600 VAC, 3 Ph, 50 Hz to Incoming Transformer which gives output of 415 VAC, 3 Ph, 50 Hz which is fed to the Bus of MCC.
Starters:415 VAC, 3 Ph, 50 Hz, Based on customer’s specification refer section starter & feeder
Feeders:415 VAC, 3 Ph, 50 Hz & 230 , 3 Ph, 50 Hz ( for lighting), Based on customer’s specification refer section starter & feeder
Bus bar :1600 A continuous, up to 42 KA symmetric fault.
Construction: Self supporting sheet metal, Insulated double wall structure, with suitable air conditioner for outdoor application, built upon four runner type Oil field skid.
Dimension: Length12.2 m x Width 3.0 m x Height 3.35 m approx.
Weight: 30 M Ton (approx)

Special requirement of oil field equipment:

All connections through plug-socket receptacles as, for east assembly and dismantling rig is mobile equipment

  • Optimum utilization of space

  • High reliability and redundancy, as equipment failure during deep drilling while the drilling pipe is negotiating with high pressure gas or oil may result in disaster.

  • Compliance to DGMS norms & IE Rules applicable for India.

AC Power Packs:

  

Purpose: AC Power Pack is used to provide centralized power to DC Control Room and AC Control Room which feeds all DC and AC motors, required for Oil Rig application.

AC-Power Pack shall consist of:

  • Four-Runner Oil Field Skid. Specially fabricated to eliminate fabrication distortion in long run.

  • Engine (Caterpillar or Cummins)

  • Alternator (BHEL or KATO)

  • Air Starting Arrangement. (IR) 

 

Specification of AC-Power Packs:

  1. 600 V, 1430KVA, 50 Hz, 1000 RPM with 3512B CAT Engine and OA 7002 AZ BHEL Alternator.

  2. 600 V, 1430KVA, 50 Hz, 1500 RPM with KTA 50 G Cummins Engine and OA 6301 AZ BHEL Alternator. 

  3. 600 V, 1215KVA, 50 Hz, 1000 RPM with D399 CAT Engine and OA 7001 AY BHEL Alternator. (Now Obsolete)

           Construction: Self supporting sheet metal structure, for outdoor application, built upon four runner
                                type Oil field skid

            Dimension:    Length 7.5 m x Width 2.9 m x Height                           3.15 m approx.

            Weight: 23 M Ton (Approx)

 

Special requirement of Oil Field Equipment:

  • Alternator Neutral is not earthed.

  • Optimum utilization of space.

  • High reliability and redundancy as equipment failure during deep drilling while the drill pipe is negotiating with gas and oil may result in disaster.

  • Compliance with DGMS norms

DC Power Control Room (DC-PCR):

 

Purpose:DC PCR system is capable of controlling up to 11  nos. 1000 HP DC  Motors consisting of 2 to 4  nos. draw works motors & 2 to 3  nos. mud pumps (2 motors each) and an Independent Rotary Drive motor. The system has provision for 600 VAC feeder circuit breaker power to Top Drive.

DC-PCR shall consist of:

  • Four-Runner Oil Field Skid. Specially fabricated to eliminate fabricational distortion in long run.

  • Generator Panels ( To control Power Packs)  - 5 Nos.

  • SCR Panels ( To control DC motors operations) - 5 Nos.

  • Field Panels (To control Field of the Motors)

  • Feeder Panels ( For different Control Supplies)

  • Feeders for Top Drive.

  • Plug & Socket Arrangement

 

Specification of DC-PCR:

  1. Controls Power pack : 600 V, 1430KVA, 50 Hz,1000 RPM with 3512B CAT Engine and OA 7002 AZ BHEL Alternator,
                                                                       or 
    600 V, 1430KVA, 50 Hz, 1500 RPM with KTA 50  G Cummins Engine and OA 6301 AZ  BHEL  Alternator.
                                                                       or
    600 V, 1215KVA, 50 Hz, 1000 RPM with D399 CAT Engine and OA 7001 AY BHEL Alternator. Now Obsolete)

  2. Controls DC Motors with rating 1000 HP, 1050 RPM, 800 VDC, shunt field/Series field DC motors for Draw-work, mud-pump, and independent Rotary table

    Construction: Self supporting sheet metal structure, for outdoor application, built upon four runner type Oil field skid

    Dimension:Length 7.5 m x Width 2.9 m x Height 3.15 m approx.

    Weight: 23 M Ton (Approx) 

Special requirement of DC-PCR:

  • Alternator Neutral is not earthed.

  • Optimum utilization of space.

  • High reliability and redundancy as equipment failure during deep drilling while the drill pipe is negotiating with gas and oil may result in disaster.

  • Compliance with DGMS norms.

  • Designed for frequent transportation after completion of each well

  • Percentage Ground fault detection for AC & DC Power System of Rig

  • Plug-Socket termination arrangement for faster rig building  at new location

  • Power Limit circuit for efficient of Power Pack capacity

  • Air-conditioned to maintain 22+/-2 degree centigrade.

  • PLC Control

Driller's console:

 

Purpose:Contains throttles, indication and metering  for interface & control of rig electrics by driller. The Driller console has safety feature like complete electrical shutdown from remote, i.e. the rig floor in case of emergency.

Special features of D'CON:

  • Pressurized with air purging

  • Stainless steel Enclosure immune to weather

  • PLC Control

  • Indications for monitoring SCR, Generators and Power Limit

  • Metering for DC Motors (Load)

  • Assignment switches for SCR selection from remote

  • Throttle for Motor speed control

BHEL Alternator:

 

 Rating

 The alternator is rated as 1430 KVA , 600V , 1000RPM ,  50 cycles ,  0.7 P.F.(lagging)
 Insulation Class : ‘H’ for stator and rotor

 

Special features of BHEL make Alternators:

Technical Data

Continuous Output

1430 KVA

Rated Voltage  

600/346 Volts  L-L/Phase

Rated Current   

1376 Amps

P.F. (Cos Ø )   

0.7 (lag)

Connection

Star, 3 Phase

Enclosure

SPDP

Frequency

50 Hz

Speed 

1000 RPM

Type of Drive   

Diesel Engine

Class of Insulation

‘H’ on stator and rotor

Stator Slots     

90

Throw  

1-14

Type of Stator Winding

Lap

Stator Coils

Diamond Pulled Coils

Conductor Size

7.1 x 2.24 mm (bare),  

Core outer dia / length

965.2mm / 625 mm

No. of turns / coil

3

Wt. of copper (Stator + Rotor)

475 Kgs

Stator current density   

7.21 A/mm2

Stator Wdg. Resistance Between phases

0.006634 Ohms at 20 oC

Resistance Field Wdg.   resistance  (2tk. Copper)

0.230 Ohms at 20oC

Exciter Fld. Wdg. Resistance    

16.5 Ohms at 20 oC

Exciter armature resistance       

0.00798 ohms at 20 oC

Weight 

4800 Kg (Approx)