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At the current stage of industrial development, oil and gas are the most popular commodities. Oil and petroleum products have penetrated almost every sphere of human activity, from fuels for transport, to cosmetics and medicines.
Natural gas is the most popular fuel in power generation stations, the cement and glass industry, the building material industry, domestic use, non-ferrous and ferrous metallurgy, metal smelting, glass production, as well as raw material for organic compounds in synthesis and other applications.
Most oil and gas is found at great depths of 6 kilometers or more. Wells are required to get these resources, and different types of drilling rigs are used to drill the wells.
Triol Corporation offers a special range of equipment for powering and controlling the motors of various types of drilling rigs – AT24 DW line (Drill Wise).
The DW line includes the following devices:
CTU TDCS –- Complete transistor unit for controlling the top drive control system
CTU MP - Complete transistor unit for controlling mud pumps
CTU TWU - Complete transistor unit for controlling tower-winch unit
CTU - Complete transistor unit for controlling the complete equipment: mud pumps, tower-winch unit, and rotor
LVSC - Low-voltage switchgear and control unit for powering and controlling the auxiliary machinery of a drilling rig
Our design challenges:
1) High equipment mounting capability;
2) The maintainability;
3) The conditions inside the container;
4) Staff comfort;
5) The location of the VFD in the boxes;
6) An individual approach;
7) Vector control;
8) Dual-motor operation with master-slave algorithm.
The cornerstone for equipment on the rig is the ability to quickly fold up and move a CTU container to a new drilling location. In order to speed up the installation process, Triol Corporation has designed the containers with this in mind:
- All CTU containers manufactured by Triol are equipped with retractable hooks in the base of the block container.
The hooks are only retracted during the lifting and moving phase of the container using lifting equipment. Once installed in the workplace, the hooks can be hidden in order to facilitate the routing of the wiring circuits next to the container.
- External container connections
To connect power and signal circuits to the CTU container, special moisture-proof covers are provided in the side walls.
All signal circuits are connected by means of explosion-proof ILME quick-release connectors.
The use of ILME connectors reduces the time required to connect and disconnect the container when moving to another drilling location.
The power circuits are connected by means of busbars.
This design of power and signal connections makes it possible to disconnect and connect the CTU at the location of operation in the shortest possible time.
СTU containers in the DW line have a removable one-piece roof. This reduces the time required to replace the cabinets and equipment inside the unit compared to standard versions of containers with a fixed roof. If equipment inside the container fails, it can be replaced without removing the container from the installation site.
The VFD power cells.
VFDs installed in the CTU have a modular design. The power section of the frequency converters installed in the CTU is designed in the form of a cell.
SD line power cells
MP line power cells
The unification of inverter and rectifier power cells makes it possible to achieve fast replacement of damaged units. Power cells of the same type (power cells in the SD line VFDs and rectifier and inverter cells in the MP line VFDs) are interchangeable between frequency drives of the same type and nominal rating.
This facilitates faster restoration of VFD operation in the event of an off-site fault.
The drilling rigs can operate over a wide range of shipping temperatures (from -45°C to +40°C). In order to ensure an acceptable temperature inside the container, a supply and exhaust ventilation with air preparation system is provided.
The supply and exhaust ventilation with air treatment and recirculation system allows the temperature inside the box to be maintained between +10°C and +40°C throughout the entire operating temperature range.
Circulation of air in the CTU cubicle
The equipment inside the CTU is installed on the walls in a single row, which makes it possible to arrange a 1000-1200 mm wide passage inside the CTU. This makes it possible to carry out commissioning, repair, and other types of work inside the container without unnecessary discomfort.
There is a separate workspace for maintenance staff with a folding table, recesses for documentation and tools, and voltage-stabilized outlets for laptops.
Example equipment layout of a complete CTU (12 m box)
Example arrangement of equipment in the CTU TDCS
The frequency drives of the MP and SD lines have been designed to fit tightly into the block box. Minimal cabinet width with high power density and the possibility of mounting several frequency drives side by side. This allows the AT24 to be accommodated in any standard container.
The main fans of the frequency drives are mounted on the roof and blow the hot air forward, which makes it easy to arrange heat exhaustion from the frequency drive by means of ducts connected to the roof of the VFD.
Block boxes of the AT24 line DW are designed according to the requirements of the customer on a particular drilling rig.
This includes requirements for the topology of frequency drives (Triol offers both individual frequency drive for mud pumps and Top drive control system, and multi-motor MP line drive for CTU/ CTU TWU, transformers, climate control system, fire and security alarms, power for additional drilling equipment and microprocessor controller cabinet ( MCC -possible design based on Siemens or Fastwel controllers).
MCC- Siemens-based and touchscreen display 19''
Vector control with author's algorithms with motor torque limitation and motor speed control in Triol frequency drives provides reliable protection against motor overload and shaft breakage, while maintaining high speed accuracy throughout the entire control range.
When the motor generated torque reaches the limit value, the drive reduces the motor speed to provide a safe torque value and therefore the motor current.
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Accuracy of speed maintenance (static) |
± 10 % of nominal motor slip in open circuit |
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± 0,1 % of nominal speed in closed circuit systems |
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Torque accuracy |
± 10 % of nominal torque in open circuit |
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± 5 % of nominal torque in closed circuit |
Motor shaft lockout at a torque limit of 200 % of nominal motor torque
Motor shaft lockout at a torque limit of 200 % of nominal motor torque
The AT24 frequency drives of the MP and SD lines can be operated in master-slave mode in mechanically coupled two-motor systems (Tower-winch unit, Overhead Drive System, Top drive control system).
The main functions of the algorithm are as follows:
- automatic maintenance of speed or torque of electric motors according to a reference signal;
- equal division of load torque between two drive motors;
- Avoidance of speed mismatch between the motors until the system is shut down due to "overspeed" fault or one of the motors is overloaded.
Possible configuration of each VFD motor: master, slave, single, not used.
Practicing the task of Top drive control system in twin-motor mode
Practicing "Motor Shaft Interlocks" in twin-motor mode
