A Training Course for Rig Electricians

VFDs

Section 5
Variable Frequency
Drives

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

2 How Does It Work.................................................... 7
3 How Do I Operate it ............................................... 20
4 Inspection............................................................. 21
5 Maintenance.......................................................... 22
6 Spare Parts ........................................................... 23
7 Trouble Shooting ................................................... 24
8 Questions ............................................................. 25
9 Reference Material ................................................. 27
10 Assignments ......................................................... 28
11 Glossary............................................................... 29

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1 Equipment Overview
Up until recent times the preferred drive system for drilling
equipment has been DC traction motors, primarily because of
the high torque and speed control ability of this equipment
from zero to full speed, regardless of whether the power source
was DC to DC, or AC to DC systems.

1.1 DC System

A DC generator is used to drive DC motors which in turn drive

the drilling equipment, using the Ward Leonard type system of
speed control. This is achieved by varying the field of the
generator which controls the output voltage feeding the DC
traction motors.

1.2 AC System

Alternatively in the case of the AC system, AC generators

supply AC to an SCR system, which converts AC to DC to drive
the DC traction motors on the drilling equipment. These SCRs
convert 600 volts AC to a 0 to 750 volt DC output for the
control of the DC traction motors.

1.3 DC Traction Motors

Shunt Motors: Can be controlled by the field windings to

refine their control and are good for constant speed.

Series Motors: Are high torque from the initial start, as the
field windings are in series with the armature, but are able to
reach destructive speeds if unloaded without protective devices
installed.

1.4 Variable Frequency Drives System

In recent years there has been a move to VFDs or Variable

Frequency Drives to drive AC induction motors as the power
medium on modern drilling equipment. The voltage and
frequency are controlled to perform the same duty as the
previous DC systems and give the same degree of control
ability with a reduced level of maintenance from that of the DC
motors.

The DC motors require constant attention to keep them trouble

free, especially at the commutator end. But the AC motor used
on Top Drives is basically a three phase squirrel cage induction
motor refined for use with this system, so it does not require
the same level of maintenance as the DC motors.

1.5 Advantages of VFD

There are advantages from the safety point of view, in that

with the DC motors, there will always be commutator sparking
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and the risk that poses in hazardous locations, even with air
purging and spark arrestors. Where as no such problems exist
with the AC motors, although they still need cooling to prevent
overheating. Another advantage with the AC motors is the fact
that the insulation is fully sealed against the offshore
environment situation of damp salt air.

The DC motor has always been a high maintenance item with

the need for cleaning to remove carbon residue from the brush
gear and commutator area, to reduce the risk of flash over and
maintain the insulation value of the motor as high as possible
when it becomes cool and damp.

Also there is the need to replace the carbon brushes, due to

wear or broken pig tails. The brushes need to be “bedded in” to
match the contour of the surface of the commutator to reduce
sparking. The brush spring arms can often create problems
where the pivots become tight or partly seize and this reduces
the spring pressure on the top of the brushes resulting in
excessive sparking.

1.6 AC Top Drives

With respect to Top Drives the main advantage of the AC VFD

system is a much better load power factor. This is important as
many rigs are running out of kVA, and would need more
generator power to cure this problem. AC motors have a better
speed range and can be run at 200% of base speed and above.
This allows for more suitable gear ratios and therefore produces
a substantially better torque curve that delivers better
performance over a broader speed range.

1.7 AC/DC Motor Characteristics

The AC motor horsepower characteristics are far better than

the DC motor, where the DC motor can only maintain
maximum horsepower at one speed, the AC motor will maintain
full horsepower from base speed up to approximately 150% of
base speed.

AC top drives can maintain continuous stall torque, whereas the

DC motor in an extended stall situation will have reduced
torque capacity due to brush/commutator current limitations.
The AC induction motor can be stalled at its continuous rating
indefinitely because it has no brushes or commutator, to create
arcing or sparking, and can supply continuous torque in this
situation without doing harm to the motor or installation.

1.8 Parameters

The AC Top Drives have a lifting capacity of up to 750 tons, and

a drive capacity of up to 1150 horse power. They are normally
equipped with instrumentation to monitor various parameters
such as, lube oil pressure, lube oil temperature, blower cooling
air pressure and temperature. Along with an RPM sensor to
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monitor the rotating speed of the Top Drive, and gauges to

monitor hydraulic oil pressures on the unit.

1.9 Comparisons

Comparing the AC unit against the DC unit for torque, the AC

unit comes is superior with the AC unit producing a max
continuous torque of 51,000 ft/lbs, and a max intermittent
torque of 72,000 ft/lbs with a gear ratio of 6.808:1.

Where as the DC unit, limited by commutation, produces about

33,000 ft/lbs of maximum continuous torque with a gear ratio
of 4.971:1. So, if the motor is not well maintained and kept in
100% condition, this figure would not be obtainable. To
continue the comparison, the GE 752 High Torque DC motor
develops 1130 horse power, and this unit has a lifting capacity
of 650 tons, with a max speed of 267 RPM, compared to the AC
motors 265 RPM.

1.10 Permanent Magnet Synchronous AC Motors

The move to AC power for Top Drives has been further

advanced by the development of liquid cooled, brushless
permanent magnet synchronous AC motors, which has been
made possible with a reduction in the cost of rare earth
magnets. Effectively replacing the conventional three phase
squirrel cage type induction motors.

1.10.1 Performance Characteristics

Now that the high performance brushless permanent magnet
motors can be constructed to heavy industrial or military
specifications, they are now suitable for rig operations where
conditions are harsh and there are stringent explosion-proof
requirements. New single motor arrangements up to 1000hp
and beyond are planned for the future and this makes these
motors ideally suitable for top drive service in the oil
exploration industry.

1.10.2 No Gearbox Required

One of the main attractions of these motors is high speed
torque where the motor can be used for direct drive without a
gear box, in a situation where the maintenance cost of
gearboxes is considered higher than that of motors. Gearboxes
require constant monitoring and are difficult as well as time
consuming to replace in the event of failure.

1.10.3 Construction
These motors are constructed with the use of rare earth
magnetic materials such as Neodymium-iron-boron (Nd-Fe-B)
or samarium-cobalt. The materials are similar but the later has
better high temperature characteristics although at a higher
price. The cost of Nd-Fe-B has fallen over the last five years

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making it more attractive, but the low production numbers

keep the cost of motors high.

As demand grows and unit production rates increase the sale

price of the motors will become more attractive.

1.10.4 Performance Benefits

The development of the magnets and the variable frequency
drives (VFDs) using insulated-gate bipolar transistors (IGBTs)
and integrated gate-commutated thyristors (IGCTs) have made
it possible to build this type of motor in the larger sizes for
applications such as drilling, where the VFD cost is outweighed
by the performance benefits.

1.10.5 Motor Cooling

Motor cooling is simplified due to the fact that heat is not
generated in the rotor. Only the stator or outer structure needs
to be cooled, where a water/glycol mix can be readily used to
cool the exterior of the motor. With the compact permanent
magnet motors there is a weight and size reduction of thirty to
fifty percent on an induction or synchronous motor when
compared to the heavier DC traction motors.

1.10.6 Greater Number of Poles

The brushless permanent magnet motors superior power
development results from a greater number of poles. These
motors can have as many as three times the number of poles
of a conventional induction motor of the same diameter. This
concept allows for a lighter, smaller, and more flexible motor
layout.

1.10.7 Accept Higher Frequency

With the higher pole numbers in the motors, the VFD can
operate at higher electrical frequencies. A permanent magnet
motor at a particular speed can require an input of up to 415Hz
in a high speed, high rating application. This can be from a
designed driver for the VFDs power topology and control band
width.

1.10.8 Application
Moving away from the top drive situation to the other main
drives on the rig such as the drawworks, mud pumps, and
rotary table drives. These equipments are now being driven via
VFDs and AC induction motors in place of the traditional DC to
DC and SCR systems. VFD units have increased in size to be
able to cope with large squirrel cage induction motors as used

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in AC top drives. These newer VFDs are now able to be used in

modified form to drive new larger liquid cooled brushless
permanent magnet synchronous AC motors.

These brushless PM motors are currently rated up to 450 HP

when liquid cooled, and though more expensive due to the
manufacturing material cost, offer smaller size, higher power
density, higher dynamic performance, and higher efficiency
without rotor losses.

A European company is producing a high performance

permanent magnet motor rated to 1341HP at speeds up to
2600RPM. In most cases a permanent magnet motor is 1-2%
more efficient than an AC induction motor or synchronous
motor at full load, and 10-15% more efficient at partial
loadings. These efficiencies are derived from full rotor
excitation without current and without losses.

1.10.9 Manufacturers
There are several manufacturers of the VFD control systems
such as:

Siemens, DRS Technologies, Square D, Allen Bradley,

General Electric, Cutler Hammer, ABB etc.

Figure 1 Cutler Hammer Variable Frequency Drive

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2 How Does It Work

2.1 VFD Basic Principle

The Variable Frequency Drive system is used for the speed

control of the AC or Alternating Current motors. It does this by
controlling the frequency and voltage of the power supplied to
the motor. This is used in the same way as the SCR system is
used to control the DC motor, so that the AC motor speed can
be controlled over the full range from zero to full speed during
drilling operations.

Variable Frequency Drives operate on the principle that the

synchronous speed of an AC motor is determined by the
frequency of the applied AC supply and the number of poles in
the stator winding. The motors used in this type of system are
normally three phase induction motors which are suitable to
most applications, and are generally the most economical
choice of motor. In some cases enhancements are made to
improve the motors VFD performance and reliability, and the
AC motor is well suited to situations where the environment is
wet, corrosive, and explosive.

The Variable Frequency Drive controller is a solid state

electronic power conversion type device. This converts AC input
power to DC power by the use of a three phase bridge rectifier,
and then the DC power is converted to quasi- sinusoidal AC
power by using an inverter switching circuit. These are called
insulated gate bipolar transistors (IGBTs ) and are used in most
inverter circuits.

Variable frequency AC motor drives, called inverters are

generally more complex than the normal SCR type DC
controllers, as they must perform two distinct functions. They
must convert AC line power to DC and filter/smooth it. Then an
inverter stage is required to convert the DC to a controlled
adjustable frequency and voltage output to the AC motor.

2.2 Advantage of VFD

The advantage of the adjustable frequency drive is in the use of

the AC induction motor, with its simplicity, reliability and low
maintenance requirements. Without the high maintenance
moving parts of a DC motor in the normal DC system, the
complexity of the AC control system is a small disadvantage.
The low cost of the AC motors is another attraction when
considering the initial cost of a system, and ongoing running
costs.

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The AC motors require the supply voltage to be adjusted

proportionally when the frequency is changed. If the motor was
designed to operate at 480 volt 60Hz, then the applied voltage
must be reduced to 240 volt when the frequency is 30Hz, to
keep the ratio of volts per hertz at a constant regulated value
(480/60 = 8 in this case). For the best performance some
voltage adjustment may have to be made, but normally the
constant volts/hertz ratio is the rule.

2.3 Characteristics of VFD

The main function of variable speed drive is the control of

speed, torque, acceleration, deceleration, and direction of
rotation of the AC induction motor to the same level of control
as that of the DC motor drives.

The drive can control two main functions of the induction

motor, speed and torque, and to understand how the AC drive
controls this performance we need to look at the principals of
the AC induction motor, which has two basic parts, the Stator
and the Rotor which create a magnetic interaction while
operating.

2.4 Squirrel Cage Induction AC Motor

A squirrel cage induction motor Stator contains pairs of poles.

These are laminated iron cores located inside the Stator, with
the insulated single core cable wound into it to create
electromagnets in pairs. They provide North and South poles
and in doing so create a revolving North and South field. The
ends of these coils are brought out to the junction box of the
motor for termination in the correct order to determine the
polarity of each coil in the system.

2.5 Base Speed/Slip

Base speed is the nameplate speed, given in RPM, where the

motor develops rated horsepower at rated voltage and
frequency. It is an indication of how fast the output shaft will
turn the connected equipment when fully loaded with proper
voltage and frequency applied. Consideration has also to be
given to slip, where slip is the difference in speed between the
Rotor and the rotating magnetic field in the Stator.

When a magnetic field passes through the rotor, the conductors

in the Rotor take on a field of their own. This Rotor field will try
and catch up to the Main rotating field in the Stator, but it will
never catch up. This difference is called slip, and the motion of
the Rotor field chasing the Stator field is the cause of the
motors rotation.

2.6 Motor Speed

The speed of the motor can be adjusted by altering the

frequency of supply to the motor, but the speed could also be
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adjusted by changing the number of poles in the motor.

However, this change would be permanent and require a
rewind.

Chart 1 Poles / Frequency / Speed

2.7 Motor Torque

To change the torque characteristics of a motor the Volts per

Hertz ratio needs to be changed, so if we take a 460 Volt 60Hz
motor with a source ratio of 7.67 and as long as this stays the
same the motor will develop the rated torque for that ratio, but
the AC inverter drive develops many different frequency
outputs, and at any given output you will get a new torque
curve.

Chart 2 Speed / Torque / Current

2.8 Pulse Width Modulation

The method used normally to adjust the motor voltage is called

pulse width modulation or PWM, in which the inverter switches

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are used to divide the quasi-sinusoidal output waveform into a

series of narrow voltage pulses and modulate the width of
pulses. Changes to the switching frequency will correspond to a
change in motor speed when comparing a,b, & c.

Figure 2 Example of PWM On/Off Cycles

An embedded microprocessor is used to control the overall

operation of the VFD, and the main microprocessor
programming is in firmware that is not accessible to the VFD
user. Some degree of configuration programming and
parameter adjustment is usually provided so that users can
customise the VFD controller to suit specific motor and drive
equipment requirements.

Figure 3 Pulse Width Duty Cycles

2.9 Basic principle

Below are the components of a basic PWM (Pulse Width

Modulation) Drive, showing the three phase supply to the
bridge which will rectify the AC current to DC current and then
the inductor or choke L 1 and capacitors C1 to filter and smooth
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the AC before it reaches the inverter which converts the DC

back to AC for the control of the motor with the aid of the
control logic, and all PWM drives will contain these main
components, with some differences in hardware and software
components.

Figure 1 AC/DC Converter

2.10 Explanation of Power Path

In the drilling exploration industry for our main drives we are

only interested in three phase units of high capacity, but to
make the following schematics better understood we will follow
a single phase through the system. If we take L 1 phase and
follow it through the diode where the current will flow in the
positive half of the cycle but stop flowing when the cycle
reverses, so one gets half cycles only through each diode. Then
on to the DC link which is an inductor or choke (L 1) and the
capacitors ( C 1 ) will work together to filter out any AC wave
form left over from the bridge rectifier. This will leave the
rectifier as a DC flow, formed by a continuous flow of positive
waves that are formed by the positive halves from all three
phases passing through the diodes.

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The inductor or choke by its nature will resist change in voltage

or current which tends to remove the ripple, and the capacitors
by their nature charge and discharge into the system. In doing
so they too remove ripple left over from the half-wave DC
created by the rectifier section, taking the positive half waves
from the three phase alternating current supply and smoothing
them to remove the ripple.

The smoother the DC into the inverter the better the wave form
out of it to the motor, and the rectified DC value is
approximately 1.35 times the line to line value of the supply
voltage, and the rectified DC value will be approximately 650
volts DC for a 480VAC input supply.

Figure 2 AC/DC Converter

2.11 Insulated Gate Bipolar Transistor (IGBT)

The Inverter will convert the DC back into AC, with a variable
voltage and frequency output to control the motor. This is
achieved by using Insulated Gate Bipolar Transistor (IGBT)
technology, to switch the DC supply on and off at specific
intervals, and in doing so creates a variable voltage and
frequency output. However the output does not provide an AC
sine wave the same as the input sine wave from the original
supply, but creates voltage pulses of a constant magnitude.

The output voltage and frequency to the motor are controlled

by the control logic and inverter section. This section consists
of 6 IGBTs and the following schematic, shows the inverter
circuit in which the control logic uses a microprocessor to
switch the IGBTs on and off, providing a variable voltage and
frequency to the motor.

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The drives control system, signals the control circuits to turn

“on“ the wave form positive half or negative half of the
inverter, this alternating of positive and negative switching
recreates the three phase output. The longer the inverter stays
on, the higher the voltage output, and conversely the shorter
the period, the lower the voltage. Consequently the longer the
device is in the off position, the lower the output frequency.

Figure 3 DC/AC Converter

2.12 IGBT Composition

The IGBTs provide the high switching speed required for the
PWM inverter to operate, and are capable of switching on and
off several thousand times per second. An IGBT can turn on
in less than 400 nanoseconds and off in approximately 500
nanoseconds.

Figure 4 Symbol of IBGT

The IGBT consists of a gate, collector and emitter, which when

a + 15VDC is applied will turn on, which is equivalent to turning
on a switch. Current will flow from the collector to the emitter,
but will turn off if the positive voltage is removed. It is normally
held in the off position by applying a – 15VDC to the device to
prevent it turning on until required.

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2.13 Frequency

The speed at which the inverter switches on and off is referred

to as the carrier frequency, or switching frequency, and the
higher the switching frequency the more resolution each PWM
pulse contains. These frequency are normally 3000 to 4000
times per second or 3KHz or 4KHz, compared with SCR type
systems which are normally 250 to 500 times per second. The
higher the switch frequency the smoother the output wave form
and the higher the resolution, but the higher frequencies will
decrease the drive efficiency because of increased heat in the
power devices. An indication of the switching used in the
inverter process is shown in the schematic below. Using
switches instead of IGBTs and following a single phase
example, an alternating voltage is developed by opening and
closing switches in a set sequence.

Looking at the generated sine wave from the VFD to the three
phase motor windings, across Line 1 and Line 2, it can be
shown that;

Step 1 & 2, by closing A+ & B- a positive voltage will be

seen across L1 & L2.

Step 3, by opening B- and closing A+ & B+ the voltage

across L1 & L2 is zero.

Step 4 & 5, by opening A+ and closing A- a negative

voltage will be seen across L1 & L2.

Figure 5 Graphical Representation of Switching

This represents one cycle across L1 and L2 and is repeated in

sequence across all L1, L2 and L3 phases that supply the
motor.

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2.13.1 VFD Voltage

Is dependant on the value of the DC voltage supplied from the
rectifier.

2.13.2 VFD Frequency

The frequency is dependant on the speed of the switching, and
an AC sine wave has been added to the output (A-B) to show
how the AC is simulated.

2.14 SCR Compared To IGBT’s

The SRC or Thyristor differs from the IGBT in that the SCR is
controlled by the use of the “Gate” by which the SCR can be
switched on allowing it to fully conduct, and will continue to
conduct until the polarity reverses. It will then automatically
turn off. The out put of the SCR depends on how soon in the
cycle the gate turns on.

With the IGTB it is much the same as the SCR, in that the
output is controlled by the amount of time the gate is on, but it
can be turned off at any time in the control cycle, and thereby
providing a more precise output waveform. The IGTB requires
control circuitry connected to the gate, but it is less complex
than the SCR and does not require reversal of polarity to switch
it off.

There are several PMW modulation techniques. The following

text and illustrations describe a typical pulse width modulation
method. An IGBT (or other type switching device) can be
switched on connecting the motor to the positive value of DC
voltage (650 VDC from the converter). Current flows in the
motor. The IGBT is switched on for a short period of time,
allowing only a small amount of current to build up in the motor
and then switched off.

The IGBT is switched on and left on for progressively longer

periods of time, allowing the current to build up to higher levels
until the current in the motor reaches a peak. The IGBT is then
switched on for progressively shorter periods of time,
decreasing the current build up in the motor. The negative half
of the sine wave is generated by switching an IGBT connected
to the negative value of the converter DC voltage.

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The more sinusoidal current output produced by the PWM, the

greater the reduction of torque pulsation, or low speed motor
cogging, and motor losses, usually noticeable when using a six
step output.

Figure 6 Pulse Width & Wave Form Comparison

The 650 volt DC output from the rectifier section is modulated

by the IGBT section to provide variable frequency and voltage.
When the IGBTs are turned on for shorter periods of time,
lower frequency and voltage are produced and the motor
voltage and current build up is low resulting in lower motor
speed. If the IGBTs are turned on for longer periods of time,
which results in higher frequency and voltage output. With this
increase in the voltage and current build up, the motor speed
will increase.

Figure 7 Voltage & Current Comparison

2.15 AC/DC Motor Comparison

In the past the dynamic response of the DC motor has always

been considered superior to that of the AC motor. However the
cost of the AC motor is significantly less than the DC motor and
the AC motor requires much less maintenance. By using a
complex motor model and internal computer algorithms, vector
control is able to exert dynamic control over the AC motor so
that its control is equal or better than that expected of a DC
motor.

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2.16 Vector Control

Vector control, flux vector, and field orientation are terms that
describe this specialised control technique of AC drives. Vector
control makes possible the control of the flux and torque in a
squirrel cage induction motor. Sensorless vector control system
calculates the base speed of the motor based on the
specifications of that motor. Calculated counter electromotive
force, inverter output voltage, inverter input current, and the
results are improved dynamic control compared with other
systems of control.

Vector control without a tachometer becomes impractical below

a few hertz due to slight variations in stator resistance, a small
counter electromotive force and other parameters which have
an effect on accurate speed calculations. Sensor less vector
control will operate at low speed, and will produce full torque at
a few hertz, with 150% or more torque available at all speed.
But there are some complicated techniques required to achieve
low speed torque, and this may require expert commissioning
to get the best results for your operation.

2.17 Speed Torque

In the speed-torque charts there are four sectors which are

governed by the direction of rotation and torque. A single
quadrant drive operates in quadrant 1 or 3 where quadrant 1 is
for forward motion, clockwise, and sector 3 is for reverse
motion, counter clockwise. Where reverse motion is achieved
by reversing the direction of the rotating magnetic field in the
stator.

Figure 9 Speed Torque Graphic

The motor torque is developed in a positive direction to drive

the load at the required speed, and this is the same as any load
in that the maximum amount of torque is required to move the
load from standstill. Once it is up to the required speed the
torque can be reduced to the amount required to maintain that
speed at a constant, but if the load increases then more torque
will be required to maintain the speed at the preset level.

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2.18 Controlled Braking

Stopping the motor in a quadrant 1 situation is achieved by

simply removing the power from the motor and allowing it to
coast to a standstill, as would happen with any motor with the
power supply removed.

Controlled deceleration can be achieved by gradually reducing

the voltage and frequency until the motor is at a standstill. The
time taken will depend on the amount of inertia in the rotor and
the connected load, to dissipate its energy, the greater the
inertia the greater the time to stop.

2.19 DC Injection Braking

The motor can also be stopped by DC injection braking, which

will stop the rotating magnetic field, and apply a constant
voltage to the stator windings which will help to stop the motor.
Where in this method up to 250% of the motors rated current
can be applied to the windings, which will rapidly bring the
motor to a standstill.

2.20 Compound Braking

Compound braking can be used with a combination of

controlled deceleration and DC injection braking, and this is
achieved where the drive monitors the bus voltage during
operation. Which triggers braking when the bus exceeds a set
threshold point, as the motor decelerates a DC voltage is
applied to the motor windings periodically, and the excess
energy is dissipated into the motor windings until it comes to a
standstill.

With certain dynamic loads quadrant 4 operation may be

required when an additional resistor is employed for braking,
torque will tend to cause the motor rotor to run towards
synchronous speed, and if synchronous speed is suddenly
reduced, negative torque is developed in the motor. Where at
this point the motor will act like a generator, converting
mechanical energy at the shaft into electrical power which is
returned to the drive and braking occurs in quadrant 2 and 4.

2.21 Pulse Resistor Braking

For a drive to operate in quadrant 2 and 4, a path must be

created to channel the electrical energy returned to the drive
by the motor. This motor energy can cause voltage in the DC
link to become extremely high when added to the existing
supply voltage, at which point various drive components can be
damaged by excessive voltage.

So in the case of companies such as Siemens an optional

braking resistor can be supplied.

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The braking resistor is added and removed from circuit by an

IGBT, and the energy returned by the motor is seen on the DC
link. So that when the DC link reaches a predetermined limit
the IGBT is switched on by the control logic, and the resistor
placed across the DC link.

Figure 10 Braking resistor & IGBT

The excess energy is dissipated by the resistor reducing the bus

bar voltage. When the voltage is reduced to a safe level the
IGBT is switched off, removing the resistor from the DC link.

This mode of braking is referred to as pulse resistor braking,

and this allows the motor to work as a brake slowing the
connected loads quickly.

2.22 Protective Features

The VFD shall include the following protective features:

Protection against input transient voltage spikes.

Separate overload protection for each motor controlled.

Protection against input power under voltage, over

voltage, and phase loss.

Protection against output current overload and over

current.

Protection against over temperature within the VFD

enclosure.

Protection against over voltage on the DC bus.

DC bus discharge circuit for protection of service

personnel.

Insensitive to incoming power phase sequence.

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3 How Do I Operate It
3.1 General Guide

Controls are provided for the operator to start and stop the
motor, adjust the motor speed to their requirement and
switching for a reversing function. The operator interface will
have all the usual drill console control and indication. This will
also provide information about the drive operation while
drilling.

When the motor is started with the VFD, it is normally low

frequency and low voltage, with a starting frequency of 2 Hz or
less is common, starting with such a low frequency avoids the
high inrush currents typical of DOL starters, so when the VFD
starts, the applied frequency and voltage are increased at a
controlled rate, or ramped up accelerating the load without
drawing excessive current, the range is from about 2 Hz to 90
Hz for the range from 0 to max speed.

This starting method allows the motor to develop 150% of the

rated torque while drawing only 150% of the rated current.
Instead of the normal 300% plus current of a normal DOL
starter, with less than 150% of the rated torque, and the load
accelerates with 150% torque which can remain constant from
standstill to full speed while still only drawing 150% of the
current.

The VFD stop sequence is the opposite of the starting

sequence, where the frequency and voltage are ramped down
at a controlled rate, and when the frequency approaches zero
the motor is shut off, and a small amount of braking torque is
available to help decelerate the load a little faster than if the
motor was just switched off and allowed to coast to a stand
still, additional braking can be obtained by adding a braking
circuit to dissipate the braking energy or return it to the power
source.

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4 Inspection
4.1 Daily General Rig Inspections

Check inside all the cabinets and make sure they clean and
dust free, and that any filters on the cooling systems are clean,
to maintain a good air flow for cooling and prevent the entry of
dust and dirt into the cabinets, in the VFD power supply system

Check all the normal interlocks to make sure they are operating
and all the auxiliaries are operating as they should, such as
motor cooling blowers, lube oil pumps, and cooling pumps,
when the assignments are made to start the Top Drive to
provide all the ancillaries for the operation of the Top Drive

There should be a daily visual inspection of the Top Drive unit

during the morning walk round inspection of the rig, to make
sure there has been no overnight damage that is obvious on
the Top Drive, or service loops during the operation, and that
there are no obvious lose nuts and bolts on the assembly.

Check the alignment cylinder operation weekly. Also, inspect all

moving parts and check the accumulator pressures on a weekly
basis.

Varco installs exhaust mufflers on the exhaust ports of the

multi-gang solenoid valve manifold for noise abatement. All
such mufflers reduce noise, and collect contaminates that can
eventually restrict the air passage. Air passage restriction can
result in back pressure on all of the solenoid valves, and erratic
valve operation.

Check the operating controls and instrumentation for the unit

on the Drillers Console on the daily walk round inspection and
check with the Driller to see if there are any problems that
have occurred over night that needs to be attended to at the
next drilling break.

Service loops are always a concern and should be observed for

any signs of damage from drilling equipment on the morning
walk around in case they are no longer being restrained to keep
them clear of rotating equipment during their travel up and
down the derrick and being kept out of harms way, as failure
can be expensive and time consuming.

In the case of Drawworks, Mud Pump, and Rotary Table

motors, these need to be kept clean, and cooling systems
inspected to be sure that adequate cool air is circulating to
maintain the motors normal working temperature and prevent
overheating of the motor.

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5 Maintenance
5.1 General Maintenance

The VFD can be considered to be two sections, power and

control, with the power section controlling high current and
variable voltage and frequency to deal with the output to the
traction motor to drive the drilling equipment on the rig. With
the control section the control is left to a Digital Signal
Processor which meets the logic and decision making
requirements.

5.1.1 Cleaning
With the maintenance on these units there are several things to
consider as basics, in that they need to be kept clean to reduce
the risk of tracking or flash over in the components which will
occur if dust and dirt are allowed to accumulate. The units
need to be blown out with clean dry air, paying attention to the
dry part, as some air systems on a rig if the air driers are not
working, will be carrying a lot of moisture and in some cases
oil, which can be dumped in the equipment with unwanted
results.

There is always the risk when blowing equipment out with

compressed air of generating electrostatic charges which can
damage components as well. There are cans of non static
generating sprays, and purpose built vacuum cleaners that will
reduce static build up, and these are available from companies
that specialise in static control equipment to prevent damage to
static sensitive equipment.

For the same reasons the units need to be kept dry, even more
so if there is a build up of dirt or dust which can become mud
with a little moisture. This can provide paths for tracking or
flash over which will leave a lot of damage if it should occur,
and may be difficult to repair quickly, so it is better if it never
occurs.

5.1.2 Termination Tightness

A check should be kept on all terminations to make sure there
are no loose connections that can become hot joints in the
future as these too can cause damage that may be difficult to
repair. Vibration and heat cycling can lead to terminations that
are not as tight as they should be and these should be checked
occasionally to make sure they are tight, but re-torquing is not
recommended as this can lead to stretched bolts if performed
too often, and the deformation of the contact faces and
reduction of current carrying capacity.

5.1.3 Filter System Checks

As with most equipment of this type cooling is critical, so any
air filter systems that are there to keep the dirt and dust out,

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need to be kept clean to maintain the air flow to the equipment

for cooling purposes. The filters should never be left off the
intakes, as once the dust or dirt gets into the heat sinks it can
be very hard to remove, and cause a fall in the performance of
the system and risk loosing components to overheating

5.1.4 Air Conditioning Checks

In most situations if the rooms are air conditioned this will
remove much of the moisture from the air and dump the
condensate outside the switch room. But if the air conditioning
system fails, the cold parts will suffer from condensation when
the warmer air hits them as the room warms up to the outside
temperature.

Because the VFD is controlled by what is basically a computer,

and that computers are temperature sensitive, and should be in
an environment where the temperature is controlled for them
so they do not become subjected to extremes of temperature.
As with any electronic equipment if this is observed one can
expect trouble free operation for a long period of time.

5.1.5 Space Heater Checks

If the system is operating continuously the warmth of the
components will drive out any moisture, and in some early
systems there was condensation protection installed that would
not allow the system to start if the temperature was below 32°
F. But very few have this now, but space heaters can be used if
the equipment stands idle for long periods of time so the
components are kept warm and free of condensation.

5.1.6 Temperature Checks

The heat sink temperatures should be monitored, and most
manufacturers have made this easy by installing a temperature
readout on the key pad or display. It should be part of the
normal routine to check these readings on a weekly or monthly
basis to monitor the VFD operation, and perhaps keep a record
of these readings in a log book.

6 Spare Parts
6.1 General Spares to be Kept

There should always be spares kept available for critical items

to the operation either on the rig or in a warehouse nearby
where they can be obtained quickly in the event of failure. At
the top of this list should be a spare motor which should be
available if required to replace the unit in service. Also any
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control modules that are critical to the operation so they can be

changed as quickly as possible in the event of failure.

6.2 Spare Components

Also there should be a stock of critical items such as throttles,

switches, solenoids, micro-switches, sensors, and printed circuit
boards, and any other items where failure is not an option in
the Top Drive system. If repairs are to be attempted on the rig
then there needs to be a stock of components to affect the
repairs, although if there are spare printed circuit boards, and
the fault has been found on the damaged board removed, then
the components required can be ordered to repair it. Bear in
mind the fact that other items may have been stressed when
that component failed, so there may be more than one fault on
that PCB.

It is not normally necessary to carry the complete

recommended spare parts list the manufacturer would have
you carry in stock, as some of these items will never be used
and take up valuable warehouse space on the rig, and only
time will confirm which parts should be kept on the rig at all
times.

It is the custom with most major manufacturers to do the same

with spare parts, where they try to have major distribution
centres where they can dispatch parts within 24 hours via air or
road freight anywhere in the World, but this may not be quick
enough for your situation so critical parts need to be within
easy reach.

Spare VFDs should be stored in a clean, dry environment with

no condensation allowed, and it should be placed in the PM
system so that it is powered up every 6 months to keep the DC
bus capacitors at their peak performance condition or their
charging ability will be significantly diminished. A capacitor is
much like a battery in that it needs to be used as quickly after
its purchase as possible or it will suffer a loss of usable life.

7 Trouble Shooting
7.1 What If It Breaks Down

Depending on what motor the VFD is controlling and what is

happening with the drilling operation at the time of the failure
will dictate the impact.

Generally if no redundancy exists with the equipment, for

example the Top Drive motor. It is critical to the safe operation
of the rig to diagnose and repair the fault as soon as possible.
It cannot be stressed more highly that any equipment that falls

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into this category should be the first that you should familiarise
and become conversant with.

7.2 Fault Finding

With VFDs the essence of keeping it in good working order is to

“ keep it clean” “ keep it dry” and “ keep the connections tight”,
which will normally give trouble free operation for many years if
the preventative maintenance is maintained. Whenever work
needs to be done on the VFD great care should be taken that
there is no stored voltage present in the form of the DC
capacitors, which will need to be discharged before work is
commenced to make the unit safe, and the DC bus capacitors
should be checked to see if they are swollen or leaking, and in
either case it could be a sign of component stress, or electrical
misuse and they will need to be replaced.

If measurements are taken of the voltage in the DC bus while

the unit is running, any fluctuations can indicate degradation of
the DC Bus capacitors, as one of the functions of the capacitors
is to act as a filter to smooth out the AC ripple in the bus, so
any AC ripple or abnormal AC voltage on the DC bus indicates
the capacitors are starting to fail and will need to be replaced.
Measurements at these points in the DC system of more than
4VAC can indicate a capacitor filtering problem, or a possible
problem with the diode bridge section ahead of the bus, and if
such voltage levels exist, consult the VFD manufacturer before
taking further action.

Most VFDs are equipped with terminal blocks at which these

test measurements can be taken and also for the connection of
the dynamic braking resistors. With the VFD in start at zero
speed, one should read an output voltage of 40VAC phase to
phase or less, and if you read more than this, you may have a
transistor leaking, and at zero speed the power components
should not be operating, but if your readings are 60VAC or
more you can expect power component failure.

8 Questions
1. What is the name of the twisting or turning force that
causes a motor to rotate?

a. Torque b. Inertia c. Friction d. Acceleration

2. The rate of doing work is called?

a. Inertia b. power c. speed d. energy

3. A motor with the rating of 60 kW would have an

equivalent horsepower rating of?

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a. 16.7 b. 47 c. 53 d. 150

4. Magnetic lines of flux in an AC motor are proportional to

a. voltage/frequency b. frequency/voltage
c. rotor speed/synchronous speed
e. synchronous speed/rotor speed.

5. A four pole motor operating at 50 Hz has a synchronous

speed of rpm

a. 1500 b. 3000 c. 1800 d. 3600

6. A motor operated within a speed range that allows a

constant volts per hertz ratio is said to be

a. constant HP. b. variable torque c. constant torque

d. variable flux

7. The section of an AC drive that controls output voltage

and frequency to an AC motor is the

a. converter b. DC link c. inverter d. L1 choke

8. A centrifugal pump is what kind of application.

a. constant torque b. constant flux

c. constant HP d. variable torque

9. IGBT’s are capable of being switched how many times a

second

a. 60 times b. hundred times

c. several thousand times d. million times

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

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.

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.

9.1 References

Institute of Electrical and Electronic Engineers:

IEEE C62.41 - Recommended Practice on Surge Voltages in

Low-Voltage AC Power Circuits.

9.1.1 Compliance
National Electrical Manufacturers Association:

NEMA ICS 7.1 Safety standards for construction and guide

for selection, installation, and operation of adjustable speed
drive systems.

NEMA ICS 7 Industrial control and systems: adjustable

speed drives.

NEMA FU1 Low voltage cartridge fuses.

NEMA 250 Enclosures for electrical equipment (1000 volts

maximum).

9.2 Web Sites

http://www.sea.siemens.com/step/default.html

http://www.vfdsystems.com/

http://www.nov.com/Archives/c2orange.pdf

http://www.mielectric.com/brochures/AcDc.pdf

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10 Work Place Assignments

Note.

This assignment is to make you aware of all the AC driven

equipment that is supplied and controlled by a VFD that
makes up your work place systems. It will lead you to the
main source of supply being the VFD Panel (variable speed
drive) and then onto the motor and control equipment that is
supplied from this equipment.

1. Find all VFD Control Cubicles (VFD) associated with

the AC motors being supplied and controlled from
this equipment. Write down the description and tag
number that is displayed on the VFD.

2. Go out into the field and locate the associated motor

that this drive controls. It should be clearly
identified with the same description and tag number
that you found on the VFD cubicle.

3. If you look closely there should be a Stop/Start

station with the ability to adjust the speed of the
equipment nearby clearly marked with the same ID.
This device should also have the ability to lock out
the motor from starting for maintenance. Be aware
that this motor may also be controlled from a
remote location.

4. Look for all of the documentation including

schematics and layout diagrams associated with this
equipment. Make yourself conversant with type of
systems you have discovered and the AC motors
that are controlled and feed from this equipment.

5. Particular attention should be given to the trouble

shooting documentation. Read carefully all of the
information given covering this area and familiarise
yourself with the locations of fault indications and
test points.

6. If your rig has an AC top drive ask your drilling

supervisor to show you the driller’s controls and to
explain the functions that are common to this
system.

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11 Glossary
Variable Frequency Drive (sometimes abbreviated VFD)
Is electronic equipment that allows an electric motor to be
run at varying rotational speeds. VFDs are frequently used to
start large three-phase AC synchronous motors. These
motors cannot be started simply by applying line frequency
mains power; the rapidly rotating magnetic field would be
unable to overcome the inertia of the rotor (and any
connected load). Using a VFD provides one possible means to
start these motors: the VFD will start using a low frequency
that the rotor can follow, ramping up the frequency as the
rotor accelerates. And unlike other starting methods, the VFD
also allows very efficient speed control once the motor is
running (simply by varying the ultimate frequency of the
supplied power).

Adjustable speed The concept of varying the speed of a

motor either manually or automatically. The desired
operating speed (set speed) is relatively constant regardless
of load.

Base speed Base speed is the manufacturers nameplate

rating where the motor will develop rated HP at rated load
and voltage. With DC drives, it is commonly the point where
full armature voltage is applied with full rated field excitation.
With AC systems it is commonly the point where 60 Hz is
applied to the induction motor.

Bi-Directional Motors have equal performance

characteristics in CW and CCW rotation.

Breakaway Torque The torque required to start a machine

from standstill. It is always greater than the torque needed
to maintain motion.

Breakdown Torque The breakdown torque of an AC motor

is the maximum torque which it will develop with rated
voltage applied at rated frequency

Constant voltage range ( AC Drives ) The range of motor

operation where the drive’s output voltage is held constant
as output frequency is varied. This speed range produces
motor performance similar to DC drive constant horsepower
range.

Constant volts per Hertz This relationship exists in AC

drives where the output voltage is varied directly
proportional to frequency. This type of operation is required
to allow the motor to produce constant rated torque as speed
is varied.

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Current Limiting An electronic method of limiting the

maximum current available to the motor. This is adjustable
so that the motors maximum current can be controlled. It
can also be preset as a protective device to protect both
motor and control from extended overloads.

Duty Cycle Is a ration of operating time to total cycle time,

expressed in percent.
.
Efficiency Of a motor is the ratio of output power to input
power, and is expressed in percent.

IGBTs Insulated Gate Bipolar Transistor Is a four-layer

(n-p-n-p) device with an MOS-gated channel connecting the
two n-type regions. In the normal mode of operation, a
positive voltage is applied to the anode (A) relative to the
cathode (K).

Inverter A term commonly used for an AC adjustable

frequency drive. An inverter is also a term used to describe a
particular section of Ac drive. This section uses the DC
voltage from a previous circuit stage (intermediate DC
circuit) to produce an AC current or voltage having the
desired frequency.

MOSFETs Metal Oxide Silicon Field Effect Transistor

A common type of transistor in which charge carriers, such
as electrons, flow along channels. The width of the channel,
which determines how well the device conducts, is controlled
by an electrode called the gate, separated from channel by a
thin layer of oxide insulation. The insulation keeps current
from flowing between the gate and channel.

No Load Speed Expressed in RPM, represents rotational

speed of the motor when no force is applied to the output
shaft.

Open Loop A system in which there is no feedback. Motor

motion is expected to faithfully follow the input command.
Stepping motor systems are an example of open-loop
control.

PWM (pulse width modulation) Type of AC adjustable

frequency drive that accomplishes frequency and voltage
control at the output section (inverter) of the drive. The
drive’s output voltage is always a constant amplitude and by
chopping (pulse width modulating), the average voltage is
controlled.

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