Catterpillar Gens Set Requirment

APPLICATION
AND
INSTALLATION GUIDE
PETROLEUM APPLICATIONS
Contents
Petroleum Applications ......................................................... 1 Petroleum Equipment & Terminology................................... 2 Drilling Rig................................................................... 2 Conventional or Compound Rig................................... 4 Split Rigs................................................................. 5 Service Rigs................................................................. 6 Workover Rig ........................................................... 6 Technical Well.......................................................... 6 Additional Service Rig Terms...................................... 7 Mobile Rigs.................................................................. 8 Carrier Designations .................................................. 8 Mobile Rig Drivetrain Configurations.......................... 10 Production Pumping .................................................... 10 Piston Pumps ......................................................... 10 Centrifugal Pumps .................................................. 10 Horizontal Pumps.................................................... 10 Rating Review for Pumps......................................... 11 Fire Pump.................................................................. 11 Offshore Crane........................................................... 11 Auxiliary Power .......................................................... 11 Electric Power Generation................................................ 12 DC Generators ........................................................... 12
AC Generators with SCR ............................................. 13 Silicon Controlled Rectifier (SCR) Drives..................... 14 Variable Frequency Drive (VFD) Systems ....................... 14 Other Petroleum Power Application Considerations ............. 16 Loading Considerations ............................................... 16 Transient Response..................................................... 16 Sizing Criterion....................................................... 16 ISO Classification ................................................... 17 Equipment Selection................................................ 17 Off Shore Requirements .............................................. 18 Island Mode............................................................... 18 Motor Loads .............................................................. 18 Motor Starting ........................................................... 19 Regenerative Power .................................................... 20
Foreword
This section of the Application and Installation Guide generally describes Petroleum Applications for Caterpillar engines. Additional engine systems, components and dynamics are addressed in other sections of this Application and Installation Guide. Engine-specific information and data are available from a variety of sources. Refer to the Introduction section of this guide for additional references.
Information contained in this publication may be considered confidential. Discretion is recommended when distributing. Materials and specifications are subject to change without notice. CAT, CATERPILLAR, their respective logos and Caterpillar Yellow, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.
2006 Caterpillar All rights reserved.
Application and Installation Guide
Petroleum Applications
The use of Caterpillar engines in petroleum applications requires specific considerations for engine selection and installation to ensure dependable performance and a long, trouble-free life. Petroleum applications for diesel engines include drilling, well servicing, production power, offshore emergency or essential services power, and pumping applications. Natural gas engines are often used in petroleum applications for gas compression drive, production power and production pumping. The information presented in this guide will aid in planning, installation and customer acceptance phases of a project. While this application and installation guide summarizes many aspects of installation, Caterpillar dealers stand ready to assist you. It is the installers responsibility to consider and avoid possibly hazardous conditions which could develop from the systems involved in the specific engine installation. The suggestions provided in this guide regarding avoidance of hazardous conditions apply to all applications and are necessarily of a general nature since only the installer is familiar with the details of a particular installation. Consider the suggestions provided in this guide as general examples only and are in no way intended to cover every possible hazard in all installations.
SECTION CONTENTS
Petroleum Equipment & Terminology ........................ 2 Drilling Rigs Service Rigs Mobile Rigs Production Pump Fire Pump Offshore Crane Auxiliary Power Variable Frequency Drive (VFD) Systems Generator Set Engine Requirements
Other Petroleum Power Application Considerations...16 Loading Considerations Transient Response Offshore Requirements Island Mode Motor Loads Motor Starting Regenerative Power
Electric Power Generation ....12 DC Generator AC Generator with SCR
Page 1
Petroleum Equipment & Terminology

Before selecting an engine, a general understanding of the driven equipment is necessary. Since nomenclature in the petroleum industry is not completely standard, the terminology used in this guide should be considered representative. Below are the terms this guide uses for equipment and systems used in the petroleum industry. Electric rigs use engine power to drive one or more generators. The generated electricity is then used to operate motors for the larger equipment on the rig. There are three types of electric rigs: DC, SCR, and VFD. DC, or direct current indicates that a DC generator supplies power to DC motors. These are the oldest type. SCR, or Silicon Control Rectifier, indicates that AC power from the generators is changed to DC by switchgear to power DC motors. This allows for more power to be generated by smaller generators and is the most common type. VFD, or variable frequency drive, is the newest kind of rig which utilizes variable rpm AC motors allowing for even more power out of the same sized equipment. The details of these applications are discussed later in this guide. Typical rig equipment, for both mechanical and electric, include a drawworks, a rotary table and mud pumps. These equipment items are among the larger equipment on the rig and will have the most significant and important power requirements. Some applications also run compressors which can have any variety of power requirements. Drawworks The drawworks is the cable reel and controls that hoist the drilling string into place. The drawworks also has accessory drives which assist the crew to
Drilling Rig
Due to the fact that oil and gas are often located far beneath the earth's surface, it can take a lot of work to tap into reservoirs containing these resources. A drilling rig creates a borehole, or well, where oil and natural gas can be extracted for the production of fuels and other petroleum-based products. An example of a land based drilling rig is shown in Figure 1. While all drilling rigs move from site to site, some rigs require considerable effort and up to 70 semi trucks to change location, while others can fit on just one truck. These easily portable rigs will be referred to as mobile rigs and are discussed later in this section. Drilling rigs may be described as mechanical or electric. These terms refer to the method in which power is supplied to the larger equipment on the rig. On mechanical rigs, power from the engine(s) drives the rig equipment either directly, through a clutch or through a torque converter.
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make up and break out the joints to and from the drill string. The power rating of the rig refers to the power rating of the drawworks. However, the total power on the rig will be more. For example, a rig referred to as a 3000 hp rig will be equipped with more than 3000 hp (likely 4500 hp,) but is equipped with a 3000 hp drawworks. Drilling String A drilling string is a length of pipe made from separate pieces on which a drill bit or other borehole tools are mounted. A portion of the rotary table turns, which turns the drill string, which turns the bit attached to the bottom of the drill string. Electric rigs might also use a top drive instead of a rotary table. In this case, an electric motor in a piece of equipment attached to the traveling block on the hoist connects to the top of the drill string and serves to turn the bit. Rotary Table The rotary table provides the rotary movement to the drilling string. The table clamps to the kelly, a special length of rectangular pipe at the top end of the drilling string and a portion of the table turns, providing a clockwise rotation to the drill string. Mud Pumps Drilling fluid, or mud, is a slurry of fluid, chemicals and suspended solids. Mud pumps circulate the mud down the drill string and up the outside of the bore hole (also called the annulus). Mud pumps are usually
piston style, high pressure pumps. To meet industry demands, mud pumps are being designed for deeper wells, requiring higher horsepower. Mud is absolutely crucial to a successful drilling operation, making reliable power to these pumps equally crucial. Various mud formulas serve as a coolant for the drill bit, a medium for removing drilled rock (or cuttings) from the hole, and as weight to stabilize drill-casing pressures and reduce the possibility of blowouts. Mud pumps also supply other fluids and chemicals to the borehole that stimulate well production. Gas Compressors Unlike crude oil, natural gas cannot be easily pumped into tanks and shipped. To achieve enough volume for economical transportation, natural gas must be compressed and either loaded as a liquid into specially designed tank vehicles, or compressed into a pipeline. Engine driven compressors are commonly used for this purpose. Compressor plants, consisting of many individual compressors, pressurize natural gas so it will flow over long distances through pipelines. The pipelines are used to carry gas from the field, to auxiliary treatment processes and to market. AC Auxiliary Generators Although mechanical rigs are driven directly by engine power, AC electricity is needed for lighting, switches and smaller electric equipment. AC auxiliary generators
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provide the electricity needed on mechanical rigs. Conventional or Compound Rig Conventional rigs use a mechanical drive system, known as a compound, to transmit engine power to the rigs hoisting, drilling and mud pump systems. Various configurations of engines, compounds and equipment are possible; for instance, a compound may be used along with additional independent drives, as shown in Figure 1 and Figure 2. Clutches are used to transfer the power from the engines to the compound and the equipment. Power transfer from the engines can be direct drive (usually through an air clutch from the flywheel) or torque converter drive. Caterpillar engines work well with both, however a torque converter is more forgiving, and acts as a shock absorber which can reduce wear on
the engine and compound components. The torque converter does require cooling however (usually a 30% increase in heat rejection requirements) which must be taken into consideration when sizing the radiator. Other conventional rig details can be seen in Figure 1. The drawworks and rotary table are on an elevated structure to provide clearance for drilling safety valves. The engines are also elevated to simplify power transmission to the drawworks. Engine outputs are connected together with the compound. A number of clutches control power distribution. Normally, engines operate in compound while hoisting and separately when running the rotary table and mud pumps.
Conventional Rig
Figure 1
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Typical Conventional Rig
Figure 2
Typical Split Rig
Figure 3 Split Rigs Split rigs utilize independent drives to power the various pieces of drilling machinery. Figure 3 shows two engines driving the drawworks and rotary table through a compound and two independent engines driving separate mud
pumps. Split rig applications allow for numerous combinations of equipment, compounds and drives. This can include the use of electric motors for a portion of the rigs power requirement.
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Service Rigs
Similar to drilling rigs, service rigs can be mechanical or electric. Service rigs perform well servicing after the primary drilling is completed. This broad category generally includes oilfield activities that provide underground repair or alteration of an existing well. They help prolong the useful life of the well. Service rigs that utilize large engines are used to perform three distinct services: cementing, acidizing and fracturing. Workover and technical well are two types of service rigs. Workover Rig Workover rigs provide maintenance support for an existing well. This can include the removal and replacement of the drill-string, the repair of casings and cementing. A workover rig may be called a pulling unit when there is no provision of rotating the tubing string. Cementing Cementing is the process of pumping cement down a well bore to anchor the casing. Cementing can be required several times during the drilling and workover of a well. Cementing units normally carry mixing equipment not found on acidizing/fracturing units. Cementing a well requires less power, 75-373 kW (100-500 hp) than fracturing or acidizing [50010000 hp (373-7460 kW)]. Cementing is thus usually done with trucks with two engines of
approximately 400 hp (300 kW) each. Additionally, some rigs include a limited rotary table capacity for use during well bore cleanout, while drilling out plugs (packers), or limited redrilling in an existing well. Technical Well Technical well service rigs are not equipped to do mechanical work on a well. Technical well services provide support functions to improve production. One capability is to provide means to change productivity of underground formations. This is usually done by acidizing and fracturing. Multiple mobile units are used for high power acidizing and fracturing operations. Acidizing Acidizing is the process of pumping an acid down the casing of a completed well into the desired producing formation. Certain types of rock can be dissolved by acid, and this dissolving process creates channels by which hydrocarbons can more readily flow to the well bore. Fracturing Fracturing is the process of applying an ultra-high pressure, 13783 to 103448 kPa (2,000 to 15,000 psi), down the casing of a completed well to a desired producing formation. This pressure fractures the rock and creates channels by which hydrocarbons can more readily flow to the well bore. The same service rig may be used to acidize or fracture. This does however require changing the fluid
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end of the pump to match various pressure and flow requirements. An acidizing and fracturing unit consists of an engine, transmission, and piston-type pump. This equipment is usually mounted on a commercial truck chassis or may be trailer-mounted. Mobil rigs will be discussed in more detail later in this section. Figure 4 shows a mobile acidizing/fracturing unit. Fracturing and acidizing are usually performed by trucks that have a 1250-2250 hp (930-1575 kW) engine. A cement unit is similar but uses smaller engines; cementing units are not normally used for fracturing and acidizing.
Additional Service Rig Terms Coil Tubing Coil tubing is a long, continuous length of pipe wound on a spool. The pipe is straightened prior to pushing into a well bore and recoiled to spool the pipe back onto the transport and storage spool. Depending on the pipe diameter, typically 25.4 to 114.3 mm (1 to 41/2 in.), and the spool size, coiled tubing can range from 610 to 4570 m (2000 to 15,000 ft) or greater length. Well Workover and Intervention Well workover and intervention is a generic term relating to the use of a coiled tubing string and associated equipment. As a well-intervention method, coiled tubing techniques offer several key benefits over alternative well-intervention technologies. The ability to work safely under live well conditions, with a continuous string, enables fluids to be pumped at any time regardless of the position or direction of travel. This is a significant advantage in many applications. Installing an electrical conductor or hydraulic conduit further enhances the capability of a coiled tubing string and enables relatively complex intervention techniques to be applied safely. Blenders Blenders are the equipment used to prepare the slurries and gels commonly used in stimulation treatments. The blender should be capable of providing a supply of adequately mixed ingredients at the desired treatment rate. Modern
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Figure 4
Nitrogen Pumping Nitrogen pumpers can be used with fracturing units. Nitrogen is used for foam-fracturing in formations that would be damaged by a large volume of fracturing fluid. Nitrogen can also be used to remove the fracturing fluid from a well after the fracturing operation; the nitrogen expands on removal of pump pressure.
blenders are computer controlled, enabling the flow of chemicals and ingredients to be efficiently metered and requiring a relatively small residence volume to achieve good control over the blend quality and delivery rate. Hydraulic Pump The hydraulic pump is an artificiallift system that utilizes an underground, or down-hole, pump. A surface hydraulic pump pressurizes crude oil called power oil, which drives the down-hole pump. When a single production string is used, the power oil is pumped down the tubing and a mixture of the formation crude oil and power oil are produced in the space between the casing and tubing; this space is also known as the annulus. If two production strings are used, the power oil is pumped through one of the pipes, and the mixture of formation crude oil and power oil are produced in the other parallel pipe.
These rigs may also be trailermounted.
Figure 5 Mobile Drilling Rig A truck or trailer-mounted unit used to drill a well is known as a mobile drill rig. The unit consists of an engine, transmission, drawworks and a rotary table. In regard to mobile drilling rigs, mud pumps are normally independent units. A mobile drilling rig may even be used for both drilling and workover, or the basic unit can be sold into either application. In such cases, the major difference is depth capacity. A drawworks and derrick used for drilling (where heavy casing is handled) has a smaller depth capacity than when used for workover (where lighter tubing or rods are handled). Manufacturers sales specifications will state both drilling and workover depth capacities. Depending upon power and derrick capacity, dualpurpose rigs (workover/drilling) can drill to more than 12,000 ft. (3600 m) and workover to more than 20,000 ft. (6000 m).
Mobile Rigs
Mobile units are defined as oil field drilling or workover units that are permanently mounted on wheels. They are frequently called chassis or carrier units, self-propelled or trailer mounted. They are a version of the split rig. Carrier Designations Figure 5 shows a back-in workover rig. It is representative of the workover rig carrier designation. A drive-in carrier has the drivers cab located at the hinge point of the derrick.
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Mobil Workover Rig A truck or trailer-mounted unit used to pull rod and tubing from a producing well describes a mobile workover rig. The unit consists of an engine, transmission and drawworks. Occasionally, a mobile workover rig includes a chassis-
mounted mud pump. This is required to kill a flowing well, provide circulation during cleanout and while drilling out plugs, etc. Normally, a mobile workover rig will use an independent mud pump kill unit.
Mobile Rig Drivetrain Configurations
Figure 6
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Mobile Rig Drivetrain Configurations Figure 6 shows a few mobile rig drivetrain configurations. There are many other possible combinations of equipment and configurations. If the unit is a trailer unit, the power system drop-box (K) and drive axle (J) are eliminated. On the twin engine in-line setup, the two engines may also be offset or the rear engine elevated to eliminate the dropbox (C). Rigs using only a torque converter behind the engine may have a drawworks with either a two-or three-speed transmission or high-low drum clutches.
pumps for drill rigs. These pumps are typically used to gather fluids from the wellheads as well as loading and unloading fluids to and from tanks and transportation. These pumps have high pressure ratios, and will demand a variable speed engine rating. Piston pumps will almost always require a speed reducer. Centrifugal Pumps Centrifugal pumps work best for steady state type pumping applications such as pipeline transmission. These pumps in constant flow applications will have moderate pressure ratios and may or may not have a speed increaser. Horizontal Pumps Horizontal pumps are an adaptation of a down-hole pump to a surface mechanical drive or VFD electric drive. The electric versions consist of three parts: a gas or diesel engine and generator, variable frequency control, and an electric variable frequency down hole pump. Properly configuring the generator to be compatible with the VFDs is crucial, because of the complex harmonics produced by the VFD. They are used primarily for gathering and waste disposal. These can have very high pressure ratios and are used in a manner similar to piston pumps. These are becoming more common in the oil field because they require less maintenance than traditional piston pumps. Note: Most mechanical drive pumps require a speed increaser or reducer. To eliminate the chance of torsional resonance in the system a torsional
Production Pumping
Petroleum applications require a wide range of pumps to move fluid (either crude oil, processed products, or salt water brine) in and out of the well, to and from processing plants, and on and off transport vehicles. Production pumps can be driven by electric motors or mechanically by direct engine power. In the case of electric motor drive, an engine and generator, or genset, is required to provide power in remote locations. This varies on a site-by-site basis and could include anywhere from one genset per pump site, to a large centrally located power house for an entire field. Several types of pumps are used for this application. Piston Pumps Piston pumps are low rpm, reciprocating, positive displacement pumps that are very similar to mud
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vibration analysis (TVA) will be required to properly select the coupling between the engine and the gearbox and/or load. Rating Review for Pumps Mainline transmission / High hour steady load A rating Gathering and processing and disposal B rating Unloading and loading pumps C rating
Offshore Crane
Offshore cranes are used for moving supplies on, off and around the platform. Electric and hydraulic systems for these cranes are usually driven by an independent engine. Figure 8 shows a typical offshore crane and a 3406 engine configured to power a crane or other auxiliary marine application.
Fire Pump
Another piece of equipment that requires power is the fire pump. Fire pumps are used to pump water for fire emergencies. Fire pumps are usually driven by an independent engine and are common in locations where access to an adequate supply or pressure of municipal water is limited; this includes offshore and remote applications. Figure 7 shows a Caterpillar 3126 engine configured for a fire pump application.
Figure 8
Auxiliary Power
In addition to the power requirements of the petroleum equipment already mentioned, many smaller systems and components also require power. These include mud mix pumps, supercharger pumps and air compressors. These must be considered when selecting an engine for petroleum applications. Mobile applications, especially single engine configurations, have additional auxiliary power concerns because the engine cooling fan, alternator, steering pump, air compressor and hydraulic pump can represent a significant proportion of total engine power available.
Figure 7
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Electric Power Generation

Many petroleum applications use engine power to drive electric generators instead of gears, belts and chains associated with mechanical compounds. Electric motors power the drawworks, rotary table, pumps and other systems with electricity from the generator. These applications are called electric drilling rigs or electric rigs. The electric motors used for hoisting, drilling and pumping require high torque at zero rpm and variable speed characteristics for efficient operation. These characteristics are possible using the following methods. Direct Current (DC) Generators Alternating Current (AC) Generators with Silicon Controlled Rectifiers (SCR) AC Generators with Variable Frequency Drive (VFD) Motors Electric Rig with DC Generator
DC Generators
DC generators, shown in Figure 9, supply electricity to DC motors. A control panel regulates the power and provides means to connect the generators to various motors or a motor assignment. Figure 9 also shows that different motor assignments are used when hoisting or pumping and drilling. Figure 9 is representative of diesel engine power modules for DC generators. It is common for these rigs to have some AC generation capability. The DC generator is at the rear of the engine and utilizes a blower, powered by a separate AC generator, for forced ventilation of the generator. Many of the older DC rigs are being converted to use the more common AC generators.
Figure 9
Page 12 2006 Caterpillar All rights reserved.
Electric Rig with AC Generator & SCR
Figure 10
AC Generators with SCR

Distribution of AC current is much more efficient than DC current; this makes AC generators an attractive selection for power generation. Unfortunately, the majority of electric motors used in the petroleum industry are DC-powered. DC motors provide the high torque at low rpm and variable speed characteristics required for hoisting, drilling and pumping. To take advantage of AC power and DC motors, Silicon Controlled Rectifiers (SCR) are used to convert AC power to DC power. The AC generators, as shown in Figure 10, supply power to a switchgear. The switchgear is essentially a control panel that regulates the AC power. The AC
power is then fed to SCR modules where it is rectified to DC. An integral DC control panel connects the SCR modules to various DC motors or a motor assignment. Figure 10 also shows that different motor assignments are used when hoisting or pumping and drilling. Figure 10 is representative of diesel engine power modules for SCR drives. Auxiliary AC power, for smaller equipment and services, is normally supplied from the same generators; however, the 600V AC power must be transformed to a lower voltage. In many SCR applications, separate main and spare AC generators are also required for auxiliary power.
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Silicon Controlled Rectifier (SCR) Drives Most electric drilling rigs use SCR systems to convert AC generator power to DC. The rated generator voltage is usually 600V AC for both 50 and 60 Hz; when rectified, this voltage provides an ideal 800V DC to the motors. SCR drives require special generators to compensate for varying Power Factor (PF) levels and surges relating to SCR operation. Operating DC motors at variable speeds causes the generator Power Factor (PF) to fluctuate. For example, the drawworks transition from 0 PF to 1.0 PF every hoisting cycle. This is expected but the generator must work harder to maintain an appropriate PF. Operation of the mud pumps at low strokes also causes a low PF. To overcome these fluctuations, AC generators in drilling applications are oversized to 0.6 or 0.7 PF and a higher KVA rating to provide more generator ampere capacity. The actual power output of a generator set with an oversize generator is limited to the engines rated power capacity even if the oversized generator has a higher KVA rating. Actual power output capacity of the generator set is given by the equation: EkW = (bhp - rad fan hp) x Gen eff x 0.746 Simply oversizing the generator will not be enough. The generator must be form wound to provide
additional mechanical bracing of the generator winding. This bracing resists the forces caused by current surges resulting from operation of the SCR controllers. The design limit for the generator winding temperature rise is also lowered to compensate for additional heating caused by the SCR load. Undersized generators may cause circuit breaker tripping, slower drawworks acceleration and unacceptably short generator life.
Variable Frequency Drive (VFD) Systems

The newest technology for electric drill rig power utilizes variable frequency drive or VFD. The same engine and generator that are used for the SCR system will suit the VFD system perfectly. The VFD applications generate at 600 or 690VAC to the rigs buss. A portion of the 600VAC is transformed to 480 VAC for hotel loads and nonvariable speed loads. The majority of the power is rectified to 800VDC and is made available to a VFD control system for variable speed 750 and 1500 hp AC motors. New technology has also improved the efficiency of the VAC motors. VFDs use of front end diode technology, which smoothes the conversion from AC to DC, removes much of the stress that the older SCR systems placed on the generator, and creates load characteristics similar to a large UPS load. However, harmonics remain a concern, and the need to use the same type of generator as in the SCR application still exists. Control of the engine and generator
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is usually left to the engine governor and generator voltage regulator. The VFD controller controls the load application rate. Drilling contractors should see significantly increased generator life when comparing the
same generator in VFD rig service to older SCR rig service. Some drill rigs could have a combination of both SCR and VFD loads.
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Other Petroleum Power Application Considerations

This section describes some key factors to consider when sizing generator equipment for common petroleum applications. Refer to the Petroleum Diesel Engine Selection, Ratings and Configuration sections of this Application & Installation Guide for a detailed discussion of engine sizing and selection. Additional guidance can be found in the Electric Power Applications & Generator Sizing section of this Application & Installation Guide. momentarily (generally referred to as overshoot), then returns to its steady-state condition. The time required for the generator set to return to its normal steady-state speed is called recovery time. This is illustrated in Figure 11.
Loading Considerations
Load acceptance, stability and response play a major role in making an installation successful. Before selecting equipment, the load requirements and starting characteristics of all the systems to be powered by the generator must be identified, and the stability and response requirements must be specified.
Figure 11 The degree of voltage dip or overshoot depends on: The amount of active power (kW) and reactive power (kVAR) changes The voltage regulator settings The total capacity and dynamic characteristics of the generator set The electrical inertia of the other loads in the system
Transient Response
When a load is applied to or removed from a generator set, the engine speed, voltage and frequency are temporarily changed from its steady-state condition. This temporary change is called transient response. When a significant load is applied, the engine speed temporarily reduces (generally referred to as frequency or voltage dip) and then returns to its steady state condition. On removal of load, the engine speed increases
Sizing Criterion Three primary criteria need to be provided to accurately size a generator set: The acceptable percent of voltage & frequency dip
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The acceptable duration of the voltage & frequency dip recovery time The percent of a load step and type of load to be connected
It is important to review the response capability of the specific generator set against the application requirements. Carburetion To match changing load requirements, the engine must adjust is the amount of fuel available for combustion. Due to the differences in the fuel delivery systems, natural gas and diesel fuel engines will have very different transient response capability. Diesel Engine Transient Response Caterpillar diesel engines utilize direct injectors for each cylinder (unit injectors), which deliver a precisely controlled amount of fuel to each cylinder. These injectors can be either mechanically controlled (MUI) or electronically controlled (EUI), however, pertaining to transient response, their basic operation is the same. A certain amount of fuel is allowed into the injector, and then at the right time for combustion, a plunger forces the fuel through very small nozzles, and into the combustion chamber. Each injector acts as an exclusive fuel system for each cylinder, which delivers fuel directly to the cylinder. When the governor or ECM signals to change the amount of fuel needed in the cylinder, the amount of fuel available for combustion is adjusted and available almost instantly. This almost instantaneous power adjustment ability allows the diesel engine to
The larger the voltage dip a generator set can tolerate, the smaller and perhaps more economical the generator set can be. Typical permissible voltage dip for oil field applications is 25%30%. By comparison, a sensitive application, such as a hospital or a hotel where loading is light and equipment is sensitive or flickering of lights would be highly objectionable, the permissible voltage dip might be only 2%. ISO Classification ISO Class 1 and 2 are international standards for generator set response criteria. Note that there are two separate and different sets of Class 1 and 2 standards for diesel engines and natural gas engines. The ISO requirements for gas engines are not as stringent as they are for diesel engines. Equipment Selection The transient response and steady state stability of generator set engines can vary with a number of factors: Engine Model Engine Speed Aspiration Power Factor Carburetion Governor
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respond to transient loads very effectively. Gas Engine Transient Response Caterpillar gas engines have either a carbureted fuel system or a gas admission valve system. There are many variations of these fuel systems, however for this topic their basic operation is the same. Similar to the diesel system, a governor or ECM signals to a valve to adjust the amount of fuel allowed into the combustion chamber, however this is the only similarity. After the valve, the fuel gas is not directly delivered to the cylinder, but is mixed in with the inlet air. Regardless of how the fuel system delivers this air fuel mixture to the cylinder, the distance (and volume) between the fuel control valve and the combustion chamber creates a lag between when the cylinder needs fuel and when it gets fuel. It is this property of gas engines that reduces their ability to respond to a transient load relative to diesel engines. Some regulations are adjusted accordingly; however, marine society regulations are not as flexible.
a resistive load bank with various step load changes. MCS transient response requirements are typically more stringent than can be met with a natural gas engine. A solution that may be accepted is to use a load management system to control the loading of the genset.
Island Mode
Many petroleum gas engine generator sets operate in Island Mode or independent of the utility grid. It is especially important in these applications to have a thorough understanding of the electrical load and transient response demands and ensure that the gas genset can meet the requirements.
Motor Loads
Off Shore Requirements
Generator sets on offshore rigs have to meet the transient response requirements of the various Marine Classification Society (MCS) rules (e.g. ABS, DNV, etc). This is true for the main drilling units as well as emergency or essential services gensets. MCS requirements are demonstrated on
Motors draw more than their rated power during starting and acceleration. Motors connected directly to high inertia centrifugal devices or loaded reciprocating compressors cause severe frequency excursions and lengthy motor start up. Comparing starting currents between loaded and unloaded motors, Figure 12 shows the extended time that loaded motors demand high current. Motors generally exhibit low power factors (pf) of 0.3 to 0.4 when starting. Engine load is calculated by: kW = Starting kVA x Starting pf
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Figure 12
As shown in Figure 12, the starting kVA can be as much as 6 times the running kVA. This results in an engine load of 1.8 to 2.4 times the normal load required to run the motor. This must be accounted for in the load analysis if there are any large motors that must be started when the generator initially closes, especially if the motor is started while loaded. Jackup drill rigs can impose large AC motor block loads with their leg jacking systems. Typically, other AC motors on land or offshore rigs do not present significant transient response challenges due to the size of these motors in comparison to the engine and generator capacity. The DC motors, powered through the SCR control system, are considered to be soft-start. The severest transient DC load (but of short duration) on a drill rig is
applied by the drawworks when lifting empty blocks.
Motor Starting
The gensets ability to start large motors without large frequency or voltage dips depends on the entire system. System factors include: Available engine power Capacity of the generator Energy stored in the rotating inertia of the genset Acceleration of the motor and its load (motor characteristics) Electrical components between the genset and motor.
A properly sized generator will support the high starting kVA (skVA) required and sustain adequate output voltage for the motor so it can produce the needed torque to accelerate its load to rated speed.
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After the initial voltage dip, it is important that the generator restore voltage to at least 90% to develop adequate torque to accelerate its load to rated speed. Full voltage starting causes the largest voltage dip.
Regenerative Power
Some motor applications, such as hoisting, depend on motors for braking. Motors then act as generators and feed power back to the generator set. The rating on the motor is greater when used as a brake, if no other loads are connected to absorb this regenerative energy, only engine frictional horsepower is used for braking. Exceeding frictional horsepower causes generator set overspeed. Regenerative potential for a common application, elevators, is estimated by:
Regeneration kW = Hoist Motor hp x Full Load Brake Rating Factor x hp to kW Conversion x Motor Efficiency
Where: Full Load Brake Rating Factor hp to kW Conversion Motor Efficiency = 1.8 = 0.746 = 0.9
Load banks activated by directional power relays must be installed to prevent engine/generator damage when combinations of connected load and engine frictional horsepower are not sufficient to restrain regenerative energy.
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Catterpillar Gens Set Requirment

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APPLICATION

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Application and Installation Guide

Electric Power Generation ....12 DC Generator AC Generator with SCR

2006 Caterpillar All rights reserved.

Application and Installation Guide

Petroleum Equipment & Terminology

Application and Installation Guide

Application and Installation Guide

Application and Installation Guide

Typical Conventional Rig

Typical Split Rig

Application and Installation Guide

2006 Caterpillar All rights reserved.

Application and Installation Guide

Application and Installation Guide

These rigs may also be trailermounted.

2006 Caterpillar All rights reserved.

Application and Installation Guide

Mobile Rig Drivetrain Configurations

Application and Installation Guide

Application and Installation Guide

2006 Caterpillar All rights reserved.

Application and Installation Guide

Electric Power Generation

Application and Installation Guide

Electric Rig with AC Generator & SCR

AC Generators with SCR

Application and Installation Guide

Variable Frequency Drive (VFD) Systems

Application and Installation Guide

2006 Caterpillar All rights reserved.

Application and Installation Guide

Other Petroleum Power Application Considerations

2006 Caterpillar All rights reserved.

Application and Installation Guide

2006 Caterpillar All rights reserved.

Application and Installation Guide

Off Shore Requirements

2006 Caterpillar All rights reserved.

Application and Installation Guide

applied by the drawworks when lifting empty blocks.

2006 Caterpillar All rights reserved.

Application and Installation Guide

2006 Caterpillar All rights reserved.

Printed in U.S.A. All rights reserved.

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