Module C4DW Control Systems

OILFIELD TUNNELING MINING FOUNDATION
Training Module C4DW

Drawworks Control Systems
06.01.2009 I Mario Bühler

OILFIELD TUNNELING OILFIELD MINING FOUNDATION
Agenda
1. ECS (Eddy Current Brake Control System)

2. DICS (Drawworks Interface & Control System)
3. ADS (Auto Driller System)
4. ZPS (Zone Position System)
Page 1
Overview Braking Systems
1. Eddy Current Brake

2. Regenerative Brake of Main Drives
3. Disc Brake
4. Regenerative Brake of ADS Drives
Note: The Disc Brake is not used as an active brake.

The Disc Brake is only used as a park- and emergency brake.
Page 2
Eddy Current Brake Control System (ECS)
Function of Eddy Current Brake

The DICS sends a reference value to the ECS which generates a proportional
current into the 2 coils of the ECB. This reference signal is configured to be
failsafe (i.e 100% = zero force and 0% = maximum force). This current
generates a magnetic field that induces an eddy current into the rotating metal
disc. The induced eddy current creates a magnetic field which works against the
magnetic field of the coils. The result is an opposing force between the rotor
and stator. The strength of this force is a function of rotor speed (drum speed)
and current. Therefore the ECB cannot hold static load or brake a slow moving
load.
A pre-tension of 5% in hoisting and 10% in lowering operations is applied by the

DICS. Pre-tensioning allows immediate reaction to a command received.
(hoisting = 95% / lowering = 90%).
In an emergency case the ECB will be fully energised (reference value = 0%).
Page 3
The ECS works in conjunction with the main drive ASDS, ZPS and the DICS. The DICS
reference value depends on main motor regenerative braking power and kinetic energy.
Page 4
Page 5
Agenda

Page 6
Drawworks Interface & Control System (DICS)
The drawworks Interface & control system DICS is the main machine control &
interface system. The DICS is the interface point to all subsystems and skid mounted
sensors. The DICS combines the complete drawworks system to one System, and
connect these System to the primary control.
Page 7
Drawworks Interface & Control System (DICS)
Page 8
Regenerative Brake
The main drives are used as dynamic brakes by utilising the regenerative principle of
the 4 quadrant mode.
Usually the regenerative power is dissipated into resistor banks. A functionality to feed
regenerated power back into the power network is available – implementation thereof is
however dependant on the capacity of the power network to absorb the magnitude of
the power fluctuations during normal drawworks operations.
Page 9
Typical Braking Sequence in normal operation
<= Joystick reference
<= Torque of <= ECB voltage

main drives
Drum speed =>
Block position => <= ECB current
Page 10
Performance Diagram: Main Motor Mode
Page 11
Braking Capacity Diagram
Page 12
Operation Sequence in Main Motor Mode
The following procedure describes in short sentences the operation sequence of the
drawworks. Precondition is that all subsystems are online.
If the button „DW ON“ is pressed, the following will happen:
1.) Start signals are sent via the DICS to the MCC to start all auxiliary drives.
2.) The operation is checked by sensors in the hydraulic systems for correct functioning. Level and
temperature transmitters are used to analyse the status.
Note: If the status of the ASDS or an auxiliary system is not correct,
the Drawworks start up is prohibited.
3.) The DICS sends the signal „Drawworks is ready“ to the ASDS and the button „DW ON“ is
illuminated green.
Page 13
4.) The operator selects the gear with the desired transmission ratio according to the hook load. The
actual selected gear will be illuminated green.
Note: The pre-selection of a gear is displayed in another colour and will be activated as soon as
the drum speed reaches zero and the disc brake is closed.
5.) When the operator deflects the joystick from the neutral position or presses the button „Park
Brake Open“ the signal „Request to open the brake“ is sent via the DICS to the ASDS.
6.) The ASDS switches the main drives on and restores the last known torque to hold the load in
equilibrium when the brake opens.
7.) After the main drives are torqued up, the ASDS sends the signal „Permit to open the brake“ to the
DICS and the disc brake will open.
Page 14
8.) The status signal „Brake is open“ is sent to the ASDS by the DICS and the button „Park Brake
Open“ is illuminated green.
Note: So long as the ASDS receives the status signal „Brake is open“ the ASDS torque controller
controls the drum speed. If a drum speed without speed reference signal is detected, the
torque controller will automatically adjust the torque value to keep the hook load in equilibrium at
zero speed. Load differences since the last stop sequence will be compensated with this control
function.
9.) A speed reference signal proportional to the joystick deflection, as operated by the driller, is sent to
the ASDS to control the drum speed.
10.) To stop the drum the operator has to bring the joystick into the neutral position. If no further
joystick deflection is detected for 15s, the DICS will close the disc brake automatically to comply
with WIRTH and ASDS manufacturer safety regulations.
Page 15
11.) By pressing the green illuminated button „Park Brake Open“ or after the afore mentioned 15s, the
signal „Request to close the brake“ is sent via the DICS to the ASDS. The torque memory function
of the ASDS stores the present holding torque for the next start sequence.
12.) Then the ASDS sends the signal „Permit to close the brake“ to DICS and the brake will close.
13.) Finally the DICS sends the status signal „Brake is closed“ to ASDS and the main drives torque
down only now. After which they will be switched off.
14.) The auxiliary drives are kept switched on as long as the Drawworks is activated. If the operator
deactives the Drawworks the auxiliary drives are kept switched on for 10 minutes as a „Follow-up
Time“ before the DICS sends the stop signals to the MCC.
Page 16
Emergency Stop
Note:
In an emergency case the disc brake will be applied immediately

independent of the actual drum speed.
The wireline protection system (WPS) will avoid the „birdnest“ effect
if an emergency stop is triggered only during a hoisting operation.
Page 17
Emergency Stop Handling
For internal use in the DICS we separate Emergency Stops in the following
categories:
Software Emergency Stop

- Quick Stop
- EM Stop
Hardwired Emergency Stop

Detailed information's for
- Drum Stop every single alarm is listed in
- EM Stop the Cause & Effect list of the
commissioning procedure.
Page 18
Definition of Quick Stop:

The stop is realised by forcing the drives to speed "0", engaging the eddy current
brake at 100% and closure of the disc brake when speed "0" is confirmed. Prior to
go on with operation the cause of this message has to be eliminated.
Example:
Fault Flow control pump phase brake HPU 1
Page 19
Definition of EM Stop:
brake at 100% and direct closure of the disc brake regardless of the current drum
speed. All drives and auxiliary drives will be deenergised.
Example:
Fault drum speed too high for gear 2
Page 20
Definition of Drum Stop:

brake at 100% and closure of the disc brake regardless of the current drum
speed. All drives and auxiliary drives stay energised and after pulling the drum
stop button out the drawworks is fully operational.
The purpose of this function is a safety issue when personnel is working around
the unprotected rotating drum e.g. during cut and slip operation.
Example:
Drum Stop buttons on the drawworks skid
Page 21
Agenda

Page 22
Autodriller System (ADS)
Page 23
Performance Diagram: Autodriller Mode
Page 24
Regenerative Brake
When operating in the Auto Driller Mode, the three ADS motors are used as an electric
brake to accurately control the drill string speed of descent into the hole. Regenerative
braking is employed for this operating mode.
The regenerative power is fed back into the power network.
Page 25
Agenda

Page 26
Zone Positioning System (ZPS)
The Zone Positioning System is designed to improve safety and efficiency

of drilling operations in conjunction with other drilling equipment.
The system is equipped with failsafe and redundant PLC technology.

All safety functions are calculated and double-checked by SIEMENS safety
function blocks to ensure high safety standards are maintained within the shortest timeframe.
Kinetic energy and the available braking capacity are continuously monitored
to ensure the reliable and safe stopping within the safe operational range
of the travelling assembly at all times.
Page 27
Page 28
Calculation of the Block Position
Length of the wraps in the different layer:

L1 1,259 m X 3,14 = 3,95 m
L2 1,346 m X 3,14 = 4,23 m
L3 1,433 m X 3,14 = 4,5 m
Max. 4 Layer
5 Offset-Wraps with extended

CMC have to be constant as
well after Cut & Slip Operation
Page 29
Functions:
ZPS Auto Mode
ZPS Manual Mode
ZPS Tool Compensation
ZPS Upper Working Point
ZPS Lower Working Point
Page 30
Cut & Slip Operation
Checklist for a Cut & Slip Operation:
- Before: Switch ZPS in Manual Mode
- Before: Bring the Block in Hang Off Sling
- Afterwards: Keep the same count of offset wraps
- Afterwards: Carry out a ZPS calibration run

- Afterwards: Switch ZPS in Auto Mode
Page 31
Agenda

Page 32
Thanks for
your Attention !
Page 33

Module C4DW Control Systems

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OILFIELD TUNNELING MINING FOUNDATION

Training Module C4DW

06.01.2009 I Mario Bühler

1. ECS (Eddy Current Brake Control System)

Overview Braking Systems

1. Eddy Current Brake

4. Regenerative Brake of ADS Drives

Note: The Disc Brake is not used as an active brake.

Eddy Current Brake Control System (ECS)

Function of Eddy Current Brake

A pre-tension of 5% in hoisting and 10% in lowering operations is applied by the

Eddy Current Brake Control System (ECS)

Eddy Current Brake Control System (ECS)

1. ECS (Eddy Current Brake Control System)

Drawworks Interface & Control System (DICS)

Drawworks Interface & Control System (DICS)

Typical Braking Sequence in normal operation

<= Joystick reference

<= Torque of <= ECB voltage

Drum speed =>

Block position => <= ECB current

Performance Diagram: Main Motor Mode

Braking Capacity Diagram

Operation Sequence in Main Motor Mode

If the button „DW ON“ is pressed, the following will happen:

Operation Sequence in Main Motor Mode

Operation Sequence in Main Motor Mode

Operation Sequence in Main Motor Mode

In an emergency case the disc brake will be applied immediately

Emergency Stop Handling

Software Emergency Stop

Hardwired Emergency Stop

Emergency Stop Handling

Definition of Quick Stop:

Emergency Stop Handling

Emergency Stop Handling

Definition of Drum Stop:

1. ECS (Eddy Current Brake Control System)

Autodriller System (ADS)

Performance Diagram: Autodriller Mode

The regenerative power is fed back into the power network.

1. ECS (Eddy Current Brake Control System)

Zone Positioning System (ZPS)

The Zone Positioning System is designed to improve safety and efficiency

The system is equipped with failsafe and redundant PLC technology.

Zone Positioning System (ZPS)

Calculation of the Block Position

Length of the wraps in the different layer:

5 Offset-Wraps with extended

Zone Positioning System (ZPS)

ZPS Auto Mode

ZPS Manual Mode

ZPS Tool Compensation

ZPS Upper Working Point

ZPS Lower Working Point

Cut & Slip Operation

Checklist for a Cut & Slip Operation:

- Before: Switch ZPS in Manual Mode

- Before: Bring the Block in Hang Off Sling

- Afterwards: Keep the same count of offset wraps

- Afterwards: Carry out a ZPS calibration run

1. ECS (Eddy Current Brake Control System)