Load Testing Drilling Rig Generators

How do you normally go about load testing Caterpillar Generators?
Catepillar Generator

I make up a bit and connect it to the TDS and pump through it to create back pressure in turn putting a load on the generators. This is much better than circulating through a choke. With four generators online I can pump 900 gpm and create 3800 psi. This is the part that I don't fully understand? I can see a percentage of load on the generators and can see the KVA for each generator. What if one is running a little slower than the other, is it best to have a CAT technician to adjust it, or is it something the Electrician or mechanic can do? What are the limits for one to be faster or slower than the others?

As you can guess I'm just an old roughneck in a new world high tech equipment (Although SCR and VFD is common now)and it's my job as a companyman to accept a rig for drilling or not. Any advice would be greatly accepted.

Tags: Catepillar, Generator, Load, Test

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Permalink Reply by Jim D. Bural on November 21, 2010 at 12:48pm

Karl, on all of the SCR rigs I have Pushed & Drilled on, Allen Bradley or Ross Hill SCR houses, the generators are balanced when you sync them to bring it online. The fine tuning comes in by balancing the killavars in the SCR house. It is not unusual for one generator to run slower than the others. It is my understanding that the first generator brought online, is the "lead" generator and the rest are synced to it. I hope this helps. Jim.

Permalink Reply by Steve on November 21, 2010 at 3:17pm

Hey Jim, if you could refresh my memory if you know if you are going to need another gen online is it best to (warm-up cycle) before synch online. I can remember one instance the drill needed immediate online so i fired up engine and as soon as i (synched) POW! generator fried.Was told later from shop mechanics they think condensation built up inside Gen caused it to fry?? So after that standing rule was fire up motor 20 minutes before synch.If possible... Logic being give condensation time to dissipate... I,m sure their have improvements since this was approx 20 yrs ago... Thanks

Permalink Reply by Steve on November 21, 2010 at 3:25pm

Ps. let me add after synch attempted to put online then pow...

Permalink Reply by Steve on November 21, 2010 at 5:03pm

Yes Carl I meant after basic warm up mine was more of a question then anything else.It was for Cal -Pac. I believe we were running cats also 3412,s. I had also thought once had the green light synch i was good to go. I would think that on load test it would be Amperage fluctuation from gen to gen. Sounds like a lot of variables wear a tear doesnt the scr house decide on the rpm and amperage it would seem that if the motors varied in speed the scr control would keep constant...But then again my car still has points on it.. sorry Karl

Permalink Reply by Steve on November 21, 2010 at 7:42pm

Alrighty Karl probably closer to 30 yrs.Been awhile but I worked for the mostly northern cal fresno up. Worked rackin pipe ,got to work motors temp. What i remember it was a nice rig. The office was out of ojai,ca. Karl we drilled pretty deep wells for northern ca back then 11,000 to 15,000 only worked about a 8 mths before rig stacked and went back to Paul Graham Drilling. Broke out air chugger chains one on one with driller no hesitation. I now many rigs with rams had to catch up with chainhand.

Permalink Reply by Steve on November 22, 2010 at 2:43pm

Dont let old age be the reason,Karl...Went back to Paul Graham out of Rio Vista,Ca . Smaller outfit but i guarantee you we poked more then our share of holes in the state of Ca. Still in business http://www.paulgrahamdrilling.com/ today Paul,s son Kevin has been running the show.. Steve

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Load Testing Drilling Rig Generators

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