Operation and Maintenance

Caterpillar 365 KW Generator for 100-ton rig package

Purpose
To introduce personnel to the components and

performance capabilities of the 365KW generator package. To provide operations guidance for the generator package. To provide maintenance and inspection expectations for the generator package. To address safety precautions for the generator package.

Components

Generator Control View

Electronic Control Module 2. Control Panel 3. Annuciator Panel (Performance Readings)
1.

Generator Panels
EMC
o Top Row Alarm Level o Second Row Run/Auto/Stop

Control Panel
1. 2. 3. 4. 5. 6. 7. 8. 9.

Low Oil Pressure Override Engine Speed Emergency STOP Generator Engage Proper Hertz (50) Test Plug Alarm Generator on Generator off

Performance and Capacities

Caterpillar C-15 engine at 373 Kw/500 hp

Kato 365 Kw 220 Volt 50 Hz generator

Impulse circuit board breaker box Quincy electric air compressor 7.5 Kw , 8.3 bar Webasto coolant heater Generator house has 4 lift eyes and 4 securing

eyes Complete generator house 5.5 meter X 2.4 meter at 10 tons

Positioning of the Generator

The generator house should be positioned at

least 15 meters from the well bore and the mud pit. Trailer jack pattern is 10.9 meters X 2.4 meter at 24.3 ton including power swivel. If the power swivel and generator are operated on the trailer each of the 4 jacks must support 6tons. Additional matting will be necessary. The generator house is secured to the trailer with 4 transport pins. It may be removed from the trailer and set independently for operation.

Electrical Safety
The generator should be electrically grounded

before and during operation to a suitable earth ground. WARNING - The circuit breaker for each electrical outlet must be disconnected/turned off before connecting or disconnecting electrical cords. WARNING Never perform work on any energized electric circuit. All repairs, additions, or modifications to electrical circuits must be performed by a qualified electrician.

Electrical Safety
Electrical plugs and

receptacles are sealed for gas or liquids & lock together locks must be engaged Electrical splices must be performed by an electrician use of electrical tape as insulation is not permitted

Starting the engine

Generator should be started 1-hour before night fall if

used only at night. Check all fluid levels engine oil and coolant before starting the engine. Fill the fluids to the normal operating range. Report any contaminated fluid to the supervisor so that they may be replaced. The engine is equipped with a coolant heating system. This heating system will preheat the engine and fuel systems. The heating system should be used to preheat the systems when temperatures are below 5 degrees C. Be certain that all personnel are clear of the engine before starting the engine.

Daily Maintenance
Check engine oil and coolant fluid levels daily

with the dipsticks or sight glass. Check to confirm that primary electrical connections are tight. Inspect the air cleaner service indicator clean or replace air cleaner element if indicator is in the red zone. Check the fuel/water separator drain any water or sediment (drain valve opens countrclockwise).

Monthly Maintenance
Inspect engine and radiator for leaks.

Inspect fan and alternator belts for wear or

deterioration. Change engine oil and filters every 500 hours of operation. Replace the primary fuel filter/water separator element every 500 hours of operation. Replace the secondary fuel filter every 500 hours of operation. Clean crankcase breather

Welding on or near the generator

WARNING Welding on the generator or the generator house can damage or destroy the electronic controls unless proper steps are followed. Improper grounding can cause damage to drive train bearings, hydraulic components, and other equipment. Clamp the ground cable from the welder to the component that will be welded.

Welding on Equipment
Use the example here. The current flow from the welder to the ground clamp of the welder will not cause damage to any associated components. 1. Engine 2. Welding electrode 3. Key switch in the OFF position 4. Battery disconnect switch in the open position 5. Disconnected battery cables 6. Battery 7. Electrical/Electronic component 8. Maximize distance between the component that is being welded and any electrical/electronic component. 9. The component that is being welded. 10. Current path of the welder. 11. Ground clamp for the welder.

Review of Key Points

The generator should positioned at least 15

meters from the well. Never connect, disconnect, or perform work on a live electrical circuit. All electric power cords have locking connections secure the connections. Do not weld on the generator or generator house without following the proper procedure to disconnect electronics and ground the welder properly.