Module

1
OCEANEERING TRAINING CENTER
Distance Training Module Series
Module One: Magnum System Power
 OCEANEERING TRAINING CENTER

MODULE ONE

MAGNUM SYSTEM POWER

Rev. 1.3 Jan. 2003

 Oceaneering Training Center

777 Delmar Rd. Bayou Vista La, 70380

Phone 985-395-5247 • Fax 985-395-8524

Table of Contents

MODULE LAYOUT ............................................................................................................ 1

INTRODUCTION TO ROV ELECTRICAL CONFIGURATION................................. 2

SYSTEM POWER ................................................................................................................ 3

MOTOR GENERATOR ...................................................................................................... 4

POWER DISTRIBUTION................................................................................................... 7

BREAKER ONE (BK1)........................................................................................................ 8

! MODULE REVIEW ..................................................................................................... 12

REVISION CHANGES ...................................................................................................... 13

M O D U L E O N E R E V 1 . 3
Module

1
Module Layout

T he following information gives a basic outline of how to use this module. The
ICON KEY below graphically represents key items used throughout this module.

Valuable information is information that the user will find

ICON KEY most beneficial in relation to the subject being presented.
! Valuable Test your knowledge are questions to test what you have
information learned.

" Test your Tech Tips are quick technical aspects that the user will find
knowledge resourceful.

Module review is a summary of what the user has learned

# Tech Tips
through out the various chapters.
! Module review

Oceaneering Training Center 1

M O D U L E O N E R E V . 1 . 3

Chapter

1
INTRODUCTION TO ROV ELECTRICAL
CONFIGURATION

The HYDRA™ MAGNUM ROV system consists of five major

sub-systems:

$ MOTOR GENERATOR, OR DIESEL GENERATOR

$ CONTROL VAN
$ WINCH
$ CAGE
$ VEHICLE
All of these sub-systems interconnect and operate together. The ROV unit as a
whole needs 480 VAC 3 Phase electrical power to operate. Each subsystem uses
this system power as needed, whether transforming it or converting it to a D.C.
voltage. The ROV system also needs a communication link among the pilots
console (located in the control van), the cage and vehicle. This communication link
provides the operator with a means of controlling the electronic and hydraulic
circuits required to operate the system.

Oceaneering Training Center 2

M O D U L E O N E R E V . 1 . 3

SYSTEM POWER
The system requires 480-vac 3 phase 60 Hz power to operate. This power
originates from an external power supply, which is normally rig or vessel power.
The location of the system is normally the deciding factor as to which supply will be
utilized.

! Important Information

Magnum systems require a 480-vac, 3-phase, 60 Hz power to operate.

This power comes from an external power supply.

Due to the normally unstable power supply on offshore oil rigs, a motor generator
will be installed between the rig’s power supply and the ROV system for long term
contracts. This motor generator unit has a 200 horsepower electric motor that
drives a generator that produces a clean source of 480 vac 3 phase 60 Hz power.
This motor generator unit may vary in size between 150 kva and 200 kva.

When a short-term contract is being performed a diesel generator is utilized. A

diesel generator is a self-contained unit using a diesel engine to turn a generator
producing the required voltage for the system. Regardless of which type of
generator is used the voltage created from either one is routed to the systems
control van and connected into a power distribution unit, where it will be distributed
as needed.

Oceaneering Training Center 3

M O D U L E O N E R E V . 1 . 3

MOTOR GENERATOR
The motor generator unit will receive 480-vac 3 phase 60-hz power, with a 250 amp
minimum rating, from an external power source through a water tight opening in the
motor generator van’s bulkhead. This power is routed to a main circuit panel inside
the van that will act as a distribution unit as well as a control unit for the motor
generator. This incoming voltage is routed to the top of a 400-amp breaker
enclosed in the panel. This acts as an Isolation point between the rigs power and
the systems motor generator. At the top of this 400-amp breaker, rig power is
tapped off and sent to the bottom of a two-position knife switch.

! Important Information

The motor generator unit receives 480-vac, 3-phase, 60 Hz power with a

250 amp minimum amperage rating from an external power source.

The 400 amp main breaker located in the main circuit panel, supplies power to the
controlling circuit and is used for powering the 200-horsepower electric motor. The
electric motor drives a belt driven generator that produces the appropriate
operating voltage via a voltage regulator mounted on the front top of the generator.
This voltage regulator is adjustable to maintain the correct system voltage as
needed.

The voltage that is produced by the generator is sent to the top of a knife switch
through a 225-amp output breaker. This output breaker provides a means of
isolating generator power to the system. The knife switch is arranged with the
center position connected to a power distribution unit in the units control van. The
top position is connected to motor generator power while the bottom position is
connected to rig power from the top of the 400-amp main input breaker. With this
arrangement, by positioning the knife switch you can select which source of power
the system will use. The center position of the knife switch is connected to the
control van using a four-conductor armor braided cable. The connection point in
Oceaneering Training Center 4
M O D U L E O N E R E V . 1 . 3

the control van is to the top of a 150-amp input breaker located in the power
distribution unit. This breaker is referred to as BK-1.

! Important Information

The knife switch selects which source of power (rig or motor generator)
the system will use.

Oceaneering Training Center 5

M O D U L E O N E R E V . 1 . 3

Figure 1 System Power

Oceaneering Training Center 6

M O D U L E O N E R E V . 1 . 3

Chapter

2
POWER DISTRIBUTION
Power is distributed through the system using a power
distribution unit (PDU) located in the systems control van.
The PDU is connected to an external power source, such as
a motor generator or diesel generator through a four-
conductor armor braided cable. This cable enters the
control van directly into the PDU through a Nelson Fire Block
Unit, which provides watertight integrity. Once entering the PDU, the four-
conductor armor braided cable is connected to the top of a 150 to 200-amp
breaker. This 150 to 200-amp breaker is commonly referred to as BK 1. It is the
first breaker in the power distribution circuit for the system. Bk1 provides isolation
for system power but not for lighting and receptacle power for the control van. The
reason for this is that at the top of BK1, 480-vac single phase is tapped off and sent
to the primary windings of the house power transformer. This House power
transformer steps 480-vac single phase down to 220-vac for the control vans air-
conditioning system and 120-vac for the vans lighting and receptacles. It is
important to note that to electrically isolate the house power transformer, it must be
isolated at the external power source.

! Important Information

BK1 a 150 to 200-amp breaker. It is the first breaker in the PDU circuit
for the system.

Oceaneering Training Center 7

M O D U L E O N E R E V . 1 . 3

Figure 2 Main Power Distributions

BREAKER ONE (BK1)

Breaker one (BK1) provides isolation for what is known as system power. System
power is described as that power which runs the control van console control, cage
control, and vehicle control circuits. There are several circuits inside the PDU that
are controlled by BK1.

% CONSOLE/SURFACE FIBER-OPTIC POWER

% CAGE ELECTRONICS POWER

% VEHICLE ELECTRONICS POWER

% CAGE MOTOR POWER

% VEHICLE PORT MOTOR POWER

% VEHICLE STARBOARD MOTOR POWER

Oceaneering Training Center 8
M O D U L E O N E R E V . 1 . 3

Six individual contactor circuits that are located in the PDU control these six
circuits.

From the bottom of BK1 each circuit is provided voltage to the top of its
corresponding contactor, where that voltage stays until it is needed.

Figure 3 Main System Breaker Distributions

480-VAC 3 phase 60-hz power is provided from the bottom of BK1 to the top of
each motor contactor through nine power conductors, three for each motor circuit,
they are labeled phases A, B, and C respectively. In some instances they will be
labeled phases 1, 2 and 3. This three-phase power will stay at the top of each
motor contactor until the operator (from the pilot’s console) remotely operates that
contactor.
Oceaneering Training Center 9
M O D U L E O N E R E V . 1 . 3

480-VAC 3 phase 60-hz power is also provided from the bottom of BK1 to the
primary windings of what is commonly referred to as the Western Transformer.
This transformer is classified as an “isolation” transformer, and will also “step up”
voltage for both the cage and vehicle electronics power circuits. The secondary
windings of the Western transformer are tapped off to meet the voltage
requirements at the cage and vehicle, which should be between 460-vac and 480-
vac, single phase. These circuits are fused protected between BK1 and their
respective contactor by three 30-amp fuses.

It is important to note that the distance between the Western transformer and the
cage and vehicle transformers (which will be discussed later) are dependent upon
where you tap off the secondary side of the transformer. The voltage from the
secondary windings of the western transformer is tapped off single phase and run
to the top of the cage and vehicles electronics contactors where it stays until
remotely operated by the operator at the pilot’s console.

480-VAC 60-hz single-phase power is also provided from the bottom of BK1
through two 30-amp fuses to the primary windings of what is commonly referred to
as the Hammond Control Transformer. This transformer is a step-down
transformer providing voltage to the power tray, which is located in the pilot’s
console, and also the surface fiber-optic unit, which is located on the main lift
winch. The secondary windings of the control transformer are tapped at 120-vac
and run to the top of the console contactor where it stays until the operator at the
pilot’s console remotely operates it.

! Important Information

The Hammond Control Transformer steps-down the voltage to the

power tray and the surface fiber-optic unit.

Oceaneering Training Center 10

M O D U L E O N E R E V . 1 . 3

This 120-vac is referred to as UN-switched voltage, it will remain UN-switched

until it is allowed to pass through the console contactor when it will then be
considered Switched voltage.

# Tech Tip

Switched Voltage is only considered that voltage that has gone through
the physical contacts of a contactor.

Oceaneering Training Center 11

M O D U L E O N E R E V . 1 . 3

MODULE
! Module Review REVIEW

!
You have learned in this module that the HYDRA™
MAGNUM ROV system consists of five major sub-systems:
motor or diesel generator, control van, winch, cage, and
vehicle.

System power originates from the motor or diesel generator and generates the 480-
vac 3-phase 60 Hz power that the system needs in order to operate.

Motor generator power is routed to a main circuit panel inside the van that acts as a
distribution and control unit for the motor generator. A knife switch located inside
the van allows you to select which source of power the system will use.

System power is sent to the PDU via a connection point called BK1. This controls
system power. The House Power Transformer provides power for lighting and
receptacle power for the control van. House power steps down the 480-vac single-
phase power to 220-vac for air conditioning and 120 vac for the van’s lighting and
receptacles.

BK1 controls 6 circuits inside the PDU: console/surface fiber-optic power, cage
electric power, vehicle electric power, cage motor power, vehicle port motor power,
and vehicle starboard power. The 120-vac is referred to as un-switched voltage
until it is allowed to pass through the console contactor where it becomes switched
voltage.

Oceaneering Training Center 12

M O D U L E O N E R E V . 1 . 3

Revision Changes

DATE REV CHANGE APPROVED BY

1/1/02 1.0 Initial Release Nick Gallien

12/30/02 1.1 Revised Quiz, grammar corrections Added Richard Kelly

answer sheet

12/30/02 1.2 Revised Quiz, grammar corrections Richard Kelly

1/15/02 1.3 Remove quiz and answer sheet in accordance Larry Mixon
with API RP2D and change “two” 30 amp
fuses to “three” 30 amp fuses on page 10.

Oceaneering Training Center 13