Variable Speed Drive (Regenerative) Type PDF
Variable Speed Drive (Regenerative) Type PDF
Variable Speed Drive (Regenerative) Type PDF
- LESSONS LEARNT -
Abstract - Variable speed A.C. drives are used in many new and already existing oil and gas applications because of their well known benefits for energy efficiency and flexible control of process.
During the past years, numerous publications [R6f] have been published relating to the various technologies of electronic Variable Speed Drives (VSD) for Electric Submersible Pumps (ESP) application. This paper explains why a "Regenerative" VSD new technology had been chosen in a specific project to supply ESP (PART I). Moreover we will present also the main benefits of using this technology when both motor and VSD Rh have to comply with ATEX category 2 or 3 (PART 2). This paper also presents the precautions to be taken during the various stages (design, construction & operation) of a project and the feed back after a few years of operation and lessons to be learnt Index Terms - VSDS: Variable Speed Drive Systems, ESP: Electric Submersible Pumps, THD: total harmonics distortion, Regenerative
During phase 1, the operating experience allowed us to notice that the bound constraints engendered important problems. Works over operations were necessary to replace pumps because the sizing was not adapted to the productivity of wells. Considering the acquired experience, for the phases 2 and 3 development, the VSD option was considered.
1 ESP l5lhp 8 ESP 222hp DPi WP2
42km
HALUL
70mm
25 EP 270hp
1haeS
260hp
MPe
0m3k
70mm2
185mm2
km
70mm2
In general, the use of electronic VSD technology has main advantages, more or less linked:
Flexibility of regulation and functional optimization:
* *
*
*
Facility for starting up with a programmable motor torque Flexibility of functionality allowing the adaptation to the driven machine with variable conditions of use and even in some cases, to increase its useful duty range Possibility to use motors with a speed higher than frequency imposed by the network Shaft line simplification
Energetic economy: * Capacity to realise significant energy savings because electro mechanical efficiency is intrinsically higher * Possibility for an equipment to work permanently with the best efficiency in all the practicable speed ranges and not only in the dimensional maximum duty point
Availability and maintainability: * High availability of equipments due to an improved reliability and reduced repairs time
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Repair facilitated by modular electronic sub assemblies and possibility of implementing automatic fault detection procedures with rapid replacement Limitation of nuisances and constraints on the equipments: * Reduction of the mechanical constraints (starting up torque, disconnection, blow of ram, etc.) * Limited inrush current on the network during motor start up * Reduction of Starting Power Requirements For ESP application, the variable speed drive is perfectly adapted to resolve the following problems: * Unknown Well Productivity * Maintaining Constant Pump Intake Pressure * Changing conditions of the well (evolution of the BSW, PI decreasing, well head pressure) * Adaptation of the power according to needs * Reduction of the constraints on the ESP during the starting up * Reducing starting power requirements * Changing well production conditions over time
* 12 or 24 pulses VSD This solution needs an additional and special transformer with complex sets of phase shifted AC output windings, the rectifier bridge of the VSD is design accordingly. So 12 or 24 pulse VSD is not the appropriate solution for ESP application.
* Regenerative VSD This technology was specially adapted for this project and is developed in the chapter VI.
IV. PHASE 2: PROJECT DEVELOPMENT STUDIES
The challenge for this fast track project was to evaluate and determine the most appropriate concept without affecting the schedule and with a reliability guarantee. The main technical objectives expected for this project were determined as following: - Voltage variation at the VSD input 10% without any effect on the motor voltage - THD Harmonics limitation 3% - No stresses on the motor (electrical and thermal) - No disturbance in particular for the down hole monitoring system
l1l. HARMONICS
Harmonics effects: Some precautions are required when using VSD's, because electronic devices engender harmonic currents which circulate due to the impedance of the network, creating harmonic voltages for other consumers connected to the same network with the following effects: * Motor: additional losses both in the copper and in the iron, these losses create over heating notably in the rotor
*
performed:
* *
* *
Oscillating torque produced by the harmonic current, this torque can have harmful effects on the stability and even on the mechanical resistance if their frequencies are the same as the rotating frequencies of the shaft line Transformers: impure sinusoidal current increase the losses causing significant overheating and in some cases, a resonant circuit is produced Cables: increased losses and risk of overheating, damage to cable insulation Capacitors: production of resonant circuitsX Disruption of the regulation devices, remote control,
cage
* Network calculation A complete study was pertormed including the choice of voltage level, short circuit calculation, stability calculation on the largest equipment starting up, harmonics calculations Due to the fact that the power generation is located 44km far away from the platforms, the short circuit power is around
30MVA.
nX3
h
ENa
vSD'
X
777[
Solutions: * Passive filter Economic solution, however the filter must be calculated for a fixed installed power and a constant harmonic level which is not the case in an ESP application because the number and the power of equipments in service are always changing; the risk is to destroy the filter. In addition, when the passive filter is stopped, significant pulses affect the network.
* Active filter Interesting solution but the filtering is not completely assured for Harmonic current exceeding the capacity of the filter.I
9i u
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ESP sizing The ESP has been defined for an operating frequency range of between 40 and 60 Hz in order to cover a complete flow range.
Pump Perfonmance Cure
Head
_Variaiyle frequency
4.9% 2.2%
4.9%
2%
70
60
50
Head Capacity
Head Capacity
With the passive filter option, the size of the filter was more or less 500 kVAr by platform for a guaranteed THD less than 5%.
40
30
Hz5H
40 H
V. 6PULSESVSDVERSusREGENERATIVE VSD
>
The input stage of a non-regenerative AC drive is usually an uncontrolled diode rectifier; therefore power cannot be fed << X S X} back onto the AC mains supply. By replacing the bridge diode 10 ____________________ _ hinput rectifier with a voltage source PWM input converter, AC power supply power flow can be bi-directional with full control 3.00 Motor Load over the input current waveform and power factor. Current can be controlled to give near unity power factor and a low 2.00 ------------------------------------ now level of line frequency harmonics. An active IGBT converter is -----------------------------.oe used as a sinusoidal rectifier and synchronized with the main supply network. Furthermore, by maintaining the DC bus voltage above the 6X 0 1W000 20 3000 3WO 4000 460 60 5600M 6WO 70 76 peak supply voltage the load motor can be operated at a Figure 3: Pump performance curve in variable frequency higher speed without field weakening. Alternatively, the higher If the consumed power of the pump is proportional to the cube output voltage available can be exploited by using a motor with of the speed, we have to remember that the motor horsepower a rated voltage higher than the AC mains supply, this reducing output rating will increase directly with the ratio of the the current for a given power. REGEN inductors must be used to ensure a minimum source impedance. The difference frequency. between the PWM line voltage and the supply voltage occurs across the regen inductors at the REGEN drive. This voltage has a high frequency component, which is blocked by the regen inductor, and a sinusoidal component at line frequency. PUmp absorbdl As a result currents flowing in these inductors are sinusoidal 3M ~~~~~power Motor sh.aft with a small high frequency ripple.
20
---
0-
power
'D
20
Figure 4: ESP power curve As shown on figure 4, the pump requires less HP than the motor is capable of delivering up to a certain frequency and then exceeds it.
Frequency (hert)
40
Low level of harmonics distortion on the main supply: ' 4% Power factor close to 1 Output voltage can be higher than input voltage (+100 V max for 400V of input voltage supply)
In fact, the input stage of the REGEN is regulated at a higher voltage value than the normal voltage value of the 6 PULSE, so this kind of converter is not affected by mains voltage fluctuation.
Step up transformer and ESP cable losses The losses have been calculated for the maximum frequency including a temperature derating factor
VSD sizing VSD power was calculated for the maximum surface absorbed power including the cables and transformer losses
IGBTRnverter
I
Harmonics calculation study was performed with the most stringent .M conditions (minimum short circuit power minimum, one 33kV/41 5V transformer etc...........) A compiete
444-
URFuses
IGBT RectiftFer
ni
>' <
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Output current
M
(LC type):
6543Ht
(D) 1.9z
-00 +O000, +O00 Main advantages: 3 - Excellent output wave form, reducing the voltage stress on LI 0LI the transformer and/or motor. - Low THD Current.<3% 135791 3579122 -Elimination of the switching frequency from the VSD, -620 typical range from 2 to 4 kHz. A VA RMS THD CF V U `=-E ~-E -Elimination of the risk of voltage reflections phenomena due to ESP cable length (2000 to 4000 meters). When the load is increasing during starting of all the wells, the harmonic distortion tends to decrease and these Step up transformer: * SteQ u~~~ transformer: ~~tests voltage demonstrated that the THD values are within the and
A389.1 A
100.0 %
100.0 %
382.5A
385.8A
~~~~~total
The output transformer is required to elevate the surface voltage. The typical voltage required to ESP driving is 2000 up
to 4000 V.
IEEsadrslmt
lEC
DP3 HARMONIC
THD -%
VI. FEEDBACK
2,5 -1000 Field tests During the start up of each well, several tests were performed and recorded as shown in the figure below: the results agree with the harmonics calculations made during the engineering
3l-5-la 3
kW ~~~~~~~~~~~~~1200
phase.
0,5
400 200 0
Input voltage
SUVOHZ
1.5 %2
U~~~~3107YO4
2.0 Z 3
11:86 Q46-k
1.9
ii...
Uh 01
2.0
%
49S9Hi
640V
3U 3V 3A
407.6 v
1 00.Oz% 2
-000, -00,
407.5v
100.Oz
03107104 11:59
Q46 + + + 03 100.Oz
407.5 v
3L
__________________________________
12
LI
1.0
13
5
U2= -269
U3= -310
RMS THD CF
1'1
13
rmit
VA
1.51'719 21
~-G
23 25
VSD
WELL
P(kW)
167
218
1 56
PF
P(kW)
151
208
PF
Hz
Efcec
Input current
49.97H~~~~
21
22
ON2z 307104 12:10
0,97
0,98
0,66
0,74
46 47,6
443 46
90,4%
95,4%
fl3ffO7V04 1209
5.4z 2
4.1x
5.8z
3V
23
+03
5
3 5
300.OA 295.6A
2 100.Ox
3 100.0 %
0OU
299.3A oo
0,98
LI~~~
1
2.
LI3
L
7
3L
28 31
34
32
4t= 5.0m
RMS THD CF
ME
911
13
33
!
53,4 55,5
46
VA
Output voltage
2.5
630V
Jj-. fi.43H
%
3-U
RMSTHDCF ~~~
355.5v
00,
100.Oz
0071C4 12.31
3V
10 V
356.0Ov -0,/
A)
io0.o
Q460 16
09
36 39 20 ,44O 16 0 41
235 139 90
19
168
15
142
VA
U ~~~E)
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Failures As expected with all new technology equipment, some problems occurred at the beginning:
- Damage to electronic cards and control transformer when
These modifications were implemented 5 years ago and there has been no further problem since.
The voltage was maintained by the rectifier for a small period and due to the commutations on the synchronous rectifier the input filter was excited and a high amplitude current and voltage wave occurred at a level higher than the limits of some diodes on electronic cards. This problem has been analyzed and solved by:
- Voltage clipper and resistance installation upstream of the - Modification on interfaces cards - Implementation of a new software on the rectifier and
control transformers
Following these modifications, there was no reoccurrence of problems linked to the VSD.
11: 18:108 A:
-1i 50 K200zo
5 Ms -0.60
=
Ms
=====
_
I9 ,/;_
A
0The
B
new
aim of PART 11 is mainly to demonstrate the interest of REGEN VSD compared to a typical VSD (6 pulses PWM inverter) when supplying an ATEX motor.
C: 3=
v l====--======_INVERTER
1 1.
_------------0.60 Y
-0.60 6
5c 3=- ======1
_
266pV 1
s
.<
5 ms~nIr
A==------
Il
7
kinds of supplementary stress, compared to a standard or 60Hz supply: Thermal and Electrical.
50Hz
2 .2 v C 3 .2 V DC
1 5 UDC
DC 0.00 K
10 D/C STPP
A1 -------1
s
Firstly, it is well known that an additional temperature rise occurs when the motor is fed by an inverter compared to a normal sine wave supply. This phenomenon can be explained by the consequence of field weakening and the rich spectra of voltage harmonics. Indeed, a voltage drop can occur inside the inverter and the cable length. This can produce generally a field weakening and for the same torque demanded by the shaft, the losses will be increased (Joules and iron losses). This is not acceptable for ATEX standards.
Particular attention must be paid when designing this kind of motor. To avoid this problem the motor designers take into 201. . 1 r| 100 ___________account the field weakening ============ by decreasing the number of in In turns the slot. this the fluxThis increases and C:3=========--winding casew above. 26 compensates the voltage drop stated practice iS eev grrnllrrlrrrBwrlllly 1 rI-I________ currently used for the lower frame sizes, and the flux is ======= , r r"r^rlt I +k f/%+n4 I4r% +,+n4 T + increased by at least 7% compared to a standard motor. _20____________
A
.I
1n
11r
"n,n
rx^
i-rr
5 5 DC .51 v DC 3.1 DC E .1 v DC
============__ I_______
STOPP[D
5
because of the lower number of turns used. For example a that has turns! lo cannot b hsv. ltb reduced to 3 turns! slot because the flux will be 33% higher. In
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this case, a power de-rating is generally used in order to keep the temperature rise at the normal value to comply with the thermal class of the insulation system.
The second factor that needs to be taken into account is electrical stress. Indeed, the use of inverters to drive rotating machines may be detrimental to the electrical insulation [1 ] [2]. Among the different explanations proposed, the most relevant are linked to the existence of over voltages due to external conditions such as large dV/dt, cable length, impedance mismatches between the cable and the motor or to the unbalanced voltage distribution in the winding [3]. Their impact is well known. They may trigger Partial Discharges (PD) [4] and lead to a reduction in the life time of the insulation. i
7--
6 PULSES DRi-VE
nputItance
l I / X/
To avoid this second problem an upgraded insulation system is generally used, particularly in the enameled wire by using a special corona resistant wire (Fibber glass wire, etc). In this case the motor is more expensive. One question arises: Is there another way to assure the security and reliability of ATEX motor VSD supplied?
In the following we will try to answer this question demonstrating the benefits of the new approach using a REGENERATIVE inverter. 111. EXPERIMENTAL
REGEN DRIVE
Inout
[CL Filter
The methodology utilized compares both VSD technologies (6 PULSES and REGEN) supplying a standard Direct on Line (DOL) ATEX motor (*) with a normal supply from the main. Focus was on the electrical and thermal points. To achieve this goal a specific test bench was developed and is shown in Figure 7.
(* 90kW4 poles and 400V5OHz)
output
LC FiIter
FLS D 280 - 90 kW- 4 poles - 400V/5OHz EEx d 112G IIB T4 * Results at Nominal voltage:
DOL
r _ F ti l
n .-
W W|D E
0__
VSD System voltage drop* (Vrms) Firter output (Vrms) Motor input voltage (Vrms) Motor input current (Arms) dv/dt motor input (kV4psec) peak motor (Vpk) ~~~~~~~~~Voltage Winding temperature rise (K) DE bearing temperature rise (K)
Nominal Torque (Nm) VSD Voltage input (Vrms) First harmonic voltage Hi (V) THD input voltage (%) VSD input current (Arms) First harmonic current H1 (A) THD Current input (%) VSD output (Vrms)
578 400
REGEN
578 401
400,7
/ / / / / / // 400
400,2
2,45
380 /
162 147 43
400,4
3,7 415
142 141
1,4
164,8
64,9
79,2
14
64
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PART Ill
OVERALL CONCLUSION
Nominal Torque (Nm) VSD input voltage (Vrms) First harmonic voltage Hi (V) THD input voltage (%) VSD input current (Arms) First harmonic current H1 (A) THD input current (%) VSD output (Vrms) VSD System voltage drop* (Vrms) Filter output (Vrms)
Motor input current (Arms) dv/dt motor input (kV/psec)
Motor input voltage (Vrms) Voltage peak motor (Vpk)
157,8
/ 360 / /
/ / / /
577
360,1
36 340 / /
340
162
157
This new technology presented an important challenge from a technical and economic point of view. The production of this oilfield was strongly linked to the reliability of the equipments andthe strong impact. and the environing impact.
The results confirm that this REGEN technology is the most adapted for many applications in the Oil and Gas industry.
II.
ACKNOWLEDGEMENTS
186,6 1,75
1001
77,6
78
97,5 81,6
67,8
74
* VSD system voltage drop: cable + input filter + inverter + output filter
The results show two main things: Firstly, we observe that the temperature rise in the motor is 70K when supplied with 400V sine wave voltage. The motor is designed with a good thermal reserve. However, when supplying the same motor with a standard PMW 6 pulses drive and at the same output torque, the temperature rise increases to 87K (97,5K when 360V at the drive input). In the case of the REGEN drive, the temperature rise is almost the same as DOL at 400V, but decreases at 360V. That means that REGEN drive compensates up to 10% input voltage drop and keeps the flux constant in the motor. In conclusion, from the thermal point of view, the REGEN solution drive keeps a constant temperature rise in the motor even if the input voltage decreases.
The authors would like to acknowledge and express their thanks to their colleagues. There are too many to acknowledge would like to individually in this paper but there are a few we IniiulyIthspprbtheeaeafw ewodlkeo specifically mention for their key roles. From LEROY SOMER: Christian PETIT Innovation & development manager Michel GALAIS - ATEX standard specialist Daniel EHANNO - Electrical environment specialist Fran9ois BOISAUBERT - ATEX standard specialist Nicolas DOS SANTOS - Project Manager / Engineering Dpt
-
ll. REFERENCES
materials degradation under repetitive impulse voltages", only available in French, Cigr6, session 15-104, 1994.
[2] E. Personn, "Transients Effects in Application of PWM Inverters to Induction Motors", IEEE Transactions on Industry Applications, Vol 28 n0 5,1095-1101, Sept/Oct 1992
[3] A. Bonnett,"Analysis of the Impact of Pulse Width Modulated Inverter Voltage Waveforms on AC Induction Motors" Proc. of the Intern. Conf. on Pulp and Paper, 68-75, 1994
Secondly, the REGEN drive will keep electrical stresses very low due to the output LC filter. The dV/dt is completely flattened and we don't have voltage peaks as in the case of a standard 6 Pulses PWM inverter. The voltage shape is a complete sine wave when a REGEN Drive fed motor. In this case partial discharges could be not triggered.
Finally, we have demonstrated that the REGEN solution has two advantages for motors: thermal and electrical. This will increases the life time of the insulation system and also the reliability. Moreover, when using a REGEN inverter we can use a standard design ATEX motor without any problems.
V. CONCLUSION PART II
[4] A.Mbaye, T.Lebey, Bui Ai "Existence of partial discharges in low voltage induction machines supplied by PWM drives", IEEE Trans.Diel. And El.ns, vol 3, 4,1996
IV. VITA
M. Guy DESCORPS: graduated in France with an electro technic associated Degree in 1970. He worked for eleven years for APAVE a worldwide independent Third Party
The above results demonstrate the benefits of the REGEN drive when supplying a standard ATEX motor. This solution complies with the ATEX directives. The subject of this approach is the influence of the type of VSD used on the motor temperature rise, the incidence on the constraints imposed when the motor works into an explosive atmosphere and to help in the evolution of INERIS officials documents.
He joined the electrical Department of ELF in 1983 and TOTAL in 2000. He has worked as an electrical engineer in engineering, commissioning and maintenance on several Oil & Gas Projects throughout the World.
Inspection Agency.
M. Philippe ESPAGNE: received his degree in mechanic technology from Paul Sabatier University, Toulouse France in 1980. Since graduation, he has been employed with FORASOL Oil&Gas Drilling Company. In 1986, he joined ELF as an electrical engineer involved in maintenance, commissioning and offshore/onshore
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development project. He is presently employed by TOTAL as Senior Electrical Engineer in Total Head Quarter.
M. Claudiu NEACSU: received the degree of Electrical Engineering in 1997 from the University Politehnica of Bucharest. He has also working for a Ph.D. at the "Laboratoire de G6nie Electique" of Paul Sabatier University in Toulouse & Leroy Somer. The subject of his doctoral thesis was "diagnostics of the failure in asynchronous motors fed by an inverter". In 2003, he joined the R&D department of Leroy Somer at CEB factory. M. Philippe WESOLOWSKI: graduated in France with a "Genie Electrique" associated Degree in 1985 CNAM. He joined Leroy Somer Company in 1988 as a specialist of drive applications in Oil and Gas market.
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