Post on 17-May-2018
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Presented by Jean-Mathieu Renault
Automation Solutions team
Moteurs Leroy Somer
Emerson Industrial Automation
ARTIFICIAL LIFT
Solutions for customer pains
ESP – PCP – RRP – Auxiliaries
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Low production ? High maintenance cost ?
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
380 to 690V 23 -> 1600 Amps 12 -> 1600 kW
Middle voltage on request
Digistart D3
Fixed speed, low cost, best efficiency: soft starter
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
380 -> 690V
6,6 -> 1600 Amps
1,1 -> 1600 kW
Powerdrive MD2 / FX / F300
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
VSDs optimize pump speed for each well
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
VSDs increase oil production Graph courtesy of Franklin Electric
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
VSDs allow easy well start up for maximum production
Production flow ? Speed ?
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
VSDs ramp up pump speed for low stress
Speed
DC bus voltage
Mains voltage
Motor intensity
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
VSDs avoid gas locks for extended pump life
Graph & image courtesy of Schlumberger
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
VSDs optimize pump working conditions for extended pump life
Graph courtesy of Baker Hughes
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
-800
-600
-400
-200
0
200
400
600
800
2) Ch 2: 100 A 5 ms
Output of unfiltered drive (voltage)
Output of Powerdrive with sine filter (intensity, THD < 5%)
Emerson VSDs send clean, equilibrated power to the pump for extended life
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Roof, panels, chassis : • Stainless steel 316L
Emerson VSDs are suitable for offshore environments
Filter boxes: • Rugged drip drain design • Stainless steel 316 L
Filters : • G4 dust filter • Coalescing filter for moisture removal
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Emerson VSDs maintain operations in harsh supply conditions
VSD
Supervision
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 19
VSD control screen (HMI)
Emerson VSDs have easy ESP menus to prevent operator mistakes
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 20
VSD Interface screen (HMI)
Emerson VSDs have dedicated ESP functions to protect the pump and the production
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Underload detection
The VSD will protect the pump from underloads
Overload detection
The VSD will protect the pump from overintensity:
• at any speed
• during start up
F adjustment on I limitation
The VSD will adjust speed so as not to go over the defined intensity limit.
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Dedicated Artificial Lift functions
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Backspin detection
The VSD is allowed to start only after the pump did coast to rest
Kick Start
The VSD inches the pump in CW/CCW directions several time
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Dedicated Artificial Lift functions
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Emerson VSDs are low voltage technology for reduced maintenance cost
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
More than 2000 drives, soft starters, transformers worldwide
Emerson VSDs are installed and serviced wordwide
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 26
Fast and easy troubleshooting
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Inverter module
Rectifier module
Forced ventilation
Control board
L1 L2 L3 U V W
Emerson VSDs are designed for fast field repair to reduce lost production costs
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Inverter module
Rectifier module
Forced ventilation
Control board
Emerson VSDs are designed for fast field repair to reduce spare parts stock
1
2
7
4
From 160 to 2800 kW
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
35% 12% 8% 5%
Total Harmonics Distorsion of Intensity
6 pulses Powerdrive
MD2S
12 pulses Powerdrive
MD2T
18 pulses Powerdrive
MD2E
24 pulses & AFE Powerdrive
MD2W & MD2R
More Emerson low harmonics VSDs can be installed in a given power supply network
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
600x600x2160 mm 400x600x2160 mm
Emerson VSDs become smaller. More VSDs can fit in a given electric room.
Powerdrive MD -> Powerdrive MD2
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
2400x600x2160 mm 1200x800x2360 mm
400V 470kVA AFE Powerdrive MD2 for ESP
Emerson VSDs can be arranged on demand. More VSDs can fit in a given electric room.
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Output sine filter within the step up transformer for more space gain
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Variable speed drives installed outdoor when no more room available in the electrical room
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Liquid cooling for less noise in the electrical room
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Examples
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Powerdrive MD2 IP21
Powerdrive MD2 IP55
Transformers
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
PCP – The need for variable speed
Adjust pumping speed to field requirements & optimize production
Ramp up to speed at required rate
Disgorge the well
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
PCP – The concerns
1. Solution reliability : production is at stake, downtime of the system must be minimal
– Motors and drives
2. Installation constraints :
– Space: high cost of shelter space for onshore, even more for offshore
– Harmonics
– ATEX zone
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
PCP – System reliability with LS ../..
Tropicalized chokes & electronic boards
– Suitable for harsh environments
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
PCP – System reliability with LS ../..
Modular design for fast on-site expertise and repair
– Power modules changed in less than 30 minutes
– Power modules are small and require no special tool for (dis)mounting and handling
• 150kVA and less drives : less than 16 kilos
• 180kVA and more drives : less than 22 kilos
Inverter module
Rectifier module
Forced ventilation
Control board
L1 L2 L3 U V W
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
PCP – System reliability with LS ../..
Easy troubleshooting
– Advanced automatic diagnostic
• Auto test under reduced voltage at power up
• Continuous recording of voltage & intensity each 330 µs
• Datalogging
• Trips timestamped
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
PCP – System reliability with LS ../..
Low harmonics (line side)
– Protects the instrumentation from electrical noise
– More and more important, since we have more and more drives on the same power supply
35% 12% 8% 5%
Total Harmonics Distorsion of Intensity
6 pulses Powerdrive
MD2S
12 pulses Powerdrive
MD2T
18 pulses Powerdrive
MD2E
24 pulses & AFE Powerdrive
MD2W & MD2R
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
PCP – System reliability with LS ../..
Electrical supply disturbances proof
– Microcut function:
On mains failure, the drive keeps control of the motor. It can reaccelerate the PCP if power resumes within 2 seconds (and if the well has enough inertia), thus avoiding a backspin situation and production loss.
Speed
DC bus voltage
Mains voltage
Motor intensity
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
PCP – System reliability with LS ../..
Electrical supply disturbances proof ../..
– Braking and reaccelerating on backspin quadrant:
If the PCP enters backspin mode, the drive is able to brake and reaccelerate when power resumes, with a field-proven torque limitation that protects the rods and prevent harmful pressures.
Speed
DC bus voltage
Mains voltage
Motor intensity
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
PCP – System reliability with LS ../..
Electrical supply disturbances proof ../..
– Backspin 5min. function :
If the PCP enters backspin mode, the drive is able to maintain control on the motor and slightly slow it down, thus enabling:
• Continuous communication of well data to monitoring system
• Ability to restart as soon as power resumes (no preload)
Motor intensity
Mains voltage
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
PCP – System reliability with LS ../..
Dedicated Artificial Lift HMI for PCP
– Display of pump values
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
PCP – System reliability with LS ../..
Dedicated Artificial Lift HMI for PCP ../..
All functions easily accessible & configurable
– Load management
• Overload
• Underload
• “F adjustment on I limitation”
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
PCP – System reliability with LS ../..
Dedicated Artificial Lift HMI for PCP ../..
All functions easily accessible & configurable
– Power supply management
• Microcut
• Backspin
• Autoreset
– Double ramps
– Datalogging
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
PCP – System reliability with LS ../..
ATEX certified motors: EEx nA, EEx e, EEx d
ATEX certified motor & drive sets
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
PCP – Easy installation with LS ../..
Light-weighted motor design
– Aluminum frame: LSE, LSN range
– Easy handling & mouting
– Less stress on the wellhead
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
PCP – Easy installation with LS
Compact design
– New Powerdrive MD2 up to 33% smaller
– Example: 400V 150kVA 6P Powerdrive for ESP
600x600x2160 mm 400x600x2160 mm
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Solutions for RRP
Fixed speed
– What users need
– The solution with Leroy Somer
Variable speed
– Issues with fixed speed and full time pumping
– Issues with fixed speed and intermittent pumping
– What users need
– What are users’ concerns in variable speed & issues with 6 pulses drives
– The solution with Leroy Somer
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LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
RRP – Needs in fixed speed
Needs for electrified wells:
– Simplicity
– Maintenance-free
– Robustness
– Must be adapted to :
• the pump cycle
• the outdoor environment
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
RRP – LS solutions for fixed speed
LS high slip motor
– Smooth torque curve : less wear on rod & casing
– Light aluminum frame : easy handling and installation
– Up to 100hp, IP55, corrosion proof design
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Cast iron end-brackets with regreaseable bearings
Aluminium frame
Large terminal box
Stainless steel nameplate
Steel fan cover
Aluminium fan
Dynamic balanced rotor (pressure cast aluminium bars)
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
RRP – The concerns in fixed speed with full time pumping Too high stroke per minute (spm) leads to low fluid level
above the pump, low filling of the pump and :
– High energy consumption relative to production level
– Lost production & high maintenance costs, due to fluid pound that damages the rod and the tubing
– Lost production because of a pump off condition were manual restart is required.
Too low spm leads to lost production
Spm change is complicated, needs pulley & belt adjustment
Monitoring possibilities are limited
Too many motors on the same electric network cause a lagging power factor, capacitor banks must be installed
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
RRP – The need for variable speed
Adjust pumping speed to field requirements
Avoid pulley and belt adjustment
– no production interruption
– no field work involved
Monitor & optimize production
Correct the Power Factor of the oil field without capacitor banks
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
RRP – The concerns of variable speed
Concern #1 : system reliability
Production is at stake, pump system downtime must be minimal, the variable speed system must be reliable.
Leroy Somer systems are installed worldwide and comply to harsh tropical conditions
Rugged design with :
Tropicalized boards
– Resin treated line choke
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Concern #2 : safety
Rod pumps actually produce power up to 20% of the time, or even more. This power must be managed by the drive. Some drive configurations include hot and bulky power resistors to comply to the running cycle.
Leroy Somer solutions are 4 quadrants and do not need resistors
RRP – The concerns of variable speed
Power consumed
Power generated
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Concern #3 : pump lifetime
Some 6 pulses drive configurations do not control the pump speed and let the rod accelerate during downstroke. High speed may lead to early pump failure due to rod & tubing wear (resonant frequencies, fluid pound…)
Leroy Somer solutions are 4 quadrants and prevent excessive speed for longer pump lifetime
RRP – The concerns of variable speed
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Concern #4: complicated startup & parameter setting
The wells are often isolated and disseminated on the field. Technician cannot afford to loose time to visit well sites to:
– get well data & set speed accordingly
– Understand and clear VSD faults
=>
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RRP – The concerns of variable speed
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
A patented, compact, 4 quadrant drive, the Powerdrive FX.
– No additional resistors
– Compacity (66% space and weight saving)
– Prevents excessive rod speed
– Close to 1 power factor
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RRP – The solution, with Leroy Somer !
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Benefit #1 : compacity
size comparison for a 90kW system
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RRP – Leroy Somer solution benefits
Common 6 pulse solution 90kW
920
Overall volume (6 pulse drive + line
reactor + RFI filter + braking resistor +
overload relay) = 0,3 m3
Total weight : 120 kgs
POWERDRIVE FX 100T
788
Overall volume (POWERDRIVE FX) : 0,06 m3
Total weight : 37 kgs
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
RRP – The solution, with LS !
Datalogging for well data sharing
– Remote with fieldbus connectivity
– Local with months of storage on SD card
Remote control
– Start/stop/speed setting possible remotely
Remote fault management :
– Autoreset of selected defaults
– Defaults analysis and resetting possible remotely
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modbusTCP
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
RRP – The Future (1)
Production optimisation with DYNEO solutions - LSRPM motor with permanent magnets
- Higher efficiency saves up to 20% of the electric bill
- Advanced « cold » design saves on maintenance:
- Better bearings lifetime & Reduced lubrication intervals
- Easy installation:
- No additionnal cable thanks to innovative sensorless control
- Same or smaller framesize than IEC
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LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
RRP – The Future (2)
Production optimisation : Pump Off controller development in progress
– Higher production on a given well
– Less stress and longer lifetime of the pump
More coming !
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LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Thanks for attending !
Please enjoy the rest of the conference
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Our global customer knowledge sharing event and technology exhibition. 300+ papers and work shops.
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
ESP – Easy installation with LS
High ampacity modules :
– Best in class power to volume ratio: up to 800A in a 445x323x292mm module, 22kg only
– Higher ampacity modules being developped
– Less insulation distance than MV drives makes the final drive more compact