ARTIFICIAL LIFT Solutions for customer pains ESP PCP …€¦ · ARTIFICIAL LIFT Solutions for...

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

Electro Submersible Pump

Solutions for ESPs

2


Low production ? High maintenance cost ?


50Hz 50Hz


380 to 690V 23 -> 1600 Amps 12 -> 1600 kW

Middle voltage on request

Digistart D3

Fixed speed, low cost, best efficiency: soft starter


50Hz 50Hz


380 -> 690V

6,6 -> 1600 Amps

1,1 -> 1600 kW

Powerdrive MD2 / FX / F300


VSDs optimize pump speed for each well


VSDs increase oil production Graph courtesy of Franklin Electric


VSDs allow easy well start up for maximum production

Production flow ? Speed ?


Early pump failures ?


VSDs ramp up pump speed for low stress

Speed

DC bus voltage

Mains voltage

Motor intensity


VSDs avoid gas locks for extended pump life

Graph & image courtesy of Schlumberger


VSDs optimize pump working conditions for extended pump life

Graph courtesy of Baker Hughes


-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


High losses of production ?


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


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


VSD Interface screen (HMI)

Emerson VSDs have dedicated ESP functions to protect the pump and the production


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


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


High maintenance costs ?


Emerson VSDs are low voltage technology for reduced maintenance cost


More than 2000 drives, soft starters, transformers worldwide

Emerson VSDs are installed and serviced wordwide


Fast and easy troubleshooting


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


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


High investment cost ?


35% 12% 8% 5%

Total Harmonics Distorsion of Intensity

6 pulses Powerdrive

MD2S

12 pulses Powerdrive

MD2T


MD2E

24 pulses & AFE Powerdrive

MD2W & MD2R

More Emerson low harmonics VSDs can be installed in a given power supply network


600x600x2160 mm 400x600x2160 mm

Emerson VSDs become smaller. More VSDs can fit in a given electric room.

Powerdrive MD -> Powerdrive MD2


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.


Output sine filter within the step up transformer for more space gain


Variable speed drives installed outdoor when no more room available in the electrical room


Safety issues ?


Liquid cooling for less noise in the electrical room


Safe torque off


Examples

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Powerdrive MD2 IP21

Powerdrive MD2 IP55

Transformers

Progressive Cavity Pump

Solutions for PCP

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PCP – The need for variable speed

Adjust pumping speed to field requirements & optimize production

Ramp up to speed at required rate

Disgorge the well


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


PCP – System reliability with LS ../..

Tropicalized chokes & electronic boards

– Suitable for harsh environments



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



Easy troubleshooting

– Advanced automatic diagnostic

• Auto test under reduced voltage at power up

• Continuous recording of voltage & intensity each 330 µs

• Datalogging

• Trips timestamped



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


MD2T


MD2E

24 pulses & AFE Powerdrive

MD2W & MD2R



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



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



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



Dedicated Artificial Lift HMI for PCP

– Display of pump values



Dedicated Artificial Lift HMI for PCP ../..

All functions easily accessible & configurable

– Load management

• Overload

• Underload

• “F adjustment on I limitation”



Dedicated Artificial Lift HMI for PCP ../..

All functions easily accessible & configurable

– Power supply management

• Microcut

• Backspin

• Autoreset

– Double ramps

– Datalogging



ATEX certified motors: EEx nA, EEx e, EEx d

ATEX certified motor & drive sets


PCP – Easy installation with LS ../..

Light-weighted motor design

– Aluminum frame: LSE, LSN range

– Easy handling & mouting

– Less stress on the wellhead


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

Reciprocating Rod Pump

Solutions for RRP

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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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RRP – Needs in fixed speed

Needs for electrified wells:

– Simplicity

– Maintenance-free

– Robustness

– Must be adapted to :

• the pump cycle

• the outdoor environment


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)


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


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


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


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


Power consumed

Power generated


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



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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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 !


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


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


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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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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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.


Back up slides

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COMPARAISON TAILLE MT/BT


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

ARTIFICIAL LIFT Solutions for customer pains ESP PCP …€¦ · ARTIFICIAL LIFT Solutions for...

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Transcript of ARTIFICIAL LIFT Solutions for customer pains ESP PCP …€¦ · ARTIFICIAL LIFT Solutions for...