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- LESSONS LEARNT -
Guy DESCORPS
TOTAL
Avenue Larribau
Pau
France
Philippe ESPAGNE
TOTAL
Avenue Larribau
Pau
France
Claudiu NEACSU
LEROY SOMER
Usine de CEB
Beaucourt
France
Philippe WESOLOWSKI
LEROY SOMER
Engineering Dpt.
Angoulme
France
INTRODUCTION
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
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
III. HARMONICS
Harmonics effects:
Some precautions are required when using VSDs, 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
cage
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 circuits
Disruption of the regulation devices, remote control,
measurements, counters, etc.
Network calculation
A complete study was performed 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.
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.
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.
DP2
2150
12.5%
4.9%
2.2%
DP3
2150
11.5%
4.9%
2%
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%.
V.
Surface package
Main advantages:
- Excellent output wave form, reducing the voltage stress on
the transformer and/or motor.
- Low THD Current 3%
- Elimination of the switching frequency from the VSD,
typical range from 2 to 4 kHz.
- Elimination of the risk of voltage reflections phenomena
due to ESP cable length (2000 to 4000 meters).
Step up transformer:
DP3 HARMONIC
THD - %
VI. FEEDBACK
U1
kW
load
1200
1000
2,5
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
phase.
800
1,5
600
400
0,5
200
0
+ ALK 36
+ ALK 34
initial
Input voltage
+ ALK 33
0
+ ALK 32
When the load is increasing during starting of all the wells, the
total voltage harmonic distortion tends to decrease and these
tests demonstrated that the THD values are within the IEC and
IEEE standards limit.
+ ALK 31
Output current
WELL
21
Input current
Output voltage
VSD INPUT
P(kW)
PF
167
0,97
VSD OUTPUT
P(kW)
PF
Hz
151
0,66
46
Efficiency
90,4%
22
218
0,98
208
0,74
47,6
95,4%
23
156
0,98
143
0,61
49,6
91,7%
24
175
0,98
160
0,68
443
91,4%
28
128
0,98
122
0,67
46
95,3%
31
204
0,99
192
0,76
53,4
94,1%
32
236
0,97
221
0,79
55,5
93,6%
33
134
0,96
119
0,69
46
88,8%
34
172
0,97
160
0,70
50,2
93,0%
36
235
0,98
229
0,75
50,8
97,4%
39
139
0,98
132
0,73
46,9
95,0%
20
90
0,95
83
0,55
40,3
92,2%
40
136
0,96
125
0,64
48,5
91,9%
41
168
0,94
157
0,55
40,4
93,5%
42
204
0,97
189
0,57
44,3
92,6%
Failures
As expected with all new technology equipment, some
problems occurred at the beginning:
I.
INTRODUCTION
578
400
400,7
/
/
/
/
/
/
/
400
164,8
1,7 E-4
577,7
70
64,9
6 Pulses
REGEN
577
400,5
400,2
2,45
162
147
43
380
/
/
380
171
1,75
1115
87,3
79,2
578
401
400,4
1,4
142
141
3,7
415
14
401
401
164,6
1,7 E-4
588
71
64
* VSD system voltage drop: cable + input filter + inverter + output filter
PART III
DOL
6 Pulses
REGEN
577
/
360
/
/
157,8
/
/
/
/
360,1
177,4
1,7 E-4
520,6
78
77,6
577
360
359,6
3,13
174,8
162
36
340
/
/
340
186,6
1,75
1001
97,5
81,6
577
365
363
1,4
158
157
2,45
414
13
400,7
400,7
164,8
1,7 E-4
578
74
67,8
I.
ACKNOWLEDGEMENTS
* VSD system voltage drop: cable + input filter + inverter + output filter
III. REFERENCES
[1] Y.Shibuya, K.Kimura, H.Mitsui, "Winding insulating
materials degradation under repetitive impulse voltages", only
available in French, Cigr, session 15-104, 1994.
[2] E. Personn, Transients Effects in Application of PWM
Inverters to Induction Motors, IEEE Transactions on Industry
Applications, Vol 28 n 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
OVERALL CONCLUSION
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
Inspection Agency.
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.
CONCLUSION PART II