Variable Speed Drives (VSD) ACS 600 OIL PALS PRU DTC Technology for oilfield applications Electric motors from 10HP to 1000HP in low voltage ACS 600

Transcription

1 1 Variable Speed Drives (VSD) PALS PRU DTC Technology for oilfield applications Electric motors from 10HP to 1000HP in low voltage

2 2 Tecnología DTC para Aplicaciones Petroleras

3 3 ABB (Asea Brown Boveri) has developed over the past decade variable speed drives for specific oilfield application, primarily for artificial lifting applications. We have codenamed this product ACS 600 Oil, worldwide it is the first of it s kind with a design based on Direct Torque Control (DTC) which offers an integral solution applicable to all the various methods of crude extraction presently in the Oil industry, in a wide range of power and voltage application. The development of the ACS 600 Oil was oriented to solve the different needs of crude extraction methods with pumps such as PCP (Progressive Cavity Pumps) ESP (Electro Submersible Pumps), and DP (Donkey Pumps or Conventional Mechanical Pumps), which when combined with Direct Torque Control permits the operator to exactly control the speed and torque across the whole range of the system even with different load requirements. VSD s + Motors = Integral Solution The Application Macros need no external controls or protections on inasmuch as they form a direct, and integral part of the ACS 600 Oil, obtaining thus, a significant reduction in installation, production and maintenance cost. ACS 600 Oil cam be used in all three methods of crude lifting; CMP, PCP and ESP without adapters, as well as in transportation and distribution systems such as Multiphase Pumps (MPP) and Pipeline.

4 4 As a Solution for Crude Handling Under Severe Weather Conditions. ABB has also developed an engineered enclosure reusable for outside use, adequated for use on wells under several weather conditions in any part of the world. The structure was developed taking into consideration the severe operating conditions under which the ACS 600 Oil might have to function, as well as the need to provide the customer with a variety of control options. The enclosures are all weather proof either for NEMA or IEC protection standards. This permits a design which requires no forced air ventilation to maintain a predetermined determined temperature inside to function, inasmuch as the ACS 600 Oil recirculates the air at ambient temperature through special entry and exhaust ducts. OCN Projects Faja del Orinoco Std. Monagas - Venezuela (PDVSA -ExxonMobil ) The customer only need to connect the feed power to the enclosure inlet and to the motor connections for system start-up. All electrical protection necessary to guarantee ideal functioning are present within the equipment. Even at distance, supervision of all systems is possible through the use of control panel CDP 312. SINCOR Faja del Orinoco Std. Anzoategui - Venezuela (PDVSA TOTAL) Along with the ACS 600 Oil, ABB can supply all the accessories desired, thus assuring immediate and fast start-up operation of all supervisory and control equipment.

5 5 ACS 600 Oil As a Solution for Conventional Mechanical Pumping (Donkey Pump or CMP ). The Direct Torque Control (DTC) executes speed control independently, both ascendant and descendant speed, without any gauges, position or load sensors, or any instruments The ACS 600 Oil controls the Float of the rods which might be produced by atmospheric or down hole conditions change, thus eliminating constant adjustments to the control parameters programming. Tia Juana Well (PDVSA Occidente) There need of no additional elements (Choppers or brakes resistors) which are aimed at controlling the regenerative effect caused by rods or weights can thus be increasing reliability and reducing unnecessary stops. Outdoor use enclosure Made in Venezuela (PDVSA Occidente) PCP & Donkey Pump

6 6 Use of the ACS 600 Oil on conventional equipment adds other advantages: Elimination of sharp brake stops of the rods and pump in the down hole Visual check (Through the SCADA system installed or the Control Panel) all electrical and process signals which monitor operation and well procedures, such as: Motor Speed (RPM) Beam pump Speed (SPM), Current (Amp), Operation Torque (LB-FT/N-m), Power (kw), BUS DC voltage (VDC) Output Voltage (VAC). Power Consumption (kwh) Schematic drawing Beam Pump Application Rod overtravel is controlled without. the need of external measurement devices. Over 30% increase in pump life. Speeds on the Beam Pump can be adjusted without pulley changes. Speed control optimizes production more than 20% typically Worn parts replacement is reduced, lowering maintenance costs,. 30% energy savings through realistic energy consumption on the well eliminating peaks produced by Beam Pump start-ups. With ACS600 Oil the power factor is 97% constant, eliminating any additional corrector equipment.

7 7 As a Solution for Progressive Cavity Pumps (PCP). In the crude extraction with PCP s, pump Torque control is the most important requirement, thus eliminating deformations or breakage to the pumps or rods in the hole. ACS 600 Oil, without utilizing additional accessories, archives this result DTC and the mathematical model produced exclusively to control Torque through peed variation. This is managed by ACS 60 Oil through control of the speed and thus the operation of the PCP, by processing the information received from bottom hole sources, which permit automation of the pump so as to optimize production while diminishing operations costs. ACS 600 Oil for PCP Dual Motors application Through pump torque and information received from the associated well system, it is possible to optimize the operation resulting in a higher production index and longer pump life Using a control panel or SCADA system allows visual check of process and electrical signals associated to the application; these signal can be displayed in engineering units, ACS 600 Oil for PCP One Motor application

8 8 For example, the information shown is as follows: Pump Torque (lb-ft/ N-m) Motor Torque (lb-ft / N-m) Pump Speed (rpm) Motor Speed (rpm) Power (Kw) Intake pressure (psi) Discharge pressure (psi) Discharge temperature ( c) Casing pressure (psi) Flowing pressure (psi) Some other controls by ACS 600 Oil for PCP application are: Function squematic PCP Application Inverted or reverse speed control to prevent the return of the rods (Back Spring) produced by inertia. This control is part of a back-up in the mechanical system. Torque control of the rods which permits pump speed control adjustment to possible changes in the down hole. This eliminates unnecessary halts in production and results in more crude pumped. Pump speed control responding to signals received such as, discharge temperature, Intake, discharge, casing or flow pressure adjust and optimize pump operation in correlation with well conditions. Variations of pump speed and Torque limits protect the pump in line with the pump operation, again in correlation with well conditions.

9 9 ACS 600 Oil As a Solution for Electro-Submersible Pumps. The control macro for Electro-Submersible Pumps, can be used with both low tension ACS 600 Oil and Medium Tension ACS 1000 Oil. The main control in the pump is the speed variation according to the working temperature in the pump. It is possible to program the automatic start-up times, considering the severe Start-Up conditions (30-60min Appox) after a drop in tension In addition it is possible to manage the logic of pump pressure and volume control, obtaining thus, as in previous cases, a logical regulation in accordance with the information received from the system Outdoor use enclosure for ESP Made in Venezuela Information supplied by either ACS 600 Oil: Pump Start-Up time. Pump Torque (lb-ft/ N-m). Motor Torque (lb-ft / N-m). Pump Speed (rpm). Motor Speed (rpm). Power (Kw). Intake Pressure (psi). Discharge Pressure (psi). Discharge Temperature ( c). Casing pressure (psi). Flow pressure (psi).

10 10 ACS 600 Oil A Solution for Multiphase Pump (MPP). When used with this type of pump, ACS 600 Oil controls the speed in the system in accordance with the intake pressure of the pump and it s discharge pressure ACS 600 Oil is designed to facilitate smooth start / stops and its speed controller, keeping on adequate temperature level, thus increasing the useful life of the pump. Project SINCOR Multiphase Pump Inside view Power House for MPP ACS 600 Oil displays all electric and process information as follows:: Motor Torque (lb-ft / N-m) Pump Speed (rpm) Power (kw) Intake pressure (psi) Discharge pressure (psi) Pump Temperature ( c) Flow pressure (psi) Recommendations to house and protect the ACS 600 Oil ands ACS 1000 Oil applications for oil field use in smart power houses. This recommendation and its acceptance is most important when weather conditions are difficult (such as severe cold or severe heat coupled with salt or brackish water in the sub-soil or atmosphere) and also when cluster control is recommended or desired

11 11 ACS 600 Oil Integral solution for the customer requiring well pad control (Utilizing enclosure and Smart Power House). The Smart Power House permits single point control of systems in a well designed and well built construction which can be cooled or heated as needed. This includes housing of the SCADA system The SPH consist of an Incoming and Power Distribution System, the OPS for Cluster Control and Communication. The OPS is an integral control and communication system for Pumping control and optimization of any artificial method as used for pipeline of crud and Cluster Control Line Production Smart Power House for MPP & BCP Made in Venezuela It is a open System providing connectivity and communication with any system, subsystem or AC800F OPS TM Architecture field device being capable to establish OPS HIS OPC Client Scada OPC Server communication with external equipment via standard communication protocols and with Ethernet - TCP/IP standard as intelligent field devices Within the developed software modules for AC 800F Profibus/Modbus OPS we count with DHS PALS - PRU - Agosto 07 S800 I/O F.O. OPS MPP (Multiphase Pump) OPS PCP (Progressive Cavity Pump) OPS ESP (Electro-Submersible Pump) OPS BP (Beam Pump) OPS MS (Main Station) OPS SCS (Smart Cluster System) OPS NC ( Nomograph Curve) OPS SECS (Smart Environmental Control System)

12 12 ACS 600 Oil Integral solution for the customer requiring well pad control (Utilizing enclosure and Smart Power House). ABB has developed different enclosures achieving significant cost reductions in cluster installations. This design facilitates the choice of method of extraction because the ACS 600 Oil can be used for the different method of crude extraction (PCP or Beam Pump) simply by changing the control macro. External view - Smart Power House The Smart Power House offers an integral solution because it centralizes and optimizes the cluster control system and supervision of all signals involved in the process of lifting, producing and transport of crude, under any conditions,. As mentioned before, Smart Power House can be used under the most severe weather conditions because the inner temperature is also monitored and controlled Inside view Smart Power House for PCP application

13 13 New development with Well Pad in PCP, MPP, ESP and Beam Pump Automation Products = VSD + Motors + Smart Power House + Active Filter

14 14 Reference List Until - February End User Company Kind of ABB's Variable Speed Drives (VSD) Oil Application Quantity PDVSA OCCIDENTE ACS500 / ACS600 PCP 407 PDVSA OCCIDENTE ACS600 DONKEY PUMP 91 PDVSA OCCIDENTE ACS600 ESP 1 PDVSA OCCIDENTE ACS600 MULTIPHASE PUMP 2 PDVSA OCCIDENTE ACS600 WATER PUMP 1 PDVSA OCCIDENTE ACS600 HIDRAULIC PUMP 1 PDVSA ORIENTE - PARIAGUAN ACS500 PCP 1 CENTRO REFINACION PARAGUANA ACS500 / ACS600 PIPELINE 23 AMUAY ACS600 CRANES 2 PDVSA OCCIDENTE LAGO ACS600 PCP 33 PDVSA OCCIDENTE LAGO ACS600 DONKEY PUMP 3 PDVSA BITOR ACS600 PCP 15 PDVSA BITOR ACS600 ORIMIXER 11 TRADICIONAL ACS600 PCP 21 PDVSA ORIENTE SAN TOME ACS600 PCP 77 PDVSA ORIENTE ANACO ACS600 PIPELINE 5 PDVSA ORIENTE PUNTA DE MATA ACS500 ESP 3 PDVSA ORIENTE OROCUAL ACS600 PCP 2 PDVSA - INTEVEP ACS600 PIPELINE 2 BOLIVAR ACS600 MULTIPHASE PUMP 1 OPERADORA CERRO NEGRO (OCN) PDVSA-EXXON-MOBIL-VEBA OIL ACS / 150 HP PCP 127 SINCOR UPSTREAM - PDVSA -TOTAL - STATOIL ACS / 550 HP MULTIPHASE PUMP 23 SINCOR UPSTREAM - PDVSA -TOTAL - STATOIL ACS / 100 HP PCP 348 SINCOR DOWNSTREAM - PDVSA -TOTAL - STATOIL ACS / 5 HP PIPELINE 98 MAXUS DE VENEZUELA ACS / 75 HP PCP 14 CHEVRON ACS / 60 HP PCP 8 PEREZ COMPANC ORIENTE ACS / 75HP PCP 3 PREUSAG-CABIMAS ACS / 50 HP DONKEY PUMP 1 PREUSAG-CABIMAS ACS / 75 HP DONKEY PUMP 3 PEREZ COMPANG OCCIDENTE ACS / 10HP PCP 1 PETROZUATA-CONOCO ACS / 75 HP PCP 1 PETROZUATA-CONOCO ACS / 75 HP PCP 1 TOTAL ABB DRIVES 1735

15 15 Equipment Available for all Pumps ACS 600 Oil only for PCP 110% Overload Hp Description Application Software 10HP ACS PCP Torque Control or PCP Torque & Down Hole Sensor 20HP ACS PCP Torque Control or PCP Torque & Down Hole Sensor 30HP ACS PCP Torque Control or PCP Torque & Down Hole Sensor 40HP ACS PCP Torque Control or PCP Torque & Down Hole Sensor 50HP ACS PCP Torque Control or PCP Torque & Down Hole Sensor 60HP ACS PCP Torque Control or PCP Torque & Down Hole Sensor 75HP ACS PCP Torque Control or PCP Torque & Down Hole Sensor 100HP ACS PCP Torque Control or PCP Torque & Down Hole Sensor 125HP ACS PCP Torque Control or PCP Torque & Down Hole Sensor and ESP 150HP ACS PCP Torque Control or PCP Torque & Down Hole Sensor and ESP 200HP ACS PCP Torque Control or PCP Torque & Down Hole Sensor and ESP 250HP ACS PCP Torque Control or PCP Torque & Down Hole Sensor and ESP 300HP ACS PCP Torque Control or PCP Torque & Down Hole Sensor and ESP 350HP ACS PCP Torque Control or PCP Torque & Down Hole Sensor and ESP ACS 600 Oil for Donkey Pump and PCP 150% Overload Hp Description Application Software 10HP ACS PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP 20HP ACS PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP 30HP ACS PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP 40HP ACS PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP 50HP ACS PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP 60HP ACS PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP 75HP ACS PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP 100HP ACS PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP 125HP ACS PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP 150HP ACS PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP 200HP ACS PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP 250HP ACS PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP 300HP ACS PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP

16 16 ABB DRIVES -Venezuela Asea Brown Boveri S.A. Av. Don Diego Cisneros Edificio ABB Caracas Venezuela Telf: , Fax: drives.venezuela@ve.abb.com drives.petroleo@ve.abb.com

17 Order from for ACS 600 Oil For PCP,Donkey Pump, ESP,Multiphase & Pumps for handling Oil If you need an ACS 600 Oil for your oilfield Artificial Lifting, copy this form And send it to our client attention center at Fax: Caracas - Venezuela Indicate your requirements 1.- kw ó Hp Well Input Voltage (V) Unit qty I/O Integrated Analog Input Digital Input Analog Output Digital Output 3 A/I 6 D/I 2 A/O 3 D/O Standard Standard Standard Standard 2 A/I Additional 4.- Communication Accesories 6.- Use of ACS 600 Oil Modbus RTU Module Device Net Module Fieldbus DNP 3.0 P.C.P. Torque Control P.C.P. Torque Control & Down Hole Sensor Donkey Pump & PCP Control de Torque Port Communication RS 485 Donkey Pump & PCP Control de Torque & Down Hole Sensor RS 232 Multiphase Pump RS 232/485 Electr-Submergible Pump 5.- Out Door Use enclosure Pipeline pumps External Use NEMA 3R Auto Sported Sported a Post Accessories for Additional control Multi-Well External use enclosure Company Well Qty Copy This Fax Caracas - Venezuela Should you wish to send comments or more information send an to drives.petroleo@ve.abb.com First,Last name Title / position Name of Project Office Address: / Fax: