ARTIFICIAL LIFT Solutions for customer pains ESP PCP RRP Auxiliaries

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Gerard Copeland
6 years ago
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1 ARTIFICIAL LIFT Solutions for customer pains ESP PCP RRP Auxiliaries Presented by Jean-Mathieu Renault Automation Solutions team Moteurs Leroy Somer Emerson Industrial Automation

2 Solutions for ESPs Electro Submersible Pump 2

3 Low production? High maintenance cost?

4 50Hz 50Hz

5 Digistart D3 380 to 690V 23 -> 1600 Amps 12 -> 1600 kw Middle voltage on request Fixed speed, low cost, best efficiency: soft starter

6 50Hz 50Hz

7 Powerdrive MD2 / FX / F > 690V 6,6 -> 1600 Amps 1,1 -> 1600 kw

8 VSDs optimize pump speed for each well

9 VSDs increase oil production Graph courtesy of Franklin Electric

10 Production flow? Speed? VSDs allow easy well start up for maximum production

11 Early pump failures?

12 Speed DC bus voltage Mains voltage Motor intensity VSDs ramp up pump speed for low stress

13 VSDs avoid gas locks for extended pump life Graph & image courtesy of Schlumberger

14 VSDs optimize pump working conditions for extended pump life Graph courtesy of Baker Hughes

15 ) 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

16 High losses of production?

17 Roof, panels, chassis : Stainless steel 316L Filter boxes: Rugged drip drain design Stainless steel 316 L Filters : G4 dust filter Coalescing filter for moisture removal Emerson VSDs are suitable for offshore environments

18 Supervision VSD Emerson VSDs maintain operations in harsh supply conditions

19 VSD control screen (HMI) Emerson VSDs have easy ESP menus to prevent operator mistakes 19

20 VSD Interface screen (HMI) Emerson VSDs have dedicated ESP functions to protect the pump and the production 20

Dedicated Artificial Lift functions Underload

underloads Overload overintensity: at any speed

VSD will adjust speed so as not to go over the

21 Dedicated Artificial Lift functions 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. 21

22 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 22

23 High maintenance costs?

24 Emerson VSDs are low voltage technology for reduced maintenance cost

25 More than 2000 drives, soft starters, transformers worldwide Emerson VSDs are installed and serviced wordwide

26 Fast and easy troubleshooting 26

27 Control board Forced ventilation Inverter module L1 L2 L3 U V W Rectifier module Emerson VSDs are designed for fast field repair to reduce lost production costs

28 From 160 to 2800 kw 1 Control board 2 Forced ventilation 7 Inverter module 4 Rectifier module Emerson VSDs are designed for fast field repair to reduce spare parts stock

29 High investment cost?

30 35% 12% 8% 5% 6 pulses Powerdrive MD2S Total Harmonics Distorsion of Intensity 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

31 Powerdrive MD -> Powerdrive MD2 600x600x2160 mm 400x600x2160 mm Emerson VSDs become smaller. More VSDs can fit in a given electric room.

32 400V 470kVA AFE Powerdrive MD2 for ESP 2400x600x2160 mm 1200x800x2360 mm Emerson VSDs can be arranged on demand. More VSDs can fit in a given electric room.

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

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

35 Safety issues?

36 Liquid cooling for less noise in the electrical room

37 Safe torque off

38 Examples Powerdrive MD2 IP21 Transformers Powerdrive MD2 IP55 38

39 Solutions for PCP Progressive Cavity Pump 39

40 PCP The need for variable speed Adjust pumping speed to field requirements & optimize production Ramp up to speed at required rate Disgorge the well

41 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

42 PCP System reliability with LS../.. Tropicalized chokes & electronic boards Suitable for harsh environments

43 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 Control board Inverter module Forced ventilation Rectifier module L1 L2 L3 U V W

44 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

45 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% 6 pulses Powerdrive MD2S Total Harmonics Distorsion of Intensity 12 pulses Powerdrive MD2T 18 pulses Powerdrive MD2E 24 pulses & AFE Powerdrive MD2W & MD2R

PCP System reliability with LS../.. Electrical supply disturbances proof Microcut function: On mains failure, the drive keeps control of the motor.

46 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

47 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

48 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

49 PCP System reliability with LS../.. Dedicated Artificial Lift HMI for PCP Display of pump values

50 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

51 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

52 PCP System reliability with LS../.. ATEX certified motors: EEx na, EEx e, EEx d ATEX certified motor & drive sets

53 PCP Easy installation with LS../.. Light-weighted motor design Aluminum frame: LSE, LSN range Easy handling & mouting Less stress on the wellhead

54 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

55 Solutions for RRP Reciprocating Rod Pump 56

56 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 57

57 RRP Needs in fixed speed Needs for electrified wells: Simplicity Maintenance-free Robustness Must be adapted to : the pump cycle the outdoor environment

58 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 Aluminium frame Steel fan cover Aluminium fan Cast iron end-brackets with regreaseable bearings Stainless steel nameplate Dynamic balanced rotor (pressure cast aluminium bars) Large terminal box 59

59 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

60 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

61 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

62 RRP The concerns of variable speed 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. Power consumed Power generated Leroy Somer solutions are 4 quadrants and do not need resistors

63 RRP The concerns of variable speed 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

64 RRP The concerns of variable speed 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 66

65 RRP The solution, with Leroy Somer! 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 67

920 788 RRP Leroy Somer solution benefits

a 90kW system Common 6 pulse solution 90kW

66 RRP Leroy Somer solution benefits Benefit #1 : compacity size comparison for a 90kW system Common 6 pulse solution 90kW POWERDRIVE FX 100T Overall volume (6 pulse drive + line reactor + RFI filter + braking resistor + overload relay) = 0,3 m 3 Total weight : 120 kgs Overall volume (POWERDRIVE FX) : 0,06 m 3 Total weight : 37 kgs 68

67 RRP The solution, with LS! Datalogging for well data sharing Remote with fieldbus connectivity Local with months of storage on SD card Remote control modbustcp Start/stop/speed setting possible remotely Remote fault management : Autoreset of selected defaults Defaults analysis and resetting possible remotely 69

RRP The Future (1) Production optimisation with DYNEO solutions

up to 20% of the electric bill - Advanced «cold» design saves on

intervals - Easy installation: - No additionnal cable thanks to

68 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 70

69 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! 71

70 Thanks for attending! Please enjoy the rest of the conference Our global customer knowledge sharing event and technology exhibition papers and work shops. 72

71 Back up slides 73

73 COMPARAISON TAILLE MT/BT

74 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. Flexible and innovative solutions to optimize well production

Artificial Lift. Flexible and innovative solutions to optimize well production Artificial Lift Flexible and innovative solutions to optimize well production Reliable and efficient Artificial Lift solutions that increase well production As the world s population continues to swell