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    Voltage Stresses in Electric Submergible Pumps Operated by Variable Speed Drives

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    andresv10
    1. Both PWM and six-step variable speed drives can cause voltage stress in electric submersible pump systems. 2. A computer model has been developed to accurately predict voltage stress and design economical solutions like using lower voltage motors, transformer taps, or carrier frequency settings. 3. PWM technology combined with filters can produce a sine wave output and more effectively address voltage stress compared to six-step drives.

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    Voltage Stresses in Electric Submergible Pumps Operated by Variable Speed Drives

    Uploaded by

    andresv10
    39 views26 pages
    1. Both PWM and six-step variable speed drives can cause voltage stress in electric submersible pump systems. 2. A computer model has been developed to accurately predict voltage stress and design economical solutions like using lower voltage motors, transformer taps, or carrier frequency settings. 3. PWM technology combined with filters can produce a sine wave output and more effectively address voltage stress compared to six-step drives.

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    VSD HARMONICS

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    002-apicasing

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    1. Both PWM and six-step variable speed drives can cause voltage stress in electric submersible pump systems. 2. A computer model has been developed to accurately predict voltage stress and design economical solutions like using lower voltage motors, transformer taps, or carrier frequency settings. 3. PWM technology combined with filters can produce a sine wave output and more effectively address voltage stress compared to six-step drives.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    39 views26 pages

    Voltage Stresses in Electric Submergible Pumps Operated by Variable Speed Drives

    Uploaded by

    andresv10
    1. Both PWM and six-step variable speed drives can cause voltage stress in electric submersible pump systems. 2. A computer model has been developed to accurately predict voltage stress and design economical solutions like using lower voltage motors, transformer taps, or carrier frequency settings. 3. PWM technology combined with filters can produce a sine wave output and more effectively address voltage stress compared to six-step drives.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 26

    Voltage Stresses in

    Electric Submergible
    Pumps Operated by
    Variable Speed Drives
    Bill Pelton (Reda)
    Kurt LeDoux (Toshiba)
    Don Kelly (ACA)
    The paper has shown…

    1. Both PWM and 6 Step VSDs can cause


    voltage stress in ESP systems.
    2. A model has been developed to
    accurately predict voltage stress and
    design the most economical solution.
    3. PWM technology provides great flexibility
    in correcting a voltage stress problem.
    4. PWM technology combined with
    economical capacitive filter technology
    can produce a sine wave.
    Definitions
    • Resonant frequency is the natural
    frequency of the ESP circuit. Most ESPs
    resonate at between 3 & 10 khz
    depending primarily on cable length, type
    and voltage.
    • Carrier frequency is the switching
    frequency of a PWM drive. Modern PWM
    drives have an adjustable carrier
    frequency.
    6 Step and PWM VSD Voltage & Spectrum
    300

    250

    200

    Peak
    150

    100

    50

    0
    0 2 4 6 8 10
    Frequency kHz

    180
    160
    140
    120
    100

    Peak
    80
    60
    40
    20
    0
    0 2 4 6 8 10
    Frequency kHz

    In both systems, voltage stress can take place


    In most installations the peak voltage is within system limits
    Analysis Model
    ACA ESP SITE MODEL - DRIVE POWER SOURCE
    SITE: SPE Test Site 1
    DRIVE: 815 kVA
    TRANSFORMER: 800 kVA
    MOTOR: 600 Hp

    Cable(Rl11ELBE_G5R, 1100,75,75)

    Cable(KERITE1_5F, 1200,75,75)
    Drive(3,480,70,2200,60) Trandy2(800,60,480,3541,5.75,1.5) Cable(Rl41ELB_G5F,40,75,25)
    X2 Rp pa sa Rs X4
    da Rd X3 ca Rc ma Rm
    X1 X5 X6 X7 X8
    db LRC pb sb LRC cb mb
    FILTER FILTER
    M
    dc pc cc mc
    sc
    D/Y LRCYfilter1(0,0,0)
    LRCYfilter1(0,0,0) Motor(M540_91, 2853,111,0.045)

    Device Parameters:
    DRIVE([Mode, 1=Sine, 2=AC Response, 3=PWM, 4=Six-Step],Input Volts, Base Frequency, Carrier Frequency, Run Frequency)
    Trandy2(kVA,Hz,Primary Voltage,Secondary Tap,%Impedence,%Resistance)
    Cable(meters,degC,Damping)
    Motor(Voltage,Amps,Slip)
    LRCYfilter(mHenrys,Ohms,uFarads)

    Computer model tool for simulating VSD & ESP interaction


    Frequency Response
    Fr = 1/sqrt (LC)

    •Increasing cable length decreases resonant frequency


    •Increasing transformer tap voltage decreases resonant frequency
    •Adding L or C decreases resonant frequency
    PWM + ESP Operation
    Fc = 2000 Hz
    Fo = 60/70 Hz
    Fr = 4000 Hz

    + =

    Noisy waveform
    2nd Carrier multiple amplified
    PWM + ESP Operation
    Fc = 8000 Hz
    Fo = 60/70 Hz
    Fr = 4000 Hz

    + Fc > (1.5 x Fr) =

    Setting the carrier frequency


    above the resonant band
    provides a sine waveform
    without the need for a filter
    PWM + ESP Operation
    Fc = 2200 Hz
    Fo = 60/70 Hz
    Fr = 1000 Hz

    + C, Fc > (1.5X Fr) =

    Economical capacitor filter


    lowers the resonant band
    below the maximum carrier
    frequency to provide a sine
    waveform
    Six-Step + ESP Operation

    Fo = 60/70 Hz
    Fr = 4000 Hz

    + =

    Ringing waveform
    Six-Step + ESP Operation

    Fo = 60/70 Hz
    Fr = Flat

    + RC =

    RC filter flattens resonant


    band to eliminate ringing
    Peak KV vs. Carrier Frequency
    13
    12

    KILOVOLTS
    11
    10
    9
    8
    7
    6
    PEAK 5
    SURGE 4
    VOLTS 3 RESONANT
    2 AREA
    1

    1 2 3 4 5 6 7
    DRIVE CARRIER FREQUENCY KILOHERTZ
    Voltage Comparison
    8
    7
    6
    5
    4 Field
    3 Model

    2
    1
    0
    well 1 well 2 well 3 well 4

    Model Matches Field Measurements


    Resonant Frequency Comparison
    7
    6
    5
    4
    Field
    kHz 3 Model
    2
    1
    0
    well 1 well 2 well 3 well 4

    Model Matches Field Measurements


    Fig. 3-1: Hooten Strouthers #5 Phase to Phase Fig. 3-2: : Hooten Strouthers #5 Phase to Phase
    Voltage Waveform – Field Measurement Voltage Waveform – Modeled

    Measurement and model appear almost identical.


    Ways to reduce voltage stresses.
    • Use a lower voltage motor
    • Reduce motor voltage using lower
    transformer tap if motor is not fully loaded
    • Reduce base frequency (applies to PWM
    VSDs only)
    • Use optimum carrier frequency setting
    (applies to PWM VSDs with adjustable
    carrier frequency only)
    • Filter the output of the VSD
    Field Case Study of
    Employing the First
    Three Methods
    Together

    • Use lower voltage motor


    • Use lower transformer tap if
    motor is not fully loaded
    • Reduce base frequency
    Average Peak Voltages
    3 HV Wells & 9 LV Wells

    12

    10

    8
    kV
    6

    0
    HV wells LV wells

    50% Reduction in Peak Voltage


    This example is an LC filter on the high voltage (secondary)
    side of the step up transformer.

    3.7 kV pk no filter 1 kV pk with filter


    Filtered voltage much closer to sine wave.
    Peak voltage reduced by 75%.
    This example is a capacitor only filter installed between
    the step up transformer and the wellhead.
    Fig. 5-7 Canada: Output Phase to Phase Voltage, Before and After Filter Installation with
    Capacitor Only Filter.

    1> T 1>

    1) Ref A: 2 V 2 ms 1) Math: 2 V 2 ms

    Filter installation turned wellhead voltage into sine


    wave.
    VSD Type Difficulty of filtering to
    produce sine wave
    Six Step Most expensive to filter
    PWM with low
    synchronous carrier
    frequency that changes
    as output frequency
    changes
    PWM with high Least expensive to filter
    asynchronous carrier
    frequency that is
    constant and
    independent of output
    frequency
    History of VSD technology
    IGBT enabled Vector
    Hi Speed Microprocessors
    BJT enhanced PWM
    GTO enabled PWM
    SCR enabled VVI
    1950s 1970s 1980s 1990s

    The focus has been on producing a better wave form


    Six-Step
    volts, amps

    PWM
    volts, amps

    PWM Sine Wave


    volts, amps
    Conclusions:

    • All components (motor, cable, feed through &


    transformer) were originally designed for sine
    wave voltages and currents.
    • PWM VSDs combined with new technology can
    produce a sine wave voltage and current.
    • A Six-Step VSD cannot produce a sine wave
    voltage or current with any practical technology.
    • A system computer model has been developed
    and the accuracy has been verified by field
    measurements.
    • The computer model is presently being used to
    design today’s applications.
    • In fields with existing PWM technology, voltage
    reduction programs have produced dramatic
    results without requiring the use of filters. A 50%
    reduction was documented in one test.
    • Properly applied, filters can further reduce the
    peak voltage. A 73% reduction in peak voltage
    was observed in the field after the installation of
    a sine wave filter.
    PWM Sine Wave

    Voltage Current

    The new oilfield standard.

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