Cost Considerations When

Selecting Variable If the room needs to be modified

Frequency Drive Solution to create more space, it could have

significant cost implications, or
prohibit the installation entirely.
Approach Boundaries listed in
NFPA 70E are increased from
480 V to 4160 V (see Table 1).
Introduction There are other factors that are
important to consider during
evaluation. Additional analysis is
Advancements made in the No two applications are the same, and
required to understand the cost
development of drive technology this means that where there is more
impact on installation and application.
mean users have more options than than one possible solution, the best
They include, but are not limited to:
ever when selecting a drive system. strategy is to conduct a cost-benefit
harmonics, input line quality, distance
Low voltage (LV) variable frequency analysis of the various options.
between drive and motor, and system
drives (VFDs) have been applied to Frequently, consideration in choosing
efficiency. Most costs discussed in this
applications up to 2500 horsepower a drive is the initial capital cost.
paper can be grouped into the
(HP) and greater. Medium voltage (MV) However, to calculate the true cost of a
following categories:
VFDs have been applied to applications drive over its entire life cycle a number
as low as 150 HP. Traditional power of other factors need to be taken into • Cost of equipment: drive vs system
system design practice suggests that account. Some considerations that may
• Cost of operation: efficiency
the motor crossover from low voltage steer the decision towards a LV or MV
to medium voltage is in the 200 to solution are clear and straightforward: • Cost of installation: cable length
600 HP range. A recent industrial and output filters
• Available Input Voltage: the
customers’ survey conducted in 2016
choice to install a medium • Cost of power quality: equipment
shows that some customers are
voltage or low voltage solution ability to withstand input power
beginning to consider switching from a
is sometimes decided by the fault conditions
LV to a MV solution as low as 100 HP.
system bus: when there is 4000 V
• Cost of input harmonics:
bus with multiple MV motors, a
equipment sensitivity to input
MV solution might be easy to
Percentage
Percentage ofof Drives
Drives by Power
by Power that
that Customers
harmonics
integrate and this would provide
Customers Switch
Switch to MVtoover
MVLVover
DriveLV Drive
a more cost effective solution. The comparison and discussion in this
2000 HP paper will be based on the SINAMICS
1250 HP 2% • Existing Distribution: if there is an
2% PERFECT HARMONY GH180 medium
Other 100 HP
existing 480 V service capable of
1000 HP 10% 25%
voltage drive manufactured by
4% handling the additional load, it
700 HP Siemens and a basic 6 pulse and 18
2% may be cost prohibitive to install
pulse low voltage drive and their
an additional service at 4160 V
possible configurations.
for one or two large motors.
• Electrical Room Size: when the 480 V 4160 V
500 HP
23% 200 HP project is a retrofit or an upgrade, Limited 3’6” 5’0”
18%
space availability is critical.
Restricted 1’0” 2’2”
Medium voltage equipment
Prohibited 0’1” 0’7”
300 HP
14%
typically takes more floor space
Figure 1 and requires greater working Table 1: NFPA 70E Boundaries for Low Voltage
Source: 2016 Industrial Customer Survey clearances in an electrical room. and Medium Voltage Equipment

usa.siemens.com/perfectharmony
System Cost Comparison: High-Low-High Solution

The cost of a low voltage AC drive input transformer to step down input The charts below represent relative
can be as little as 50% to as much as voltage to 460-600 V. If the existing price comparisons of various VFD
105% when compared to the cost of motor is medium voltage, it will need solutions for low power medium
a medium voltage AC drive – it all a step-up transformer from 460-600 V voltage motors. The solutions are:
depends on site conditions and to the medium voltage of the motor.
• 6-pulse low-voltage drive with
requirements. However the initial
As power electronics continue to step-up transformers
purchase price of the drive is only part
develop, the size of medium voltage
of the equation. When the costs for • 18-pulse low voltage drive with
drives have become significantly
components, cabling and installation, input and step-up transformer
smaller over the past several years.
and efficiency are included, the
The figures below show the footprint • 18-pulse medium voltage drive
economic advantages of the two drive
advantage that MV solutions, like the
options may not be as apparent. The data shows that at 250HP, the
SINAMICS PERFECT HARMONY GH180
medium voltage drive is comparable to
Low voltage drives have been offers over standard low voltage drive
the 18-pulse low voltage solution in
positioned as an alternative, cost implementation. The total footprint,
High-Low-High applications (See Figures
competitive solution to medium including all components in High-Low-
3 and 4). As power of the medium
voltage drive when using medium High solutions, can be as much as
voltage motor increases, the advantage
voltage motors at lower power ratings. 300” (See Figure 2). The standard
of MV over LV continues to increase to
This solution in industry is known as dimensions for a 6-pulse drive is:
the 6-pulse design as well. Medium
High-Low-High and there are two width and depth 40”x 34,” while a
voltage drives now offer users significant
instances where this exists. The first medium voltage drive with integral
cost advantages when compared to
case is where there is an existing MV transformer and 18-pulse
low-voltage solutions, particularly in
motor that runs directly on line and configuration is W48”xD40”. When
high-low-high applications.
the desire to install a VFD to improve comparing these solutions side-by-
system efficiency exists. The second side, the total footprint of the
case is used on a specific application SINAMICS PERFECT HARMONY drive is
in the oil and gas industry for approximately six times smaller when
Electrical Submersible Pumps (ESP). compared to a standard High-Low-
Low voltage drives will require an High configuration.

LV VFD MV VFD
Input Sine Output Input Sine Output
Xfmr Wave Xfmr Xfmr Wave Xfmr
Filter Filter

Up to 300” 48”

Figure 2
High-Low-High Solution vs. MV Drive Solution

250HP VFD Solution Cost

250HP VFD Comparison
Solution Cost Comparison 500HP VFD Solution
500HP VFDCost Comparison
Solution Cost Comparison

MV VFD+Cable 6 pulse LV VFD+Input 18 Pulse LV VFD+Input MV VFD+Cable 6 pulse LV VFD+Input 18 Pulse LV VFD+Input
XFMR+Step Up XFMR XFMR+Step Up XFMR XFMR+Step Up XFMR XFMR+Step Up XFMR

VFD Input Transformer Step Up Transformer VFD Input Transformer Step Up Transformer

Figure 3 Figure 4
System Efficiency
GH180 6SR520 MV The driving force behind the increased
6 pulse LV Losses 18 pulse LV Losses
Losses use of VFDs is the energy savings it
VFD 2.0% 3.0% 3% provides. Table 4 compares system
Input filter 0.5%-1.0% 0% 0%
efficiency for LV and MV solutions.
This comparison is specifically looking
Input Transformer 2.0% 2.0% 0%
at high-low-high solutions. When
Output Transformer 2.0% 2.0% 0% efficiency is taken into account
Output Sine Filter 1.0% - 2.0% 1.0% - 2.0% 0% medium voltage offers a preferred
Total Losses 7.5 - 9.0% 8.0 - 9.0% 3% solution. In 10 years, users can save as
much as $100,000 in electricity costs
alone for a 500 HP solution.
6 pulse LV Solution 18 pulse LV Solution 18 Pulse MV Solution

Total Efficiency 92.5% - 91% 92% - 91% 97%

The savings by using a more efficient
solution is represented in the table
Table 4: Side by Side Comparison of Typical Efficiencies of Varies Configurations below. The key assumptions are:
• Average Price of Electricity to
Industrial Customers - 0.07 $/kWhr
LV Drive System GH180 6SR520
Savings MV vs LV solution • Average Distribution charge to
92% Efficiency 97% Efficiency
Industrial Customers - 0.03 $/kWhr
1 year cost 1 year cost 1 year 5 years 10 years

250 HP $12,340 $6,790 $5,550 $27,750 $55,500

500 HP $21,800 $11,760 $10,040 $50,200 $100,400

Table 5: MV Drive Savings over Time

Cost of Installation – Cables and Output Filters

During upgrades and expansion The cable cost difference between the As distance between the LV VFD and
projects, for the loads with lower power 480 V and the 4160 V VFD solutions the motor increase, the cost of cables
requirements, users often consider grows disproportionately as the motor is not the only concern: the drive may
both medium voltage and low voltage current increases. At 100 feet of cable also require an output filter. Low
solutions. The available input voltage, (see Figure 5), the cost for 250 HP low voltage VFD’s have two level output
existing distribution system, and the voltage drive is 10 times the cost of voltage wave forms. This output
distance from the distribution system to medium voltage cable for the same waveform contains significant 5th and
the load location will play a significant power. Costs are 12 times higher for 7th order harmonics that cause torque
role in the total cost of installation. A the 500 HP drive and 24 times higher pulsations at six times the fundamental
major advantage with MV drives when for 750 HP and 1,000 HP drives. The frequency, creating stress on the motor
compared to LV drives is lower current distance between the power source, and load. In addition to torque
flow for a given power output. LV drives the VFD and the motor has a big impact pulsation, the long feeding cable can
draw about 9 times the current on cable costs as well. As distance cause resonance at the motor terminal
compared to MV drives when using the increases so does the cost: the cost due to impedance mismatch between
same power. This means that a LV VFD of low voltage cables can be at least the cable and motor. When resonance
requires larger and more cables per double when comparing distances of occurs, large voltage spikes are present
phase, larger and heavier cable trays or 100 feet versus 200 feet. Additional at the motor which can damage the
conduit, resulting in a more costly cable costs not referenced in the charts that insulation and shorten its operating
installation. Cable size and cost vary follow are in the form of cable trays and life. Most LV drive manufacturers
with the level of current being labor. As the number of cables required recommend an output filter when the
conducted: the higher the current, the increases contractors will favor the use cable length between the VFD and
larger the cable and the greater its cost. of two cable trays to reduce derating motor exceeds 150 ft.
Tables 2 and 3 show the differences requirements but this also increases
between the two solutions. the cost of installation.

250 HP 500 HP 750 HP 1000 HP

Voltage 480 V 4160 V 480 V 4160 V 480 V 4160 V 480 V 4160 V

Current 313 A 32 A 500 A 65 A 911 A 100 A 1200 A 130 A

Table 2: Current Requirements for Low Voltage and Medium Voltage Drives for the Same Power
 HP Cable Size # Of Conductors

480 V 4160 V 480 V 4160 V

250 3/0 #4 2 1
500 4/0 #1 4 1
750 373 MCM 3/0 5 1
1000 535 MCM 250 MCM 5 1

Table 3: Side by Side Comparison of Cable Size and Number of Conductors Required

*Notes:
1. Inverter Duty VFD Cable was used for LV drive and Standard Cable for MV drive
2. NEC Table 310.15(B)(3)(a)
Adjustment factors for more than 3 current carrying conductors:
4-6 Conductors @ 80%; 7-9 Conductors @ 70%; 10-20 Conductors @ 50%
3. Ampacities taken from NEC table 310.15(B)(3)(a)
4. The cost does not include cable tray or installation cost

Cable Cost Comparison by Power, 100ft

Cable Cost Comparison by Power, 100ft

VFD Power

480 V

4160 V
250 500 750 1000

Figure 5 VFD Power

480 V 4160 V

Tek Run: 10.0kS/s

[
Sample
]
Certain medium voltage drives, such as Siemens SINAMICS PERFECT HARMONY
drives, have inherent, almost sinusoidal output voltage waveform (See Figure 6),
low harmonics and negligible torque pulsations:
Motor Motor
Voltage Current • Less than 1% VFD induced Torque Ripple for any given frequency: no motor
heating and no bearing wear
• 13 level output waveform line to line and Small output voltage steps (1.3kV)
- no voltage spikes at the motor
• No need for filters up to 7500ft (2.3km)
Ch2 2.00V M5.00ms Line ∫ -61.3V
Math 1 1.00V 5.00ms
• Waveforms remain high quality at lower speeds due to multi-level PWM output

Figure 6
SINAMICS PERFECT HARMONY Output Waveform
Cost of Power Quality
The financial impact of poor power The study states that digital economy Frequency of Power Quality Problems
quality is often underestimated or and process industries combined lose at Customer Sites of Power Quality
Frequency
Problems at Customer Sites
poorly understood because they are $1 billion per year due to power quality
typically reported as maintenance issues. This number excludes cost of Other,
4%

issues or equipment failures. The interruptions. Impact varies from Load

Interaction,
true economic impact is often not industry to industry when measured in 5%
Voltage
evaluated - especially when power terms of costs per kW of the plant load Capacitor
Switching, Sags/Swells,
48%
quality halts a process. A US study2 size. Power quality issue costs range 6%

determined that the economic cost from $3-$8 per kW for the textile
of power outages and power quality industry to $15-$20 per kW per event
disturbances across all U.S. business for industries like metals and chemicals Wiring/
Grounding,
sectors is between $120 and $190 (See Figure 9). Cost impact depends on 15% Harmonics,
22%
billion per year. In Europe, according each plant and industry product and
to the report,³ this type of cost cost of inputs. Since a facility typically
exceeds $167 (€150) billion annually. experiences several events per year, Figure 7
the annual cost, due to sags, is often Source: EPRI Report, 2003
Power quality (PQ) is defined as the
over $75,000. These costs can include:
grid’s ability to provide a clean and
stable power supply. It is always • Replacement of damaged equipment Major Causes of Power Outages
available, noise-free and within voltage in the U.S.
• Cost for repair of failed parts Major Causes of Power Outages in the U.S.
and frequency tolerances. Fluctuations
in the electrical supply in the form of • Spoiled or off spec product Maintenance
1%
momentary interruptions, voltage
• Loss of revenue due to downtime Power Grid
sags or swells, transients, harmonic Failure
5%
distortion, electrical noise, and flickering • Additional labor costs Public
or Animal
lights, reduce power quality. Fewer such Contact
Weather/
Industrial customers experience an 7%
Tree-Related
incidents indicate greater power quality. 62%
average of 75 instances of voltage Unknown/
Other
The most reported disturbances (See sags per year² – in 50% of the cases 10%

Figure 7) by industrial customers these events can stop a process. Equipment

include voltage sags and swells with Figure 10 represents average number Failure
15%
sags accounting for 38% and swells of events per site, per year – voltage
representing 10%, followed by sag of less than 10% are considered
harmonics with 22%¹. Most of the normal. Most of the recorded events
Figure 8
existing grid in the USA was built were minor sags, though the average Source: Edison Electric Institute
30-50 years ago5. Due to aging, PQ site also experienced about 9
events are even more relevant today momentary or longer service
and in some instances are on the rise.4 interruptions per year (available
There are several causes behind voltage between 0 and 10% is
voltage sags and power outages (See considered interruption). Whether
Figure 8). Some are generated by the your process stays online during a
site itself: start-up of large loads, power quality event depends on your
utility switching or utility equipment site equipment operating envelope
failure and bus transfers; others are and tolerances.
related to weather, construction,
traffic or animal accidents.

Cost
Cost of of Power
Power Quality,Quality,
$/kW per$/kW per
Event Event
(Total Plant Load) Interruption and Sag Rates as a Function of Voltage
(Total Plant Load) Interruption and Sag Rates as a Function of Voltage
$25 25
Events per Site per Year

$20.60
$20 20
Events per Site per Year

$15.50
$15 15

$11.70

$10 10
$8 $8

$5 $3 5

$1.70
$0 0

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85
od

ile

ts

s
ica
pe

ct

al
uc
xt
Fo

et
du
Pa

em

od
Te

M
ro
Ch

Pr

y
sP

ar

% of Site’s Average Available Voltage

tic

as

im
as

Gl

Pr
Pl

Figure 9 Figure 10
Source: EPRI Report, 2003 Source: EPRI Report, 2003
 Low Voltage Drive 6 pulse PERFECT HARMONY GH180 6SR520

Standard Input Voltage

+10% / -15% +10% / -10%
Tolerances

• DC bus capacitance in VFD allows for minor sag • VFD output power is rolled-back linearly from 100%
Voltage Sag duration compensation (ex: 80 ms (5 cycle) sags at 70% available power @ 90% input voltage down to 50% power @ 65%
is up to voltage)⁷. Some manuals state operation at 85% for up input voltage
1 minute to 1 minute »» Output power is reduced by limiting the available
»» Voltage drop below these tolerances results in drive’s motor torque
Undervoltage lasts ride through mode
longer than »» The VSD can operate continuously in this mode
1 minute • The drive’s dc bus will usually trip on undervoltage at an
equivalent line voltage of 65% of nominal rated voltage »» Voltage drop below 65% results in drive’s ride
VFD Performance (the trip level varies from manufacturer to manufacturer through mode
some offer as lows 51%)

Input Voltage Falls Below 65% Input Voltage Falls Below 65%

• Manufacture manuals state: the dc bus can deliver • The VFD will “ride-through” without tripping for 80 ms
full power to a load for about one cycle or 15-16 ms (5 cycles) minimum and up to 500 ms (30 cycles).
(1 cycle) by allowing itself to decrease from its nominal During “ride-through” the motor voltage is maintained
Input Power Loss Ride voltage. It may be shorter due to load conditions and but no torque is produced until input VFD voltage is
Through motor speed. re-established.

• If the combination of the load’s inertia and energy • An automatic restart and spinning load functions are
stored on the bus are inadequate to prevent the bus available to catch and restart motors when the motor
from tripping, the drive will use an automatic restart flux has collapsed during the line outage.
function to recover.

Table 6: Low Voltage Drive and Medium Voltage Drive Solution Performance Comparison during Input Voltage Sag

Cost of Input Harmonics

Input harmonic distortion was identified compared to voltage sags, very rarely There is another cost that is not related
as the second largest cause of input does harmonics distortion lead to a to the equipment. In the USA, a utility
power quality issues. These harmonics process interruption. The majority of typically specifies harmonic current
are related to the increasing use of the costs are attributed to process limits in their contract with a customer
non-linear loads such as computers, slow down (ex: small errors, minor and when the level of harmonics
AC and DC variable frequency drives, nuisance tripping or loss of exceeds IEEE519 recommendations
uninterruptible power supplies, static synchronization and increased error at the Point of Common Coupling
VAR compensators, or any device with rate). According to the report, 25% between a utility system and a
a solid state AC to DC power converter. of the harmonic costs were related customer, the utility issues a fine.
Harmonics are a form of voltage or to equipment, either in the form of Most customers have filters at this
current waveform distortion. A recent damage or additional maintenance. point but the system may need to be
study in the U.S. shows that the level The list below highlights the effects reevaluated if there is new equipment
of harmonics in a distribution system of excessive input harmonics in the that introduces additional harmonics.
continues to increase over time: 60% power bus on plant equipment:
Using a 6 - pulse LV drive configuration
of all circuits in the project showed an
• Excessive temperature rise in produces high input harmonics if not
increase in harmonics. The range of
motors and transformers corrected. One of the most common
increase was 3% per year or 30% over
solutions used by many low voltage
10 years, for example: 2% THD in 2005 • Sensitive electronic equipment
drive manufacturers is to place an input
increased to 2.6% THD in 2015⁴. malfunctions
line reactor (3% to 5% impedance)
Several studies in the USA and Europe • SCADA issues between the drive and the power
identified harmonics as a contributor supply. Table 7 shows methods to
• Accelerated aging of equipment
to economic loss. A study of industrial reduce input harmonics content that a
users in the European Union found • Tripping of circuit breakers VFD creates and the level of distortion
that input harmonics were responsible as a result of mitigation.
• Capacitor bank failure
for about 5% of all power quality costs
or $8.4 (€7.5) billion annually.³ When • Cable insulation breakdown
 Technology Total Harmonic Distortion (THDi)

6-Pulse Low Voltage VFD 50-70%

6-Pulse Low Voltage VFD with Reactor 35-45%

6-Pulse Low Voltage VFD with Passive Filter 6-10%

6-Pulse Low Voltage VFD with Active Filter 3.5-5%

12-Pulse Low Voltage VFD 10-14%

18-Pulse Low Voltage VFD 4-6%

Active Front End Low Voltage VFD < 5%

18-Pulse Medium Voltage VFD SINAMICS PERFECT HARMONY GH180 AC < 5%

Table 7: Mitigation techniques to reduce input harmonics and their effectiveness

Table 7 identifies various solutions While low voltage drives require distortion, even if the source capacity
to mitigate harmonic distortion. As additional measures to improve input is no larger than the drive rating.
effectiveness of the solution to reduce harmonics, medium voltage drives
It provides:
input harmonics increases so does the have, as a minimum, a 12-pulse diode
costs associated with it (See Figure 11). rectifier configuration due to the high • Less than 3% total voltage distortion
When considering the best fit for an DC voltage requirement. Drives come
• Less than 5% total current distortion
application, one should remember in a range of pulse counts depending
that the total cost of the system will on the manufacturer (12 to 36 pulse
18-Pulse, Multi-Level PWM
include not only VFD and accessories configurations). In many cases, the
costs, but also installation, maintenance, number of pulses is driven by the drive
footprint and hauling costs. To obtain topology and design. In order to meet
the best overall harmonics mitigation IEEE 519, an 18-pulse configuration
Current
solution, the user must view the with phase shifting transformer is
system as a whole circuit and evaluate required, at the same time it also offers
different mitigation methods to an optimized cost benefit solution. Voltage

prevent a power quality concern. In

For example, SINAMICS PERFECT
North America, the IEEE 519-2004
HARMONY GH180, 9 cell, 18-pulse
standard provides recommended
configuration waveform (see Figure 12)
limits for individual harmonics and
meets the most stringent requirements
total distortion.
for voltage and current harmonic Figure 12

Low Voltage Drive Input Harmonic Mitigation

Relative Cost Comparison
Low Voltage Drive Input Harmonic Mitigation Relative Cost Comparison
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Figure 11
Case Study: Use of Low Voltage and disruptions from outages, poor voltage paper, LV drive solution, if not
Medium Voltage solution in Electrical regulation, and transient voltage properly selected and engineered,
Submersible Pump (ESP) Application conditions. These design, operational may produce high output voltage
and site constraints make these motors spikes that lead to insulation break
Historically, low voltage drives have
sensitive to the following conditions: down of both cable and motor.10, 15
dominated in ESP applications but
recently more and more users are • Input line overvoltage Based on challenging design,
considering and using medium voltage and transient spikes operation and site conditions of ESP
drives. According to industry applications SINAMICS PERFECT
• High inrush torques
publications, somewhere around 90% HARMONY GH180 provides the best
of all oil wells require some form of • High dv/dt and solution for this application. Siemens
artificial lift to improve oil flow. ESPs has already installed over 700 GH180
• Torque pulsations
are one of several methods used in this units globally in this application
industry. Once the oil reservoir stops The ESP failures have a very high cost. alone. The drive’s robust input line
producing oil under free flow, electrical The average ESP run-life is between 2 performance, low input harmonic
submersible pumps are used to pump and 2.5 years but the trend in the content and sinusoidal output voltage
the oil to the surface. Over time the industry is to increase it to 5 years in waveform without need of an output
field conditions change and so does order to reduce the cost of the field. filter for motor cable lengths up to
the requirement for motor power. An The total cost to an end-user of one 7500ft promotes longer cable and
ESP is a centrifugal pump driven by a ESP failure is about $133K13. Below is motor life. In addition, the SINAMICS
medium voltage electric motor that the breakdown of the average cost PERFECT HARMONY GH180 drive
ranges from 1000 V to 4800 V. associated with the Onshore ESP provides the following benefits when
operation of 100 wells: compared to a LV solution:
Electrical submersible pump
applications create certain motor • Average loss of revenue • No step-up transformer needed,
design limitations: they are compact $45x200x7=$ 63K based on: the drive has direct feedback
in nature to be able to fit in a tube »» price per barrel - $45 (can be from the motor
located in a well bore; the level of as high as $100 depends on • No restriction on starting torque
insulation available is lower when market conditions) - 100% of torque is available at
compared to conventional motor
»» average oil production per well: 1.6Hz speed
designs, and frame parameters cannot
200 bopd (barrels of oil per day)
be increased to handle mechanical • When pump gets stuck due to
stresses. To achieve different »» average workover & waiting sediment collection at the
horsepower ratings, the motor modules time: 7 days bottom – to free the motor the
are required to be connected in series. • Average intervention cost: $20K drive can produce 150% of rated
(maybe higher depending on a torque required without the
In addition to space restrictions there
cost and availability of a rig) need of a rocking start reducing
are operational ones as well. These
stress on motor
pumps must be capable of pumping a • Average equipment cost: $50K
combination of oil, water, brine and • To ensure fault free operation
According to an ESP Reliability
gas. To reduce wear, the motor the drive can be programed to
Information and Failure Tracking
requires special abrasion-resistant run without output ground fault
System project, the top three ESP
bearings. This process generates high
components that fail in the first 90 • Short Power Loss Ride through at
heat and in order to run the motor in
days are: motor, followed by cables least 5 cycles (80 ms) to provide
this environment it is typically filled
and pumps. Over time motors also trip free operation during system
with refined dielectric oil to provide
show increasing trend for failure rate bus reclosure events
bearing lubrication and thermal
compared to other components. Short-
conductivity. More often than not, ESPs • In locations that have frequent
circuited motors and cables are the
are installed in remote locations. The lightning storms the drive offers
most severe mechanisms of early ESP
power is more susceptible to standard lighting arrestors to
failures (See Figure 14)14. The reason
provide protection to drive,
for short circuit events is insulation
cables and motor
break down. As has been stated in this
ESP – Primary Failed Items Most Severe Failure Mechanisms – Early Failures
– Early
ESP –Failures
Primary Failed Items – Early Failures

Other - 3% Most Severe Failure Mechanisms – Early Failures

Seals
9%
Low Impedance Motors 4%

Intakes Overheated Motors 4%

9%
Motors Broken/Fract. Intakes 8%
37%
Plugged Pumps 8%

Pumps Phase Unbal. Motors 9%

21%
Short Circuited Cables 15%

Cables
21%
Short Circuited Motors 15%

0% 5% 10% 15% 20%

Figure 13 Figure 14
Source: ESP-RIFTS Report, 2009 Source: ESP-RIFTS Report, 2009
Key Takeaway:
Medium voltage drives provide users • For applications and locations »» Best in Class Input Voltage
with optimal performance and a cost that require cables longer then Brownout Conditions - no trip
effective solution when compared to 150ft, a medium voltage drive down to 65% of nominal voltage
typical low voltage drive systems. offers the best solution when »» Input Power Loss Ride Through
compared to LV drives. For up to 500 msec
• The size and cost of medium
example, a Siemens SINAMICS
voltage drives continues to »» Built-in input transformer with
PERFECT HARMONY drive can be
improve, when compared to lightning arrestors
applied on motor applications
High-Low-High solutions offered • A medium voltage drive is able to
with distances up to 7500ft
by low voltage drives. meet IEEE519 requirements with
(2.3 km) without any filters.
• Medium voltage drives have clear built-in 18 pulse configuration with
• Medium voltage drives, specifically phase shifting integral transformer
price and system advantages
the SINAMICS PERFECT HARMONY while typical 6 - pulse low voltage
when used with motors rated at
drive, can offer users flexibility with drive needs additional equipment
250HP and above.
simplified and optimized system: to achieve similar results.
• Medium voltage drive solutions
»» Built-in input transformer -
improve operating efficiency of
input voltages ranging from
High-Low-High configurations up to
480 volts up to 6.0 kV
5%. The energy savings contributes
to the user’s bottom line. »» No need for output filter
»» No need for step up transformer
• Reduced cabling cost: low
- output voltage ranging from
voltage cable cost compared to
1.8 kV volts up to 4.0 kV
medium voltage cable can be as
high as 10 times and up to 24 • Robust design provides immunity
times more expensive for the from most input power
same power. The use of medium disturbances and interruptions
voltage cables reduces material to ensure protection of user
and installation cost associated equipment and trip free operation
with the traditional LV solution. during most common and
frequent power quality issues:

Sources:
1. “The Cost of Power Disturbances to Industrial & Digital Economy Companies”, EPRI Report 3002000476, June, 2001
2. “Distributed Resources Premium Power Solutions - Market Analysis and Business Case for Distributed Resources-Based Premium Power”, EPRI
Report 1004451, January 2003
3. “Application Note: The Cost of Poor Power Quality” Leonardo Power Quality Initiative, October 2015
4. EPRI TPQ/DPQ III PQ Benchmarking Project, 2010
5. “Transmission & Distribution Infrastructure”, A Harris Williams & Co. White Paper, Summer 2014
6. “A Cement Plant’s Experience in Investigating Power Sags Leads to a Reduction in Kiln Outages by Utilizing Power Hardening Methods”, Alan
Finch, Plant Manager, Ash Grove Cement, Chanute, KS, 2014-CIC-1037, IEEE 2015
7. “Design, development, and testing of a voltage ride-through solution for variable speed drives in oil field applications”, Daniel J. Carnovale,
P.E. Manager,Power Systems Experience Center, Eaton; Juan Biternas, ChevronTexaco, Boscan Field Maracaibo, Venezuela, White Paper
WP040004EN, Eaton, 2014
8. U.S. Energy Information Administration, Form EIA-826, Monthly Electric Sales and Revenue Report with State Distributions Report;
9. “Choosing the Proper VFD Can Limit Harmonics”, Jeffery Lovelace, P.E., Published in Pumps & Systems, December, 2015
10. “Protecting Submersible Motors from the Effects of PWM Voltage”, M. D. Texiera, ARTECHE EDC, J. A. Houdek, ARTECHE PQ, INC., Brazil
Conference for Quality of Electric Energy, 2009
11. Edison Electric Institute
12. ESP Reliability Information and Failure Tracking System (ESP-RIFTS), Joint Industry Project,
13. ESP-RIFTS Overview Presentation, March 2009
14. “VFD Protection Report”, Kevin Hinds, Andrew Saturno, NAVSEA NSWCCD-SSES, 2016
15. “Load Harmonics Analysis and Mitigation”, Xiaodong Liang, Senior Member, IEEE, Schlumberger, Edmonton Product Center; Rotimi Adedun,
Schlumberger, Edmonton Product Center, IEEE 2012