ARTIFICIAL LIFT

Solutions for customer pains

ESP – PCP – RRP – Auxiliaries
Presented by Jean-Mathieu Renault
Automation Solutions team
Moteurs Leroy Somer
Emerson Industrial Automation

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

Solutions for ESPs
Electro Submersible Pump

2
 Low production ?
High maintenance cost ?

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 50Hz 50Hz

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 Digistart D3

380 to 690V
23 -> 1600 Amps
12 -> 1600 kW

Middle voltage
on request

 Fixed speed, low cost, best efficiency: soft starter

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
 50Hz 50Hz

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 Powerdrive MD2 / FX / F300

380 -> 690V

6,6 -> 1600 Amps
1,1 -> 1600 kW

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

  VSDs optimize pump speed for each well
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
  VSDs increase oil production
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark Graph courtesy of Franklin Electric
 Production flow ?
Speed ?

 VSDs allow easy well start up for maximum

production
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
 Early pump failures ?

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 Speed

DC bus
voltage

Mains
voltage
Motor
intensity

 VSDs ramp up pump speed for low stress

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
  VSDs avoid gas locks for extended pump life
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark Graph & image courtesy of Schlumberger
  VSDs optimize pump working conditions for
extended pump life
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark Graph courtesy of Baker Hughes
 800

600

400

200

0
 
 
-200

-400

-600

-800 2) Ch 2: 100 A 5 ms

Output of unfiltered drive Output of Powerdrive with sine filter

(voltage) (intensity, THD < 5%)

 Emerson VSDs send clean, equilibrated power to

the pump for extended life
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
 High losses of production ?

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 Roof, panels, chassis :
• Stainless steel 316L

Filter boxes: Filters :

• Rugged drip drain design • G4 dust filter
• Stainless steel 316 L • Coalescing filter for moisture removal

 Emerson VSDs are suitable for offshore

environments
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
 Supervision

VSD

 Emerson VSDs maintain operations in harsh

supply conditions
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
 VSD control screen (HMI)

 Emerson VSDs have easy ESP menus to prevent

operator mistakes
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 19
 VSD Interface screen (HMI)

 Emerson VSDs have dedicated ESP functions to

protect the pump and the production
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 20
 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.

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 21

 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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 22

 High maintenance costs ?

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

  Emerson VSDs are low voltage technology for
reduced maintenance cost
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
 More than 2000 drives, soft starters,
transformers worldwide

 Emerson VSDs are installed and serviced

wordwide
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
  Fast and easy troubleshooting

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 26

 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
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
 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
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
 High investment cost ?

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 Total Harmonics Distorsion of Intensity
35% 12% 8% 5%
6 pulses 12 pulses 18 pulses 24 pulses & AFE
Powerdrive Powerdrive Powerdrive Powerdrive
MD2S MD2T MD2E MD2W & MD2R

 More Emerson low harmonics VSDs can be

installed in a given power supply network
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
 Powerdrive MD -> Powerdrive MD2

600x600x2160 mm 400x600x2160 mm

 Emerson VSDs become smaller. More VSDs can fit

in a given electric room.
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
 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.
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
  Output sine filter within the step up transformer for
more space gain
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
  Variable speed drives installed outdoor when no
more room available in the electrical room
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
 Safety issues ?

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

  Liquid cooling for less noise in the electrical room

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

  Safe torque off

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 Examples
Powerdrive MD2 IP21 Transformers

Powerdrive MD2 IP55

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 38

Solutions for PCP
Progressive Cavity Pump

39
 PCP – The need for variable speed
 Adjust pumping speed to field requirements &
optimize production
 Ramp up to speed at required rate
 Disgorge the well

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 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
Total Harmonics Distorsion of Intensity
35% 12% 8% 5%
6 pulses 12 pulses 18 pulses 24 pulses & AFE
Powerdrive Powerdrive Powerdrive Powerdrive
MD2S MD2T MD2E MD2W & MD2R

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 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”

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 PCP – System reliability with LS ../..
 ATEX certified motors: EEx nA, EEx e, EEx d
 ATEX certified motor & drive sets

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 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
LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
Solutions for RRP
Reciprocating Rod Pump

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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 57

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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 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

Cast iron end-brackets
Aluminium fan with regreaseable bearings

Stainless steel
nameplate Dynamic balanced
rotor (pressure cast
aluminium bars)

Large terminal box

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 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

=>

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 66

 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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 67

 RRP – Leroy Somer solution benefits
Benefit #1 : compacity
size comparison for a 90kW system

Common 6 pulse solution 90kW POWERDRIVE FX 100T

788
920
Overall volume (6 pulse drive + line
reactor + RFI filter + braking resistor +
overload relay) = 0,3 m3
Total weight : 120 kgs Overall volume (POWERDRIVE FX) : 0,06 m3
Total weight : 37 kgs

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 68

 RRP – The solution, with LS !
 Datalogging for well data sharing
modbusTCP
– Remote with fieldbus connectivity
– Local with months of storage on SD card

 Remote control
– Start/stop/speed setting possible remotely

 Remote fault management :

– Autoreset of selected defaults
– Defaults analysis and resetting possible
remotely

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 69

 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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 70

 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 !

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 71

 Thanks for attending !
Please enjoy the rest of the conference

Our global customer

knowledge sharing
event and technology
exhibition.

300+ papers and work

shops.

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 72

 Back up slides

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark 73

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark
 COMPARAISON TAILLE MT/BT

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark

 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

LS DEI AS JMR, Emerson Offshore Technology Day, 2015/03/26, Denmark