Advantages of the Variable Frequency Generator (VFG)© Presented By: •Juergen Schulz, Canadian Advanced Inc. Paper Authored By: •Andy Limanowka, Canadian Advanced Inc. •Dana Pettigrew, Nexen International Petroleum © Worldwide Patent Pending Advanced Thinking >>> Down to Earth Service >>>
What is a VFG VARIABLE FREQUENCY GENERATOR (VFG) • Power Generator that varies Frequency and Voltage output • Operates 30-70 Hz, 400-5000 Volts • For use with ESP’s & other Variable Torque Loads requiring variable speed • Eliminates Variable Speed Drive and Transformer • Developed by: Canadian Advanced Inc. • With Nexen International & Finning Canada (Caterpillar) Advanced Thinking >>> Down to Earth Service >>>
How the VFG works • Reduced Speed Start • Reduced Voltage Start • Control Module controls: – Voltage, Current & Hz (RPM) – Diesel or Natural Gas Engine with Governor – Motor Protection – SCADA/Communication
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Well ESP
Power Generator
Generator Control/ Motor Protection
Start-up traces (40Hz Ramp Start) 3508 CAT; 12000 BPD pump and 644HP/3480V/117A motor Ramp Start Nominal full load Volt 3480V@60Hz Nominal full load Amps 90A@60Hz 2sec for system stabilizations inrush current 2.4 x full load current 200
3000
180 2500 160
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40 500 20
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0 3
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TIME [s] Gen Volts
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Gen Current
11
12
13
14
15
AMPS
VOLTS
2000
Advantages of VFG
• Lower Capital & Maintenance Cost • More Efficient System, less Diesel fuel • Smaller Engines required to Drive Large ESP’s • No Harmonics, spikes or mirroring • Increase Production • Easy to Use – Fully Integrated System • Touch Screen Operation
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VFG Advantages
• • • • •
Improved Run Times Voltage / Current Optimization Hard Starting Advancements Recoverable Asset (Compared to High Line) Smaller Foot Print-Offshore Applications
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System Comparison Typical Variable Speed Drive System Power Generator
Variable Speed Drive
Load Filter
Step-Up Transformer
ESP
Step-Up Transformer
ESP
Typical Switchboard System Power Line
Switch board
Variable Frequency Generator System (Less Equipment) Power Generator
Generator Control/ Motor Protection
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ESP
Lower Capital / Maintenance cost • Engine Matched to Full Load of ESP • Low frequency Soft Start-up – No Need to Oversize Engine – VFG = 2.5 X Nameplate Current – Switchboard = 6-8 X Nameplate Current • Eliminates VFD & Transformer Capital Cost • Eliminates VFD Maintenance Cost
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Capital cost comparison Capital Cost Comparison, 3512 CAT 900 ekW
VFD & Step-up Transformer
Engine & Generator Traditional VFD
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VFG Controller
Engine & Generator
VFG System
Maintenance cost comparison Maintance Cost Comparison, 3512 CAT 900 ekW
VFD & Step-up Transformer
VFG Controller
Engine & Generator
Engine & Generator
Traditional VFD
VFG
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Fuel cost comparison Fuel Cost Comparison, 3512 CAT 900 ekW
Traditional VFD Fuel Consumption
VFG Fuel Consumption
Traditional VFD
VFG
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Output Waveform VFD vs VFG
Typical VFD Output Waveform - Unfiltered
Typical VFG Output Waveform
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Improved Run Times
• • • •
Soft starts reduce shaft stress Cable runs cooler – longer life Motor runs cooler – longer life No voltage spikes – ideal sine wave w/o any filter
RESULTS: Longer ESP Electric and Mechanical System Life – Reduced Electrical Losses
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Increased Production (Heijah 49) • Improve Efficiency by 5-10% – Less Heat! • VFG eliminates Heat and Turns to Oil Production • Example for Maximum of 3508 CAT Diesel Generator, 562 Series CKC12000, 650 hp ESP
• • • •
Traditional VFD & Transformer
VFG System
Maximum Frequency = 58 Hz
Maximum Frequency = 63 Hz
Gross Fluid = 11,600 bbl/day
Gross Fluid = 12,400 bbl/day
Net Oil (90%WCT) =1160 bbl/day
Net Oil (90%WCT)=1240 bbl/day
Production increase of 80 bbl/day of oil At $ 65/bbl add’l revenue of $ 5.200 per day Increase of annual revenue of over $ 1,8 Mio. Return of initial CAPEX in less than 3 months
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Increased Production (Qataban 11) Q11 VFG TEST.sp7
Pump Performance (TDH @ Design) CLift 562 KC16000 / 86 Stgs / 57.0 Hz 6000
5000
TDH, ft
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Liquid + Gas Rate, Bbl/D Pump Curve , Case 1 Pump Curve , Case 2 Min-Max Optimum Rate
Well System Curve , Case 1, (Truncated) Well System Curve , Case 2, (Truncated)
Reg: Nexen Inc. - Nexen Inc.
•On a VSD at 114 Amps and 57.0 Hz, 18,250 bfpd RED SOLID LINE •On a VFG at 114 Amps and 59.0 Hz, 19,550 bfpd BLUE DASHED LINE •VFG measured benefit of an extra 1,300 bfpd for a 7.1% increase. Advanced Thinking >>> Down to Earth Service >>>
VFG Entire unit prepared for shipment
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VFG Control panel during testing
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VFG Canadian Nexen Yemen (Heijah 49)
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VFG Touch-pad controls
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VFG Touch-pad controls
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VFG Touch-pad controls
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When to use a VFG
• • • • • •
Every time a Generator is used on an ESP Temporary or Permanent Installation Portable Well Testing Areas of Power Quality Problems Weak or Insufficient Supply Power Other Applications – PCP, Beam Pump, Ships, Fans, etc.
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Questions
For more information or pricing contact: Juergen Schulz or Sid Degen CANADIAN ADVANCED INC. 5307-72A AVENUE EDMONTON, ALBERTA, T6B 2J1 PHONE: 780-469-0770 FAX: 780-450-4592 Advanced Thinking >>> Down to Earth Service >>>
Thank you for your attention
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