advantages of the variable frequency generator (vfg)© · pdf fileadvanced thinking...
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Advantages of theVariable Frequency Generator (VFG)©
© Worldwide Patent Pending
Presented By: •Juergen Schulz, Canadian Advanced Inc.
Paper Authored By: •Andy Limanowka, Canadian Advanced Inc.•Dana Pettigrew, Nexen International Petroleum
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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)
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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
PowerGenerator
GeneratorControl/Motor
ProtectionWell
ES
P
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Start-up traces (40Hz Ramp Start)
Ramp StartNominal full load Volt 3480V@60HzNominal full load Amps 90A@60Hz
2sec for system stabilizationsinrush current 2.4 x full load current
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3 4 5 6 7 8 9 10 11 12 13 14 15
TIME [s]
VOLT
S
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AM
PS
Gen Volts Gen Current
3508 CAT; 12000 BPD pump and 644HP/3480V/117A motor
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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
PowerGenerator
VariableSpeedDrive
LoadFilter
Step-UpTransformer
PowerGenerator
GeneratorControl/Motor
Protection
Typical Variable Speed Drive System
Variable Frequency Generator System (Less Equipment)
Typical Switchboard System
PowerLine
Switchboard
Step-UpTransformer
ESP
ESP
ESP
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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
Engine&
Generator
Engine&
Generator
VFGController
VFD&
Step-up Transformer
Traditional VFD VFG System
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Maintenance cost comparison
Maintance Cost Comparison, 3512 CAT 900 ekW
Engine&
Generator
Engine&
Generator
VFD&
Step-up Transformer
VFG Controller
Traditional VFD VFG
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Fuel cost comparison
Fuel Cost Comparison, 3512 CAT 900 ekW
VFGFuel
Consumption
TraditionalVFDFuel
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
VFG System
Maximum Frequency = 63 Hz
Gross Fluid = 12,400 bbl/day
Net Oil (90%WCT)=1240 bbl/day
Traditional VFD & Transformer
Maximum Frequency = 58 Hz
Gross Fluid = 11,600 bbl/day
Net Oil (90%WCT) =1160 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)
0
1000
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6000TD
H, f
t
0 5000 10000 15000 20000 25000Liquid + Gas Rate, Bbl/D
CLift 562 KC16000 / 86 Stgs / 57.0 HzPump Performance (TDH @ Design) Q11 VFG TEST.sp7
Reg: Nexen Inc. - Nexen Inc.Pump Curve , Case 1 Well System Curve , Case 1, (Truncated)Pump Curve , Case 2 Well System Curve , Case 2, (Truncated)Min-Max Optimum Rate
•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.
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VFG
Entire unit prepared for shipment
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VFGControl panel during testing
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VFG
Canadian Nexen Yemen (Heijah 49)
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VFGTouch-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.CANADIAN ADVANCED INC.5307-72A AVENUEEDMONTON, ALBERTA, T6B 2J1PHONE: 780-469-0770FAX: 780-450-4592
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Thank you for your attention