A Status Review OF IPM MOTOR DRIVES FOR ELECTRIC SUBMERSIBLE PUMP IN HARSH COLD OCEANS

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1 1 A Status Review OF IPM MOTOR DRIVES FOR ELECTRIC SUBMERSIBLE PUMP IN HARSH COLD OCEANS M. A. Rahman Memorial University of Newfoundland St. John s, NL, Canada, A1B 3X5

2 2 PES 2015

3 3 Outlines Introduction Objectives Current Trends in Oil and Gas Industry Submersible Prototype Simulation and Experimental Results Conclusions

4 4 Artificial Lift: Offshore Oil and Gas Electric Submersible Pump Technology: Artificial lift offshore oil recovery Operated at various depth from 1000 to feet High volume oil production High cost due to production time loss High torque requirement High wear and tear Source: O. J. Romero and A. Hupp, Subsea electrical submersible pump significance in petroleum offshore production," ASME Journal of Energy Resources Technology, vol. 136, no. 1, pp , September 2014

5 5 Multi-Stage HIPM-ESP Drives Cross section of a multi-stage HIPM-ESP Exploded view of an HIPM-ESP

6 6 Current Technology: ESP Drive Squirrel cage multi rotor induction motor: Self starting Poor efficiency Poor power factor Low reliability High temperature rise High starting current

7 7 New Technology: HIPM-ESP Drive HIPM Submersible Motor Drive: High power and torque density High efficiency High power factor Self-starting Complex speed control Rotor position sensor not required Source:

8 8 Advantages of Hysteresis IPM over Induction motor ESP drives synchronous operation no energy wasting slip loss. faster and more adaptive control. 40% shorter motor length and 40% lighter motor weight. 20% current decrease and 20% increase of motor efficiency. 25%-30% increase of efficiency and power factor product. low electrical loss and decrease of heat dissipation. large cost savings and minimum ESP commissioning. ability to self-adapt to changes in the well conditions without reliance on additional sensors.

9 9 IM vs. IPM Submersible Motor Drive IPM motor Source: ESPs with Permanent Magnet Motor (PMM) in Salym, West Siberia (Russia), Anton Bydzan, Production Technologist, Subsurface Team, SPD, European Artificial Lift Forum 2008, Aberdeen

10 10 Hysteresis IPM Motor Hysteresis IPM Motor: Double layer stator windings Solid rotor motor Hysteresis ring is made of 36% Cobaltsteel Rare-earth magnets are buried inside the ring Aluminum sleeve supports the ring Shaft is keyed to the sleeve

11 11 Hysteresis IPM Motor Hysteresis IPM Motor: Smooth self-start Good synchronization capability High starting torque due to hysteresis torque and eddy current torque Moderate starting current Predominantly PM motor when synchronized

12 12 Electrical Equivalent Circuits State equations of the motor: θ r = t ω r 0 t dt + θ r 0 V qs = R s I qs + dλ qs dt V ds = R s I ds + dλ ds dt + ω r λ ds ω r λ qs V qr = 0 = R r I qr + dλ qr dt V dr = 0 = R r I dr + dλ dr dt λ qs = I qs L mq + L ls + L mq I qe + I qh λ ds = I ds L md + L ls + L md I de + I dh + I m λ qr = I qe + I qh L hr + L mq + L mq I qs λ dr = I de + I dh L hr + L md + L md I ds + L md I m V qs V ds V 0 = 2 3 cosθ r cos(θ r 2π 3 ) cos(θ r+ 2π 3 ) sin θ r sin(θ r 2π 3 ) sin(θ r+ 2π 3 ) V a V b V c R r = R e R s h = R e + R s h s R h R e T e = 3 2 p λ dsi qs λ qs I ds

13 13 Design of a Soft-starter A stable V/F controller is designed using the current feedbacks Hysteresis ring behaves like damper windings and no frequency stabilization loop is required The instantaneous command voltage V s is calculated at each time step using the current feedbacks Line voltage drop is compensated Low pass filter is used to remove the ripples in the command voltage Block diagram of the V/f controller

14 14 Design of a Soft-starter (Cont d) Equations to calculate the command voltage: V s = i q e R s + 2πf 0 λ m 2 + i q e 2 R s 2 I s 2 R s 2 I s = i α 2 + i β 2 i α = 2 3 i a i b 2 i c 2 i β = 2 3 i b 2 i c 2 i q e = 2 3 i a cos θ s + i b cos(θ s 2π 3 ) + i c cos(θ s + 2π 3 ) θ s = (2πf 0 )dt

15 15 Bond Graph Model for Multi-Stage (Torsional Vibration Control) BOND GRAPH MODEL OF A HYSTERESIS IPM MOTOR BOND GRAPH TORSIONAL MODEL OF A SHAFT SEGMENT. BOND GRAPH TORSIONAL LUMPED MODEL OF AN IMPELLAR.

16 16 Experimental Set-up

17 17 Simulation Results 3-PHASE CURRENTS OF A HYSTERESIS IPM MOTOR PERFORMANCES OF THE ESP DRIVE SYSTERM FOR DIFFERENT SHAFT LENGHTS: (a) SPEED AND (b) TORQUE.

18 18 Simulation Responses PERFORMANCES OF THE ESP DRIVE SYSTERM FOR DIFFERENT SHAFT DIAMETERS: (a) SPEED RESPONSE AND (b) TORQUE.

19 Comparative Performances (IM ESP Hysteresis IPM ESP) 19 (a) (b) (c) (d) COMPARATIVE PERFORMANCES BETWEEN AN IM ESP DRIVE AND A HYSTERESIS IPM ESP DRIVE: (a) IMPELLER LOAD, (b) SHAFT SPEED, (c) SHAFT TORQUE AND (d) INPUT LINE CURRENT

20 20 Experimental Results

21 21 Conclusion Modeling and V/f control of a hysteresis IPM motor is presented. A V/F controller has been used to run the motor at different command speeds. Modelling of Multi-stage shaft vibration by Bond graph method. The designed V/F controller limits the starting current and compensate for the line voltage drop. Both simulations and experimental results are presented. Both the results exhibit good run-up and synchronization performances of the hysteresis IPM motor.

22 22 Questions?? Thanks!!!

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