Nidec asi electric power solutions for pipeline applications


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Nidec asi electric power solutions for pipeline applications

  2. 2. Pipeline Applications Experience NIDEC ASI provides electric power solutions for pumps and compressors in oil and gas pipelines, guaranteeing the best technology and the best operational conditions along the entire process: from extraction to distribution. Our engineering team fully realizes your dreams and desires, designing customized solutions which meet our client’s need in terms of: power quality, network connection, power and frequency flexibility, low maintenance costs and time, machine durability, optimization of capital expenditure, best allocation of available space. With over 40 years of experience we work in close collaboration with End Users, Engineering and OEM in order to develop the best global solutions for pipeline field operations. PPT2013.01.01.08EN 2
  3. 3. Electric Power Solutions Meeting the operational needs Meeting the operational needs for oil & gas pumps and compressors in terms of operational speed range is a primary issue, specific to these applications. The cost, complexity, and reliability of the drive train will be impacted as more components are added. To guarantee maximum reliability, uptime and performance in terms of efficiency, electric motor-drive systems for pump and compressor applications require specific studies considering all the different operating requirements. This will affect the motor type, motor size, system configuration, power requirements, network power connection, costs and losses, coupling and operational methodologies. We meet requirements and desires of our customers, in the selection of the electric motor and drive train configuration, through a customized approach. PPT2013.01.01.08EN 3
  4. 4. Traditional Approach Application up to 5 MW In these types of solutions 2 or 4 poles fixed frequency machines are traditionally used, but the interest in VFD technologies is steadily growing. Electric Utility or Other Generated Power Constant 50 or 60 Hz, AC ~ Voltage Softstarter Electric Motor N 1 N 1 Gas Pump or Compressor Compressor Softstarter + Motor Directly Driving Pump or Compressor The traditional approach is usually applied to compressors and centrifugal pumps on oil and gas pipelines where substations are near or else in derivation plants. The motor operates Direct on Line (DOL) at constant speed and torque. Today, in order to increase plant longevity and maintain simplicity and costs, the preferred option for the drive train is to install a softstarter to ramp up the motor to its nominal rated operating conditions. PPT2013.01.01.08EN 4
  5. 5. Softstarter By starting a motor at a low effective frequency and then ramping up the speed, motor current and torque can be limited to near full load values. The Softstarter can provide a motor soft-start while providing full load torque, also helping to reduce the motor current requirements for start-up. Advantages in using a Softstarter: • Least severe option for torsional load and current demand by motor upon start up means less wear on equipment • Guarantees motor can be started on virtually any electrical grid Medium Voltage Softstarter 3,3 KV up to 15,000 KV PPT2013.01.01.08EN 5
  6. 6. Softstarter One Line Diagram Incoming line By pass switch Softstarter M PPT2013.01.01.08EN 6
  7. 7. VFD Solutions Flexibility & Life Cycle Management Another option would be to use a VFD as a softstarter. This solution requires a higher intial capital investment but guarantees maximum flexibility for future operation. M Pump or Compressor VFD M Pump or Compressor N° motors Plant Phase 1: start up – full efficiency: Plant Phase 2: changes in conditions The VFD System technologies can be used as Softstarter. With this configuration it is possible to activate a X number of motors with a gradual increase of power. This solution permits to optimize frequency flow, without bearing upon the external electrical network and increasing life span machines. In this second phase Flexibility and Optimization of initial investiment are key needs. PPT2013.01.01.08EN In this phase the drive is used not only to start the motors but also to adjust the speed to the required load, thus saving energy. 7
  8. 8. Silcovert S Principle one line diagram for one Softstarter system 11 kV – 50 Hz Line Power PPT2013.01.01.08EN 8
  9. 9. Silcovert TN Principle one line diagram for one Softstarter system 13,2kV-60Hz Power Supply line NIDEC ASI SCOPE OF SUPPLY 3a By_pass Circuit Breaker 1 Input line Circuit Breaker 3b By_pass Circuit Breaker SILCOVERT SVTN Synchronization Unit Mot. Protect. Mot. Protect. 2b Output Circuit breaker 2a Output Circuit breaker M 1 PPT2013.01.01.08EN M2 Asynchronous Motor 1-2 One run. the other is Stand-by (reserve) 9
  10. 10. VFD Solutions Investment planning We support the installation of the Variable Frequency Drive System both as a new build and through retrofitting. This allows our customers a choice in their investment planning. Retrofitting can be handled in one of two ways: • • TN VFD in Container PPT2013.01.01.08EN Control - room space management. The station can easily be designed from the beginning to accomodate the future installation of the VFD. In this case NIDEC ASI can act as consultants, providing the engineering team with the Dimensions and Electrical schemes to size the original station. Or NIDEC ASI can provide the installation of the complete solution in container ready to be connected to the existing plant. 10
  11. 11. VFD Packages Application up to 30 MW Some applications will require the use of a Variable frequency drive (VFD) from the beginning to vary the pump or compressor speed. Typically, these are higher power applications or installations where the flow rate is not constant throughout the year. The VFD works to vary the input frequency and voltage supplied to the electric motor. NIDEC ASI supplies VFD Technologies in complete Fully Integrated Packages consisting of: • Switchgear • Drive Transformer • VFD • Disconnectors (supplied by a third part) • Electric Motor or Motor/Generator PPT2013.01.01.08EN 11
  12. 12. VFD Solutions Life Cycle Cost Evaluation  the highest efficiency on the market today (lower energy consumption)  the Lowest Maintenance Costs  the Highest reliability (no down time means higher productivity) Load % VFD Efficiency % VFD+Transf+motor Efficiency % Power Factor % 100 98.6 – 98.0 97.3 – 96.1 0.96 75 98.5 – 97.5 97.7 – 95.8 0.97 50 98.0 – 97.0 97.5 – 95.0 0.98 PPT2013.01.01.08EN 12
  13. 13. Optimize Electric Motors Efficiency To reduce component losses eliminating Gearbox To optimize the elecrtic motor’s efficiency the installation of tailor – made solutions is a primary need Electric Utility or Other Generated Power Constant 50 or 60 Hz, AC ~ Voltage Variable speed Variable freq AC ~ Electric Electric Motor Motor VFD VFD N N 1 1 1 Gas Gas Compressor Compressor Single motor Directly Driving a Gas Compressor with VFD (without Gearbox) Electric Utility or Other Constant 50 or 60 Hz, Generated Power AC ~ Voltage Fixed Speed Ratio, Variable freq AC ~ VFD VFD Variable Speed Electric Electric Motor Motor N1 Gearbox N2 Gas Gas Compressor Compressor Electric Motor with VFD (with Gearbox) Efficiency of the electric motor drive train will be determined by the losses. The gearbox is one of the main significant causes of drive train component losses. Typically, these are on the order of 5 to 8 %(*). (*) “Application guideline for electric motor drive equipment for natural gas compressors”, Gas Machinery Research Council Southwest Research Institute, Jan 2008 PPT2013.01.01.08EN 13
  14. 14. Integrated Engineering Approach Typical Electric Drive System EM ~ ~ = = Electric Drive Grid Side connection • Current & voltage distortion • Power factor • Filters PPT2013.01.01.08EN Motor Side connection • Torque distortion • Motor thermal stresses • Train dynamics • Train operability Subsystems • Transformers • Power Converters • Control system • Auxiliaries 14
  15. 15. Integrated Engineering Approach Integrated Mechanical & Electrical Design Torque Input from VSDS Drive Control Torsional Mode Analysis Drive Steadfast Drive FR9 FR9E FR9 EM MCL1402 3MCL1403 EM Optimizing Max Ripple at Torsional Modes in Speed Range… torque spectrum at 3300 rpm and 33 MW 1000 900 1000 |Fsw - 15f0| 800 600 |Fsw - 21f0| 400 200 0 1st torsional mode 700 2nd torsional mode 600 500 400 300 200 100 20 25 30 35 40 Fundamental frequency, Hz 45 Speed/fundamental frequency (Hz) PPT2013.01.01.08EN torque harmonic in Nm T o r q u e A m p l it u d e , N m @ R ip p le f r e q u e n c ie s … 800 0 0 20 40 60 80 100 120 frequency in Hz 140 160 180 200 Damping torque response by control algorithms 15
  16. 16. Integrated Engineering Approach Mechanical Design For Electric Motors Our engineering team performs specific studies to develop customize concept based on the characteristics of each plant. Integrated engineering approach regards all aspects related to all technology selection process, taking into consideration thermal and mechanical performance under diverse operating conditions to minimize harmonics and identify the optimal trade off between Voltage and Current to guarantee maximum stability of the system: Operating performance Site Conditions Shaft Line & Vibration • Reduce Complexity • Guarantee Maximum Reliability & Availability • Maximize Overall Performance • Optimize Auxiliary Systems • Maximize Flexibility • Optimize device response & Stress • Optimize Maintainability • Optimize choice of motor Technology • Minimize Costs PPT2013.01.01.08EN • Optimize choice of Motor Technology Cooling & Maintenance • Improve System Design 16
  17. 17. Integrated Engineering Approach Motor Design – Operating parameters The load features • Quadratic load Vs. speed are in general required for the VSDS design. • Speed range must be well defined from the beginning – critical speeds must be avoided – maximum operating speed and the over-speed (120%) shall be mechanically verified – lower speed shall be compatible with motor cooling and bearings design. • In case of an operational speed margin (example 110% speed), constant power will be considered according to the rated power of the VSDS. Otherwise, with quadratic torque load, the VSDS should be oversized and rated accordingly (example 133% power). • Compressor load can be highly influenced by the process (gas pressures/temperatures), so proper margins must be considered. PPT2013.01.01.08EN Motor Power Vs. Speed speed m argin @ const. pow er cubic pow er (quadratic torque) rated speed compressor load points Motor Torque Vs. Speed speed m argin quadratic torque rated speed com pressor load points Motor Voltage & Current Vs. Frequency voltage V/Hz = const current rated speed 17
  18. 18. Integrated Engineering Approach Motor Design – Site Conditions Russia - Sakhalin Island LNG Plant High Power Traditional Solution 4 poles Sakhalin is a large Russian island in the North Pacific and is crossed by the one most important pipeline of Russia. Technology: Shell / JGC Scope Of Supply: n.2 21 MW LCI drives Silcovert S n.2 motors plus 4 MW fixed speed motors for Overhead Stabilizer Compressors PPT2013.01.01.08EN The strong cold and the other extreme weather conditions, constantly wear out the electrical and mechanical equipment of the pipeline Due the site conditions, NIDEC ASI provided the best solution for the customer, choosing the critical components to guarantee proper performance at -50°C. 18
  19. 19. Integrated Engineering Approach Motor Design – Site Conditions Qatar - Ras Laffan Re-injections Plant High Power Induction motor + PWM-NPC Solution Ras Laffan Industrial City is the Qatar's main site for production of liquefied natural gas and gas-to-liquid. In the desert (Ambient temperature +54°C) and in the maritime environment, structural integrity is vulnerable to wind blown sand and to saline of the sea, therefore the equipment had to be sealed against the elements and positioned in areas where they were least at risk. NIDEC ASI supplied the right equipment and the best solution, resolving the problems of its customers PPT2013.01.01.08EN Scope Of Supply: n.3 CR 1000 Y 4 – 13.7 MW 11 kV 50 Hz dual shaft end for gas re-injections compressors n.2 CR 900 X 4 9.6 MW Silcovert GN 2 x 3300 V for NGL 4 & NGL 5 19
  20. 20. Integrated Engineering Approach Motor Design – Shaft Line & Vibrations Example of Rotor Dynamics Analysis y z x Shaft Model Example of Prediction of Rotordynamic Response Unbalance Response Deflection Shape Dynamic Couple Unbalance Speed = 6060 rpm PPT2013.01.01.08EN 20
  21. 21. Integrated Engineering Approach Motor Design – Shaft Line & Vibrations Traditional LCI approach - Gas turbine driver - Large compressors: Propane Mixed Refrigerant Nitrogen G/T LP Comp HP Comp High speed LCI driven motor LCI Electric system Note to the traditional approach     PPT2013.01.01.08EN LCI machines have longer shaft line Complex mechanically Torque pulsations from the electric system Only low pressure restart 21
  22. 22. Integrated Engineering Approach Motor Design – Shaft Line & Vibrations 4 Pole Solution - Gas turbine driver - Large compressors: Propane Mixed Refrigerant Nitrogen Parallel drive driven motor/generator G/T LP Comp HP Comp High speed 4 pole motor w/Parallel Drive Electric System Note to the 4 Pole approach       Shorter shaft lines to reduce vibrations Power compensation for high temperature turbine derate No torque pulsations from the electric system Full pressure restart (Higher starting torque) Regenerative to the network independent from the speed Power factor correction and/or filters are not necessary PPT2013.01.01.08EN 22
  23. 23. Integrated Engineering Approach Motor Design – Cooling Rotor Winding Head Ventilation PPT2013.01.01.08EN 23
  24. 24. Integrated Engineering Approach Motor Design – Cooling Internal Ventilation NCVC2: Number of radial ventilation slots in central chamber NCVC1: Number of radial ventilation slots in end chambers Stator Rotor Stator end windings Rotor retaining rings Rotor fans PPT2013.01.01.08EN 24
  25. 25. Integrated Engineering Approach Motor Design – Maintenance Critical Components for Maintenance Level I components • bearings and bearing seals • air-to-water heat exchangers • pressurizing system Level II components • windings (stator & rotor) • excitation system windings • shaft seals • instrumentation Level III Components Bearings supplied by Top manufacturers, designed according to our specifications to maximize up time. PPT2013.01.01.08EN • gaskets and seal on fixed components • hold-down bolts and alignment shims • painting • terminal box components • soundproof insulation 25
  26. 26. Integrated Engineering Approach Drive System The same care is taken in the choice of Drive Topology and overall system design Switching Device • Assure device reliability • Minimize Costs Drive Topology Control Strategy • Reduce Complexity • Maximize Overall Performances • Optimize Auxiliary Systems • Optimize Maintainability • Reduce Parts count • Optimize device response & Stress • Maximize Flexibility • Optimize choice of Drive Technology PPT2013.01.01.08EN Packaging • Improve System Flexibility 26
  27. 27. Integrated Engineering Approach Drive System – Switching Devices Thyristor/SCR IGBT/IEGT IGCT • Current controlled device • Voltage controlled device • Current controlled device • Semi-controlled (turn-on only) • Fully controlled • Fully controlled • Highest V-I rating @ lowest cost • Faster switching • Lower conduction loss • Press-pack packaging • Mature technology • Module (mature) or press-pack (emerging) • Proven technology • Proven technology PPT2013.01.01.08EN 27
  28. 28. Integrated Engineering Approach Drive System – VFD Circuit Topology LCI VSI (3-Level NPC) VSI (Stacked H-bridge) • Distortion • Extensively adopted in Steel industry • Complexity @ high power • More subsystems to get high performances • Easy & flexible to control • Complex failure modes • Use IGBT, IGCT, IEGT • Use IGBT and IGCT NIDEC ASI has significant knowledge in drive topologies and can offer customers the right choice for their application PPT2013.01.01.08EN 28
  29. 29. Our MV Products Drive Topology Silcovert S Thyristor based LCI for synchronous motors provides speed regularity, monitoring and braking torque regulation PPT2013.01.01.08EN Series N Air cooling: up to 10400 KVA Water cooling: up to 24000 KVA (higher power on request) Voltage: up to 3300 V Series H Air cooling: up to 8100 KVA Water cooling: up to 18700 KVA (higher power on request) Voltage: up to 7200 V (12000 V on request) 29
  30. 30. High Speed Solutions PPT2013.01.01.08EN 30
  31. 31. High Speed Capability Motors Types and Ratings A 80 70 60 Recent projects update 50 Consolidated New MW A Exxon / QatarGas – RasGas HS 4-pole turbo motor-generator Under discussion Delivered 40 B 30 20 B 10 Petrocanada HS 2-pole turbo motor C C 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 rpm Transco / Tenneco HS 2-pole induction motor PPT2013.01.01.08EN 31
  32. 32. High Speed Solutions Main Advantages HS motors vs. conventional motors with gear boxes • Reduction of power losses in the drive system • Smaller size • Higher reliability • Lower maintenance (time - cost) • Lower noise PPT2013.01.01.08EN HS Motors vs gas Turbine • Higher efficiency • Lower cost • Smaller size • Lower noise • No air pollution Electrical Solutions • Best flexibility • Lower noises • Lower maintenance costs (> 10 years continuous field operation demonstrated) 32
  33. 33. Economic Comparison 3700 kW (5000 hp) System Parameter Recip. Turbine Electric Total Installed Cost 1.00 0.65 0.52 Space Requirement 1.00 0.75 0.65 Maintenance 1.00 0.60 0.15 Spare Parts 1.00 0.60 0.40 Environmental 1.00 0.80 0.10 Availability 96% 98% 99% Fuel Efficiency 31-40% 21-36% 35-45% Electric Motor Driven Compressor Stations: $10/hp/yr Gas & Steam Turbine Driven Stations: $35/hp/yr Transco 205: Operating and Maintenance Cost Comparison Gas Reciprocating Engine Driven Stations: $55/hp/yr PPT2013.01.01.08EN 33
  34. 34. High Speed Applications One Line Diagram SVTN 24 Pulses PPT2013.01.01.08EN 34
  35. 35. References High Speed Motors PPT2013.01.01.08EN 35
  36. 36. Machines & System Testing Capabilities Up to 10 MW NIDEC ASI works in close collaboration with Project engineering management and End users and the OEM supplier to guarantee that equipment is fully tested before being shipped on site.  Routine tests (according to IEC & IEEE standards);  up to 10 MW @ 9000 r/min: no load tests at motor speed range supplied by a motor-generator set.  Factory facilities, no job equipment needed;  greater than 10 MW @ 9000 r/min: no load tests at motor speed range.  Job transformer, converter, capacitors and other equipment needed;  Main Testing Area for Drives: 2500 kVA Extra power if needed for PCS testing: 1300 kVA PPT2013.01.01.08EN 36
  37. 37. PDS System Testing Capabilities Convertitore frequenza SVGN SVGN Frequency Converter Cabina stabilmento 20 kV / 20 kV Plant Cabin / IPT1 (T1) M SG CR 630 Y4 IPT2 Trasformatore abbassatore 10/3,3 kV / 10/3.3 kV Step-down Transformer G2 IG2 (T2) 10 kV / 415 V G1 SG1 SIG 10 Z4 Nuovo interruttore / breaker new Back to Back - Full Load Testing Up to 75 MW 10 kV / 380-220V GSCR1000Z4 IPT4 IPT3 (T3) “Turning-gear” & “pre-charge” 10 kV / 415 V Autotrasformatore di prova 10/33 kV / 10/33 kV Tool Autoransformer In order to meet the challenges of de-risking large powered motors we can provide full load machine testing in back-to-back full load configuration at our Monfalcone Italian facility if 2 or more machines have been ordered. We are able to support our customer with complete test in back to back configuration (IEEE 112) for applications up to 75 MW. S/S Generazione Potenza / Power generation S/S Perdite / losses Unità di commessa / Job Units Quadro interruttori 33 kV / HV Switchgear Q+P Q+P Trasformatori VFD / VFD Transformers 1 2 3 4 5 6 7 8 Convertitori frequenza / VFD “Perfect harmony” Ecc / exc Q+P Q+P 4 MGSCR1120Z Motore / motor PPT2013.01.01.08EN 4 MGSCR1120Z Generatore / Generator Q+P Back to back testing is a complete test which gives our customer additional assurance about machine’s efficiency. 37
  38. 38. Active Partener in String Tests String test at OEM facility MV Switchgear Thread 1 Thread 2 33kV / 3 kV Thread 3 M G Thread 4 Test stand layout back-to-back test: electric motor coupled with a generator and 30 MW resistor banks We work closely with the compressor suppliers to conduct complete string tests at their facilities. This guarantees the final end user that there will be no surprises or risks in the field. PPT2013.01.01.08EN 38
  39. 39. Remote Diagnostics System Remote connection Ethernet Local network USB Data signals:  Inputs for vibration probes (mechanical data)  Input for speed sensor (mechanical data)  Inputs for line current / voltage (electrical data)  Excitation current (synchronous machines)  Inputs for Pt100 (thermal data)  PPT2013.01.01.08EN Outputs (alarm, trip, status) Stand alone unit capability:  Data log  Basic analysis  Ethernet communication  Re configurable acquisition tasks  Customizable / expansible  Available for Hazardous area 39
  40. 40. Remote Diagnostics Demostration On this project, for example, diagnostics were managed from Japan via internet from our factory in Italy using our drive’s remote diagnostics capabilities. Our drive control system can be easily integrated and interfaced with existing Control Systems. PPT2013.01.01.08EN 40