VARIABLE SPEED
DRIVES
Variable Speed Drives
Iraq – ROO – Basra Field Training
VARIABLE SPEED
Why do we need a VSD DRIVES
Improved System Efficiency
Maximised Well Production
Production Matched To Process
Down Hole Equipment Isolated
Reduced Starting Stresses
VARIABLE SPEED
What is a Drive? DRIVES
The Variable Speed Drive is a
device that controls the motor
speed
– By adjusting the frequency of
supplied voltage
– And varying the voltage
supplied to the motor
VARIABLE SPEED
Pump Performance vs. Motor Speed
DRIVES
Changing the RPM of the pump changes the pump performance curve
Troubleshooting p 31
The new performance curves can be calculated using the pump and
fan “Affinity Laws” for RPM changes…
– New Flow Rate = Old Flow (New RPM/Old RPM)
– New Head = Old Head (New RPM/Old RPM)2
– New Brake HP = Old BHP (New RPM/Old RPM)3
– New Motor HP = Old MHP (New RPM/Old RPM)
The pump will rotate at the same RPM as the motor
VARIABLE SPEED
RPM & Hertz DRIVES
Since the GCS and the ICS Drives read out in hertz, and hertz is
almost directly proportional to the RPM, the affinity laws may be
re-written as follows:
– New Flow Rate = Old Flow (New Hertz/Old Hertz)
– New Head = Old Head (New Hertz/Old Hertz)2
– New Brake HP = Old BHP (New Hertz/Old Hertz)3
– New Motor HP = Old MHP (New Hertz/Old Hertz)
VARIABLE SPEED
Affinity Laws – an example DRIVES
70
Flow 70 2000 BPD 60 2333 BPD
60
2
70
Head70 25.3 FT60 34.4 FT
60
3
70
BHP70 0.6160 0.969 BHP
60
Efficiency 70 Efficiency 60 60%
VARIABLE SPEED
Pump Speed & Flow Rate DRIVES
By varying the
pump speed, the
flow rate and the
pump head can
be adjusted with
no modification
of the downhole
unit
VARIABLE SPEED
Frequency vs. Motor Speed DRIVES
Given: 562 Series, 100HP, 60HZ, 2145 Volt, 27Amp motor
Find: Nameplate Data at 70HZ
70 70
HP70 HZ HP60 HZ 100 117 HP
60 60
70 70
Volts 70 HZ Volts 60 HZ 2145 2503Volts
60 60
Nameplate Amps90 = 27
VARIABLE SPEED
Motor loading at different Frequencies
DRIVES
Motor HP
HP
Motor HP = Pump HP
Design Point
Pump HP
0
Hertz
VARIABLE SPEED
Motor loading at different Frequencies
DRIVES
When the frequency applied to an induction motor is
changed, the applied voltage must also be changed
Failure to maintain the proper volts-per hertz ration will affect
motor torque, temperature, speed, noise, and current draw
New Voltage = Motor Voltage x New Hz
Old Hz
VARIABLE SPEED
GCS VSD Motor controller DRIVES
Available in two types of
enclosure:
NEMA 1 – general purpose
NEMA 4 – weatherproof.
It operates directly from 380 –
480 VAC 3 Phase power supply
at 50/60Hertz
VARIABLE SPEED
Features & Capabilities DRIVES
System Firmware & Software
Field Proven
Revisions Now Limited
Upgrades can be Field Installed
Updated Online Support
– Software available
– Information & Upload Instructions
– Version Lists
– Compatibility Matrix
VARIABLE SPEED
Features & Capabilities DRIVES
MaxStart
– Automatically applies forward then reverse
torque to free locked pumps
– 5 attempts allowed then locked out
Frequency Sweep
– Program extended time to bring well with
abrasive fluids to full production over
extended periods (hours or even days)
Torque Control
– Provides more accurate control of downhole
unit in pump off conditions
– No tachometer sensing required
VARIABLE SPEED
Features & Capabilities DRIVES
Custom Modbus maps
500 addresses
– Reduces time for SCADA access
– Reduces transmit time for data
Frequency control in RPM
– PCP pumps
– Programmable to set speed in RPM
– RPM counter for PCP’s
Display downhole amps & voltage
– HS&E advantage
– Service friendly
– Reduces exposure to high voltages
VARIABLE SPEED
Features & Capabilities DRIVES
User PID loop control
– Reduces need for special programming
– Easily modify programs on site
Input Power Outage Ride-Thru
– Power sags up to 30%
– Power outage to 5 cycles
– Ability to extend for sags or outage to 500
msec with
– additional DC buss capacitor for energy
storage required
Motor Stall
– Feature for applications for surface motors
Graphic display – enhanced for greater
clarity in sunlight
VARIABLE SPEED
DRIVES
GRAPHIC DISPLAY INTERFACE
(GDI)
VARIABLE SPEED
GDI DRIVES
Is the display and operator interface and
comprised of three components
– Keypad
– Interface board
– LCD display housing
Initially will go to the Main Menu screen
User can view and or modify all
setpoints contained within the controller
VARIABLE SPEED
GDI KEYPAD FUNCTIONS DRIVES
Start GDI KEYPAD
– Manually starts the motor
Stop
– Manually stops the motor and resets the
“lockout” condition
Arrow keys
– Move the cursor around the screen and
increase or decrease setpoints
VARIABLE SPEED
GDI KEYPAD FUNCTIONS DRIVES
Enter GDI KEYPAD
– Use to select highlighted menu items or
to program or finalise a setpoint
Menu
– Used as a backup or cancel key. If
repeatedly pressed it will return to the
Main menu screen
The green, amber and red panel LED’s
indicate the present status of the motor
VARIABLE SPEED
GDI MENU DRIVES
The GDI Main menu has 9 modules which in-turn contain several
screens containing the parameters which need to be set to start an
ESP system, they are:
GCS Modules Custom User Screen
ElectroSpeed™ GCS Setup SCADA, Security and System
Datalog and History Analog Setup and Display
Faults and Alarms Status
Programmable Logic Functions
VARIABLE SPEED
GDI MENU DRIVES
VARIABLE SPEED
Status DRIVES
The primary screen for the
operator
Displays most of the
parameters needed to
ascertain the run status of
the controller
VARIABLE SPEED
Use the arrow keys to move the
DRIVES
Indicates Speed control (Mode) is
cursor then select ENTER to edit motor is FR SET (Frequency
the parameters:- Set Hz, running at governed.
Rotation and Mode. 59.7hz.
Highlight this symbol and you
can access the electronic amp
chart. If the unit is locked out
Output rotation this icon will be a padlock.
is FWD.
This displays the output
current.
This displays the
output voltage.
The real time clock
time.
Any two parameters
can be displayed here
by using the Utility
menu. Displays active alarms, it
will clear when the active
alarm has cleared.
This box displays the
most recent shutdown.
VARIABLE SPEED
DRIVES
VARIABLE SPEED
Contrast Adjustment DRIVES
By pressing both the left and right arrows at the same time the contrast
screen will come up. Adjustments can now be made to the screen for
better viewing by pressing the up or down arrows.
VARIABLE SPEED
Utility Menu DRIVES
The Utility Menu is activated by depressing the UP and DOWN arrows
keys at the same time
VARIABLE SPEED
GCS (Graphical Control System) DRIVES
Modules
Screens used to enable, calibrate or scale built in inputs, outputs, and
optional input/output modules (up to a maximum of 3).
VARIABLE SPEED
GCS (Graphical Control System) DRIVES
Modules
Device1 Tags
Screen where you find down hole
gauge ( WellLift H) data
informations.
VARIABLE SPEED
Espeed GCS Setup DRIVES
Contains a majority of the
parameters that need to be
set and maintained for a
basic ESP installation
The Menu contains Four
screens:
– GCS Setup 1
– GCS Setup 2
– GCS Setup 3
– Starts
VARIABLE SPEED
GCS SETUP 1 DRIVES
Screen where the drive
operating parameters for
normal operation and start
are entered
These arrows indicate the parameter
can be edited
VARIABLE SPEED
GCS SETUP 2 DRIVES
Screen is for setting drive
control modes for different
inputs during operation and
starting
These arrow keys indicate
more parameters below.
VARIABLE SPEED
GCS SETUP 2 DRIVES
This screen is for enabling
parameters to help filter drive
input and setting the level of
operator access
VARIABLE SPEED
GCS SETUP 3 DRIVES
Screen is only available if the
software configuration is
equivalent or later than:
– GDI 4v74
– PCM 8r00
– SysCon 6v300
Setting these parameters will
allow the drive to operate in
“Torque Control Mode”
VARIABLE SPEED
GCS SETUP 3 DRIVES
The addition of Speed In RPM is
only displayed if the software
configuration revision is:
– GDI 6V00
– PCM 10v35
– SysCon 8v04
VARIABLE SPEED
Starts DRIVES
The final screen within the
ESpeed GCS Menu and where
you set automatic start
conditions
Page 29 of Manual
VARIABLE SPEED
Datalog and History DRIVES
This section provides
screens to access the
historical data and graphs
that are recorded within the
GCS controller
VARIABLE SPEED
Shutdown History DRIVES
Displays cause, date and time
of the last 99 shutdowns
Screen can hold 11 records at
once
VARIABLE SPEED
Event Records DRIVES
Displays the 254 most
recent events.
At the bottom of the screen
you will see a brief
description of the
highlighted event
VARIABLE SPEED
Run History DRIVES
Displays counters and
timers that record various
operating information about
the installation
VARIABLE SPEED
PC Card & Datalogging DRIVES
Provides access to the
datalogging functions
provided with the GCS
controller.
The data is stored onto the
PC Card, which is non-
volatile.
PC Cards are now only
available in 128 MB, they
are physically smaller and
must be fitted with an
adaptor to plug into the GDI
slot
VARIABLE SPEED
PC Card & Datalogging DRIVES
Removing the PC Card:
To remove the PC Card
Disable data logging.
Ensure that the Logging:
disabled icon is displayed.
Press the small eject button
situated just below the PC
Card and remove.
when Insert back PC Card
make sure that you Enable
data logging, you will Logging
is active
VARIABLE SPEED
PC Card & Datalogging DRIVES
VARIABLE SPEED
PC Card & Datalogging DRIVES
VARIABLE SPEED
Faults and Alarms DRIVES
Provides access to screens
that are used to enable,
disable, and adjust timing of
most conditions that cause
motor shutdowns
– Overload
– Underload
– Input Overvolt
– Input Undervolt
– Input Voltage Unbalance
– Low Speed Trip
– Temperature Sensors
– Telemetry Fail
VARIABLE SPEED
Alarm Setup DRIVES
Overload:-
Protects the motor from excessive
current draw by the motor.
Setpoint:-
Determines the maximum output
current that can be delivered to the
motor without causing a shutdown.
It is recommended that you set this
value at :
motor nameplate x transformer
ratio x 100 to 115%.
VARIABLE SPEED
Alarm Setup DRIVES
Under load:-
Under load is defined as
insufficient current drawn by the
motor.
Set point:-
This is set to the value of motor
current below which the motor
controller will shutdown the motor.
Typically set at :
15 to 20% below the lowest current
phase at the minimum frequency.
VARIABLE SPEED
Alarm Setup DRIVES
Input overvoltage:-
This screen setting protects the drive
from stresses that result from
excessive input voltage indicating to
the operator that power supply
problems exist.
Setpoint:-
This parameter should be set to the
value of input voltage above which the
controller will instigate a motor
shutdown. Typical set at :
5% over the drive input rating.
VARIABLE SPEED
Alarm Setup DRIVES
Input under voltage:-
This alarm helps to detect and
highlight the possibility of power
supply problems.
Setpoint:-
This is set to the value of the input
voltage below which the controller
will shut down the motor. Typical set
at :
10% below the controller nameplate
rating.
VARIABLE SPEED
Alarm Setup DRIVES
Input voltage unbalance:-
As before this screen is used to set
an alarm which detects and
highlights problems with the
incoming supply.
Setpoint:-
This is set to a percentage value of
the input voltage unbalance above
which the controller will shutdown
the motor. Typical set at: 4 to 10%.
VARIABLE SPEED
Alarm Setup DRIVES
Low speed trip (LST):-
Prevents the motor running below a
set frequency for longer than the
specified time delay.
Low speed clamp:-
This is linked to the low speed
clamp so that once the actual
output fcy drops 0.5hz below the
setting the controller will begin to
process a low speed trip shutdown.
Typically setting not less than 35
Hz.
VARIABLE SPEED
Alarm Setup DRIVES
A convenience to the user as
all alarm status’ are
displayed
VARIABLE SPEED
Programmable Logic Functions DRIVES
As the title suggests this
menu provides numerous
screens which provide
access to the programmable
logic functions of the GCS
VARIABLE SPEED
Programmable Function Setup DRIVES
User Define Alarms:
Provides access to the
down hole pressure and
Temperature Alarms.
VARIABLE SPEED
Programmable Function Setup DRIVES
User Alarm 2:
Defined as Motor
Temperature.
the Set point for this
Temperature set at highest
value of the down hole
Motor Temperature to avoid
Motor over Heated.
High Threshold Set at : 135 C
VARIABLE SPEED
Custom User Screen DRIVES
Provides a user
configurable display
screen.
Parameters from other
display screens can be
copied to this one so a
customised screen of
required data can be
constructed
VARIABLE SPEED
Custom User Screen DRIVES
Displays eleven data
variables
VARIABLE SPEED
SCADA & Security System DRIVES
This menu provides access
to several system
maintenance, security and
communication option
features:
– System
– SCADA Setup
– Security
– Clock
VARIABLE SPEED
System DRIVES
Provides access to several
parameters concerning
overall system
maintenance
VARIABLE SPEED
SCADA Setup DRIVES
Displays the parameters
controlling external
computer systems and
telemetry devices
VARIABLE SPEED
Security DRIVES
This menu accesses the
system security features
which when set can limit
customer access
VARIABLE SPEED
Clocks DRIVES
Displays the present setting
of the battery backed real
time clock
– Primary purpose is to
record time and date for
shutdown history and
datalogging functions
VARIABLE SPEED
Clocks DRIVES
Screen used to adjust the
real time clock to the
current date and time
VARIABLE SPEED
Analog Setup & Display DRIVES
This screen permits display
of the output current and
input voltage readings
VARIABLE SPEED
Analog Setup DRIVES
On this display you
calibrate your measured
input voltages
VARIABLE SPEED
DRIVES
ANY QUESTIONS?