deep submersible hayward motors
DESCRIPTION
submergible motors from HaywardTRANSCRIPT
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Deep Submersible MotorsDeep Submersible MotorsWhatWhats possibles possible
Hayward Tyler Ltd Group Technical DirectorKen Sears
Subsea Europe 200830 October, London
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Progressive innovationProgressive innovation
1908 First submersible (water filled)
electric motor
Gold Medals awarded
Paris 1878Calcutta 1884London 1884
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Technology developmentTechnology development......BCPBCPss to Subseato Subsea
Wet Stator Glandless Motor Pump
1948Remains industry
standard! Submersible motorSWLP, FWP
Subsea motor
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The case for Subsea The case for Subsea processingprocessing
Sea Water Injection
Crude Oil Boosting
Produced Water Re-Injection
Multi Phase Pumping
Separation
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Benefits of subsea pumpingBenefits of subsea pumping
Time
Value
Normal production capability
Improved productivity through pumping
Time
Value
Normal production capability
Additional production accessiblethrough pumping
Installing subsea pumps close to wellheads may increase the total recovery rate for subsea wells by up to 25%
when compared with unboosted production (Aker Solutions)
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General Subsea Motor General Subsea Motor requirementsrequirements
High VoltageUp to 11kV
Variable speedUp to 4000 rpm
CompactHigh casing pressures
Suitable for 3000m
Fully compliant to Oil Industry StandardsIEC 60034NorsokOil Company StandardsAPI 610
Ultra high reliabilityProven technologyConservative design
Fully compliant to Oil Industry Standards
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Deep Submersible motorsDeep Submersible motors
0
1000
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1990 1995 2000 2005 2010 2015 20200
1000
2000
3000
4000
5000
6000
7000
8000kW Depth (m)
kW
Depth (m)
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19921992
Kvaerner boosting station
350kW
500m
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19991999
EniAGIP
multiphase pumping
2.5MW
1000m depth
120 bar int. 95 bar ext
9kV (operating) 11kV (specification) VSD
3m x 1.01m dia
12.8 tonnes
Superduplex
materials
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20022002
Subsea mud pump
935kW
2300m depth
6.6kV VSD
3m x 1.2m dia
7.15 tonnes
Superduplex
materials
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20082008
Subsea water injection pump
2.5MW
3000m depth
6.6kV
VSD super synchronous
2,500 to 4,000 rpm
3.3m x 1.2m dia
12.4 tonnes
Superduplex
materials
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Tyrihans SRSWI ProjectTyrihans SRSWI Project
Increased oil recovery Power supplied from Kristin Platform over 30 km awayVariable Frequency Drive (VSD) system at Kristin Subsea step-down transformers adjacent to the modules2 AKS LiquidBooster modules
AKS 8-stage centrifugal pump Hayward Tyler 2.5 MW motor
Platform over 30 km away
s adjacent to the modules
SRSWISRSWI == SSubseaubsea RRawaw SSeaea WWaterater IInjectionnjection
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Technical risk managementTechnical risk management
Performance prediction
Insulation capability
Penetrator
Starting conditions
Thrust bearing life
Coolant circulation pump
Thermal stability
Material compatibility
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Motor functional requirements Motor functional requirements
Rated power (shaft output) 2500 kWMax current 320 AOperating speed range 2500-4000 rpm Rated voltage / frequency 6.6 kV / 60 HzWinding insulation level 11 kVCasing internal design pressure P 150 bar Casing external design pressure P 30 bar Design lifetime 20 year (minimum)Time between intervention Minimum 5 yearMaximum total thrust (standstill) 46 kN Min seawater temperature +1 CMax seawater temperature +10 C Max pit water temp during testing +25 C
Rated power (shaft output)Rated power (shaft output)Max currentMax currentOperating speed rangeOperating speed rangeRated voltage / frequencyRated voltage / frequencyWinding insulation levelWinding insulation levelCasing internal design pressure Casing internal design pressure PPCasing external design pressure Casing external design pressure PPDesign lifetimeDesign lifetimeTime between interventionTime between interventionMaximum total thrust (standstill) Maximum total thrust (standstill) Min seawater temperatureMin seawater temperatureMax seawater temperatureMax seawater temperatureMax pit water temp during testingMax pit water temp during testing
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Multi disciplinary engineering Multi disciplinary engineering challengeschallenges
Electrical analysis
Internal hydraulic losses
Thermal analysis
Rotor dynamics analysis
Bearing analysis
Casing Stress analysis
Shaft deflection analysis
Cooling system analysis
Electrical losses
Hydraulic Design of cooling pump Radial & Axial Thrust analysis
Rotor dynamics analysis
Shaft deflection analysis
Electrical losses
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Oil Oil vsvs
Water/Glycol filled Water/Glycol filled TechnologyTechnology
Oil
High viscosityHigh frictional losses particularly at higher speeds
High dielectric propertiesStandard industrial motor insulation
Higher operating tempsCan lead to increased corrosion
Seawater ingress leads to immediate catastrophic failure
Water / Glycol
Low viscosityLower frictional lossesHigher speeds possible
Good dielectric propertiesFully insulated cables & joints
Cooler operation Corrosion inhibiting
Seawater ingress does not cause immediate failure
Water / Glycol is a commonly used control fluid
Environmentally friendly
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Motor descriptionMotor description....
3.3 m
12400 kg
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Pressure CasingPressure Casing
Machining of Outer casing
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Stator shell and windingsStator shell and windings
XLPE insulated cables and joints
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Bearing Design Bearing Design Tilting Pad Tilting Pad JournalsJournals
Stiff radial bearings
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High Voltage PenetratorHigh Voltage Penetrator
Power supply: Crossing the pressure boundary
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Junction box & Junction box & compensatorcompensator
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Coolant circulation pumpCoolant circulation pump
High efficiency impeller
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Cooling CoilsCooling Coils
Spiral Heat Exchanger
6 parallel circuits
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0102030405060708090
100
0 2 4 6 8 10 12
Design iterations Design iterations ..
Length LLength LDiameter dDiameter d
High
sha
ftde
flect
ions
&Cr
itica
l Spe
edpr
oble
ms
UnbalancedMagnetic Pull
L/d ratioL/d ratio
M
o
t
o
r
E
f
f
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c
i
e
n
c
y
M
o
t
o
r
E
f
f
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c
y
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Design iterations Design iterations ..
Length LLength LDiameter dDiameter d
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Predicted Performance DataPredicted Performance Data
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Some of the many Qualification Some of the many Qualification TestsTests
Penetrator Vibration TestsPenetrator Vibration TestsThrust Bearing performance and endurance tests
Coolant pump tests
and endurance testsThrust Bearing performance
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Factory Full Load Performance Factory Full Load Performance TestsTests
Header TankElectrical Supply Cables
Fluid Pressure/Temp Transmitters Here
Load Machine
Epicyclic Motor Drive
Epicyclic Gearbox
Flow
FlowmeterPump & Fluid Storage For Filling System
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ConclusionsConclusions
Motor Technology is now catching up with the demand for Subsea drivesQualified machines2500 kW at speeds up to 4000 rpm a proven realityDesigns suitable for 11kV voltage spikesDesigns suitable for 3000m depth waterWater/glycol filled motors provide proven reliabilityScaleable designs valid for higher powers and speeds
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Customer & Supplier Customer & Supplier partnershipspartnershipsCustomer & Supplier Customer & Supplier Customer & Supplier Customer & Supplier Customer & Supplier partnershipspartnershipspartnershipspartnershipspartnerships
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Deep Submersible motorsDeep Submersible motors
0
1000
2000
3000
4000
5000
6000
7000
8000
1990 1995 2000 2005 2010 2015 20200
1000
2000
3000
4000
5000
6000
7000
8000kW Depth (m)
?
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Deep Submersible MotorsDeep Submersible MotorsWhatWhats possibles possible
Hayward Tyler Ltd Group Technical DirectorKen Sears
Thank YouThank You
Progressive innovationBenefits of subsea pumpingDeep Submersible motors1992199920022008Oil vs Water/Glycol filled TechnologyConclusions