variable speed drives (vsd) acs 600 oil pals · pdf filevariable speed drives (vsd) acs 600...
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Variable Speed Drives (VSD)ACS 600 OIL PALS PRUDTC Technology for oilfield applicationsElectric motors from 10HP to 1000HP in low voltage
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ACS 600 OILACS 600 OIL
TecnologíaTecnología DTC DTCpara Aplicacionespara Aplicaciones
PetrolerasPetroleras
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ABB (Asea Brown Boveri) has developed over the past
decade variable speed drives for specific oilfield
application, primarily for artificial lifting applications.
We have codenamed this product ACS 600 Oil,
worldwide it is the first of it’s kind with a design based
on Direct Torque Control (DTC) which offers an integral
solution applicable to all the various methods of crude
extraction presently in the Oil industry, in a wide range of
power and voltage application.
The development of the ACS 600 Oil was oriented to
solve the different needs of crude extraction methods
with pumps such as PCP (Progressive Cavity Pumps)
ESP (Electro Submersible Pumps), and DP (Donkey
Pumps or Conventional Mechanical Pumps), which
when combined with Direct Torque Control permits the
operator to exactly control the speed and torque
across the whole range of the system even with
different load requirements.
The Application Macros need no external controls or
protections on inasmuch as they form a direct, and
integral part of the ACS 600 Oil, obtaining thus, a
significant reduction in installation, production and
maintenance cost.
ACS 600 Oil cam be used in all three methods of
crude lifting; CMP, PCP and ESP without adapters, as
well as in transportation and distribution systems such
as Multiphase Pumps (MPP) and Pipeline.
VSD’s + Motors = Integral Solution
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ACS 600 OIL – As a Solution for Crude Handling Under Severe Weather Conditions.
ABB has also developed an engineered enclosure
reusable for outside use, adequated for use on wells
under several weather conditions in any part of the
world.
The structure was developed taking into
consideration the severe operating conditions under
which the ACS 600 Oil might have to function, as well
as the need to provide the customer with a variety of
control options. The enclosures are all weather proof
either for NEMA or IEC protection standards.
This permits a design which requires no forced air
ventilation to maintain a predetermined determined
temperature inside to function, inasmuch as the ACS
600 Oil recirculates the air at ambient temperature
through special entry and exhaust ducts.
The customer only need to connect the feed power to
the enclosure inlet and to the motor connections for
system start-Up. All electrical protection necessary to
guarantee ideal functioning are present within the
equipment.
Even at distance, supervision of all systems is possible
through the use of control panel CDP 312.
Along with the ACS 600 Oil, ABB can supply all the
accessories desired, thus assuring immediate and fast
start-up operation of all supervisory and control
equipment.
SINCOR – “ Faja del Orinoco “
Std. Anzoategui - Venezuela
(PDVSA – TOTAL)
OCN Projects – “ Faja del Orinoco “
Std. Monagas - Venezuela
(PDVSA -ExxonMobil )
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ACS 600 Oil As a Solution for Conventional Mechanical Pumping (Donkey Pump or CMP ).
The Direct Torque Control (DTC) executes
speed control independently, both ascendant
and descendant speed, without any gauges,
position or load sensors, or any instruments
The ACS 600 Oil controls the “Float “ of the rods
which might be produced by atmospheric or
down hole conditions change, thus eliminating
constant adjustments to the control parameters
programming.
There need of no additional elements (Choppers or brakes
resistors) which are aimed at controlling the regenerative
effect caused by rods or weights can thus be increasing
reliability and reducing unnecessary stops.
Outdoor use enclosure Made in Venezuela
(PDVSA –Occidente)
PCP & Donkey Pump
Tia Juana Well (PDVSA –Occidente)
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Use of the ACS 600 Oil on conventional equipment adds
other advantages:
• Elimination of sharp brake stops of the rods and
pump in the down hole
Visual check (Through the SCADA system
installed or the Control Panel) all electrical and
process signals which monitor operation and well
procedures, such as:
� Motor Speed (RPM)
� Beam pump Speed (SPM),
� Current (Amp),
� Operation Torque (LB-FT/N-m),
� Power (kW),
� BUS DC voltage (VDC)
� Output Voltage (VAC).
� Power Consumption (kWh)
• Rod overtravel is controlled without. the need of external
measurement devices.
• Over 30% increase in pump life.
• Speeds on the Beam Pump can be adjusted without pulley changes.
• Speed control optimizes production more than 20% typically
• Worn parts replacement is reduced, lowering maintenance costs,.
• 30% energy savings through realistic energy consumption on the
well eliminating peaks produced by Beam Pump start-ups.
• With ACS600 Oil the power factor is 97% constant, eliminating any
additional corrector equipment.
Schematic drawing
Beam Pump Application
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ACS 600 OIL – As a Solution for Progressive Cavity Pumps (PCP).
In the crude extraction with PCP’s, pump Torque control
is the most important requirement, thus eliminating
deformations or breakage to the pumps or rods in the
hole. ACS 600 Oil, without utilizing additional
accessories, archives this result DTC and the
mathematical model produced exclusively to control
Torque through peed variation.
This is managed by ACS 60 Oil through control of the
speed and thus the operation of the PCP, by processing
the information received from bottom hole sources,
which permit automation of the pump so as to optimize
production while diminishing operations costs.
Through pump torque and information received from
the associated well system, it is possible to optimize
the operation resulting in a higher production index
and longer pump life
Using a control panel or SCADA system allows visual
check of process and electrical signals associated to
the application; these signal can be displayed in
engineering units,
ACS 600 Oil for PCP One Motor application
ACS 600 Oil for PCP Dual Motors application
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For example, the information shown is as follows:
� Pump Torque (lb-ft/ N-m)
� Motor Torque (lb-ft / N-m)
� Pump Speed (rpm)
� Motor Speed (rpm)
� Power (Kw)
� Intake pressure (psi)
� Discharge pressure (psi)
� Discharge temperature (°c)
� Casing pressure (psi)
� Flowing pressure (psi)
Some other controls by ACS 600 Oil for PCP application
are:
• Inverted or reverse speed control to prevent the return
of the rods (Back Spring) produced by inertia. This
control is part of a back-up in the mechanical system.
• Torque control of the rods which permits pump speed
control adjustment to possible changes in the down
hole. This eliminates unnecessary halts in production
and results in more crude pumped .
• Pump speed control responding to signals received
such as, discharge temperature, Intake, discharge,
casing or flow pressure adjust and optimize pump
operation in correlation with well conditions.
• Variations of pump speed and Torque limits protect
the pump in line with the pump operation, again in
correlation with well conditions.
Function squematic
PCP Application
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ACS 600 Oil – As a Solution for Electro-Submersible Pumps.
The control macro for Electro-Submersible Pumps, can be
used with both low tension ACS 600 Oil and Medium
Tension ACS 1000 Oil. The main control in the pump is the
speed variation according to the working temperature in
the pump.
It is possible to program the automatic start-up times,
considering the severe Start-Up conditions (30-60min
Appox) after a drop in tension
In addition it is possible to manage the logic of pump
pressure and volume control, obtaining thus, as in previous
cases, a logical regulation in accordance with the
information received from the system
Information supplied by either ACS 600 Oil:
� Pump Start-Up time.
� Pump Torque (lb-ft/ N-m).
� Motor Torque (lb-ft / N-m).
� Pump Speed (rpm).
� Motor Speed (rpm).
� Power (Kw).
� Intake Pressure (psi).
� Discharge Pressure (psi).
� Discharge Temperature (°c).
� Casing pressure (psi).
� Flow pressure (psi).
Outdoor use enclosure for ESPMade in Venezuela
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ACS 600 Oil – A Solution for Multiphase Pump (MPP).
When used with this type of pump, ACS 600 Oil
controls the speed in the system in accordance
with the intake pressure of the pump and it’s
discharge pressure
ACS 600 Oil is designed to facilitate smooth start
/ stops and its speed controller, keeping on
adequate temperature level, thus increasing the
useful life of the pump.
ACS 600 Oil displays all electric and process information
as follows::
� Motor Torque (lb-ft / N-m)
� Pump Speed (rpm)
� Power (kW)
� Intake pressure (psi)
� Discharge pressure (psi)
� Pump Temperature (°c)
� Flow pressure (psi)
Recommendations to house and protect the ACS 600 Oil
ands ACS 1000 Oil applications for oil field use in smart
power houses. This recommendation and its acceptance is
most important when weather conditions are difficult (such
as severe cold or severe heat coupled with salt or brackish
water in the sub-soil or atmosphere) and also when cluster
control is recommended or desired
Inside view Power House for MPP
Project SINCOR Multiphase Pump
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ACS 600 Oil – Integral solution for the customer requiring well pad control (Utilizingenclosure and Smart Power House).
The Smart Power House permits single point control
of systems in a well designed and well built
construction which can be cooled or heated as
needed. This includes housing of the SCADA
system
The SPH consist of an Incoming and Power
Distribution System, the OPS for Cluster Control
and Communication. The OPS is an integral control
and communication system for Pumping control and
optimization of any artificial method as used for
pipeline of crud and Cluster Control
It is a open System providing connectivity and
communication with any system, subsystem or
field device being capable to establish
communication with external equipment via
standard communication protocols and with
standard as intelligent field devices
Within the developed software modules for
OPS we count with
� OPS MPP (Multiphase Pump)
� OPS PCP (Progressive Cavity Pump)
� OPS ESP (Electro-Submersible Pump)
� OPS BP (Beam Pump)
� OPS MS (Main Station)
� OPS SCS (Smart Cluster System)
� OPS NC ( Nomograph Curve)
� OPS SECS (Smart Environmental
Control System)
Line Production Smart Power
House for MPP & BCPMade in Venezuela
© P
ALS
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Ago
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S800 I/O
•OPS HIS•OPC Client
DHS
Ethernet - TCP/IP
AC 800F
AC800F OPSTM Architecture
Profibus/Modbus
F.O.
•Scada•OPC Server
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ACS 600 Oil – Integral solution for the customer requiring well pad control (Utilizingenclosure and Smart Power House).
ABB has developed different enclosures
achieving significant cost reductions in cluster
installations.
This design facilitates the choice of method of
extraction because the ACS 600 Oil can be used
for the different method of crude extraction (PCP
or Beam Pump) simply by changing the control
macro.
The Smart Power House offers an integral solution
because it centralizes and optimizes the cluster control
system and supervision of all signals involved in the
process of lifting, producing and transport of crude, under
any conditions,.
As mentioned before, Smart Power House can be used
under the most severe weather conditions because the
inner temperature is also monitored and controlled
Inside view Smart Power House
for PCP application
External view - Smart Power House
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New development with ACS 600 OILWell Pad in PCP, MPP, ESP and Beam Pump
Automation Products = VSD + Motors+ Smart Power House + Active Filter
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Reference List Until - February
End User Company Kind of ABB's Variable Speed Drives (VSD)
Oil Application Quantity
PDVSA OCCIDENTE ACS500 / ACS600 PCP 407
PDVSA OCCIDENTE ACS600 DONKEY PUMP 91PDVSA OCCIDENTE ACS600 ESP 1PDVSA OCCIDENTE ACS600 MULTIPHASE PUMP 2PDVSA OCCIDENTE ACS600 WATER PUMP 1PDVSA OCCIDENTE ACS600 HIDRAULIC PUMP 1PDVSA ORIENTE - PARIAGUAN ACS500 PCP 1CENTRO REFINACION PARAGUANA ACS500 / ACS600 PIPELINE 23AMUAY ACS600 CRANES 2PDVSA OCCIDENTE LAGO ACS600 PCP 33PDVSA OCCIDENTE LAGO ACS600 DONKEY PUMP 3PDVSA BITOR ACS600 PCP 15PDVSA BITOR ACS600 ORIMIXER 11TRADICIONAL ACS600 PCP 21PDVSA ORIENTE SAN TOME ACS600 PCP 77PDVSA ORIENTE ANACO ACS600 PIPELINE 5PDVSA ORIENTE PUNTA DE MATA ACS500 ESP 3PDVSA ORIENTE OROCUAL ACS600 PCP 2PDVSA - INTEVEP ACS600 PIPELINE 2BOLIVAR ACS600 MULTIPHASE PUMP 1OPERADORA CERRO NEGRO (OCN) PDVSA-EXXON-MOBIL-VEBA OIL ACS604-0170-4 / 150 HP PCP 127SINCOR UPSTREAM - PDVSA -TOTAL - STATOIL ACS607-760-5 / 550 HP MULTIPHASE PUMP 23SINCOR UPSTREAM - PDVSA -TOTAL - STATOIL ACS607-0120-5 / 100 HP PCP 348
SINCOR DOWNSTREAM - PDVSA -TOTAL -STATOIL ACS601-0005-5 / 5 HP PIPELINE 98
MAXUS DE VENEZUELA ACS 601-0120-5 / 75 HP PCP 14CHEVRON ACS504-071-5 / 60 HP PCP 8PEREZ COMPANC ORIENTE ACS601-0100-5 / 75HP PCP 3PREUSAG-CABIMAS ACS601-070-5 / 50 HP DONKEY PUMP 1PREUSAG-CABIMAS ACS601-120-5 / 75 HP DONKEY PUMP 3PEREZ COMPANG OCCIDENTE ACS501-016-5 / 10HP PCP 1PETROZUATA-CONOCO ACS601-0040-5 / 75 HP PCP 1PETROZUATA-CONOCO ACS601-0100-5 / 75 HP PCP 1
TOTAL ABB DRIVES 1735
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Equipment Available for all PumpsACS 600 Oil only for PCP 110% Overload
Hp Description Application Software
10HP ACS 601-0016-4 PCP Torque Control or PCP Torque & Down Hole Sensor
20HP ACS 601-0020-4 PCP Torque Control or PCP Torque & Down Hole Sensor
30HP ACS 601-0030-4 PCP Torque Control or PCP Torque & Down Hole Sensor
40HP ACS 601-0050-4 PCP Torque Control or PCP Torque & Down Hole Sensor
50HP ACS 601-0060-4 PCP Torque Control or PCP Torque & Down Hole Sensor
60HP ACS 601-0070-4 PCP Torque Control or PCP Torque & Down Hole Sensor
75HP ACS 601-0100-4 PCP Torque Control or PCP Torque & Down Hole Sensor
100HP ACS 601-0120-4 PCP Torque Control or PCP Torque & Down Hole Sensor
125HP ACS 601-0140-4 PCP Torque Control or PCP Torque & Down Hole Sensor and ESP
150HP ACS 601-0170-4 PCP Torque Control or PCP Torque & Down Hole Sensor and ESP
200HP ACS 601-0210-4 PCP Torque Control or PCP Torque & Down Hole Sensor and ESP
250HP ACS 601-0260-4 PCP Torque Control or PCP Torque & Down Hole Sensor and ESP
300HP ACS 601-0320-4 PCP Torque Control or PCP Torque & Down Hole Sensor and ESP
350HP ACS 601-0400-4 PCP Torque Control or PCP Torque & Down Hole Sensor and ESP
ACS 600 Oil for Donkey Pump and PCP 150% Overload
Hp Description Application Software
10HP ACS 601-0020-4 PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP
20HP ACS 601-0030-4 PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP
30HP ACS 601-0040-4 PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP
40HP ACS 601-0060-4 PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP
50HP ACS 601-0070-4 PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP
60HP ACS 601-0100-4 PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP
75HP ACS 601-0120-4 PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP
100HP ACS 601-0140-4 PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP
125HP ACS 601-0170-4 PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP
150HP ACS 601-0210-4 PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP
200HP ACS 601-0260-4 PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP
250HP ACS 601-0320-4 PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP
300HP ACS 601-0400-4 PCP / Donkey Pump Torque Control or PCP Torque & Down Hole Sensor and ESP BCP
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ABB DRIVES -VenezuelaAsea Brown Boveri S.A.Av. Don Diego Cisneros – Edificio ABBCaracas – VenezuelaTelf: +58 2 2031799, Fax: +58 2 2376270www.abb.come-mail: [email protected]: [email protected]
Indicate your requirements
1.- Well Input Voltage (V)
2.-
3.-
2 A/IAdditional
4.- Communication Accesories 6.- Use of ACS 600 Oil
P.C.P. Torque Control
P.C.P. Torque Control & Down Hole Sensor
Port Communication
RS 485
RS 232 Multiphase Pump
RS 232/485 Electr-Submergible Pump
5.- Out Door Use enclosure Pipeline pumps
External Use NEMA 3RAccessories for Additional control
AutoSported
Sporteda Post
Multi-Well External use enclosure
Copy This Fax +58-0212 2376270Caracas - VenezuelaShould you wish to send comments or more information send
Company
First ,Last nameTitle / position
Name of Project
Office Address:
E-mail / Fax:
& Pumps for handling Oil
3 D/OStandard
6 D/IStandard
3 A/IStandard
Donkey Pump & PCP Control de TorqueModule
Device Net
ModuleFieldbus
ModbusRTU
Well Qty
2 A/OStandard
kW ó Hp
DNP 3.0
Order from for ACS 600 OilFor PCP,Donkey Pump, ESP,Multiphase
If you need an ACS 600 Oil for your oilfield Artificial Lifting, copy this formAnd send it to our client attention center at Fax: +58 212 2376270 Caracas - Venezuela
DigitalOutput
AnalogOutput
I/O Integrated
Unit qty
AnalogInput
DigitalInput
Donkey Pump & PCP Control de Torque & Down Hole Sensor
an e-mail to [email protected]