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O i l a n d G a s Ap p l i c a t i o n s
P
roduction, distribution and ren-
ing applications in the oil and gas
industry rely heavily on motor-driven
pumps and pumping systems. Keeping elec-
tric motors driving critical operations at peak
performance is vital to ensure maximum
protability.
For continuous motor performance,
engineers are focusing on variable frequency
drive (VFD) and motor control technology.
Because of their ability to regulate motor
speed, VFDs are effective for controlling
energy use.
Centrifugal loads, such as pumps and
fans, offer great energy savings potential
when the application requires less than 100
percent ow or pressure. Although very few
oil and gas applications require 100 per-
cent ow continuously, many of the motors
employed in these pumping systems are
started at full speed and remain running at full, xed speed
while in use. In these applications, users can integrate VFDs in
both low- and medium-voltage congurations.
Companies can gain energy savings by using VFDs to
control ow by modulating motor speed. A 20 percent speed
reduction can help save energy use by up to 50 percent, which
means VFDs often quickly pay for themselves in energy savings.
The higher the level of motor operating time and the larger the
variation in load duty cycles, the greater the savings.
For many large energy userssuch as renerieselectric
utilities will often charge higher peak-demand electricity prices
when the plant exceeds a preset limit or base load of electricity.
These peak demand charges typically occur when motors draw
large peaks of current when started across-the-line. Variable
frequency drives help reduce power peaks by gradually ramp-
ing the motor up to speed. By automatically controlling motor
speed, the drive allows the motor to run at full horsepower only
when necessary. The result is lower energy costs and increased
operating efciency.
Numerous oil and gas customers also choose VFDs for
tighter process control. Tighter control on variable process
means less energy used. For example, a control valve may not
be able to properly control a process variable due to range
Variable Frequency
Drives in Oil and Gas
Pumping Systems
Luis G am boa and N ancy Rivard, Rockw ell A utom ation
As oil and gas companies look for ways to conserve energy and reduce costs,
a growing area of focus is on the efciency benets of variable speed drives.
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O i l a n d G a s Ap p l i c a t i o n s
limitations or pressure drop problems, resulting in wide pro-
cess variations. The use of a VFD can provide tighter control,
reduce overall waste and improve plant efciency.
No Time for Downtime
Equipment reliability is crucial in any industry, but is espe-
cially important in oil and gas operations where every minute
of uptime counts and lost production time carries costly con-
sequences. Any schedule backup, from crude production to
rened delivery, affects the entire process. Since many of these
operations need to run continuously, engineers need constant
monitoring and maintenance access to pumps, compressors
and other system components to provide maximum through-
put and uptime.
When looking at a drive investment, look for simplic-
ity. Simplicity will help eliminate excess space demands and
weight, while ensuring easy to troubleshoot design. In addi-
tion, simple VFDs will result in highly reliable solutions.
One inherent maintenance challenge in many oil and gas
applications is remote or difcult-to-access locations, such as
oil elds or offshore platforms. Advancements in intelligent
motor control technology, along with the proliferation of high-
speed Ethernet and wireless networks, have expanded access to
component and production information.
Many of todays drives, soft starters and electronic over-
load relays offer condition-based monitoring capabilities that
protect motor assets and warn of impending faults so users can
take preventive action. With the ability to monitor motor cur-
rent and speed, drives can perform protective functions based
on that information. With access to more detailed information
over longer periods of time, engineers can better use predictive
trending to anticipate prob-
lems and prevent catastrophic
failures.
In more extreme situ-
ations, the drive will act to
protect the motor. Most drives
have a built-in electronic
motor thermal overload fea-
ture. When a motor is in a
state of severe exertion, beyond
its safe operating limits, the
motor overload feature can
help reduce the output current
or shut off the motor and pro-
tect it from thermal damage or
catastrophic failure.
Equally important is
the far-reaching impact that
drives can have on the overall
health of automated systems.
In fact, converting a process
from xed speed to variable
speed can minimize wear and
tear and reduce maintenance
requirements for mechanical systems by reducing start/stop
cycles and eliminating valves and other mechanical compo-
nents. In addition, it can also maximize the efciency of the
motor and extend the life of many rotating parts in a typical
motor-pump combination.
Expanding Capabilities
Recent VFD technology offers expanded communications
capabilities, more compact designs and integrated control fea-
tures driven by powerful, faster microprocessors. Among the
biggest breakthroughs are advances in medium voltage drives
that save cost and space.
For example, the simplied design of new transformerless
drive technology eliminates the need for a transformer, thus
reducing space and weight requirementsan essential consid-
eration in the oil and gas industry. These drives use pulse width
modulated switching patterns and an integrated DC choke as
an alternative to heavy and costly transformers that were once
the only option for mitigating harmonics and common-mode
voltage. By connecting the power supply directly to the drive
without an isolation transformer, this technology results in a
drive that is smaller and lighter. Transformerless medium volt-
age drives are ideal for tightly conned applications, such as oil
platforms, reneries and pipeline pump stations.
Overall operating costs can also be reduced by the trans-
formerless drives high efciency and regenerative capabil-
ity that converts the variable frequency power generated to a
signal that can be pushed back to the utility. The drive can
provide 100 percent continuous full-current regenerative brak-
ing without putting thermal stress on the motor.
A variety of drives are available for oil and gas applications.
PU M PS & SYSTEM S w w w .pum p-zone.com A PRIL 2008 69
VFDs today also provide integrated control and
power. Connecting these simplies information gathering,
conguring and programming. For example, programming
wizards for drive start-ups operate much like the setup pro-
grams in new consumer PCsafter a few prompts, the
wizard automatically installs the software and required
drivers, sets all the parameters and recognizes the hardware
devices plugged into the PC.
In a drive application, the wizard will prompt the user
for information about the application, size of the motor
and other critical information. It will then automatically
set up all the parameters to help meet the dened appli-
cation and hardware requirements. These tools also allow
users to easily save all of their drive parameters and control
logic in a single database. In the event of a failure, replace-
ment and restoration of the original drive parameters is a
relatively simple process.
Like any industry, the oil and gas sector is evaluating
new approaches to increase performance with lower produc-
tion risk. As the industry works to nd new reserves, increase
capacity and upgrade its existing infrastructure, it will increas-
ingly rely on drive and power control technology to protect
assets, improve motor performance and boost operational and
energy efciency.
P & S
Luis Gamboa is the oil and gas industry solutions manager
and Nancy Rivard is the product manager for Rockwell
Automation, 6400 W. Enterprise Drive, Mequon, WI
53092, 414-382-2000, www.rockwellautomation.com.
Recent advances in mediumvoltage
drives have saved users cost and
space.
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