Advantages of the

Variable Frequency Generator (VFG)©

Presented By:
•Juergen Schulz, Canadian Advanced Inc.

Paper Authored By:

•Andy Limanowka, Canadian Advanced Inc.
•Dana Pettigrew, Nexen International Petroleum

© Worldwide Patent Pending

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 What is a VFG

VARIABLE FREQUENCY GENERATOR (VFG)

• Power Generator that varies Frequency and Voltage

output
• Operates 30-70 Hz, 400-5000 Volts
• For use with ESP’s & other Variable Torque Loads
requiring variable speed
• Eliminates Variable Speed Drive and Transformer
• Developed by: Canadian Advanced Inc.
• With Nexen International & Finning Canada (Caterpillar)

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 How the VFG works

• Reduced Speed Start

• Reduced Voltage Start
• Control Module controls:
– Voltage, Current & Hz (RPM)
– Diesel or Natural Gas Engine
with Governor
– Motor Protection
– SCADA/Communication

Generator
Power Control/
Generator Motor Well
Protection

ESP
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 Start-up traces (40Hz Ramp Start)

3508 CAT; 12000 BPD pump and 644HP/3480V/117A motor

Ramp Start
Nominal full load Volt 3480V@60Hz
Nominal full load Amps 90A@60Hz
2sec for system stabilizations
inrush current 2.4 x full load current

3000 200

180

2500
160

140
2000

120
VOLTS

AMPS
1500 100

80

1000
60

40
500

20

0 0
3 4 5 6 7 8 9 10 11 12 13 14 15

TIME [s]
Gen Volts Gen Current

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 Advantages of VFG

• Lower Capital & Maintenance Cost

• More Efficient System, less Diesel fuel
• Smaller Engines required to Drive Large
ESP’s
• No Harmonics, spikes or mirroring
• Increase Production
• Easy to Use – Fully Integrated System
• Touch Screen Operation

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 VFG Advantages

• Improved Run Times

• Voltage / Current Optimization
• Hard Starting Advancements
• Recoverable Asset (Compared to High Line)
• Smaller Foot Print-Offshore Applications

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 System Comparison
Typical Variable Speed Drive System

Variable
Power Load Step-Up
Generator
Speed
Filter Transformer ESP
Drive

Typical Switchboard System

Power Switch Step-Up

Line board Transformer ESP

Variable Frequency Generator System (Less Equipment)

Generator
Power Control/
Generator Motor ESP
Protection

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 Lower Capital / Maintenance cost

• Engine Matched to Full Load of ESP

• Low frequency Soft Start-up
– No Need to Oversize Engine
– VFG = 2.5 X Nameplate Current
– Switchboard = 6-8 X Nameplate Current
• Eliminates VFD & Transformer Capital Cost
• Eliminates VFD Maintenance Cost

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 Capital cost comparison

Capital Cost Comparison, 3512 CAT 900 ekW

VFD
&
Step-up VFG
Transformer Controller

Engine
Engine &
& Generator
Generator

Traditional VFD VFG System

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 Maintenance cost comparison

Maintance Cost Comparison, 3512 CAT 900 ekW

VFD
&
Step-up VFG
Transformer Controller

Engine Engine
& &
Generator Generator

Traditional VFD VFG

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 Fuel cost comparison

Fuel Cost Comparison, 3512 CAT 900 ekW

Traditional
VFD VFG
Fuel Fuel
Consumption Consumption

Traditional VFD VFG

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 Output Waveform VFD vs VFG

Typical VFD Output Waveform - Unfiltered

Typical VFG Output Waveform

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 Improved Run Times

• Soft starts reduce shaft stress

• Cable runs cooler – longer life
• Motor runs cooler – longer life
• No voltage spikes – ideal sine wave w/o any filter

RESULTS: Longer ESP Electric and Mechanical System

Life – Reduced Electrical Losses

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 Increased Production (Heijah 49)
• Improve Efficiency by 5-10% – Less Heat!
• VFG eliminates Heat and Turns to Oil Production
• Example for Maximum of 3508 CAT Diesel Generator, 562 Series
CKC12000, 650 hp ESP

Traditional VFD & Transformer VFG System

Maximum Frequency = 58 Hz Maximum Frequency = 63 Hz
Gross Fluid = 11,600 bbl/day Gross Fluid = 12,400 bbl/day
Net Oil (90%WCT) =1160 bbl/day Net Oil (90%WCT)=1240 bbl/day

• Production increase of 80 bbl/day of oil

• At $ 65/bbl add’l revenue of $ 5.200 per day
• Increase of annual revenue of over $ 1,8 Mio.
• Return of initial CAPEX in less than 3 months

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 Increased Production (Qataban 11)
Q11 VFG TEST.sp7
Pump Performance (TDH @ Design)
CLift 562 KC16000 / 86 Stgs / 57.0 Hz
6000

5000

4000
TDH, ft

3000

2000

1000

0
0 5000 10000 15000 20000 25000
Liquid + Gas Rate, Bbl/D

Pump Curve , Case 1 Well System Curve , Case 1, (Truncated)

Pump Curve , Case 2 Well System Curve , Case 2, (Truncated) Reg: Nexen Inc. - Nexen Inc.
Min-Max Optimum Rate

•On a VSD at 114 Amps and 57.0 Hz, 18,250 bfpd RED SOLID LINE
•On a VFG at 114 Amps and 59.0 Hz, 19,550 bfpd BLUE DASHED LINE
•VFG measured benefit of an extra 1,300 bfpd for a 7.1% increase.

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 VFG
Entire unit prepared for shipment

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 VFG
Control panel during testing

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 VFG
Canadian Nexen Yemen (Heijah 49)

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 VFG
Touch-pad controls

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 VFG
Touch-pad controls

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 VFG
Touch-pad controls

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 When to use a VFG

• Every time a Generator is used on an ESP

• Temporary or Permanent Installation
• Portable Well Testing
• Areas of Power Quality Problems
• Weak or Insufficient Supply Power
• Other Applications – PCP, Beam Pump, Ships, Fans, etc.

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 Questions

For more information or pricing contact:

Juergen Schulz or Sid Degen

CANADIAN ADVANCED INC.

5307-72A AVENUE
EDMONTON, ALBERTA, T6B 2J1
PHONE: 780-469-0770
FAX: 780-450-4592

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 Thank you for your attention

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