Eni S.p.A.

Exploration & Production Division

COMPANY SPECIFICATION

ELECTRICAL MOTOR DRIVES

20217.VAR.ELE.SDS

Rev. 0 December 2004

0 NEMA TAGLIAFERRI FASOLI 12/2004

REV. DESCRIPTION COMP. VERIF. APPR. DATE

ENGINEERING COMPANY STANDARD

Documento riservato di proprietà di Eni S.p.A. - Divisione Exploration & Production.

Esso non sarà mostrato a Terzi né utilizzato per scopi diversi da quelli per i quali è stato inviato.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 2 di 49

PREMISE

Rev. 0 Pages 49

30/12/2004
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 3 di 49

INDEX

1. PURPOSE................................................................................................................................

2. FOREWORD............................................................................................................................

3. MAIN ac DRIVES TYPES........................................................................................................

3.1 POWER FEEDING SWITCHBOARDS 5
3.2 ASYNCHRONOUS MOTORS 6
3.3 STARTING SYSTEMS for 3PHASE ASYNCHRONOUS MOTORS 8

4. SELECTION CRITERIA & COMPARISON TABLE 39

5. SIMPLIFIED CALCULATIONS for SIZING and VERIFICATION 41

5.1 MAXIMUM ALLOWED NETWORK VOLTAGE DROP 41
5.2 VOLTAGE DROP CALCULATION 41
5.3 SELECTING the STARTING SYSTEM 43
5.4 EXAMPLE on VARIABLE SPEED DRIVE (VSD) APPLICATION 44
5.5 SUBMERSIBLE PUMPS DRIVES (ESP) 47
5.6 SYSTEM's SIZING 48
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 4 di 49

1. PURPOSE

Purpose of the present specification is to describe the various modes of driving for electric
motors as well as illustrate the guidelines for their use and applicability on both onshore
and offshore plants.

2. FOREWORD

Indications given hereinafter are to be intended as general and not ultimate indications on
the matter, since final solutions that will be chosen, have to be tailored on effective
engineering and technical-economical requirements; which nevertheless are part of the
Company’s proven plants traditions.
In defining the types of motor driven systems, called for in this document, the following
definitions apply:

DRIVE SYSTEM: group of electrical equipment suitable to provide and/or cut the power
supply, to protect, check and monitor start and running of an electric motor.
The drive systems may be grouped into the following main two categories:

• FIXED SPEED DRIVES: under this category, fall all those systems that connect the
electric motors to the power network; motor’s rated speed only depends upon the
number of poles.
Starting systems may be at full voltage (D.O.L. type) or at reduced voltage.

• VARIABLE SPEED DRIVES: under this category, fall all those systems that connect the
electric motors to the power network throughout equipment and devices capable to
electronically regulate either the frequency and the voltage of supply system, thus
adjusting motor’s revolution speed.

Several transmission systems, especially designed for installation between the motor and
the driven machinery, allow the motor’s speed regulation by means of proper RPM
reduction and/or increase speed devices availble on the market, eg differential systems
and/or oil operated couplings.
Nevertheless, these systems are based on the steady (constant) speed of the driving motor
thus not falling, for the purposes of this specification, under the category of variable speed
drives.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 5 di 49

3. MAIN TYPES of ac MOTOR DRIVES

3.1 POWER FEEDING SWITCHBOARDS

Electrical equipment to feed and control of motor drives, are generally located within the
distribution boards, installed indoor the plant’s electric cabin. In some cases, eg package
type supplies, said electrical equipment may be housed within proper boxes and/or local
panels, close to field users.
Depending upon the size (rated power) of motor to be supplied, the feeding switchboards
are subdivided as follows:
• “MCC” Motor Control Centre: it is a Low Voltage (LV) switchboard composed by a
number of drawers of various sizes, in withdrawable type execution. Drawers are
interchangeable with similar ones having equivalent mechanical and electrical features.
Rated power of electric motors supplied by this type of switchboards ranges from 0,25 to
0,55 kW.
• A more economical solution of MCC’s, denominated as “fixed execution”, in which the
motors control components are located within dedicated compartments instead of
withdrawable type drawers are also available on the market; this solution, obviously
requires more time spending for maintenance operations.
• “PC Power Centre”: it is still a Low Voltage (LV) switchboard which is normally used to
provide power supply to MCCs and other switchboards, as well as to electric motors
having rated power ranging from 55 kW up to 132 kW (in some cases motors with rated
power above 132 kW may also be supplied). In small size plants Power Motor Control
Centres (PMCC’s) are used, as constructive implementation of both PCs and MCC’s.
• “QMT”: it is a medium voltage switchboard which is normally used to provide power
supply to different type users, including electric motors having rated power 200 kW and
larger.
The voltage levels normally used for the power supply to electric motors, are as follows:
• 400 V, 3 phase, 50 Hz, for motors with rated power up to 200 kW
• 6 kV & 11 kW, 3 phase, 50 Hz, for MV motors with rated power 200 kW and larger

Small size motors (usually in the order of some hundreds watts), single phase supply at
230 V, 1 phase, 50 Hz, is normally used.
In compliance with regulations and laws in force to the country of installation, different
voltage levels and/or frequencies may be used
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 6 di 49

3.2 ASYNCHRONOUS MOTORS

Speed of asynchronous motors depends on frequency of the power supply network and the
number of poles of the motor itself. Said speed is very close to synchronous speed of the
magnetic rotating field, which is given by the following formula:

60 • f
ns= [rpm/min]
P
where
ns= synchronous speed
f= frequency Hz
P= number of pair poles

The difference between speed of rotation (nr) and the synchronous speed (ns), is known as
‘slip’ (S) defined by the following formula:
ns − nr
S=
ns
Slip of cage type asynchronous motors mainly depends upon motor’s constructive features
and the load coupled to it; the slip raises with the increase of the load itself, in accordance
to the characteristic curve shown in Fig. 1, below.
In rated conditions of power supply and load, the slip figure is normally ranging between
0,01 and 0,05.
The torque developed by an asynchronous motor supplied at rated voltage and frequency,
has not a steady value but it varies according to a typical curve which depend on the
motor’s slip (see Fig. 1).

Fig. 1
Representation of the torque related to the speed of cage type asynchronous motors
fed at rated voltage and frequency
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 7 di 49

In the above typical curve, the following ‘torque’ definition are given:
Cn: motor’s nominal torque, denotes the value for which the motor has been
designed and its own continuous duty guaranteed.
CM: maximum torque, denotes the value the motor can develop, that can
maintainable for short periods. Generally its value is about 200% of Cn.
Cs: “starting” or “locked rotor” torque, denotes the value developed during start
phase, when the motor is still idle. Its value mainly depends on motor’s
constructive features, the number of poles and the resistance of the rotor.
Cmin: minimum or stalling torque, denotes the value developed during start
phase. Its value mainly depends on motor’s constructive features.
Cr: denotes the resistant torque represented by the load coupled to the motor.
Ca: denotes the accelerating torque, that is the sudden difference between
starting torque (Cs) and the resistant torque (Cr)

Moreover in the Fig. 1, are also shown the following parameters:

S=1: Operation at slip figure equal to 1 (rotor stopped)
S=0: Operation at slip figure equal to 0 (rotor at synchronous speed)
Sn: Operation at rated load
Comments:
CM figure for a motor, is essential as it indicates the limit of steady-state operation thus the
speed range, from a determined figure of slip S1 to slip equal to zero, within which the
motor is capable, raising the slip, to adequate itself to increase of Cr.
Starting torque must in any case be higher than the resisting torque due to load coupled to
the driving motor or the motor will not be allowed to reach its rated speed, for all duration of
starting phase.
Figures relevant to both Cs and Cmin are very variable as they depend on rotor cage type;
in some cases Cs equals Cmin.
When a lower Cs is satisfactory, eg for users like fan motors where Cr raises with the
square of revolutions, it (Cs) can be remarkably smaller than Cn.

Mechanical power (Pm) supplied by the motor is given by the following relationship:

Pm = ω • C [W]
Where:

• ω is the speed of rotation, expressed in radiant per second

• C is the operation torque, expressed in N • m (Joule)

Electrical power absorbed by the supply network depends upon the efficiency of the motor
(η) corresponding to operating point, given by the following relationship:

Pm
Pe= [W]
η
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 8 di 49

3.3 STARTING SYSTEM FOR 3PHASE ASYNCHRONOUS MOTORS

In typical E&P electrical installations, the following motor drive types subdivided into starting
method, are normally used:
• Direct on line start [DOL] (fixed speed drive)
• Star-Delta start (fixed speed drive)
• Autotransformer start (fixed speed drive)
• Soft-start (fixed speed drive)
• Start and supply with both voltage and frequency variable (variable speed drive)

As it will become evident, all problems related to the start of asynchronous motors are
mainly connected to limit the starting current.
To do this it is necessary reducing the motor’s supply voltage by means of different
systems.
Reduction in supply voltage automatically reduce the Cs too which is essential to win the Cr
of the load.
To enable motor to reach its nominal speed it is therefore required that torque of the motor
be greater than Cr for all duration of the start.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 9 di 49

3.3.1 Direct On Line (DOL) Start System

Among diverse drives, the fixed speed drive is the most common used system any time
operating machines requiring higher starting torques are present, by the matter of fact, fixed
speed drive, is the sole system. Major advantages are given by reduced costs ( simple
construction as constituted by a single power contactor), reduced maintenance
(replacement of power contactor in case of its damage, as the sole, required intervention).
As already stated, with this type of start an elevated starting torque is available.

Motor start is made at full voltage, hence with full torque and starting current: starting
current is not limited.

Co-ordination among the protection devices and the drives equipment of DOL low voltage
motors can be found on any Co-ordination Tables provided-for by the Manufacturers of
various electrical components.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 10 di 49

- Based upon the size of the motor and feeding switchboard, the following typical
schemes are applicable:

TYPICAL 1 – STARTING from MOTOR CONTROL CENTER

QM Automatic circuit breaker with opening coil and the magnetic protection F-50, for the
short circuit protection.
K-42 Power contactor, device which switch ‘on’ and ‘off’ the motor from the electrical
supply.
F-49 Thermal relay. Device protecting the motor from overload. Depending on the driven
equipment, thermal relay may be suitable for normal service or heavy duty.

F-64 Devices for the protection of earth faults occurring on motor-cable and it is
constituted by a ring type current transformer installed within the MCC compartment,
or the outgoing cable from earth fault relay F64.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 11 di 49

PBS Push Button Station (LOCAL). It is normally placed close to the motor and is fitted
with switches and/or buttons depending on required duty. An ammeter is provided
for motors having rated power of 7,5 kW and larger.

REMOTE Process control connection to DCS (REMOTE). By means of this connection both
‘start’ and ‘stop’ of the motor, are controlled.

NOTE: Proper integrated type devices for the protection and control of the motors, are
available on the market (Compact Motor Protection). Such devices are constituted
by a combination of a circuit breaker, fitted with adjustable magneto-thermal
element and power contactor. Use of these systems in E&P plants, is limited to
local units supplied with packaged type equipment.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 12 di 49

TYPICAL 2 – STARTING from POWER CENTER

QM Automatic circuit breaker with opening coil and the magnetic protection F-50, for the
short circuit protection.

RELAY Generally a multifunction protection (may send/receive data from a hierarchical

upper system, for the management/supervision of electrical network).

PBS Push Button Station (LOCAL). It is normally placed close to the motor and is fitted
with switches and/or buttons depending on required duty. An ammeter is also
provided.

REMOTE Process control connection to DCS (REMOTE). By means of this connection

both ‘start’ and ‘stop’ of the motor, are controlled.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 13 di 49

TIPYCAL 3 – STARTING from MV SWITCHBOARD

52 MT circuit breaker (NOTE)

B-U Protection relay, command and switching (By-unit).

RTD Thermo elements, normally used to give alarm for high temperature, installed inside
the magnetic core, which house the motor’s windings. Some time signals of the
thermo elements are delivered directly to supervision/management system for
monitoring from remote Control Room.

PBS Push Button Station for field motor control

REMOTE Process control connection

RA Anticondensation heater

NOTE: It is possibile to use starters provided with fuses and contactor in lieu of the circuit
breaker for low voltage motors, having rated power up to 600 kW approx.
This configuration allows room saving, because of reduced switchboards
dimensions, as well as the ninvestment costs.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 14 di 49

3.3.2 Star-Delta Starting System

The most diffused system for starting of low voltage asynchronous motors, at reduced
voltage, is the ‘star-delta’ system (see figure 3).
System is used on L.V. networks when the DOL starting current is such to cause voltage
drop on the electrical feeding network.
As described herebelow, the use of DOL starting system does not fully solve the problems
caused by starting current which may sometime be worst.
For this type of starting motors to make available at the terminal board all ends of the
windings (6 terminals), moreover the motor’s rating voltage connected to delta to be the
same as the supply network (eg 400V - 50 Hz).
Star-Delta operatine principle (see single line diagram)
During start phase the motor windings are connected to ‘star’ instead of ‘delta’ (power
contactors K42 and K42Y are closed). Voltage level at the ends of every winding is 1/√ 3,
of the rated one; consequently the starting current circulating in the supply line is 1/3 of the
one obtained with a full voltage DOL starting system.
As soon as the motor has reached a given speed, only the ‘star’ contactor K42Y
automatically open while the ‘delta’ contactor K42D close, at this point windings are ‘delta’
connected and supplied at full voltage.
It should be noted that during run of motor having the windings connected to star also the
torque is reduced of 3 times (even less, usually it does not reach the 25% of the nominal)
so that it is necessary to verify said torque with the one of the load coupled to the motor
Moreover, the switching from star to delta may originate high harmonic currents which
anyway create problems in the supply network. For these reasons, application of the star-
delta starting system becomes less diffused.
The star-delta system can still be used for driven machinery having low starting torque or
off-load start.

Fig. 3
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 15 di 49

QM Automatic circuit breaker with opening coil and the magnetic protection F-50, for
the short circuit protection.

K42 Line power contactor (sized for a current equal at least to 58% of the rated value,
for starting times up to 20 s)

K42-D Delta power contactor (same as above)

K42-Y Star power contactor (sized to 33%, for starting times up to 20 s; if exceeding
usually it is equivalent to the others)

F49 Motor thermal protection (it may be installed downstream the power contactor K-42
instead of upstream, in this case relay setting must be reduced of √3 with respect to
full line current)

Disadvantages of the Star-Delta starting system compared with Direct start (DOL)
1. It needs three (3) power contactors (line: K42; delta: K42-D and star: K42-Y),
instead of one, and the use of two cables (even if reduced cross-section), instead
of one, with significant increase in investment costs; mainly due to larger O.D.
dimensions of feeding switchboards as well as the required room in electric cabin
(negative impact in offshore plants).
As a matter of fact, its cost is three times bigger than the direct start
2. Reduction of the starting torque (Cs) to 1/3 extendes time duration and often make
difficulty the motor starting. Besides the Cmin (reduced of 1/3 too), may be smaller
than Cr. Operators may sometime not be aware of lost star phase running as the
motor starts anyhow, following the switching from star to delta (operated by a timer
which is adjusted so as the start be completed in short time); under these
conditions the motor is started at full voltage
3. Passing from star to delta a short interruption of power supply, is being faced,
caused by contactors commutation. Closing of contactor K42-D can occur in
“counterphase” with consequent instantaneous inrush current whose level is higher
than the theoretical one, linked to ‘slip’ figure corresponding at the moment the
star-delta commutation takes place.
In case the conditions about lost start described at point 2. above are met, the
peak current due to star-delta commutation shall be equivalent to the starting
current performed at full voltage, to be furtherly increased if said commutation
occurs in counterphase.
It is therefore necessary to pay attention in designing/engineering star-delta starting
system: the choice of commutation time to be very accurate.
4. It is also not possible to select the starting characteristics, as the parameters are
pre-defined and cannot be adjusted
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 16 di 49

There is anyway the possibilità of drastically reduce peak current during switching from star
to delta and prevent motor deceleration, by unloading the current in eccess on proper
electric resistors, to connect before commutation (at the end of acceleration phase) and
disconnect once the commutation is completed (close transition system).
For this arrangement an additional fourth contactor (K42-D1) together with a transition
resistance R, have to be considered and provided (see schematic diagram below).
Switching from star to delta begins with the closing of K42-D1 which energises the
resistances R, followed by the opening of star contactor K42-Y; in this moment the motor is
connected to delta with the transition resistance R, connected in series with motor
windings, later delta contactor (K42-D) supplies the motor full voltage and disconnect the
resistances R (opening of K42-D1).
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 17 di 49

3.3.3 Autotrasformer Starting System

As for the star-delta system, the one with the autotransformer is used to start motors on
electric network that do not allow direct start system (DOL). Such a system can be used
for either low voltage (usually limited to rating power larger than 55 kW) and medium
voltage applications.
Use of autotransformer, enables to select/adjust the starting voltage in such a way that the
driving motor starting torque to be in any case bigger than the torque of the load coupled to
the motor.
Associated to this type of motor starting autotransformers with V2 output voltage equal to
approximately 75% of the nominal V1, are normally utilised. Besides, a series of taps
allows selecting the starting voltage between 65 & 85 % of V1.
During starting phase, see schematic diagrams below, the contactor 52Y of star point (can
be sized for a factor equal to 0,58 of the full power in AC-3 category) and the circuit breaker
52L (sized for the full power in AC-3 category), close. The motor is consequently started
with the V2 reduced voltage level.
After the motor has started, the circuit breaker/contactor of star point only are open and,
hence, closing by-pass 52L1 (sized in AC-1 category). During this switching there is no
interruption of the power supply to motor, thus avoiding problems caused by transient
counterphase starts and re-accelerations, faced with star-delta starting system.

Advantages of the autotransformer starting system:

• Starting torque even smaller than that of the direct start system (DOL), is adjustable
since it is possible to change/select the taps of autotransformer’s output voltage, in
function of load;
• With relation to direct start system (DOL), during starting phase at reduced voltage, both
starting torque and current on supply line are also reduced to a proportional value of
2
⎛ V2 ⎞
⎜⎜ ⎟⎟ , in a quadratic way.
⎝ V1 ⎠
Disdvantages:

• Investment costs, significant O.D. dimensions and equipment weights;

• Increased maintenance costs.

Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 18 di 49
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 19 di 49

3.3.4 Soft-Start Starting System

3.3.4.1 Operating Principle

It is a starting system of a static type, based upon the power thyristors technology (2 in
anti-parallel connection to each phase) which is capable to optimise the starting factors
of an asynchronous 3-phase motor, either on low voltage and medium voltage supply.
In this way soft and gradual starts through the partialisation of voltage performed by the
thyristors, are realized.
All static type starters are fitted with a control unit, microprocessor based, that manages
basic operations of the starter during both the starting phase (Soft-Start) and the motor
stopping (Soft-Stop) - by adjusting supply voltage at the terminals in such a way that it
gradually increases or decreases - even at full rating by optimising operative parametres
(Energy-Saving described below).
A specific protection system inherent with the soft-start, provides the following main
facilities: thyristors failure, phase loss, non-symmetrical phases and starter overload.
The same protection system also takes care of stopping the motor and cut the starter off
as soon as possible failures could raise.

Base starter’s operating cycle, can be subdivided into three different steps:

Phase I – Starting ramp (Soft-Start)

Starting sequence
Phase II – Operation to rated voltage (Dwell-Time)

Working rate Phase III – Likely operation at reduced voltage (Energy-Saving)

Basic Operating Principle

A voltage supplied at the motor’s terminals identified as: “voltage beginning ramp”, allow
the motor itself to get the torque necessary to start it.
Ramp duration, variation of the above voltage beginning ramp to rated voltage, is
adjustable according the needs and it is normally ranging between 0,5 and 60 sec.
The normal value of “voltage beginning ramp” is about 40% of the rated one. It is
possible to regulate such a value on the nature of load.
It is however necessary to point-out that with a high value of the voltage beginning
ramp, many of the beneficial effects proper of a static type starter will be lost; since
motor starting would almost be similar to the direct (DOL) system.
On the contrary, any attempt to lower the beginning of voltage ramp below the 40% of
the rated one, could make unlikely to bring at its rate or start the motor, keeping into
consideration that the torque provided by motor itself varies in a quadratic mode at the
voltage varying, thus risking to be lower than the resistant torque.
The current absorbed during the acceleration phase, mainly depends about the time set
for the duration of starting ramp itself. The peak current achieved at acceleration, is as
much as higher as short the time starting ramp is.

A “natural” time duration for starting ramp, associated to every motor/user, applies:
this time is tied with both inertial and mechanical characteristics of the system it self.
If duration of starting ramp is shorter: system’s acceleration increases together with the
absorbed peak current value.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 20 di 49

If duration of starting ramp is longer: the system, obviously, requires more time to reach
its full speed rate, but absorbed current value is reduced.
This phenomenon is generally advantageous, providing that (keeping into consideration
the system application in its whole) unacceptable operating condition due to speed rate
that is reached later, is determinated. It is necessary to consider presence of possible
other machinery or systems, whose operations are connected to that one in subject.
Starter’s managing software may be in any case tilored on operating features of the
user, which need functionalities or performances outside of normal applications.
Soft-starters may be provided with the following additional functions/features:
• starting ramp with control and limitation of starting current (Current-Limit)
• dwell-time
• energy saving
• the OVERRIDE to cut both energy saving function and malfunction supervision
system
• by-pass system
• soft-stop or control stopping ramp.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 21 di 49

3.3.4.2 Starting ramp with current-limt control

This function allows checking current absorbed by motor in such a way that pre-fixed
value is not exceeded.
As already described if the pre-fixed ramp would be too steep in relation to inertia of the
motor/load, absorbed current could reach values similar to that of direct starting (DOL).
Current-limit function continuosly monitors the current absorbed during starting phase
and provide, if necessry, to momentarily stop the voltage ramp, ready to restore it when
the current falls bellows the maximum pre-fixed value caused by the motor’s increased
speed.
Current-limit function is normally associated with a protection for stall or locked rotor.
If the ramp would be stopped for a time bigger than an adjustable control step, once the
time is expired, the soft-start equipment gives an alarm and cut off the power supply; or
stops the starting phase supplying full voltage to motor terminals (DOL)

3.3.4.3 Dwell-Time
Dwell-time starti begins at the moment the starting ramp is stopped and at the motor
terminals the full voltage is supplied.
The pause period has a time duration equal to duration of the starting ramp.
During the pause period, at the motor terminals the full voltage is steadely maintained:
the purpose is to give motor and load, time and manner to reach stable operating
conditions.

3.3.4.4 Energy-Saving

Energy-saving function regulates the motor supply on the effective load condition so
allowing energy saving. It is automatically actuated and remains continuosly running
for all the time ranging between expiring of Dwell-time and the moment the STOP
control is given.
During the starting ramp, the system’s software calculates a reference value for the
‘power factor’ (full load cosϕ).
For all the time the energy-saving function is ‘on’, the instant value of power factor
(cosϕ) is continuosly monitored with the above mentioned reference value. Result of
such comparison is used by microprocessor of the system to modulate the soft-starter’s
output voltage to effective motor instant torque demand, without wasting energy
required to generate an excessive and useless magnetic flux within the motor. This
way, allows power factor (cosϕ) to motor terminals be maintained at the highest possible
value, in function of effective power demand (load conditions).
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 22 di 49

The described power factor management does not affect the motor capabilty to supply
the power required by load. Motor performances (together with its own speed) are in
no way involved. Energy-saving function is a purely electrical function, which simply
assures that – in every moment – motor to generate the required torque, but enabling it
to absorb a quantity of magnetisation current necessary to sustain such a torque only.
If energy-saving function is lost, the motor would absorb the maximum magnetisation
current instead, in a way not dependant from its own load status. Final purpose of
energy-saving function is, globally consedered, to reduce electric energy consumption.
Energy-saving function cannot improve the power factor (cosϕ) and rise it to values
bigger than full load ones, as such value depends on constructive features of the motor.
It is therefore wrong to affirm that the static type starter owns the characteristics of a
power factor improvement equipement.

3.3.4.5 OVERRIDE and BY-PASS Function

For diverse reasons, in some operative applications, may be necessary - once the motor
has started – to disconnect the Soft-Start from electrical supply, by operating a By-Pass
(throughout proper power contactor when non already provided as part of the soft-start
device itself) thus leaving the motor is directly supplied by the mains. Every time a
static type is by-passed but not disabled, it becomes essential to exclude either the
Energy-Saving function and the inherent protection equipment as well.
Whole by-pass of the soft-start device is put into action on all motors devoted to plant
safety (eg: fire fighting pumps).
Where normal dissipation of heat generated by soft-starter could be a problem, the
starter’s by-pass is usually foreseen.
As an example, the above condition applies any time the static starter is installed within
an enclosure or a board with high mechanical degree of protection and where no
specific ventilation facilities are foreseen; indeed the advantage achieved is that a
significant source of heat generation, is removed from the board.
For sake of information a soft-starter suitable for motor 75 kW, 400 V, dissipates 500 W
approx. at rated load.

3.3.4.6 Soft-stop or progressive stop or controlled

Result of PROGRESSIVE STOP function is to avoid a sudden unwanted deceleration of
the motor/load torque, typical consequence of stopping the motor made by simply
disconnecting it from power supply (non-direct stop), in this way motor slow down up to
complete stop in a time that is related to its own inertia moment and the actual frictions.
When pumps are the driven equipment, the rapid stop of motors has to be absolutely
avoided. Everybody knows that the rapid stop of impellers creates in the piping the
phenomenon defined as “water hammer”.
In pumping systems any time sudden changes in flow arise, peaks or change in
pressure occur. Many mechanical methods to reduce said effects are available, but
they are costly and difficult to handle.
Use of a softstarter equipped with controlled functions for start and stop, can be
considered a very good low cost solution. As flow of the liquids is proportional to the
speed, utilising electric systems with DOL type starters, a faster acceleration of the
pump is achieved.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 23 di 49

Keeping into consideration that fluids have low attitude to be compressed but have
kinetic energy, rapid change in flow in a so short time can originate high pressure
strokes that put into hard test the pipe walls, which some time blow up (“water
hammer”). In order to avoid said dangerous effect modern softstarters are often
integrated also with a facility called “Pump Control”. It consists in performing both start
& stop by a special and controlled mode; in such a way torque of the motor match
completely the one of the pump, thus minimising either accelerating and decelerating
torques, hence the water hammer.
Above results is achieved thanks to special microprocessor provided with softstarter
having this function. As a matter of facts if water hammer is reduced by the use of
a simple controlled stop function, it is almost totally eliminated by the use of
pump control.
Controlled stop may be performed at any time after the acceleration ramp is over: even
with the softstarter by-passed.
Normal time duration of Soft-Stop ramp, is equal to twice the time duration set for Soft-
Start ramp.
Once the ramp for CONTROLLED STOP is activated, supply voltage at the motor
terminals is lineary decreased, beginning from full voltage (source of power supply) up
to a voltage value equal approx. to 40% of full one. When reaching such a voltage
level, the power connection is being automatically disabled and the unit motor/driven
equipment stops by inertia.
In no cases Soft-Stop function is to be considered - and therefore used - as a motor
brake. Emergency braking is to be redundant and of a mechanical type, in full
accordance to the rules and safety codes in force.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 24 di 49

3.3.4.7 Use of soft start for more motors

When several motors in the same plant have starting difficulties, it is feasible, by utilising
the schematic diagram represented below, to use a single Soft-Starter system (as
alternative a second one ‘spare’ can be provided) suitably sized on the larger load/user
then with a power contactors/circuit breakers system, arranged and wired so as to start
in a required sequence all remaining motors.

Main advantages of the softstart are summarised here below:

• Opimisation of starting phase (gradually and no rapid accelerations) to better tailor it

to requirements of installation. Data of starting (voltage supply ‘V’ and time for start
or acceleration ‘Ta’) are selectable by the operator;

• Mechanical stress (and related wear) of both motor and driven machinery, limited;

• No peak current at start;

• Maintenance free (as electronic type);

• Often fitted with energy saving function;

• Good adaptation of the mechanical characteristic and absorbed currents to the

conditions of installation;

• Soft-stop and pump control functions capable to generate significant benefits in some
applications;
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 25 di 49

• Possibility to connect the softstart equipment to a communication bus, thus

performing remote control of the same.

Against above advantages, their main disadvantage is the high cost.

3.3.5 Power supply and starting with Variable Frequency

In industrial plant applications where it is necessary to vary speed of electric motors driving
pumps, fans, mills, etc. the use of asynchronous type motors coupled to double conversion
static frequency converters (from a.c. to d.c. and again from d.c. to a.c. variable & voltage
frequency) provide a technically faster and profitable solution.
Furthermore the static frequency converters, mainly the PWM type (see next paragraphs),
have reached a high degree of reliability together with the best results to both efficiency
(98% approx.) and cosφ (>0,95).
Variable frequency drive primarily allows continuous adjusting of the speed thus enabling
precise positioning of the system on the best working point related with the effective
operating conditions.
In such a way an adequate energy saving is matched too.
The motor’s operating field may range from minimum frequencies of few Hertz up to a
maximum of twice the rated one.
Operative limits are given by motor Manufacturer which keeps into consideration the
cooling conditions, when working at low rate and mechanical restrictions of the rotor, when
running at high speed.
Drive unit in its whole is a multipart equipment that include use of power semi-conductors
components.
Besides, an aspect of great importance that sometime requires the utilisation of variable
speed drives even when the speed regulation would not be strictly needed, is that such
drives make possible to start motors assuring nominal torque for all operating phase with a
maximum current equal to the rated one
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 26 di 49

3.3.5.1 Regulation principles and operating features of the drives

Drives in subject are based on the principle that changing motor’s supply frequency a
speed variation is achieved.
For the above features they are defined Variable Speed Drives (VSD) and to this purpose,
proper inverters are utilised to provide power supplies with voltages and frequencies at the
required levels.
Two different types of regulation are available: in the lower frequencies field, “at constant
magnetic flux (constant torque)” and in the higher frequencies field, “at constant power”.
Actually the torque of an asynchronous motor, is strictly related in a proportional mode to
the magnetic flux induced in the stator of motor itself, therefore with different power supply
conditions, if the magnetic flux is maintained constant, then torque’s figures with equal
maximum values are achieved.
C≡Φ
since, in turn, the magnetic flux is related to the expression:
V
Φ≡ ,
f
hence if the supply voltage is adjusted proportionally with the frequency, the magnetic flux
is maintained at a steady value, whereas the power will proportionally vary with speed.
Such a proportionality between voltage and frequency will remain steady throughout the
regulation range of VSD, from the minimum value to the motor’s (to which the rated voltage
matches) - lower frequencies field -
Over this limit (rated frequency) it shall be possible to furtherly increase the frequency up to
2 to 3 times its rated value, but keeping fixed the voltage at its own rated value, in such a
way the rotor does not over heat because of bigger iron losses.
In this range either the flux and the torque decrease as the frequency and speed increase
correspondingly, whilst the motor runs and works at constant power.

Summarizing, two functioning fields are thus available (see figure 2).
1) Operation at constant torque:
- regulation field ranging between minimum frequency and the rated one (lower
frequencies), whereas the magnetic flux remains at a constant value,
- in this field we obtain a regulation with power proportional to speed.
2) Operation at constant power:
- regulation field ranging between rated frequency and the maximum one, range in
which the voltage remains at a constant value,
- in this field the magnetic flux and the torque decrease as the speed rises, whereas
the power remains at a constant value.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 27 di 49

Fig. 2
a) curves of the voltage ‘V’ and the power ‘P’ with reference to frequency;
b) curves of the torque with reference to frequency.

NOTES: 1) The performances described above can be achieved theoretical only, in

practice the curve of torque does not remain steady in the field ranging
between minimum frequency and the rated one, but gradually decreases as
the frequency decreases. This is due either to reasons of motor cooling (the
less is the speed, the less is the flow of cooling fluid) and for the presence of
harmonic content in the inverter’s output voltage, that induce a heating in the
motor bigger than normal.
2) It is important to note that within the operating field at constant torque
(equivalent to starting ramp too) the motor absorbs “at large” its own rated
current.
Nevertheless on power line side, the current will be lower and depending on
the ratio VU / VN
where:
VU is the VSD’s output voltage
VN is the motor’s rating voltage
The above is applicable for VSDs of the PWM type (see next paragraphs)
which are the most largely utilised.
This aspect is very useful for the plant and makes VSD the best solution for
drastic reduction of starting currents in electric motors.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 28 di 49

3.3.5.2 Available Drives types

3.3.5.2.1 Basic types
Variable Frequency Drives (VSD) are installed within enclosures and are mainly composed
by the following sections:
a) power supply incoming section, complete of switching devices (circuit breakers,
switches, power conctactors, etc)
Supply of VSDs is usually by a.c. 3phase, low voltage for rating powers up to 200 kW
approx.and medium voltage for rating powers up to 50 MW and larger.
With the incoming section a transformer can be foreseen. The transformer is normally
provided with medium voltage drives.
The transformer provides the following facilities:
1) to adjust the supply voltage of a network to rated values proper of the VSD a/o the
motor.
2) possibility of realizing a 12phase rectifier system at 12 pulses, as described here
below, so in this case the transformer is to have three windings: one primary and two
secondaries.
The two secondary windings will have different vectorial groups in such a way to
make available two 3phase lines dephased 30° between them.
b) rectifier section for the supply voltage from a.c. to d.c.
In function of the VSD constructive feature, rectifiers may be constituted by
- controlled diodes (tyristors) connected in 3phase bridges, or
- non-controlled diodes, or
- 3phase bridges composed by three tyristors and three non-controlled diodes

In big drives, where an incoming transformer is provided to achieve the 12phase rectifier
system at 12 pulses, two separate rectifier bridges: one on each winding, are installed.
c) filter circuit and d.c.rectifying
The components of circuit (reactances, capacitors, choppers, etc) sized in function of
VSD type, have the purpose of filtering and rectifying the current in order to allow correct
operation (on and off) of the inverter section.
d) current reverting section from d.c. to a.c. (commonly called inverter) and regeneration of
the power system (3phase, 1phase, etc).
e) control circuit that allows to modify and monitor both voltage and frequency values
coming from inverter, as well as the cycles of regenerated phases.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 29 di 49

6 PULSE RECTIFIER SYSTEM

Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 30 di 49

12 PULSE RECTIFIER SYSTEM

Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 31 di 49

3.3.5.2.2 Main VSD typologies

Depending on technology and components utilized in the fabrication of drives, VSD can
be subdivided into the following main typologies:

a) Impressed current
This system deals with the use of tyristors in the rectifier section, which are
controlled by a circuit that measures the current output towards the user and try to
maintain it at a preset value.
Frequency is adjusted separately within inverter section.
In the impressed current VSD, reactance of motor is a parameter of the control
oscillating circuit that allows the inverter section to work.
Therefore value of said reactance, including the motor connecting cable, to be
known in order to “tune” the system.
Consequently the system is suitable to feed a single motor only, with known
parameters, besides cross-section area and length of the cable have to be already
defined during VSD purchasing activity.
This range of VSD is utilized for large motors only having rating sizes of 15 to 20
MW and over.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 32 di 49

b) Impressed voltage
This system deals with the use of tyristors in the rectifier section, which are
controlled by a circuit that measures the voltage output towards the user and try to
maintain it at a preset value.
Frequency is adjusted separately within inverter section.
The impressed voltage VSD in relation to motor performs as a 3phase voltage
generator.
Besides, if compared with the one “at impressed current”, in which main motor
parameters have to be carefully checked, with the impressed voltage converter the
control circuit is not influenced by motor’s parameters.
This range of VSD is utilized for large motors only having rating sizes of 15 to 20
MW and over.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 33 di 49

c) P W M (Pulse – Width – Modulation)

This system deals with the utilisation in the rectifier section of a simple diodes
bridge so as the d.c. system remains at constant voltage, while the reverting unit
is set in such a way to adjust either the frequency and the output voltage
towards the user.
Within the reverting (inverter) section it is foreseen the use of IGCT type
tyristors (Integrated Gate Commutated Thyristors) or IGTB type transistors
(Insulated Gate Bipolar Transistor) to which the following parameters are kept
continuously controlled:
- number of impulses (electic conductivity) per cycle,
- impulse duration,
- pause between an impulse and the successive,
- polarisation of impulses.
From the combination of above parameters the effective corresponding values of
required frequency and voltage are achieved.
The VSD with PWM facility in relation to motor performs as the converter at
impressed voltage.
This range of VSD is the most utlised utilized either in low voltage and medium
voltage for motors having rating sizes of 15 to 25 MW.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 34 di 49

3.3.5.3 Commands, regulation and protection of the drive

The operating feature of variable speed drives is evidentiated by two regulation

fields:
- the one at constant torque where voltage and frequency vary proportionally from a
minimum to a maximum
- the other one at constant power where voltage remains steady while only frequency
increases.
Knee point of the curve, that is the working limit at constant torque, is denominated BEP
(Break Even Point) or Field Weakening Point.
By defining said point the working characteristic is defined too and consequently all
related output values of frequency and voltage from the VSD.
At this point it is enough to vary the working frequency of motor to get a consequent
voltage variation up to BEP point.
The control devices foreseen on VSD allow the following operations:
- Setting of the BEP (or Field Weakening Point)
- Motor starting
- Motor stop
- Motor speed variation
- Command for reverse rotation of motor (when requested)
- Selection for manual/automatic speed adjust
* manual ad just is performed by operator acting on buttons provided-for on the
board or from an external signal. Once the value for running speed has been
set, the system auto-adjust itself to keep pre-set value with automatic control of
motor’s torque (vectorial control of the flux), based on assessment of working
parameters of the same (frequency, voltage, current, power factor).
* automatic adjust is performed on the basis of an external analog signal (encoder
mounted on motor, or flow transmitter or pressure, etc.) which is compared with
a set value, adjustable from the board. This type of regulation is applied when
a very high precision of motor speed is needed even at low velocity ratings, or
when it is necessary to keep flow and pressure of a line in a steady condition.
- Selection of local / remote commands
* in ‘remote’ position all commands for set, start, stop, etc, are transferred to an
external location.
- Emergency stop
Drive is equipped with its own electrical protection system which operate either for
internal and external faults. In particular the following protections are provided:
- maximum current and overload
- minimum and maximum voltage
- earth fault
- tyristors a/o diodes failure
- integrated type motor protection: stall, locked rotor, max. temperature (detected by
temperature sensor built-in with the motor)
- reverse sequence, etc.
Furthermore the VSD intrinsic control system fits facilities for monitoring, measure,
alarm, events recorder, etc. that enable operator to know time-by-time the motor’s
running conditions hence to analyze origin of possible failures.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 35 di 49

Generally within the VSD control system communication ports are provided in order to
allow connection of the drive to the plant’s management and control network (DCS) thus
transferring commands, measuring and controls to hierarchies of upper grade levels.
As an optional, VSD may be provided of a by-pass to allow power supply to motor in the
event of failure of the drive; in this condition by-pass effectively performs as a direct
starter.
Again the VSD can be switched off when motor has reached its speed rate to frequency
of the network so as to cut-off the drive form maintenance a/o energy saving, in this
case allowing the by-pass to close, the system is provided with a synchronizer between
the network and output voltage from VSD.

3.3.5.4 Harmonics and Reactive Power

3.3.5.4.1 Harmonics

Variable speed drives, as all equipament which utilize semiconductors, generate

harmonic content, within supply network.
Value of harmonic content expressed in percentage with respect to fundamental current
(at 50 Hz or 60 Hz), together with the harmonic n, (which is the ratio between frequency
of the harmonic itself and frequency of the system), depends on the drive type and from
the VSD’s working point.
In detail the harmonic contenti is strictly connected with number of phases a/o number
of pulses of converters.
Said number mainly depends on how the VSD power incoming and rectifier sections are
realized.
Generally for applications on low voltage networks, where an incoming power
transformer is not foreseen, the systems are 6phase (p = 6); if, on the contrary, an
incoming power transformer is foreseen, the systems can be 6phase (p = 6) if
transformers have two windings or 12phase (p = 12) if transformers have three
windings.
Number of phases or pulse corresponds to the number of rectifier diodes:
- 6 in the above first case, equivalent to classic 3phase rectifier bridge;
- 12 in the above second case where the two secondary windings of transformer
(dephased 30° between them), supply each a 6 diodes bridge.
With more sophisticated power supply systems using transformers having vectorial
groups properly dephased, it is possibile on special applications, to achieve systems
with p = 18 and p = 24.
The following order of harmonics are present:
n=kxp±1
where k is a number variable from 1 to ∞.
In 6phase systems (p = 6) harmonics of following orders can hence be expected:
5; 7; 11; 13; 19; 23; 25; 29; 31 etc.
In 12phase systems (p = 12) harmonics of following orders can be expected:
11; 13; 23; 25; 35; 37; 47; 49 etc.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 36 di 49

Theoretically, the value of harmonic content expressed in percentage with respect to

fundamental current referred to every order of harmonic outcomes from the relationship:

1
⋅ 100
n

Where n is the related order of harmonic

Converters p = 6 will therefore induce on network the following harmonic content:

20% for 5a
14,3% for 7a
9,1% for 11a
7,7% for 13a
5,88% for 17a
5,26% for 19a
etc.
Converters p = 12 will induce on network the following harmonic content instead:
9,1% for 11a
7,7% for 13a
4,35% for 23a
4% for 25a
etc.
In practice the value of harmonic content will be defined by Manufacturer on the basis of
constructive features and the damping foreseen in VSD.
Values to be requested and considered durino offers evaluation.
Effects of harmonics on supply networks depend on short circuit power of the network
itself.
Effects of harmonics are negligibe if short circuit power is very great.
On weak networks or anyway where the ratio between rated power of VSD installed and
short circuit power is not negligibe (> 4 ÷ 5%), harmonics can induce distortions on
supply voltage and may jam a/o damage other equipement connected on same network
(capacitors, motors, control devices, etc.).
It is necessary that total harmonic distortion factor (THD) of the supply voltage network
generated by running VSD units and any other rectifier system installed in the plant is
less than 3%.
In order to limit harmonic content on the network it is possible to utilize suitable filters on
output voltage, their elimination will be as easy as their frequency is higher.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 37 di 49

In the case said distortions are unavoidable (eg very weak networks) it is possible to
reduce impact with the installation on same network feeding VSDs of properly sized
capacitors/reactors banks.
Use of PWM regulation, is possible contain problem of harmonics yet; it is likely to
obtain an output voltage with fundamental sinusoidal component containing high
frequency harmonics, hence easily filterable. In accordance to EMC Directive, to
reduce nuisance emissions on the network and the surrounding environments, speed
drives are provided with EMC inlet filters.

3.3.5.4.2 Reactive Power

Reactive power absorbed by VSD mainly depends on type of rectifier utilized into
conversion and rectifier section.
In PWM where rectifier section is composed by diodes, cos φ is practically steady over
all working field and is about 0,95 to 1.
Obviously such cos φ is referred to fundamental current.
Again to this type of drives it is not necessary to provide power factor improvement
systems.
In impressed current a/o voltage drives, power factor is quite low (0,7 to 0,8) and
variable in relation to working rating.
Therefore, if the impact of VSD on the network is significant, it may be necessary to
provide power factor improvement, keeping into account presence of harmonic
components, which could damage the capacitors if not adequately tuned with
reactances.

3.3.5.5 VSD installation

3.3.5.5.1 Location

VSD drives are usually installed within dedicated eclosures/boards. For small power
units (low voltage) up to 30 to 45 kW can be housed inside dedicated section of power
distribution boards (MCC; PMCC).
The transformer of cabin.
Special care to be paid to cooling problems of VSD; for the sizing of ventilation and
conditioning systems of the cabins it is necessary to consider that power dissipated by
VSD is 4% of their own rating power.
Some times for lager units the cooling of VSD is nade with de-ionized water for which it
is necessary to define location of relevant heat exchangers.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 38 di 49

3.3.5.5.2 Use of VSD for motors in hazardous areas

With VSD used to drive motors installed in hazardous areas, it is necessary that motors
in addition to Ex excecution suitable for specific installation are also provided of
temperature detectors to cause cut-off of power supply to motor as soon as the
maximum admissible temperature is reached.

3.3.5.5.3 Power feeling cables

Except on applications of submerged pumps (ESP), where length of cable can be

considerable (some thousands of meters) in which cable supply, of a special type, is an
integral part of package Pump-VSD-Transformer, for other plant applications it is
required that length of cable connecting the drive with the motor is the shortest possible:
50 m approx., for bigger lengths an inductance coil between the drive and motor feeding
cable is to be installed in order to avoid nuisance causes to the system. Maximum
admissible lengths of cables even with the association of said coils are specified by VSD
Manufacturers
To avoid EMC problems to other electric system the cables sould be of a shielded type.
Three core armoured power cables are already adeguate.
For large power systems where single core cables could be used, the supplier of VSD is
to be contacted.

3.3.5.5.4 Motors

Motors for VSD applications must be suitable for the working rate; it is appropriate to
specify the speed variation field to which the motor is submitted in order to assure
proper ventilation even to low revolution (rpm) rates. Besides, as the shape of output
voltage from VSD is not perfectly sinusoidal, in order to compensate bigger losses the
motor is oversized of approx. 10%. Some time harmonics can originate an increase of
motor’s sound level.
In extremely precise speed regulation system devoted to special working cycles only,
motors could be equipped with encoder for the right transmission of revolutions.
As already described for installations in hazardous areas, motors to be fitted with
suitable probes to avoid overcoming of maximum admissible temperatures (varistors,
thermostats, thermo-resistances, etc.), besides to limit induced currents on the shaft one
of the bearings is isolated.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 39 di 49

4. SELECTION CRITERIA AND COMPARISON TABLE

In following Table one the main characteristics relevant to different typologies of electric
motor drives previously described, are summarized.
It is to be noted that in general the best reliability of electric plant and the drives too, is
achieved by the use of as simple as possible equipement and devices. Under this side
direct start (DOL) is the winning one for its own low cost, reliability system’s simplicity
and its applicability is generally diffused in both low and medium voltages.
Nevertheless, when network condition impose starting current limitation, it is required to
use motor starting system at reduced voltage.
Among these systems the star-delta one is to be avoided because it does not give
resolutive solutions to the problem of starting current, indeed during commutation
between star and delta the re-connection current can be bigger than that of direct start
(DOL).
VSD system is the best system under the technical profile thus offering also the
opportunity to regulate the motor working speed, on the contrary it is much expensive.
The starting system with autotransformer is undoubtly the most proven and proposed
due to need of start motors at reduced voltage, in both low and medium networks.
Soft-start system, imposes itself on the market as it offer a large range of different
functions for the control of motor. Anyway its application in controlling start of medium
voltage motors is not largely diffused yet.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 40 di 49

TABLE 1

STARTER MAIN COST ESTIMATION

LIMITATIONS APPLICATIONS
TYPE CHARCTERISTICS (motors excluded))

Simple construction, as Not advaisable to start big All asynchronous motors L.V. feeders (PMCC).:
constituted by a single motors on weak networks, with fixed speed. - 37kW ~ 1.000 $
power contactor. e.g. when the motor starting - 75kW ~ 1.400 $
DIRECT START Reduced maintenance. causes a network voltage - 132kW ~ 1.800 $
(DOL) Very high starting current. drop >=15% M.V. feeders (MVP) 6kV
Nominal characteristics of - contact + fus. 15.000 $
motor torques. - circuit breaker 25.000 $
System composed with Usable only for application To start motors on weak L.V. feeders PMCC):
three contactors and control where is requested a low network. - 37kW ~ 2.000 $
circuit with time relays. starting torque. The current during star- - 75kW ~ 2.600 $
STAR-DELTA Significant maintenance. delta commutation can - 132kW ~ 3.500 $
Reduction of starting current be higher than DOL
to 1/3 starting current.
Reduction of starting torque UNADVISABLE
to 1/3
System composed with The starting torque is Used to reduce the L.V. feeders PMCC):
three contactors, an reduced in relation with the voltage drops during - 37kW ~ 3.000 $
autotransformer and control square of starting chosen motor starting on weak - 75kW ~ 3.800 $
AUTO- circuit with time relays. voltage. networks. - 132kW ~ 5.200 $
TRANSFORMER Significant maintenance. To define characteristics of System used also to
Reduction of starting torque autotransformer is necessary start big motors. M.V. feeders 6kV
according to the a torques analysis. At medium voltage is - contact + fus. ~ 800kW
autotransformer output preferable than soft-start ~ 50.000 $
voltage. method. - Circ. brk ~ 1÷5000kW
Commutation between ~ 80.000 $
reduced voltage to nominal
voltage without interruption.
System based upon power In case of need of very high To start motors on weak Cost estimation for L.V.
thyristor technology with starting torque, the limitation network. drives, PMCC equipment
variation of output voltage. of starting current is not Allows to eliminate included.
Allows the soft satrting of significant. “water hammer” durino - 37kW ~ 3.000 $
motor limiting the starting start up and stop of the - 75kW ~ 5.000 $
current to a value necessary pumps. - 132kW ~ 7.000 $
SOFT-STARTER
to cope the resistant torque. The application of soft- Cost estimation for M.V.
Allows also the soft stop starter system is drives, MVP equipment
procedure and the partial advisable only for low included.
energy saving. voltage. - ~ 1800 kW ~ 70.000 $
- ~ 3600 kW ~ 75.000 $
- ~ 5000 kW ~ 85.000 $
System based upon power No limitations. Usable for all motors Cost estimation for L.V.
thyristor technology with Probable need of harmonics (synchronous and drives, PMCC equipment
output voltage and filtering system in case of asynchronous) with included.
frequency variation. Allows installation on weak network. power from fractions of - 37kW ~ 16.500 $
the soft start and soft stop of kW up to 50 MW and - 75kW ~ 19.000 $
the motor, and the running above. - 132kW ~ 42.000 $
VARIABLE
with speed variation.
The starting current is Cost estimation for M.V.
SPEED drastic reduced (maximum drives, MVP equipment
equal to motor rated included
DRIVE current). -for 350kW – 690V and
No limitation of the nominal input transformer
torque characteristic of the 6000/690V ~ 95.000 $
(VSD) motor.
Allows energy saving during -for 2000kW – 6kV and
the motor running, and also input transformer with two
the kinetic energy recover secondary windings
during motor stop phase. ~ 300.000 $
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 41 di 49

5. SIMPLIFIED FORMULAS FOR SIZING AND VERIFICATION

5.1 MAXIMUM VOLTAGE DROP ADMITTED IN A NETWORK

In order to guarantee service continuity is necessary to limit the voltage drop in the
network every time a motor is started by utilizing one of the diverse starting methods.
Maximum voltage drop (∆U) tolerated in a plant, depends from installed loads/users
(motors, resistances, lighting, etc.). Normally for motors the admitted ∆U depends on
the maximum torque CM of motors themselves. Infact, if a running motor is loaded with
a resistant torque Cr equal to nominal torque Cn, a lowering of admitted voltage, which
as known originates a quadratic lowering of the torques, must be such that in any case
the new value of CM is bigger than resistant torque otherwise the motor would stop.
Even if generally motors guarantee CMs higher then 2•Cn, yet the Rules establish
minimum values of 1,6•Cn for motor of standard production and 1,5•Cn for motors
having reduce starting current (large motors).
Admissible maximum voltage drop comes from the following relationship:

Cn
∆U< (1 − ) • 100 (%)
CM
Thus replacing CM=1,5•Cn, a ∆U<18 % is obtained.
This is maximum voltage drop value to motor terminals. If voltage drop on supply cable
equal to approx. 3 to 5% is considered, together with a greater current absorbed by
motors caused by the lowering of voltage, the voltage drop tolerated in the network must
normally be less then 10 to 14%.

5.2 VOLTAGE DROP CALCULATION

Apparent starting power absorbed by a motor comes from the following relationship:

SAVV= U • 3 • I AVV

Voltage drop at starting depends on short circuit power SK3 af the network and it is given
by the following relationship:
∆U=100/(1+SK3/SAVV) (%)
Short circuit power SK3 to keep into account is that of the network without considering
motor contribution. For networks supplied by their own generator, short circuit power
determined by transient reactance (X’d) of generetor is to be considered instead of the
subtransient one (X”d). As a matter of facts either the subtransient reactance and the
asynchronous motors contribution ends in few cycles, without significantly contributing
to sustain voltage of network

1. Example
Network 400 V supplied by a transformer Srt=800 kVA; Ucc=5%; short circuit power on
primari side SK3 = 100 MVA.
Motor to be started: 132 kW; In = 232 A; ISTART = 7,1•In
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 42 di 49

Short circuit power downstream transformer is:

SK3 = Srt/(Ucc+Srt/SK3) = 0,8/(0,05+0,8/100) = 13,8 MVA
Motor starting power is:

S AVV = U • 3 • I AVV = 400 • 3 • 232 • 7,1 = 1141kVA = 1,14 MVA

400 V network voltage drop at motor starting is:
∆U=100/(1+SK3/SSTART)=100/(1+13,8/1,14)=7,63%
Motor can be direct starter (DOL).
If the transformer would have been 400 kVA, SK3=7,4MVA, voltage drop at starting
would be:
∆U=100/(1+7,4/1,14)=13,35%
Above value is at the acceptability limit so that in function of the plant criticality, a choice
on maintain direct starting (DOL) or a different system,is to be made.

2. Example
Network 400 V supplied by a 900 kVA generator with subtransient reactance equal to
X’d=19%.
Motor to be started: 132 kW; In = 232 A; ISTART = 7,1• In
Network transient short circuit power supplied by the generetor itself is:
SK3 = 100•Srg/X’d=100•900/19=4737 kVA = 4,7 MVA
Motor starting power as already calculated in example 1 above, is 1,14 MVA, voltage
drop becomes:
∆U=100/(1+SK3/SAVV)=100/(1+4,74/1,14)=19,4%
It is evident that the motor cannot be direct started.

Calculation formulas represented above are simplified, but they offer a sufficient degree
of precision and mainly basic parameters for the initial plant’s selection.
Other calculation methods that utilize the various parameters (R+jx) of equipment
composing the plant, can be used for a more accurate analysis of the electric system.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 43 di 49

5.3 SELECTING STARTING METHOD

Direct starting method is the one to be preferred because of its own simplicity
characteristic. In the case, as in example 2 of previous paragraph, its utilization is not
possible, it becomes necessary to consider alternative methods at reduced voltage.
As first investigation it is necessary that starting torque Cs of the motor, supplied at
reduced voltage, is adequate to win the resistant torque Cr during starting of motor-user
unit.
If, as an example, torque Cr at starting is presumed to be 30% approx. of starting torque
Cs of motor, referred to rated voltage V1, it is then necessary:
a) To consider a safety margin of 1.3, so that
Cr= 1,3•30% ≈ 40% of Cs
b) Calcolate the reduce voltage V2 sufficient to guarantee such a torque, being:

V2 2
0 .4 = ( ) ;
V1
It becomes:

V2 = 0,4 ⋅ V1 = 0,63 ⋅ V1

a) Star-delta starting
Star-delta starting, anyway not recommended, would not guarantee starting of the
motor because the voltage to the motor itself should be 1/√3 V1 = 58%

b) Autotransformer starting
Voltage V2 of the autotransformer is selected at approx. 65% of V1.
Starting current supplied by the network, is:
I’START= ISTART•(V2)2.
Keeping into consideration the example 2 of previous paragraph, we get:
I’START= 7,1•0,652=3• In
To which the corrispondent starting power, is:

SSTART=U• 3 • I AVV = 400 • 3 • 232 • 3 = 482 kVA = 0,48 MVA

Voltage drop on 400 V network durino starting, is:

∆U=100/(1+SK3/SSTART)=100/(1+4,74/0,48)=9,2 %
Starting method is adeguate to the purpose.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 44 di 49

c) Soft-starter starting
Starting current of the motor can be monitored/contpumprolled by the current limit
function that in order to guarantee the required torque shall be approx. ISTART < 65%
of the starting current at full voltage, which is:
0,65•7,1• In < 4,6• In
Power requested to the network at starting phase, shall be in worst condition.

PAVV ≤ 400 • 3 • 232 • 4,6 < 740 kVA = 0,74 MVA

Voltage drop on 400 V network durino starting, is:
∆U<100/(1+4,74/0,74)<13,5%
Value acceptable.
On this example the extreme heavy value has been assumed by considering an
oversizing of the starting torque of 1,3 times. Indeed functionality of soft-starter will
allow to start the motor with the effective torque needed to start, therefore with the
correspondent starting current; as a consequence voltage drop shall be less than
that calculated.
The example is however considerable to indicate that when a high starting torque is
requested, the soft-starter system cannot be adequate.

5.4 TYPICAL APPLICATION FOR VARIABLE SPEED DRIVES

One of the most used applications is associated to well pumps (ESP).

These are composed, as represented in figure 3.1, by an “in-line” system which
includes:
- an asynchronous electric motor, cage type, totally closed, externally cooled by the
pumped fluid; aircore and the internal interstices of the motor are filled with a special
high thermal conductivity mineral oil to transfer heat produce by the stator and rotor
windings to the external enclosure;
- a coupling system between motor and pump which guarantees seal preventing
ingress of liquids inside the motor;
- a rotating gas separator, to avoid that gas contained in the pumped liquid causes
the pump to cavitate and wear of pump’s impellers. The separator is being
provided when the gas content in the liquid to be pumped is bigger than 10% in
volume;
- multistage pump of a centrifugal type with a number of “in-series” impellers, related
to the required head.
Sizing of pump/motor system is made on the basis of head (difference between the
upper static head of pumping liquid and height to which such a liquid is to be delivered)
and also related to the estimated flow of the well.
In the metric system the flow is measured m³/sec and the head in meters.
Multiplying the folw by the head and by the specific density of liquid [kg/m³] gives the
value of mechanical power requested to the pump:
Pm = Q • H • γ
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 45 di 49

Where:
Q = flow of the liquid
H = head (refer to Figure 3.1; H = Hd + Pd + Ft )
γ = specific density
The right size of the motor/pump system is obtained when in the working rate the level of
upper static head of pumping liquidi s maintained steady (see Figure 3.1 = ProducingFluid
Level). Infact this condiction means that pumped volume is equal to that one regenerated
within the well.
If the flow were bigger the level of static head would lower up to cause cavitation of the
pump.
If the flow were less, the correct exploitation of the well would not occur.
It becomes evident that if the motor pump system could regulate the flow, reaching of the
balance point would be optimized.
Such a possibility is assured varying speed revolutions of the pump.
Variations of the pump characteristics in function of speed in comparison with rated speed,
are as follow:
n1
Q1 = • Qn
n
2
⎛n ⎞
H 1 = ⎜ 1 ⎟ • Hn
⎝n⎠
3
⎛n ⎞
P1 = ⎜ 1 ⎟ • Pn
⎝n⎠
where:
• Qn, Hn, Pn are respectively the flow, the head and the power at speed rate of the pump
(n).
• Q1, H1, P1, are respectively the flow, the head and the power at the new speed rate of
the pump (n1).
As previously stated varying the frequency of supply to motor can change the speed.
The frequency is therefore selected in relation to flow and dimensional characteristics of the
well and it is to be regulated on the variation of static head.
Variable Speed Drive systems VSD can be automatically regulated, frequency of supply to
motor may be adjusted by means of a signal coming from a proportional pressure
transducer to free static head (see the PSI system of REDA or the PHD of CENTRILIFT).
On the VSD drive it is possible to set the relevant parameters corresponding to determined
static head value
If the static head is going to increase, the transducer will deliver to pump a signal for
accelerating; on the contrary if the static head decreases the same transducer will ‘order’
motor to decelerate accordingly.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 46 di 49

Hd = vertical distance between the wellhead and estimated producing fluid level at the expected
capacity
Ft = friction head in tubing (head required required to overcome friction loss in the tubing)
Pd = discharge pressure head (head required to overcome friction in the surface pipe,
valves and fittings and to overcome elevation changes between wellhead and tank
battery).
Fig 3.1
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 47 di 49

5.5 ELECTRIC SUMMERSIBLE PUMP (ESP) DRIVES

The driver used to feed ESP are of voltage impressed type with or without PWM control.
This kind of drive are more appropriate for this application as they offer best flexibility
than the current impressed ones.
The impressed current drives are not advisable, as already pointed out, because each
driver is individually designed in accordance to the characteristics of relevant motor and
connecting cable. This reason will not allow the minimum interchangeabilty of equipment
as can be requested in an oil-well field.
It is remarked that the great part of ESP are provided with medium voltage motors. This
reason is due to the motor cable connecting length (of some km) associated with the
motor power. The medium voltage will allow the use of a small size cable.
Normally due technical and economical reasons, and according to the relative power the
ESP drives are supplied from a low voltage system.
As consequence the drive output voltage must be raised up through a suitable step-up
transformer.

The simplified diagram of above-said circuit is the following:

Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 48 di 49

5.6 SIZING OF THE SYSTEM

Motor sizing
The choice of the ESP motor according to the various operating conditions (rpm,
delivery, pressure etc.) is carried out by the Manufacturer making use of dedicated
software calculations programs based on the characteristics of the oil to deliver, and
installation conditions (e.g. depth of the well, etc.).
These kind of calculations programs define also, for each working point, the absorbed
current of the motor, power and the supply voltage level necessary at the terminal of the
surface connection box.
The cable voltage drop between the surface terminal box to the ESP motor is
considered by calculation program.
Summarising, the results given by above said-calculations are the following:
a) Motor rated data
Vn = rated voltage of the motor at nominale frequency (50 Hz or 60 Hz)
Pn = rated power of the motor, to nominal supply conditions (at rated voltage)
Vmax = maximum allowed operating voltage

b) Operating data
For each working point of the motor, included that one at rated voltage / frequency:
Pm = absorbed power [HP oppure kW]
Fm = operating frequency of the motor [Hz]
Vm = supply voltage at motor terminals [V]
Vjb = supply voltage at surface terminal box [V]
Im = absorbed current by motor [A]

Transformer sizing
To define the main transformer ratio, the values of motor working operation at rated
voltage and rated frequency must be considered.
During this operation the output voltage and frequency of the VSD (V & F), are the
same of the supply network (e.g. 380 V – 50 Hz or 480 V 60 Hz, etc.).
The transformer ratio is chosen in order that, with the above working operation, the
voltage at the terminals of the surface box shall be equal to Vjb.
As the voltage drop within cables connection between the transformer and the surface
terminal is normally negligible, it can be assume Vjg=V2 where V2 is the secondary
voltage of the transformer at full load condition.
Eni S.p.A. 20217.VAR.ELE.SDS
Rev.0 December 2004
Exploration & Production Division
Pag. 49 di 49

In case that the voltage drop within cables connection between the transformer and the
surface terminal is not negligible, the relevant drop value must be considered to define
the transformer ratio.
The ratio M = V/V2 corresponds to transformer ratio at full load.
To define the steps of the transformer tap changer, the other working operations points
of the motor must be considered.
The tap changer range shall be chosen in order to warranty as much as possible, that in
all ratio steps, the transformer magnetic flux will remain equal or less of the nominal
one; moreover the following conditions must be verified:
VSD Fm
M1 = with V SD< Vn and VSD ≤ Vn
V jb Fn
where:
Vjb = V2 secondary voltage of transformer (and/or surface box) corresponding to
the considered working point
M1 = transformer ratio corresponding to the selected tap changer
Vn e Fn = voltage and frequency (rated) of the supplì system (380 V – 50 Hz or 480 V
– 60 Hz, etc.)
VSD = VSD output voltage relevant to the working condition considered
Fm = VSD output frequency relevant to the working condition considered

The number of steps of the tap changer between the ratio M and M1, must be chosen
with regular steps; it i salso advaisable to increase the number of steps in addition to
those caculated.
The transformer rated power must be chosen in order to cope all the working condition
of the motor.
It can be defined by means of the following relation:

3 • V2 MAX • I 2 MAX
where V2MAX e I2MAX are the maximum forseen values of the secondary voltage and
current.
Anyhow transformer rated power must bigger than kVA absorbed by motor.
An over-sizing of at least 20% must be considered.