PERMANENT MAGNET MOTOR SYSTEM

October 2015

Amin Sorour

Sales Manager
 PMM Overview
High Efficient 120 HP
 3-phase, oil-filled motor with permanent magnets mounted Induction Motor
directly in the rotors sections

 Control provided using Axiom II drive.

 Improved application flexibility & a near constant

operational efficiency across a broad range of HP

 System energy savings ranges from 10% - 20% PMM 120 HP 17 ft

 Increased power density results in reduced motor length,

enabling installation in wellbores with higher deviation 10.6ft

 Low temperature-rise characteristics enables low flow

cooling operation

CONFIDENTIAL
 Two Electromagnetic Concepts

• A current passed through a conductor will create a magnetic field around the
conductor.

• Relative motion between a magnet and a coil will induce a current in the coil

CONFIDENTIAL
 Motor Construction

 Mounting magnets in the rotor eliminates the

major losses involved with an induction rotor.

 The stator phase windings are designed to create

flux that only penetrates to the depth of the rotor
magnets, unlike the induction motor.

 The stator energy is now more efficiently used to

create torque.

 The rotor position must be known in relation to

the stator continuously to insure optimum power
transmission from the Drive to the stator.

 The complexity of rotor position has been solved

with our proprietary control algorithms in the
drive.

 Rated at 392°F(200°C) motor winding

temperature.

CONFIDENTIAL
Construction Highlights
Induction Motor vs PM motor
 Stator is essentially the same.
 Rotor bars are replaced with
magnets.
 Special control method is needed.

CONFIDENTIAL
 Operation Highlights

• The PMM is a 3‐phase machine. The stator magnetic fields operate in a very
similar method to those in the induction motor.
• As the stator coils are energized, a rotating magnetic field is created.
• With the always‐present magnetic fields on the rotor, there is no associated
loss from having to create these fields, as in the induction motor.
• There is no relative motion required between the rotor & stator magnetic
fields.
• The rotor turns at the same speed as the stator magnetic field—it is a
synchronous machine.
• In order to do this, the surface controller must always know the position of the
rotor. How to measure this position is the challenge for an oil well application
where thousands of feet of cable is between the motor & controller.

CONFIDENTIAL
 5 Advantages

• Synchronous operation—no speed drop with load.

• Exact speed control.
• Tailor system to run at highest efficiency point of pumps.
• Potential to require fewer pump stages.

3650

PMM vs IM Speed Comparison

3600

3550
Speed (RPM)

3500
PMM
IM
3450

3400

3350
70 80 90 100 110 120 130 140 150
Percent Nameplate Load

CONFIDENTIAL
 5 Advantages

 Higher Power Density—same power output from a shorter motor. Typical 180 HP
 Up to 50% shorter motors. Induction Motor

 Less weight, easier installations in deviations.

 Smaller volume of oil for motor seals to accommodate.
24.7 ft

PMM 180 HP

14.5 ft

CONFIDENTIAL
 5 Advantages

 Lower Temperature Rise—can be run in a hotter well, or at lower flowrates.

 No induction in rotor = no rotor heating.

Temperature Rise vs. Torque

225.0
Poly. (PMM Temperature Rise) Poly. (IM Temperature Rise)
200.0

175.0
Temperature Rise (°F)

150.0

125.0

100.0

75.0

50.0

25.0

0.0
0 50 100 150 200 250 300 350 400 450
Load (ft‐lbs)

CONFIDENTIAL
 5 Advantages

 Low Idle Current—no minimum power requirement for rotor induction.

 IM no‐load current typically ~30% of rated current.
 PMM no‐load current typically ~3‐4 amps.
 Precise underload control settings.
180

160 Input Current Comparison

140
Percent Nameplate Current

120

100 IM

80 PMM
Poly. (IM)
60
Poly. (PMM)
40

20

0
0 20 40 60 80 100 120 140
Percent Nameplate Load

CONFIDENTIAL
 5 Advantages

 Increased System Efficiency—10‐20% direct impact on monthly utility costs.

 No energy wasted inducing rotor magnetic field.
 Larger air gap between rotor & stator improving oil lubrication of motor parts.
 Constant speed & constant torque.
 Fewer moving components.
Motor Only Efficiency
100.0

95.0

90.0
Efficiency

IM
85.0
PMM

80.0

75.0
75 100 125 150
Percent Load

CONFIDENTIAL
 Advantages of PMM Vs IM
 15% lower operating current (Cable 40
35

Size – Transformer Size – Higher 30

25
Temp. Well)

I, А
20
15

 84% lower idle current (Broken

10
5

Shaft) 0
0 5 10 15 20 25 30 35 40 45 50
P, kW

 10 to 20% increased efficiency at

nominal power 100
90

 14% higher power factor

80
70

Eff, %
60
50
 10% to 20% less power consumption 40
30

(Gen. Size – Power Cost) 20

0 5 10 15 20 25 30 35 40 45 50
P,kW

 Reduced electrical losses

 Decreased motor heating [No Need 1

0,8
for a Shroud] (Plugging – Gas Lock – cos, f
0,6

TBG Leak) 0,4

0,2

 Up to 50% shorter and lighter motor 0

0 5 10 15 20 25 30 35 40 45 50

 Soft‐Starting capability reducing Р, kW

Starting Current (Gen. Size)

CONFIDENTIAL
 456 PMMS Product Line
Power, HP Voltage V Current A Efficiency, % Power Length, ft Weight,
Factor Pounds

40 672 35 90.0 0.955 5.21 238.1

60 1022 35 90.0 0.955 6.47 297.7
80 1356 35 90.5 0.960 7.74 359.4
100 1698 35 91.0 0.960 9.01 419
120 2028 35 91.0 0.960 10.27 480.7
140 2370 35 91.0 0.960 11.54 540.2
160 2167 43 91.0 0.960 12.80 599.8
180 2541 44 91.0 0.960 14.07 661.5
200 2028 58 91.0 0.960 15.34 721
220 2264 58 91.0 0.960 16.60 782.8
240 2424 57 91.0 0.960 17.87 842.3
280 2830 57 91.5 0.960 20.40 961.4
320 2180 80 91.5 0.960 22.93 1082.7
340 2286 79 91.5 0.960 24.20 1137.8
360 2384 88 91.5 0.960 25.46 1197.3
400 2646 88 91.5 0.960 28.00 1318.6

CONFIDENTIAL
 512 PMMS Product Line

Power, HP Voltage V Current A Length, ft

80 1370 44 6.07
120 2019 44 7.72
160 2283 51 9.37
200 2846 50 11.02
240 2679 60 12.67
280 3111 60 14.32
320 3531 60 15.97
360 3176 76 17.62
400 3511 75 19.27
440 2897 100 20.92
480 3157 101 22.57
520 3405 101 24.22
560 3665 101 25.87
600 3926 100 27.52
640 2791 152 29.18
680 2948 151 30.83
720 3106 151 32.48
760 3251 150 34.13

CONFIDENTIAL
Questions
Axiom-II Drive &Advanced
HMI
 Axiom II

 Axiom II has the option to operate in PMM mode or Induction mode

 Input voltage: 380/480 VAC
 Input Frequency: 47 – 63 Hz
 Output Frequency: 10 – 200 Hz
 ‐40to +55 degrees C
 Altitude: Full rating to 1000 meters.
 Advanced HMI with SD card.
 SCADA Slave (Outside Access)
 RS485 (115 kbps) or Ethernet MODBUS TCP SCADA interface.
 5 Digital inputs (24 VDC).
 3 Analog Inputs (0‐10 VDC / 4‐20 mA).
 3 Relay outputs.
 2 Analog outputs (0‐10 VDC / 4‐20 mA).
 Separate Breaker for Control Electronics

CONFIDENTIAL
 Advanced HMI

•6.5 “ Touch screen display.

•Ethernet communication.

•RS-232 serial port for logic controller

communications.

• Two USB ports for attaching mouse, keyboard &

printing.

•Battery Backed real-time clock.

• SD Card memory slot.

CONFIDENTIAL
 Operator Menu

• First menu displayed upon

power up.

• Gateway to all other main

menus.

• Contains system status.

• Contains fast controls

(START/STOP) & key
parameter shortcuts
(OL/UL/Frequency).

CONFIDENTIAL
Monitoring Parameters

CONFIDENTIAL
Quick Setup

CONFIDENTIAL
Full Setup Menu

CONFIDENTIAL
 ADVANCED HMI
HARDWARE + SOFTWARE

CONFIDENTIAL
 Advanced HMI

• Data Archiving.
‐ Real‐time data trending.
‐ Historical trending.
‐ Memory card log.

CONFIDENTIAL
Archive Menu

CONFIDENTIAL
 Data Trends
Real‐time trend Historical trend

CONFIDENTIAL
 Advanced HMI

• Data Archiving.
• Event History.
128 events

CONFIDENTIAL
 Pump Unfreeze

• Used when Pump is stuck due to scale,

sand….etc.
• User inputs amount of Torque permitted &
Frequency of turning.
• If the pump is unfrozen the drive will return to
original running frequency.

CONFIDENTIAL
CONFIDENTIAL
 Gas Lock Current Control

• Some well conditions may stop the pump

from producing fluid due to high gas content.
• If output current decreases below “Gas Lock
Detection Threshold” setpoint the drive
Accel/Decel to “Gas Lock speed” set by the
user.
• The drive will keep repeating this cycle
according to “Gas Lock ride thru” setpoints.
CONFIDENTIAL
CONFIDENTIAL
 Pump Shaking
• Experimental function.
• Used in wells where solids are known to be
present.
• Speeds up the pump in a periodic and
controlled manner to free the pump from any
solids that may have accumulated and cause
plugging.
• User inputs the “Pump Shake interval” in days,
the no of Cycles, duration of the shake and
the speed of the pump shake. CONFIDENTIAL
CONFIDENTIAL
Thank you