Petroleum Equipment

Innovative Thinking

PCP & ESP Pump Package
VARIABLE FREQUENCY DRIVE PCP/ESP APPLICATION.
Specifications:
 
  • Skid Dimensions 87″H x 100″W x 87″D, Weather-Resistant
  • Enclosure: NEMA 3R for Enclosure Proper, AC drive Cabinets.
  • Main Circuit Breaker
  • AC Drive Input Fuses.
  • 20,000 BTU AC Unit
  • Ethernet Communication Network, 4 ports
  • Cabinet Temperature Monitoring system, reduce load if temperature exceeds 45deg C
  • Intruder Alert monitoring system
  • 1 KVA Single-phase Step-down Control Power Transformer
  • 200HP Input Dv-Dt Filter
  • 200HP Output Sine wave Filter
  • Data Logger: Maple Systems.
  • Power Supply: 120 Watt, 24 VDC
  • Appurtenances (e.g. Terminal Blocks, Wire, Wiring Duct, and Duplex Receptacle).
  • Skid Interconnecting Cables (Input Filter to AC drive and AC Drive to Output Filter)
Drive: Model: ABB ACS800 – 200 HP:
 
  • Ethernet Communications
  • PCP & ESP Program Module
  • Input Voltage: 480 Vac
  •  Output Current: 240 Amp (150% 1 min – Heavy duty).
  • Type: Non-Regenerative.
  • Brake Chopper
Transients Voltage Suppressors:
 
  • Sinetamer 300 KA per phase, 480V delta
  • Sinetamer 120 KA per phase, 480V, with DRC
  • Sinetamer 80 KA, 120 V PLC protections
  • Sinetamer 10 KA, 12 VDC Data line protections with DIN
Input & Output Load Cabinets:
 
  • Termination of field power wiring
  • Motor Overload relays
PCP and ESP Software Functionality Features:
 
  • The ACS800 with PCP&ESP sw can work without any external inputs or with down-hole surface and pump sensors
  • It will protect the pump by accurately controlling the rod speed and torque at all times.
  • It includes several process control functions for the protection of the pump equipment and the optimization of production rates
  • Protection is provided by monitoring selectable input signals and automatically shutting down the pump during conditions that could harm the equipment.
  • Optimization is realized through automatic pump speed adjustments based upon control set points and limits.
  • Speed reference for the pump by motor or pump rotation speed.
  • Can be used both engineering units – English and Metric

Control Functions

The ACS800 with PCP&ESP sw provides following control functions:
Common, with or without external / down-hole instrumentation:
 
  • Pump Torque – Limit control
  • Pump Torque – Protection (High/Low)
  • Pump Shutdown – Backspin Control
With an external / down-hole instrumentations:
 
  • Pl- Controller for fluid level
  • Pump sleep/wakeup control for high & low fluid level conditions
  • High down-hole discharge pressure protection

 

The unit is prepared to control, protect and supervise the pump based on the following signals: ACS800 PCP/ESP and ROD pump control (G174).

Drive Actuals:
 

Pump Speed, Motor Speed, Pump Torque, Motor Torque, Active Power, Input Voltage, Output Voltage, Temp Klixon Devices.

Process Actuals (like from down-hole instrumentation):
 

Intake Pressure, Level Oil Pressure, Internal Pump Pressure , Casing Pressure, Tubing Pressure, Discharge Pressure, Intake Temperature, Discharge Temperature.

Protection Generally

Pump torque- Protection:
 

The PCP Rod string is protected against high and low torque conditions by stopping the driver under the following conditions

  • High torque – “Stall” protection
  • Low torque – broken rod
PUMP Shutdown protection:
 
  • These protection functions are separately configurable, depending upon the down hole and surface instrumentation available at the well.
  • High pressure Casing Pressure Protection, Tubing Pressure Protection, Pump Klixon Protection, Pump Temperature Protection, Pump Torque Protection
  • PCP application includes several pump protective functions for shutting the pump down at critical limits that could harm the pump equipment.
All These With:
 
  • Backspin Control
  • Preventing the unit from going into uncontrolled backspin of the rods in the well or back flow of fluid through the pump

Variable Frequency Drive

Progressive Cavity Pump And Electrical

Submersible Pump Application

Specifications:
CABINET:
 
  • Dimensions 72″H x 36″W x 18″D, Weather-Resistant
  • Enclosure: NEMA 3R for Enclosure Proper, AC drive Cabinets.
  • Main Circuit Breaker
  • AC Drive Input Fuses.
  • 1 Kva Single-phase Step-down Control Power Transformer
  • Datalogger front panel.
  • Power Supply: 120 Watt, 24 vdc.
  • Appurtenances (e.g. Terminal Blocks, Wire, Wiring Duct, and Duplex Receptacle).
  • Skid Interconnecting Cables (Input Filter to AC drive and AC Drive to Output Filter)
1. Drive:
 
  • 250 HP
  • 0270 KVA
  • U4 – Module
  • Modbus RTU Adapter Module
  • Input Voltage: 480 Vac
  • Output Current: 240 Amp (150% 1 min – Heavy duty)
  • Type: Non-Regenerative
  • Enclosure: IP00
  • Drive size: R8
  • Brake Chopper
2. Transients Voltage Suppressors:
 
  • 300 KA per phase, 480V delta
  • 120 KA per phase, 480V, with DRC
  • 80 KA, 120 V PLC protections
  • 1.-10 KA, 12 Vdc Data line protections with DIN
3. Harmonic Filter at the VFD Input:
 
  • 200 hp
  • 150 kw
  • Enclosure: Nema 3R
4. Sine Wave Filter at the VFD Output:
 
  • 200 hp
  • 150 kw
  • Fuses for the capacitor bypass included (to Select PCP or ESP).
  • Enclosure: Nema 3R
5. Cooling System:
 
  • Capacity: 20.000 BTU
  • 480 / 1 / 60
  • This ensures a temperature less than or equal to 50 ° C
6. Drive Win Light V2.9:
 
  • Drive Windows Lite V2.7
7. NPCU-01 FLD OPT:
 
  • Drive Windows Light hardware for ACS800
8. Communication and Software:
 
  • Each drive includes software for BCP y ESP.
  • Analog/Digital Extension Modules.
  • Modbus RTU Adapter Module.
  • DDCS Communications Module and Control Panel Cabinet Mounting Hardware.
  • Three (3) RS-485 Connections:

 

      1. ModBus RTU to Control Room.
      2. Datalogger (Bottom Sensor) to VFD.
      3. VFD to Door connection for Datalogger.

 

For the PC connection (VFD programming), the RJ-45 from the VSD control panel is going to be used. The VFD Control Panel can be removed in remote mode for the use of the RJ-45 port.

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