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Who is Stellar Tech?  Stellar Tech Energy Services is a wholly owned Canadian company  Manufacturer of WellMax Datalogger / Controller  Specializing.

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Presentation on theme: "Who is Stellar Tech?  Stellar Tech Energy Services is a wholly owned Canadian company  Manufacturer of WellMax Datalogger / Controller  Specializing."— Presentation transcript:

1 Who is Stellar Tech?  Stellar Tech Energy Services is a wholly owned Canadian company  Manufacturer of WellMax Datalogger / Controller  Specializing in the integration and distribution of VFD’s and motors.  Strengths in Pumping Systems  Oil, Water, and Municipal

2 What we do!  Oil & Gas production pumping  Commercial Pumping  Municipal Pump Controls  Datalogging and Control  Work in a Global Market

3 Our Capabilities  Variable frequency drive (VFD) systems design and integrator.  Over 15 years experience in drives and automation  Thousands of successful installations  Complete systems integrator with design, manufacturing, start-up and service capabilities

4 Our Products  WellMax Datalogger  Variable Frequency Drives  Down hole Pressure / Temperature Recorders

5 Our Strengths  All products are manufactured to the highest quality standards  Knowledgeable customer service representatives and technical support groups  Worldwide commitment to customers with sales and service facilities around the globe

6 WellMax Datalogger / Optimizer / Controller  Designed and engineered for pumping applications to optimize production  Can be used with VFD’s, Hydraulics or Across the line / Motor starter. Extensive options available  Drive / motor control

7 WellMax Features  Rod protection  Well OPTIMIZATION  Immediate data storage and retrieval  Fluid level control  Pump off  Multiple communication features and protocols  Trend analysis  Screen for on-site data viewing

8 Well Conditions WellMax Data Logger and Controller

9 LEVEL AND RPM CONTROL Equimavenca – Capital Nacional Levantamiento Artificial / Servicio Integral Equimavenca – Capital Nacional Levantamiento Artificial / Servicio Integral

10 Pump Off – Complete Overview A–SPEED CHANGE B-PRESCO FAULT C-POWER BUMP D-PRESCO E-BROWN OUTS F-PUMPOFF SIGNS G-PUMPOFF OCCURS LEADING UP TO A PUMPOFF CONDITION

11 A - Speed Change

12 B - Presco Fault

13 C - Presco Fault

14 D - Power Bump

15 E – Power Brown Outs

16 F – Signs of Pump-off or Pump Damage

17 G – Pump-off occurs

18 Tubing Leak Torque fluctuations are caused by excess volume of gas Significant drop in torque displays tubing leak

19 Tubing Leak Significant drop in torque displays tubing leak

20 Tubing Hair line fracture The increase of RPM caused enough pressure to open up the hair line fracture in the tubing, flow decreased but never completely stopped

21 Sand Avalanche Pump slowly filling with sand Pump is full of sand

22 Pumped Off Well Pump Off Occurs 80 Ft Lbs 75 Ft Lbs

23 Waxing Condition

24 Parted Rods

25 WellMax Menu Structure

26 SUMMARY REPORT

27 NEMA 3R Panel

28 VERTICAL NEMA 1 Unwired 3 Contactor Bypass Package Showing Fused Disconnect Line Reactor Contactors O/L

29 IEEE 519 The total harmonic voltage distortion at any point of common coupling with a nominal voltage of less than 66kV shall not exceed 5%. Point of Common Coupling (PCC): That busbar electrically closest to any consumer through which any current must flow to that consumer and one or more other consumers.

30 Uncontrolled Rectifier Harmonics Line 1 Line 2 Line 3 LOAD D1 D2D3 D4 D5D6 Current in D1 Current D1 & D5 Current D1 & D6

31 Square Wave Harmonics Content Square wave & Fundamental + 3rd

32 Types of Harmonic Filters  A VFD with no input reactor or filter may result in 100% THID or more, measured at the VFD input terminals  A 3%Z line reactor will limit THID to 35~ 40%  A 5%Z line reactor will limit THID to 30 ~ 35%  A 5%Z line reactor & 3%equivalent Z DC reactor will limit THID to 25~30%  Tuned 5 th harmonic trap will limit THID to 20 ~ 25%  12 pulse phase shifting will reduce THID to a minimum of full load  18 pulse phase shifting will reduce THID to a minimum of full load  Matrix wide spectrum filter limits THID to 8% or 5% at full load

33 Input Current – Enhanced 5 th Harmonic Trap (w/VFD input reactor) Load: 100% Input Voltage: balanced Line Impedance: 0.25% Input Reactor: 5% Output Reactor: 1.5% Input Current THID: 23.07%

34 THID Performance 8% Filter

35 12 Pulse w/ 1% & 3% Line voltage unbalance Matrix w 1% & 3% Line voltage unbalance Matrix Filters perform better than 12-pulse under Real Life operating conditions (unbalanced line voltages, 0% to 100% loading)

36 6-pulse VFD with 5% Matrix Filter performs better than 18-pulse drive under normal operating conditions (0% to 100% load, voltage unbalance)

37 Voltage Unbalance….. ANSI Standard C Reports: 98% of power systems are within 1 - 3% 66% of power systems are within 0 - 1% –all at the point of common coupling Load unbalance within the building power distribution system adds to the utility unbalance at the point of utilization.

38 Reducing Harmonics  Ensure a low network Impedance  Distribute harmonic generating loads  Use AC line or DC link reactors  Install Harmonic filters

39 IEEE – 519 Solutions Desired % THID at PCC (IEEE- 519) 3% Line Reactor 5% line Reactor 5% Line + 3% DC Reactors 8% Matrix Filter (M8) 5% Matrix Filter (M5) % Maximum VFD Load if all VFD’s use same Harmonic Mitigation Method

40 Motor Inverter Compatibility Topics  Reflected Wave Theory  Waveform Analysis with output reactors & filters  Long Motor Leads  Drive Solutions  Motor Solutions

41 Reflected Wave Theory Mismatch between surge impedance of: Drive-to-motor cable & Motor winding  Cable surge impedance fairly constant through hp range  Motor surge impedance inversely proportional to hp  2 per unit voltage evident on motors up to 500 hp  Motor terminal voltage doubling on leads over 15 feet

42 Full Voltage, 60 Hz PWM Waveform Half Voltage, 30 Hz PWM Waveform PWM Waveform

43 VFD Output & Motor Terminal Voltage, Reflected Waves

44 IGBT VFD, Motor Terminal Peak Voltage & Rise Time Characteristics  Peak voltage = twice DC Bus voltage at critical cable length and longer. DC bus voltage = AC input voltage *  e.g. 600 VAC * = 850 * 2 =1,700 V Peak.  Rise time = 0.015uS to 1uS Depending on IGBT Current Rating  Critical cable length = speed of propagation * rise time.  e.g. 150meters/uS * 0.03uS = 4.5 meters

45 IGBT VFD, Motor Terminal Voltage, 10 HP, 460 Volt, 6 KHz Carrier Frequency, 60 Hz Output Frequency, No Load Reactor, 10 Feet of Cable, Peak Voltage 1,200 Volts, Rise Time.03uS

46 IGBT VFD, Motor Terminal Voltage, 10 HP, 460 Volt, 6 KHz Carrier Frequency, 60 Hz, 3%Z Load Reactor, 10 Feet of Cable, Peak Voltage 820 Volts, Rise Time 2uS

47 IGBT VFD, Motor Terminal Voltage, 10 HP, 460 Volt, 6 KHz Carrier Frequency, 60 Hz Output Frequency, Sine Wave Output Filter, 10 Feet of Cable, RMS Voltage 460 VAC, No Spikes

48 IGBT VFD, Motor Terminal Voltage, 10 HP, 460 Volt, 6 KHz Carrier Frequency, 60 Hz Output Frequency, No Load Reactor, 250 Feet of Cable, Peak Voltage 1380, Rise Time.05uS

49 IGBT VFD, Motor Terminal Voltage, 10 HP, 460 Volt, 6 KHz Carrier Frequency, 60 Hz Output Frequency, 3%Z Load Reactor, 250 Feet of Cable, Peak Voltage 1,000 Volts, Rise Time 10uS

50 IGBT VFD, Motor Terminal Voltage, 10 HP, 460 Volt, 6 KHz Carrier Frequency, 60 Hz Output Frequency, Sine Wave Output Filter, 250 Feet of Cable, RMS Voltage 460 VAC, No Spike

51 Long Cables  From critical cable length and longer, motor terminal voltage remains at 2 per unit  Time spent at 2 per unit voltage increases with cable length therefore transient energy level much higher  Insulation stress much higher  proportional to transient energy*carrier frequency

52 NEMA Minimum Design Standards For 3 Phase Induction Motors MG1 part 30 As a minimum motor insulation must withstand  1000 volt  2uS rise time MG1 part 31 As a minimum motor insulation must withstand  1600 volt  0.1uS rise time

53 VFD Solutions For NEMA MG1 part 30 Motors  No output reactor or filter required for 208/240Volt applications  Use output reactor for 460 volt applications  Use output dv/dt filters for 575 volt applications  Keep motor leads short  Keep carrier frequency low  Keep motor cool

54 Motor Solutions For NEMA MG1 part 31 Motors  No output reactor or filter required for 208/240 volt applications  No reactor or output filter required for 460 volt applications unless cable length is extreme  Use output reactor for 575 volt applications

55 END OF PRESENTATION THANK YOU


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