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Deep Submersible MotorsDeep Submersible MotorsWhatWhat’’s possibles possible
Hayward Tyler Ltd Group Technical DirectorKen Sears
Subsea Europe 200830 October, London
Progressive innovationProgressive innovation
1908 First submersible (water filled)
electric motor
“Gold Medals awarded
Paris 1878Calcutta 1884London 1884”
Technology developmentTechnology development......
BCPBCP’’ss to Subseato Subsea
Wet Stator Glandless Motor Pump
1948…Remains industry
standard! Submersible motorSWLP, FWP
Subsea motor
The case for Subsea The case for Subsea processingprocessing……
Sea Water Injection
Crude Oil Boosting
Produced Water Re-Injection
Multi Phase Pumping
Separation
Benefits of subsea pumpingBenefits of subsea pumping
Time
Value
Normal production capability
Improved productivity through pumping
Time
Value
Normal production capability
Additional production accessiblethrough pumping
“Installing subsea pumps close to wellheads may increase the total recovery rate for subsea wells by up to 25%
when compared with unboosted production” (Aker Solutions)
General Subsea Motor General Subsea Motor requirementsrequirements……
High VoltageUp to 11kV
Variable speedUp to 4000 rpm
CompactHigh casing pressures
Suitable for 3000m
Fully compliant to Oil Industry StandardsIEC 60034NorsokOil Company StandardsAPI 610
Ultra high reliabilityProven technologyConservative design
Fully compliant to Oil Industry Standards
Deep Submersible motorsDeep Submersible motors
0
1000
2000
3000
4000
5000
6000
7000
8000
1990 1995 2000 2005 2010 2015 20200
1000
2000
3000
4000
5000
6000
7000
8000kW Depth (m)
kW
Depth (m)
19921992
•
Kvaerner boosting station•
350kW
•
500m
19991999
•
EniAGIP
multiphase pumping •
2.5MW
•
1000m depth•
120 bar int. 95 bar ext
•
9kV (operating) 11kV (specification) VSD•
3m x 1.01m dia
12.8 tonnes
•
Superduplex
materials
20022002
•
Subsea mud pump•
935kW
•
2300m depth•
6.6kV VSD
•
3m x 1.2m dia
7.15 tonnes•
Superduplex
materials
20082008
•
Subsea water injection pump•
2.5MW
•
3000m depth•
6.6kV
•
VSD super synchronous•
2,500 to 4,000 rpm
•
3.3m x 1.2m dia•
12.4 tonnes
•
Superduplex
materials
Tyrihans SRSWI ProjectTyrihans SRSWI Project
Increased oil recovery Power supplied from Kristin Platform over 30 km awayVariable Frequency Drive (VSD) system at Kristin Subsea step-down transformers adjacent to the modules2 AKS LiquidBooster™ modules
AKS 8-stage centrifugal pump Hayward Tyler 2.5 MW motor
Platform over 30 km away
s adjacent to the modules
SRSWISRSWI == SSubseaubsea RRawaw SSeaea WWaterater IInjectionnjection
Technical risk managementTechnical risk management
Performance prediction
Insulation capability
Penetrator
Starting conditions
Thrust bearing life
Coolant circulation pump
Thermal stability
Material compatibility
Motor functional requirements Motor functional requirements ……
Rated power (shaft output) 2500 kWMax current 320 AOperating speed range 2500-4000 rpm Rated voltage / frequency 6.6 kV / 60 HzWinding insulation level 11 kVCasing internal design pressure ΔP 150 bar Casing external design pressure ΔP 30 bar Design lifetime 20 year (minimum)Time between intervention Minimum 5 yearMaximum total thrust (standstill) 46 kN Min seawater temperature +1 ºCMax seawater temperature +10 ºC Max pit water temp during testing +25 ºC
Rated power (shaft output)Rated power (shaft output)Max currentMax currentOperating speed rangeOperating speed rangeRated voltage / frequencyRated voltage / frequencyWinding insulation levelWinding insulation levelCasing internal design pressure Casing internal design pressure ΔΔPPCasing external design pressure Casing external design pressure ΔΔPPDesign lifetimeDesign lifetimeTime between interventionTime between interventionMaximum total thrust (standstill) Maximum total thrust (standstill) Min seawater temperatureMin seawater temperatureMax seawater temperatureMax seawater temperatureMax pit water temp during testingMax pit water temp during testing
Multi disciplinary engineering Multi disciplinary engineering challengeschallenges
Electrical analysis
Internal hydraulic losses
Thermal analysis
Rotor dynamics analysis
Bearing analysis
Casing Stress analysis
Shaft deflection analysis
Cooling system analysis
Electrical losses
Hydraulic Design of cooling pump Radial & Axial Thrust analysis
Rotor dynamics analysis
Shaft deflection analysis
Electrical losses
Oil Oil vsvs
Water/Glycol filled Water/Glycol filled TechnologyTechnology
Oil
High viscosityHigh frictional losses particularly at higher speeds
High dielectric propertiesStandard industrial motor insulation
Higher operating tempsCan lead to increased corrosion
Seawater ingress leads to immediate catastrophic failure
Water / Glycol
Low viscosityLower frictional lossesHigher speeds possible
Good dielectric propertiesFully insulated cables & joints
Cooler operation Corrosion inhibiting
Seawater ingress does not cause immediate failure
Water / Glycol is a commonly used control fluid
Environmentally friendly
Motor descriptionMotor description……....
3.3 m
12400 kg
Pressure CasingPressure Casing
Machining of Outer casing
Stator shell and windingsStator shell and windings
XLPE insulated cables and joints
Bearing Design Bearing Design –– Tilting Pad Tilting Pad JournalsJournals
“Stiff” radial bearings
High Voltage PenetratorHigh Voltage Penetrator
Power supply: Crossing the pressure boundary
Junction box & Junction box & compensatorcompensator
Coolant circulation pumpCoolant circulation pump
High efficiency impeller
Cooling CoilsCooling Coils
Spiral Heat Exchanger
6 parallel circuits
0102030405060708090
100
0 2 4 6 8 10 12
Design iterations Design iterations ……..
Length LLength LDiameter dDiameter d
High
sha
ftde
flect
ions
&Cr
itica
l Spe
edpr
oble
ms
UnbalancedMagnetic Pull
L/d ratioL/d ratio
Mot
or E
ffici
ency
Mot
or E
ffici
ency
Design iterations Design iterations ……..
Length LLength LDiameter dDiameter d
Predicted Performance DataPredicted Performance Data
Some of the many Qualification Some of the many Qualification TestsTests……
Penetrator Vibration TestsPenetrator Vibration TestsThrust Bearing performance and endurance tests
Coolant pump tests
and endurance testsThrust Bearing performance
Factory Full Load Performance Factory Full Load Performance TestsTests
Header TankElectrical Supply Cables
Fluid Pressure/Temp Transmitters Here
Load Machine
Epicyclic “Motor” Drive
Epicyclic Gearbox
Flow
FlowmeterPump & Fluid Storage For Filling System
ConclusionsConclusions
Motor Technology is now catching up with the demand for Subsea drivesQualified machines2500 kW at speeds up to 4000 rpm a proven realityDesigns suitable for 11kV voltage spikesDesigns suitable for 3000m depth waterWater/glycol filled motors provide proven reliabilityScaleable designs valid for higher powers and speeds
Customer & Supplier Customer & Supplier partnershipspartnershipsCustomer & Supplier Customer & Supplier Customer & Supplier Customer & Supplier Customer & Supplier partnershipspartnershipspartnershipspartnershipspartnerships
Deep Submersible motorsDeep Submersible motors
0
1000
2000
3000
4000
5000
6000
7000
8000
1990 1995 2000 2005 2010 2015 20200
1000
2000
3000
4000
5000
6000
7000
8000kW Depth (m)
?
Deep Submersible MotorsDeep Submersible MotorsWhatWhat’’s possibles possible
Hayward Tyler Ltd Group Technical DirectorKen Sears
Thank YouThank You