WEG Oil Gas News 2010

8/6/2019 WEG Oil Gas News 2010

1/8

OIL & GAS NEWS2010

www.weg.net

You can be sure about one thing:when youre out there,

so is WEG.

First X BOW built

in Brazil will

have WEG

products

Excellent cost x beneft page 7

Learn more about the W22 motors with reduced

energy consumption and easy maintenance.

WGM Compact andextremely powerul

The line o water jacket cooled motors

is made up o high perormancemotors with reduced space usage.

Learn more on page 2.

Good perormance and saety page 6

Learn more about the dry transormers which

eliminate the risk o combustion.

WEG supplies the

largest motors o theplatorm or the

Guar pilot projectRead more on page 3.

Read more on page 5.

New CFW-11 Modular Drivespeed variator: watercooled versionWEG develops the water-cooled CFW-11

Modular Drive version especially designed or

marine and oshore applications.

See more on page 7.


2/8

WGM Motors: Water jacket Cooled

The motor cooling is guaranteed by a water jacket

circulating between the stator core and the outer rame,

which allows a more eective heat exchange resulting in a

higher power per weight ratio thereore reducing the size

o the motor. This system is ideal or variable speed

applications since the thermal eciency is optimized evenon reduced speeds and where space constrain is a

concern.

WGM motors can be used in several segments o the

industry, especially driving machines that require constant

torque even in low rotations. Thus, they are the right

choice or applications in high temperature environments,

limited space availability or motor operation or motor

submitted to dusty environments. This solution has a wide

range o applications. Not only on the marine and oshore

segments, but in all applications where water cooled

motors are benecial.

In the marine segment, or instance, when operating at DP

(Dynamic Position), the vessels thruster motors can

In operation

In 2008, several water jacket cooled motors were sold in

the domestic and international markets. Edison Chouest

Oshore who currently acquires rom WEG the complete

electrical package or all the Brazilian built vessels, has

already purchased several units o WGM motors that will

be used on supply vessels being built in the USA.

Developed to provide cooling through water ow on the end bells and around the rame allowing an increase on the

horsepower / weight ratio and a decrease on the space usage.

2

By continuously keeping up with market needs andtrends, WEG oers an outstanding solution: TheIntegrated Bridge. These are operation consoles orplatorm support ships installed on the ootwalks o thevessels and making all inormation necessary or sailingavailable to the user.

The solution is based on computers prepared or navalapplications all interconnected in a redundantETHERNET net. The solution is extremely reliablebecause in case o eventual ault in one o thecomputers the user can alternate any unction on anyone o the other computers just by browsing throughthe screens. This is because they are all available on all

the console workstations.

Besides integrating the whole alarm and monitoringsystem o the ship, the managing system o energyand load control, each o the computers perorms theunction o nautical chart and radar and givesinormation about the speed o the wind, theinclination o the vessel, etc.

Integrated solution or ships and platorms

Output power: 315 to 2.800kW

Frame sizes: 315 to 560 (IEC)

Voltages: 690 V to 6600 VNumber o poles: 2 to 8

withstand prolonged periods o operation at very low

speeds. Under this operation condition, standard cooling

methods that rely on shat mounted ans have the heat

exchange capacity greatly reduced since the cooling is

directly dependant on motor speed. The water jacket

solution has its cooling eciency guaranteed throughout

the speed range as the heat removing capacity is

independent o motor rotation.

The water jacket cooling system consists o heat

dissipation through the circulation o water through the

channels inside the rame which provide an even and

continuous fow. The water is supplied by an external

system and enters the motor through the connections on

the motor end bell (drive end or non drive end). Thepassage o water rom the end bell to the rame is made

through mechanically shielded hoses which avoid the risko internal leakages.


3/83

Platorm or Guar pilot

project will have WEG motors

One o the rst Petrobras platorms or the pre-salt, theFPSO - Floating Production Storage and Ofoadingplatorm which will operate on the Guar pilot projecton block BM-S-9, will have its largest electric motorssupplied by WEG. The limitation o the starting currento the motors on this project was a very important

actor due to the high electric loads o the platorm andWEG was given preerence because it worked togetherwith the company responsible or the project showingdeep knowledge o the applications and also oeringthe best technical-economic solutions. The Guar eldis located in the pre-salt region o the Santos Basin andthe new platorm will be chartered or a period o 20years by PETROBRAS who has Repsol and the BGGroup as partners on this project.

The new unit, which will be converted by the Schahin/Modec consortium, will have the capacity to produce120 thousand barrels o oil and 5 million cubic meters ogas per day. Among the main modules where WEG issupplying large size motors are the ones or export onatural gas, reinjection o natural gas, water injection

and intake o seawater. All the orders are currently inproduction. Learn more about each o these supplies.

Assigned to the pre-salt, the new MODEC platorm chartered by Petrobras will use motors with low starting currents produced

by WEG.

Natural Gas Export Compressor

The natural gas produced on the platorm is taken to thecoast through the ducts which run or hundreds okilometers at the bottom o the sea. For this, the gasneeds to be pressurized by compressors on the

platorm. WEG supply: 4 motors o 10.100 kW which willdrive compressors supplied by MAN Turbo (Germany)Natural Gas Reinjection Compressors

The reinjection o natural gas is a way to improve therecovery o petroleum. The gas is reinjected into the oilreservoir and, consequently, this increases the quantityo oil which can be recovered. WEG supply: 2 motors o9920 kW which will drive compressors supplied byDresser-Rand (USA).

Water Injection Pumps

Used on petroleum platorms to reinject water intoreservoirs. The purpose is to increase the pressure and

thus, stimulate production. This method is also used toincrease the recovery o petroleum o a specicreservoir. WEG supply: 2 motors o 5500 kW which will

drive pumps to be supplied by Clyde Union (Scotland).

Seawater Intake Pumps

Seawater is widely used or cooling and also injecting

water into reservoirs on platorms. WEG supply: 3motors o 900 kW which will drive pumps to be suppl iedby DMW (Japan).

Pictures o Petrobras P-54 Platorm


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The Integrated Electric Systems - IES were created tosupply assembled and interconnected electricsolutions ready to receive external connections. It ispossible to install the whole electrical plan o a vessel

such as the main switchgear, switchboardpanels, transormers, speed variators and automationsystem inside the IES. When using the IES solution,the construction o a ship or platorm can occur inparallel allowing or the panelboards to be installedwhen the electrical room is ready.

Another application o the IES is on revamps orreorms o platorms, on which, in some cases, thework is done on only one specic module. The IES iseasily adaptable to each project because a team otrained engineers is at the customers disposal toadjust the solution to meet the demands o theapplication.

The structure o the IES is made up o lateral

columns and superior and inerior steel beams withinspection and quality certication. External andtransversal welding o the foor using the MIGsemiautomatic process. The sheets are sealed withsilicon and the doors with naval standard rubbers.

The lining o the internal walls and the ce iling is made

IES: Durability and practicality in a complete structure

with a double carbon steel sheet ASTM 36, 100%galvanized and xed with sel-threading screws. Veryresistant, the roo stands a load o 200Kg/m. It also hasan air cushion between the tiles and the ceiling and

gutters on the sides to allow the outfow o water.

The access door opens out with a minimum angle o 90degrees and has an anti-panic bar. The foor stands aload o 1,250Kg/m due to the welded carbon steeltransversal and longitudinal beams. A mechanicalcleaning, sanding and removal o oil and grease is donebeore the coating is applied. Primer Epoxy coatingswith polyurethane anti-lymphatic nishing are used toassure the durability o the IES.

WEG was also concerned with the transport and litingo the IES when the structure was built. For this reason,the system was manuactured with reinorced edgesand the liting can be done with overhead cranes or bymeans o air cushions or on an appropriate

transportation vehicle (fat car).Monitoring is permanentthroughout the transport. The internal lighting isdesigned according to the luminous density requested.

All the wiring goes through re galvanized conduits andcondulets. There is emergency lighting and specialluminaries and sockets can be ound in strategic places.

Besides all that, the structure has air conditioningwhich provides better working and operatingconditions or the equipment.

The MVW01 presents state-o-the-art technology ormedium voltage inverters through a structure withIGBTs o 6,5 kV combining resistance and security withthe minimum quantity o power components whichassures great reliability and simplicity to the equipmentin a compact solution with last generation technology.

The multilevel NPC topology (neutral point clamped, 3/5levels) allows a great balance between the output waveorm to the motor and the number o powercomponents without the need to connect them inseries.

Due to the unique characteristics o the IGBTs alreadyacclaimed in the low voltage inverters such as ver y lowlosses and simplicity on the peripherals, the requencyinverter presents high eciency (97% and reaching99% at rated conditions) and very low heat dissipation.

The input rectier conguration or 12 or 18 pulsesreduces the harmonics currents to extremely low levels,provides high power actor on the power supply andully attends the recommendations o IEEE519. Atcontrol stage, the MVW-01 has a multiprocessingdesign using 32 bit processors (64 b it busbars) withmathematics in foating point and high perormanceassuring high eciency on the motor control.

The most complete Inverter or the oshore segmentThe MVW01 line o medium voltage inverters rom 500 to 6000 HP attends the needs and expectations o the naval industry,

associating state-o-the-art technology and robustness with simplicity in the conception and ease in programming and handling

which assures high perormance and reliability. A wide range o solutions in speed variation or medium voltage motors o

2,300 V, 3,300 V and 4,160 V besides the line o low voltage inverters up to 1500 HP. In this way, the user eels comortable to

choose the most convenient solution considering the purchase, implantation and installation values, energetic consumption and

physical space.

In trying to demystiy the application o medium voltageinverters, the MVW01 ollows the same programmingphilosophy o the WEG line o low voltage inverters. Byusing the same standard o MMI o the line o lowvoltage inverters, the MVW01 makes itsparameterization extremely simple with no need orspecial training or sotwares sold aside. It is also

possible to parameterize the MVW-01 through theSuperdrive, a WEG drives parameterization sotwarewhich attends the whole line o WEG drives.

To assemble and replace power elements quickly, the

IGBT modules are separated into three inverter armsassembled on removable individual racks, one oreach phase o the motor. The control and powercomponents are interchangeable among the severalsizes o inverters in such a way as to standardize andreduce the number o spare parts as well as to reducethe purchasing and storage costs o these

components. The changing o these racks doesnttake more than three minutes due to their greatmechanical practicality. The racks are available bothwith air and water cooling systems which increaseseven more the versatility o this product.

Main eatures:

Ride-Through/Flying-Start

Alarms and Faults

Superdrive

Trace Function

Operation with Ground Fault


5/85

First electric diesel vessels built by CBOwill be equipped with WEG products

The our Petrobras Platorm Supply Vessels which are being built by CBO will have electric propulsion and energy management

system supplied by WEG.

CBO is a 100% national oshore shipping companywhich supplies oil platorms and has been inoperation or over 30 years. Headquartered in Rio deJaneiro, the company is part o the Fischer Group, aBrazilian conglomerate which operates in severalsegments and countries. Currently, it has a feet o 17platorm supply vessels which operate on theBrazilian coast and another eight vessels are underconstruction.

Companhia Brasileira de Oshore CBO, who recentlywon the bidding or this supply to Petrobras, closed adeal with WEG to supply an electric package or the ourplatorm supply vessels. The scope o the contract hasgenerators o the diesel group, principal and lateralpropulsion motors, all the electric panels includingregenerative water-cooled variable speed drives distribution transormers and the energy managementsystem.

These will be the rst vessels with a Ulstein X BOWdesign to be built in Brazil. O the our ships, two will beo the PSV 3000 type and the other two, 4500, explains

Marcos Menezes, supervisor o the Marine and ElectricTraction Department at WEG.

WEG was called to participate o the project because itoers the most complete line o Brazilian products orthe Marine and Oshore industry. Besides supplying theequipment, the company is also responsible or theintegration o the other systems o the ship and or themaintenance o the products.

The demand o the project or electric diesel propulsionmade us search or a partner who could provide hightechnology. And WEG is the company that not onlymeets our needs technically, it also give us support inthe maintenance o the vessel ater it starts operation,points out Alredo Naslausky, Director o CBO.

Another actor that made CBO choose WEG productswas the act the equipment is produced in Brazil. Thishas been a company policy since it began renewing itsfeet.

When WEG decided to work with the marine sector wedidnt believe the company would dedicate suchattention to it because this was just another segment othe whole universe it services. But we were taken bysurprise and WEG is showing the market that thisdecision was planned and that it has come to stay,says Alredo Naslausky.

WEG electric panels are being manuactured accordingto the designers plans to meet the high levels odemand o CBO. With the use o xed azimuththrusters, the variable speed drives which wereespecially developed to meet marine needs mainly interms o the levels o harmonic noise, will drive the shipsmain propulsion motors. Ater conclusion, theequipment will be sent to the Aliana shipyard where theships are being built.

This contract consolidates WEGs presence on themarine market even more and shows the company isincreasingly prepared to meet the needs o this segmentwhich has very specic characteristics and requiresqualied proessionals who understand theseapplications, adds Menezes.

To meet the strategy o renewing its

eet and to assure the construction o

new vessels within the necessary

deadlines and the quality standards

o the company, CBO acquired the

EBIN shipyard, now called Aliana

(photo at the let, in 2004). It is

strategically located in an area

covering 60,000 m2 on the banks o

the Baa de Guanabara on the BR-

101 highway in Niteri.


6/86

Sel-confguration with Plug-and-Playaccessories

Easy and rapid upgrading and customising o theCFW-11 are acili tated by the Plug-and-Play modularclick-in design o the accessory units which areinserted inside the control casing. The CFW-11automatically recognises and congures the accessoryand option units or accurate and sae installation whileeliminating the time and possible errors o manualconguration. The customer insertable, modular unitsinclude I/O expansions, encoder interaces, memorycard and communication protocols. The CFW-11 alsoeatures Normal and Heavy Duty ratings or quickoptimal load type adaptation.

In-built value and cost savings

Furthercustomer value oered by the CFW-11 includesthe internal PLC unction that eliminates mostrequirements or an additional external PLC device.

The SOFT-PLC unction enables the creation o manypossible applications like winding, multipump,cascaded control, crane or elevator. Many o WEGsalready developed applications will be ree o chargeor the customer. The customer can also develop hisown applications using high level ladder blocklanguage (according to IEC 61131-3) and he canprotect his knowledge by using his own password toaccess the application sotware. This sotware can besaved in the memory card. Another possible option isthe PLC11 accessory which is a high perormanceprocessor card or advanced unctionality. This card is

also programmed using the same high level languageas beore.

Uniquely easy confguration options

Ease or customer use inconguration and operation isone o the important benets o the CFW-11. Theremovable Human/Machine Interace (HMI) handheldcontrol panel, with its cellphone inspired unction and

jog-selection keyboard, is one way the operator cancommunicate with the drive, and covers 100% o thedrive unctionality. Uniquely amongst drives, the CFW-11also oers a USB port on its ront panel, allowingadditional unctionality and updating o drive rmwarethrough connection with a lap top. Alternatively, the

CFW-11 is compatible with Probus, DeviceNet,CANopen, Modbus and Ethernet communicationprotocols, or actory-wide DCS operation.

New WEG CFW-11: water cooled version

Designed or long lie, greaterreliability, a longer Mean

Time Between Failure are assured due to a conservativedesign using the latest generation IGBTs and advancedpassive components. The user can access inormationabout every aspect o each Power Module while the

VFD is in operation, or example current, temperatureand overload. Increased reliability is ensured by the useo intelligent thermal management to enable ullprotection o IGBTs, monitoring o heatsink and theinternal air temperature. The heatsink an isautomatically controlled and easily disassembled romthe product or cleaning and maintenance.

To match users oshore requirements, WEG hasdeveloped a water cooled CFW-11 version, which goesthrough a special process to make it deep sea resistant.

It is not only a small unit, this product has another greatadvantage: it can be installed very close to the motor inoperation, at the powerhouse. Its the perect t to startazimuthal and tunnel motors as it can achieve a 3000kWpower in low voltage. It allows an easy integration withthe ships main systems, such as the dynamicpositioning and propeller control.

Efciently matching application needs

By applying this technology to 400kW basic powermodules, WEG has enabled the CFW-11 to oer VFDcontrol rom 300kW to 3000kW. Up to 5 modules inparallel may be driven by one CFW-11 control module.

The compact dimensions make it easy to locate in anew or existing plants and the CFW-11 Modular Drivecontrol panel is available either built by WEG (AFW-11M)or as a kit or completion by the customer or WEG agent.

WEG has also introduced a water cooled CFW -11 specifcally designed, produced and tested to support users oshore needs to

ace the tough conditions o marine environments. Paulo Roberto Kruger, Automation Sales Manager explained: The CFW-11M

has a modular concept where one can use Power Modules in a book ormat to create a whole range o power ratings using

standard parts. The Power Modules can be mounted side by side allowing a very compact construction or high power rating drives.

Complete solutions with transormers

One o WEGs main concerns is to match saety andoutstanding perormance o machines it supplies.

Thinking about the integrity o companies properties,WEG engineers developed dry transormers as analternative to the oil-lled equipment. For oshoreapplication, this is the perect choice, since Dry

Transormers are environmentally riendly since they are

toxic-ree machines and the risk o combustion ignitionis completely eliminated. This is assured with theapplication o re-proo CW229 resin, which is the onlyproduct item available on the market with ULcertication. They are manuactured in accordance with

NBR 10295 and IEC60076-11 Standards. DryTransormers are available rom 300 to 15,000 kVA,voltages 0.6; 1.2; 7.2; 15; 24.2; 36.2 kV and with Degreeo Protection rom IP 00 to IP 55.

Oil

When the application is onshore, WEG has the bestsolution as well. Oil-lled transormers or power,distribution and industrial purposes. These products areavailable in classes up to 550kV and outputs up to350MVA.

It doesnt matter i you choose dry or oil. WEG has the exact solution or onshore and oshore applications.

This is an eco-riendly motorwhich due to its Super

Premium Eciencydemands less

energy rom thepower supply. Itslevels oeciency arethe highest o

the market andthat translates into a

prompt ROI with reduction

WQuattro More economy with less CO emissionThe WQuattro line o motors was developed or applications which consider energy saving a priority.

on electricity bills and o the levels o CO emission onthe environment.

Among some o the benets o the WQuattro are the

interchangeability with motors o normal induction(same power x rame ratio), increase o useul lie andreduction o maintenance hours, wide range o speedvariation with constant torque and easy speedsynchronization with multiple motors driven by thesame inverter. Besides all that, the line does notrequire the use o sensors/encoder in applications withrequency inverters nor the use o protection withspecial overload relays.

With the same rame size o a conventional inductionmotor, the user has more eciency in his application.

The WQuattro line o motors contemplates powersrom 1 to 15HP on 80 to 132 M/L rames. It is a

hybrid motor with a conventional squirrel cageequipped with high energy permanent magnets(NdFeB) which enable direct starting rom the powersupply. Scalar control requency inverters can beused or applications which require speed variation.

The WQuattro is already contemplated on the newWEG W22 motor platorm.


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W22 Plus

Higher eciency electric motors exceeding EFF1levels, yet with lower lietime costs, have beendeveloped by WEG in its new W22 platorm threephase induction range.

The new W22 industrial motors are being introduced inthree dierent stages covering dierent rame sizesand outputs, with the 225 355 (up to 400 kW) ramesize exhibited by WEG rst time at Hannover 2008, the132 200 size in early 2009 and the 63 112 size inmid - 2009. Other innovative improvements, supportedby patent and registered design applications, oerlower noise and vibration, even higher reliability with anextended lietime, and easier maintenance.

Cutting losses

Siegried Kreutzeld, managing director o WEGMotores, commented: With losses reduced by 10% to40 % across the range, W22 industrial motors provideeciency improvements equal to or better than EUEFF1. These improvements will enable the W22 motorsto meet the latest requirements or high energyeciency.

New WEG W22 three phase motors

W22 Premium

To oer these improvements at lower running andlietime cost o ownership, WEG has undertaken

extensive redesign o key components motor.

Improved efciency and reliability:the result o improved cooling system

A highly critical redesign is the an cover shape and theventilation an itsel. The innovative WEG designsprovide better airfow over the motor rame, thusmaintaining temperatures within the optimum operatingrange and improving reliability and lietime; the design issubject to international patent applications.

Additional aerodynamic improvements to the outsidearea o the rame have enhanced the airfoweectiveness and minimized any hotspots, urtherbeneting reliability. For example the terminal box and

the central eyebolt seating have been moved to avoidthe air fow reduction (rames 225-355 IEC). The lowertemperature urther enhances the benets o WEGsunique WISE WEG Insulation System Evolution (withinternational patents pending), which oers extendedresistance to temperature degradation o the insulation.

Built-in inverter compatibility

The W22 industrial motor range has been designedrom the start or operation with advanced requencyinverters, to oer fexibility and increased energyeciency, while resisting voltage spikes and voltage risetimes. It is available as a package with WEGs CFW11Optimal Flux Frequency inverter drives.

Substantial noise reductions

Noise levels due to the ventilating system have beensubstantially reduced, by 3dB (A) to 8dB (A). This bringsthe W22 noise levels rom 72dB to 80dB, substantiallylower than IEC recommendations and equal to or lowerthan competitors.

Improved durability and environmentalresistance

The W22 industrial motors are manuactured withWEGs own high quality cast iron to ensure maximumdurability and lie under aggressive conditions.Redesign o the an cover (cowling) has also ensuredgreater strength to resist everyday impacts andeventual accidents. In addition, the an cover hasbeenredesigned or improved heat dissipation romthe bearings, while being strengthened or increasedresistance to deormation and better bolt protection.

The eet are now cast integrally with the motor rame,giving greater stiness, better damping in highvibration installations, and ensuring fatness or easymounting on the motor plinth. Additionally, thestrengthened eet have been designed with integral

liting holes; this has enabled the eyebolt seating tobe removed rom the rame. For more even cooling.Standard degree o protection is IP 55. This is easilyupgraded to IP65 with a WEG adaptation kit,comprising a replacement housing with new bearingseals, or improved dust and water ingress protection,enabling high pressure water cleaning to beemployed. This can be supplied or customer tting,or by WEG maintenance service.

The electromechanical design meets the needs o thedemanding applications in the continuous processingindustry, where reduced maintenance interventions areessential. Available in the new W22 platorm, Plus and

Premium Eciency, the WELL line meets the BrazilianEciency Legislation - Decree 553. The WELL line -WEG Extra Long Lie - is tted with the most advancedtechnologies developed by WEG or manuacturingelectric motors, such as the W3 sealing system that

provides ecient sealing against the ingress o waterand dust into the motor. The WISE insulation system(WEG Insulation System Evolution) uses WEG GIII 200C enameled wires, allowing the motor to be operatedby requency inverters. With proven high eciency andlow losses, the WELL motor line is guaranteed by thePROCEL mark that ensures its high perormance andeciency.

The WELL motors can also be used in hazardous areassuch as Ex-n (non sparking), with controlled starting

current (Ip/In). As an option, the line also allows thelubrication system through the oil mist, an automaticlubrication system that aims to minimize machineinterventions, ensuring a lower temperature in thebearing, extending its lie. Due to an exclusivecertication in the Brazilian market, the WELL line orhazardous areas can start D.O.L (Direct On Line) or by

VFD (requency inver ter).

High Eciency Extra Long Lie motor generation

Developed especially or maximizing the equipment reliability and productivity, ensuring

both lower noise and vibration levels, higher mechanical accuracy, longer lietime, more

energy saving, better per ormance and requiring less maintenance.

The special electromechanical design o this linemeets the demanding IEEE 841 Standard, relating

to the Petrochemical Industry. The reducedtemperature rise provides a L10 lietime (50,000

operation hours, considering direct coupling; orother conditions contact WEG) and extends thelubrication intervals. The WELL line is supplied withcoatings that meet the demanding market standards.For protecting the internal motor suraces, the motorsare painted with WEG exclusive tropicalized paintingsystem, thus increasing the resistance in aggressiveenvironments. WELL line motors, a unique WEG eaturethat provides reliability and economy or any appl ication

or this demanding market.

FeaturesSpecial rotor balancing

High precision machined shat

Lower bearing temperature

Improved oot fatnessW3 Seal System

Internal anticorrosive painting

Plus and Premium Eciency

WISE insulation system

Painting plan or aggressive environments

Customization

Increased bearing lietime and extendedlubrication intervals.

Special sealing against the entry o water and dirt,(IPW66).

Lower energy consumption (meets the BrazilianEciency Legislation Decree 553).

Motors can be operated by requency inverterswithout causing damages by voltage peaks.

More resistance to corrosive environments.

Product suitable to meet the requirements o themost demanding application in the industry.

BeneftsLower vibration levels, meeting internationalstandards.


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Documents

WEG Oil Gas News 2010