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SINCOR, C.A.
REVISION INDEX:
This Document Consist of 31 pages
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Project Title: SINCOR, C. A. Sincor Document: CA04-04-33-P-SP-033-X0
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INDEX
PAGE
1. SCOPE 4
4. GENERAL 8
5.1. Technology 9
5.6. Communications 15
6. CONSTRUCTION REQUIREMENTS 24
6.1. General 24
6.3. Enclosure 25
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6.4. Wiring and Terminations 26
6.6. Nameplates 28
7. HARMONIC ANALYSIS 29
9. SPARE PARTS 30
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1. SCOPE
A. This specification covers the basic requirements for the design, engineering, testing,
certifying, installing and commissioning of Regenerative or Active Front End (AFE) Variable
Speed Drive, hereinafter assigned as VSD and shall power the Progressive Cavity Pumps
(PCP), Electro Sumergible Pumps (ESP), Multiphase Pump (MPP) or Electro Submergible
Progressive Cavity Pumps (ESPCP) motors that should be installed at the new SINCORs
clusters.
B. The sizing of the VSD and motor shall be determined from the maximum range of the pump
that would be installed in the field and shall have the ability to operate at minimal flow rates
without significant affect on efficiency.
D. The electrical motor shall be induction (asynchronous) and certified to be used and powered
by VSD. The motor technical requirements are stated in separated specifications numbers
CA04-04-33-P-SP-018 and the Data Sheet of the Electrical Motor.
E. To comply with the standard IEEE 519 1992, the manufacturer of the VSD shall perform a
harmonic study that evaluates the total harmonic distortion (THD) for voltage and current
between the cluster and existing electrical power system assuming that the same type of
VSD shall be installed at each cluster. Each cluster should be considered to have 25 PCPs
and 1 MPPs. The project shall expand over time and therefore the recommendation should
address a solution that minimizes the harmonic content at a cluster level to ensure the THD
for the system does not exceed 5 % as the standard states.
F. Cables from VSD to the motor and switchgear shall be out of the scope of supply.
Nevertheless, the seller shall inform the buyer of any special technical requirements for
power and control cables connecting the VSD to the motor.
G. It is intended that basic data, component data sheets, arrangement layout and specific
requisition shall supplement this specification. These shall delineate the specific
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requirements for each. In the event of conflict, the specified data sheets in the Material
Requisition (MR) shall take precedence.
H. Vendor shall provide evidence of local support capabilities, spare parts availability and
complete the Questionnaire in Annex 1.
I. The scope of work also includes a complete VSD MOTOR equipment system analysis,
assistance during commissioning and start up, training and spare parts.
Compliance with this specification shall not relieve the Manufacturer of responsibility for
furnishing equipment of proper design, construction and scope of supply, fully suitable for all
specified operating conditions.
The seller shall comply with the requirements of this specification. In case of arising any conflict
between this specification and the Material Requisition (MR) or Data Sheet (DS), the MR shall
take reference. In the event of ambiguity in any portion of the subject documents, it shall be
responsability of the seller to contact SINCOR for clarification.
Except where indicated otherwise in this specification, the design, equipment, materials, and
installation there of, shall conform to as a minimum, the applicable requirements of the latest
edition of the following standards and codes:
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The most important publication relevant to the matter of this specification is:
IEC 61800-2 (1998-03) Adjustable speed electrical power drive systems Part
2:General requirement Rating specifications for low
voltage frequency a.c. power drive systems
IEC 61800-3 (2004-08) Adjustable speed electrical power drive systems Part 3: EMC
requirements and specific test.
Other recognized National Codes and Standards will be accepted, provided the electrical
installation and equipment based on such documents are at least equal to those conforming to
the standards listed above.
Latest editions of applicable SINCOR specifications and addenda including the following:
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CA04 - 04 - 33 P SP 006 Battery, Charger and DC Distribution System Redundant.
The equipment and materials furnished shall be labeled, listed, certified, accepted or otherwise
assured to be safe for the intended use by an internationally recognized testing laboratory.
A. General
B. All equipment shall be treated and packaged for tropical environment, due to possible
storage in an open area before installation or air-conditioning failure. In addition, all
necessary anti-condensation space heaters shall be provided.
If mechanical cooling fails, equipment shall withstand without any damage or degrading a
temperature of 40C and 71% relative humidity.
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E. The equipment shall be located indoors
4. GENERAL
A. Unless otherwise specified, the power shall be drawn from 480 VAC, 3-phase, 3-wire, 60
Hertz and solidly grounded system. Voltage 10% with occasional drops of 20% can be
expected.
B. Unless otherwise specified, the control and instrument power supplies available shall be:
Control 24 VDC
Instrument 24 VDC
D. The VSDs should mainly comply with the Total Harmonic Distortion (THD) for current and
voltage according to the standard IEEE 519 1992.
E. The VSD and components shall be of, or modification of, the Manufacturers standard
product line in order to facilitate procurement of spare parts.
a. System cabinet.
c. Main Contactor.
d. Precharge circuit.
e. Filter LCL.
k. The VSD shall have the last generation of IGBTs (Insulated Gate Bipolar
Transistors).
l. The IGBTs modules should be installed either in rectifier section and the
inverter section of the VSD.
The VSD should comply with at least the following technical requirements:
5.1. Technology
A. The variable speed drives VSDs shall have the last generation of IGBTs (INSULATED
GATE BIPOLAR TRANSISTORS) and furnished to limit total harmonic distortion (THD) on
power system down to less or equal to 5% for current and voltage as indicated in IEEE 519
1992. The manufacturer shall select the last generation of the IGBTs to achieve that goal.
B. The design of the VSD shall include one precharge circuit with LCL filter and line inverter
with latest generation of IGBTs in rectifier section and latest generation of IGBTs in
inverter section. Control of logic functions will be accomplished through microprocessor
with latest technology and integrated control system.
C. The manufacturer should furnish the appropriate and adequated filter at the output of the
VSD in case of installing ESPs or ESPCPs motors to avoid the resonance phenomenon
because of the transmission of electrical travel waves in the cable between VSD and ESP
or ESPCP.
The VSD shall be furnished to work as minimum with the following technical characteristics:
OPTIMUM CHARACTERISTICS
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The VSD shall be 100% capable of regenerative power feedback without the need for an
autotransformer. Even during regenerative mode, power losses should not occur as in the
case with a braking resistor. The transition from monitoring to regenerative mode shall be
very quick, with pulse-frequency response. The voltage DC link will be exactly regulated to
ensure optimum supply of the drive inverter and almost independently of the supply
voltage.
With the VSD, the harmonics and commutating dips shall be avoided except for a very
small residue. Optimum matching between the electronically controlled active section and
the passive section shall ensure that almost sinusoidal voltages and currents will be
impressed in the direction of the supply and will not occurr network perturbations.
If the voltage moves outside the permissible range or if it fails completely, the VSD shall be
able to take all the necessary electronics actions to continue working properly in seconds
and the VSD shall automatically resume the set speed after returning the line voltage within
the acceptable range.
The VSD shall maintain a 0,96 to 1,0 true (total) power factor over the specified speed
range, unless otherwise specified in the Data Sheet (DS). This requirement shall be fulfilled
by the VSD preferably without needing additional power factor correction units.
1. Incoming Power: Three-phase, 480 VAC (+10% to -15%) and 60 Hz (+/-5 Hz) power.
2. Output frequency stability of +/-0.05% for 24 hours with voltage regulation of +/-1% of
maximum rated output voltage.
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5. Relative Humidity: 71%.
The Control Panel should be the user interface to monitor, adjust the parameters and control
all the operations of the VSD.
It shall be mounted on the front side of the enclosure and accessible for the operator.
It shall have an alphanumeric programmable display with high resolution and status indicators
in different languages (Spanish / English as minimum) with at least six (6) lines x 24
characters.
b. Control the VSD with a reference signal, start, stop and direction commands.
f. Adjust for contrast with large characters easily visible in normal ambient light.
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a. Frequently accessed VSD programmable parameters shall be adjustable from a digital
operator keypad located on the front of the VSD.
c. Keypads should be able to use plain Spanish words for parameters, status and diagnostic
messages.
d. Keypads shall be adjustable for contrast with large characters easily visible in normal
ambient light.
f. The operator shall be able to scroll through the keypad menu to choose among the
following:
a) Monitor
d) Active faults
e) Fault history
g) Information to indicate the standard software and optional features software loaded.
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g. The following setups and adjustments shall be available but not limited to:
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20. Bus regulation.
22. Compensation.
h. The variable frequency, variable voltage AC controller shall be vectorial type the latest
technology and suitable for:
1. 110% min. overload for thirty (30) minutes (variable torque load only).
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2. Voltage Boost Sync: 0 to 200 V AC.
q. Forced air-cooling shall be supplied with failure alarms and requires customer approval.
1. Overload in excess of 110% for thirty (30) minutes and short circuit conditions-current.
4. Motor thermal overload signal. The manual reset shall be located at the electronic
power supply module.
6. Single phasing.
5.6. Communications
The VSD should be managed from different locations of control and should at least
comply with the following requirements:
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a. The VSD shall include one standard software Modbus facility and link (serial
connection RS-485).
b. The VSD shall give facilities for the link with a computer, which can configure the
equipment and/or load particular applications, via the VSDs RS232 port. Accesible
RS-232 Port for communication link to computer.
d. The communication modules shall be connected to the VSD by means of fiber optic
cables.
The VSDs should have the following system interfaces and accessories:
A. The VSD shall be provided in a complete wired enclosure with the control system interface
and shall be shown on the contract drawings.
B. Push buttons and indicating lights shall be at least of 22.5 mm diameter and heavy duty oil
tight.
C. Indicating lights shall have enough intensity to be clearly visible when are installed indoors.
D. Clamp type terminal blocks shall be provided for all fields wiring complete with marking tabs
and wire numbers.
E. Internal control wiring shall have ring or sleeve type wire labels.
F. The VSD shall be furnished to have interface with input and output signals with the
following technical characteristics:
Digital I/O
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Three (3) digital output relays of 24VDC switchover contact, Max 2A.
Analog I/O
G. The VSD shall be capable of sensing the following reference loss conditions:
H. In the event of loss of an analog input reference signal, the VSD shall be user
programmable to the following:
I. Signal loss detection shall be available and the signal is going to be monitored as:
J. The input and output signals listed above shall be programmable to the following functions
as a minimum:
Digital Input
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Start Forward
Start Reverse
Run Enable
Reverse
Fault Reset
Digital Output
Ready
Run
Fault
Fault inverted
Overheat warning
Warning
Reversed
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At speed
Analog Input
Analog Output
Motor current
Motor frequency
Motor speed
Motor torque
Motor power
Motor voltage
DC link voltage
K. The VSD shall have the following local controls operated by door mounted control switches:
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5.8. Monitoring and Displays
1. Output frequency
2. Motor speed
3. Pump speed
4. Motor current
5. Motor torque
6. Pump torque
7. Motor power
8. Motor voltage
9. DC-link voltage
The VSD shall have comprehensive safety and protection features including safety trips in the
event of various internal or external faults conditions. The VSD shall have logic to protect itself
from trips due to improper operation of protective devices.
The VSD shall be furnished at least with the following protective functions:
1. Output Overcurrent
2. DC link Overvoltage
3. Inverter fault
4. DC link Undervoltage
7. Under-temperature
8. Over-temperature
9. Motor blocked
The VSD shall provide ground fault overcurrent protection during power-up, starting, and
running. VSDs with no ground fault protection during running shall be not acceptable.
Additional Protections at the input of the VSD should be provided such as:
1. Phase loss
2. Underload
3. Current unbalance
6. The VSD shall be supplied with overvoltage protection that should de-energize and
isolate the VSD during prolonged input overvoltage. The overvoltage protection setting
shall be specified by the VSD manufacturer and selected to prevent damage to the
VSD. The overvoltage setting should not be below 120% of VSD's rated input voltage.
7. The VSD shall be provided with an alarm system. This system shall consist of visual
and acoustical alarms in the control room and individual annunciator alarms or
equivalents indications at the control equipments cubicles. All alarms shall have a First
out Feature. Acknowledgement of the alarm group in the control room shall silence the
acoustical signal and shall steady the flashing annunciator. Resetting of individual
alarms should only be possible either by removing the cause or manually at the drive
control cubicle by complying the interlock conditions.
The software should be open in such way that SINCOR shall be able to modify the logic
applications and functions whenever is required.
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SINCOR should be able to upload or download the whole software application without need of
specialist supplier.
In case of being necessary any special tool, it should be supplied with the driver.
Control Software
In addition to comply with the Control Functions (point 5.5.) of this section, the manufacturer
shall furnish with the following control functions for the pumps PCP, ESP, ESPCP or MPP as a
minimum:
Protect the rod, tubing and pump from unnecessary stress by accurately controlling the
rod speed within each stroke.
Protect the rods from sudden load changes, minimizing rod stretch and compression.
The following parameters shall be used to control, protect and supervise the pump:
Pump Speed
Motor Speed
Pump Torque
Motor Torque
Active Power
Input Voltage
Output Voltage
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6. CONSTRUCTION REQUIREMENTS
6.1. General
The VSD shall be constructed for easing the maintenance and minimize the
downtime. The components shall be grouped by function and shall be
interchangeable between any other components that have the same function.
All power semiconductor-switching modules shall be removable from the front of the
enclosure. When a lifting device is required, the Seller shall provide it.
The unit shall be designed to permit ready access to control modules and printed
circuits boards. The placement of components, test points and terminals shall be
such that they are accessible for circuit checking, adjustments, troubleshooting and
maintenance from the front of the enclosure without removing any adjacent module
or assembly.
All power buses shall be of copper. The short circuit rating shall be capable of
withstanding let through current capability of the isolation transformer rating.
All bolted power bus connections shall be of materials against corrosion and be
secured with corrosion resistant, silicon-bronze hardware, including bolts, locking
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washers and nuts or jam nuts. Connections shall be made with a minimum of two
bolts.
A label shall be installed inside each cubicle listing torque requirements for bolted
connections.
A copper earthing bus that extends throughout the length of the stationary structure
shall be provided. The earthing bus shall be designed to carry the maximum short
time current expected for minimum 2 seconds.
The earthing bus shall be rated for the available short-circuit current and electrically
connected together all metallic parts of the assembly.
Provisions for connection of two hole connectors at each end of the earthing bus
shall be provided.
6.3. Enclosure
The enclosure shall comply as a minimum with the following technical characteristics:
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Enclosures shall be properly identified as to contents and purpose. Identification
shall be laminated plastic nameplates with black letters on a white background.
Rigid galvanized steel conduits or pipe to be used only as mechanical protection for
cables, open-ended and without seals and fittings. Cable trays are preferred for
support of cables.
The VSD shall have complete front accessibility with easily removable assemblies.
The enclosure shall be suitable for bottom cable entry for power of the motor (U, V,
W) and control cables.
The input power from the electric network (L1, L2, L3) and control cables shall be
on the top of the enclosure.
Modules and panels shall be protected from condensation. If any part of the
equipment is not going to be installed immediately, it shall be stored in a clean, dry
place and protected from variations in temperature, high humidity, and dust. If
possible, sudden changes in temperature and humidity should be avoided. If the
temperature of the storage room varies to such an extent that the equipment
surfaces are exposed to sweating or freezing conditions, the equipment shall be
protected by a safe, reliable heating system, which will keep the temperature of the
equipment slightly above that of the storage room. If the equipment will be exposed
to low temperature for an extended period of time it should not be unpacked until it
has reached room temperature, otherwise it will sweat. The presence of moisture on
certain internal parts can cause electrical failure.
The enclosure shall be treated and packaged for tropical environment, due to
possible storage in an open area before installation or air-conditioning failure. In
addition, all necessary anti-condensation space heaters shall be provided.
The manufacturer shall specify off load periods even if the ambient temperature is in
the range defined in this specification.
A. Control wiring in the motor starter units shall be stranded copper conductors not
less than 1.5mm2 having 600 volt 90C minimum operating temperature heat
resistant insulation.
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B. Power wiring from motor controller to motors shall be 4mm2 minimum, having 600
volt 90C minimum operating temperature heat resistant insulation.
C. Control wiring shall be terminated on marked terminal blocks. 20% spare terminal
points shall be provided on terminal block for use by others.
D. Control wiring in the VFD shall be marked with heat shrink type wire markers.
E. Control wiring shall be shielded provided with suitable brackets and connection
accessories for EMC reasons.
F. All internal wiring shall be color coded or tagged with permanent labels at each
termination, junction box and device. Wire label designations and color coding
shall correspond to the schematic and wiring diagrams furnished with the unit.
H. All wiring harnesses shall be securely bundled and supported and shall be
protected against abrasion within the enclosure.
I. Internal wiring shall be connected to only one side of all field wiring terminal
blocks. No more than two wires per terminal shall be permmited for internal wiring
within a panel. No more than one wire per terminal shall be permmited on field
side of the terminal block. A minimum of 10% spare terminal blocks shall be
provided.
K. Adequate wireways for connection of field wiring from conduit entry to location of
terminal blocks shall be provided in the enclosures.
L. Control and power wiring shall be distinguishable and separated. Low voltage
analog and digital control circuits shall be provided with shield and routed
separately so the power circuit does not induce error.
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M. All compartments containing circuits energized by sources of power that are not
de-energized when the main power disconnect is opened shall be provided with an
isolating device which de-energizes all components, and a red warning nameplate
stating that foreing voltage is present.
The heaters shall be rated at 240 VAC, but they shall be sized to provide the
required heat output when operated on a 120 VAC system. The surface
temperature of heaters shall never exceed 180C at 110% of supplied voltage and
40C ambient.
The space heaters of the electrical motors (PCP) shall be connected to independent
electrical connection out of principal electrical feeder of the VSD.
6.6. Nameplates
A. Main power terminal shall be clearly marked in accordance with IEC 60146.
B. Each VSD line-up shall be provided with one phenolic main nameplate with black
lettering on white background, mounted in center of VSD line-up. Lettering height
shall be minimum 12.5mm.
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C. Each controller shall have one phenolic nameplate with black lettering on white
background which shall be fastened by means of stainless steel screws. Vendor
may quote an alternate permanent yet changeable method for approval if he
chooses.
2. 5mm for main titles such as circuit or cubicle designation, motor or feeder
number and service title.
E. Labels and nameplates shall be mounted on the front of the cubicle with stainless
steel pins or screws.
F. Meters, relays, switches and other devices shall be permanently identified using the
same symbols as those appearing on the schematic diagrams.
G. Termination points for all wiring brought from an external power source shall be
identified by means of a red nameplate with 6 mm or higher white lettering as
follows:
H. All warning and instruction nameplates shall be written in English and Spanish.
7. HARMONIC ANALYSIS
The Seller having unit responsability, shall provide all the necessary studies that warranties and
verifies the VSD shall comply all the requirements as outlined in the latest edition of IEEE 519 for
total harmonic voltage and current distortion and as indicated in this specification.
The magnitude of harmonics reflected or impressed onto the direct connected AC incoming line
shall not adversely affect the existing or the future electrical system.
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Project Title: SINCOR, C. A. Sincor Document: CA04-04-33-P-SP-033-X0
Sincor Interface Code: 0
Project Title: Sincor Document CLASS: 0
UPSTREAM SURFACE FACILITIES PROJECT Sincor Document Class: 00
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8. SHOP INSPECTION AND TESTING
B. Each controller unit in Manufacturers shop shall include, but not be limited to, the following:
visual inspection, megger test, load test, voltage and frequency control test, loss
measurements, polarity and phase rotation test, output wave shape test, etc.
9. SPARE PARTS
The manufacturer shall at least include for each VSD the following spare parts:
The manufacturer shall recommend to SINCOR any other device or part according the experiences
in other similar installations.
The manufacturer shall supply the spare parts for startup of each VSD.
The manufacturer shall include the spare parts list recommended for two years of operations.
1. Overall dimensions.
2. Approximate weight.
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Project Title: SINCOR, C. A. Sincor Document: CA04-04-33-P-SP-033-X0
Sincor Interface Code: 0
Project Title: Sincor Document CLASS: 0
UPSTREAM SURFACE FACILITIES PROJECT Sincor Document Class: 00
Page/File: 31/CA04-04-33-P-SP-033.doc
Rv./ Date: X0 / 12 MAY 2005
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3. Heat dissipation.
4. Harmonic Study
6. Proposed P&IDs.
7. Control Description
Official language, unit system, drawings and documentation, identification and folding shall
be as shown by: General Notes for Requisitions.
The manufacturers of Motors and VSD`s shall be responsible for obtaining all coordination of
information needed, such as the planned speed range and VSD harmonics content, with copies of
such correspondences to SINCOR.
The manufacturer of Motors (for PCP application) shall provide to SINCOR the ATEX conformity
certificate given by a Notify Body, which states that the motor in Zone 2 Classification Area shall
work properly with the VSDs .
On the other hand, the manufacturer of the VSD shall provide to SINCOR the certificates given by
international tests and standards described in CODES AND REGULATIONS of this documents. In
this way the manufacturer shall warranty to SINCOR that the VSD`s should work properly with the
motors proposed.
The VSD`s should have warranty of eigtheen (18) months from commissioning or two (2)
years from delivery whatever happens first.
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