Permanent Magnet maskin i subsea applikasjoner. IFEA-Subsea Seminar May 2011 ASYNKRON V.S PERMANENT MAGNET MASKIN

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1 Permanent Magnet maskin i subsea applikasjoner IFEA-Subsea Seminar May 2011 Inge Nordsteien Content OM PETROMAKS PM TEKNOLOGI ASYNKRON V.S PERMANENT MAGNET MASKIN LONG STEP-OUT, MODELLERING OG KONTROLL PERMANENT MAGNET MASKIN I SUBSEA APPLIKASJONER POWER ELECTRONICS DOWNHOLE 1

2 Drive systems Oil & Gas applications NFR PETROMAKS Program Scope Efficient and survivable electric drive-trains for subsea and downhole applications. 5 years duration Budget: 31.1 MNOK. Consortia in progress University cooperation; 3 MsC thesis NTNU 2010, 3 professors & students NTNU, Internship from Eindhoven, PhD Achievements Strategic focus Mapping drive train technologies versus a wide range of applications subsea Assessing dynamic behavior and controllability of PMSM over long umbilical with VSD and transformers. Comparisonand evaluation of SmartMotor HT machine platform to other existing solutions, e.g. PMSM with damper winding, Flux switching machines. Configurations of permanent magnet, reluctance, and flux-switch machines. Cooling and pressure withstanding solutions for electronics in ultra-deep wells. HTHP (High Temperature High Pressure) Converter, SiC (silicon carbide) Powerstage Long StepOutLab. Dynamic behavior and controllability of PMSMover long umbilical with VSDand transformers. Investigation of new PMSM Subsea motor for long stepouts Minimization of friction losses in oil-filled subsea and downhole electric machines Development of multidrive solutions for high torque/power applications in wells Development of wire line communication integrated with main power electronics Content OM PETROMAKS PM TEKNOLOGI ASYNKRON V.S PERMANENT MAGNET MASKIN LONG STEP-OUT, MODELLERING OG KONTROLL PERMANENT MAGNET MASKIN I SUBSEA APPLIKASJONER POWER ELECTRONICS DOWNHOLE 2

3 Lenz lov Den induserte spenning og strøm vil lage en fluks som motsetter seg den påtrykte fluks Angir retningen på den induserte strømmen og spenning. Hvorfor PM? Trenger ikke forsyne felt til rotoren med ekstra strøm Har kjøpt et permanent rotorfelt Maskinene er kompakte kw/m 3 Høy virkningsgrad Better dynamic performance than motors with electromagnetic excitation (Higher magnetic flux density in the air gap). Simplification of construction and maintenance. Space saving. Permanent magnet - Permanentmagnetprisene falt - Remanensflukstetthet opp mot 1.5T - Tåler høyere temperaturer opp mot 250 gr.c - Vanskelig å avmagnetisere - Limkvalitet 3

4 Magnets Typer: Neodym (NdFeB) max210 C RemanenceB r Up to 1.42 T Samarium-kobolt(SmCo) max C RemanenceB r Up to 1.15 T AlNiCo max C New materials Samarium Cobalt magnets instead of Neodymium Iron Boron Enables higher temperatures High temperature glue, 260 ⁰C Magneter, Pris og Tilgang Siden 90-tallet har Kina dominert PM-markedet Økt eksport Prisnedgang Kina har over 90% av verdensmarkedet Ulønnsom drift av gruver i USA og Australia gjorde at disse ble stengt ned Økende pris de siste årene Politisk bevisstgjøring i Kina rundt verdien på rare-earth materialer I 2009 ble eksport av rare-earth materialer kvoteregulert i Kina økte kostnader I 2010 ble det innført toll på eksport av Neodym ut fra Kina økte kostnader Økt fokus på renere utvinning ved gruven i Kina økte kostnader på råvaren 30% av kjent forekomst Nd er i Kina 70% befinner seg i andre deler av verden Mot slutten av 2010 inngikk Molycorp Mining i USA og tunge japanske PM-leverandører samarbeid for å gjenåpne amerikansk gruvedrift og sikre supply-chain av bla Nd Antatt drivverdige forekomster er blandt annet: Mountain Pass (USA) Thor Lake og Hoidas Lake (Canada) Mount Weld (Australia) Steenkampskraal (South Africa) Dong Pao (Vietnam) 4

5 SmartMotor PM technology Patented, multi-pole Permanent Magnet (PM) machines with concentrated coils Distribuerte viklinger, mye kobber. Konsentrerte viklinger gir enkel stator SmartMotor patented Permanent Magnet machines outperform other designs Concentrated Coils Winding Optimal flux, higher slot fill factor, better cooling Pre shaping of the coil. Low cost of production No insulation is needed between different phases US 6,664,692 Slot / Pole Combinations Slot/pole combinations described by mathematical expressions <0,5% cogging US 12/280,180 Segmentation Segmentation without losing performance. No torque density losses Ironless Advantageous for machines with large diameter No attracting force between rotors and stator Structure not sensitive to relative displacement of rotors and stator NO

6 Liquid filled machine Liquid filled machine for Pressure compensation Machine cooling Friction losses in liquid filled machines Losses in bearings and seals Viscous losses Calculated and verified by measurements, 1500rpm Viscous losses in the airgap. Can be substantial High speed Luftgap. Ønsker å designe for stort luftgap for å redusere friksjonstap Rotor diameter. Ønsker å lage rotordiameter så liten som mulig for å redusere friksjonstap. PM-magneter gir mer kompakt rotor enn asynkron. Proprietary in-house design tool SmartTool Pre-sizing; calculation of weights and costs; estimation of losses Approx 1000 designs / sec. CosmoWorks models Own optimized models for thermal analysis iterations COMSOL add-ons Automatic generation of models for FEA; calculation of losses in magnets and iron parts MATLAB & Excel-based tool Recalculation of actual length; winding design; calculation of ohmic losses 6

7 Content OM PETROMAKS PM TEKNOLOGI ASYNKRON V.S PERMANENT MAGNET MASKIN LONG STEP-OUT, MODELLERING OG KONTROLL PERMANENT MAGNET MASKIN I SUBSEA APPLIKASJONER POWER ELECTRONICS DOWNHOLE PM technology vs. induction machines More Compact. kw/m 3 (or torque /m 3 ) Higher efficiency Power factor High torque -> Enables Direct Drive and gearbox elimination High degree of freedom in design. -> Length OD, geometry -> Air gap. Larger air gap more tolerable to manufacturing variations -> Enables integrated design -> Competes both on cost and performance! 7

8 PM technology vs. induction machines Anta volum = 1 P Asynk = 1 Kost Asynk = 1 P Perm = 2.5 Kost Perm =1.57 Kost/kW PM =1.57/2.5 Kost/kW Asyn Kost/kW PM =0,628 Kost/kW Asyn Ref: Blant andre ABB-designere som bruker nye erfaringer fra papirindustri. Permanent Magnet Machines outperform traditional induction machines Lower Cost and Weight Compact -50% of typical IM Machine 60% material cost of tradi onal IM Machine Improved Performance Higher efficiency Low cogging (<0.5%) Super silent Large air gap without degrading performance Direct Drive enables significantly lowered OPEX/CAPEX (gearbox elimination) Low cost pump drives Simplified construction More effective stator production Enables segmentation with no torque density loss Easier cooling arrangement 8

9 PM technology vs. induction machines High speed rotating machine: rpm. 2 -pole, three-phase. Comparing two Standard downholemachines from BoretsCompany, OD: 117 mm. Ref: A.Bydzan, A. Strokolist, CJ Affeld, A. Hagelaars, A. Zanimonsky, A. Mabian, Y. Nikulin, ESPs with Permanent Magnet Motor in Salym, West Siberia, European artificial lift forum 2008, Aberdeen, February, PM technology vs. induction machines The Goodness of Small Contemporary Permanent Magnet Electric Machines D J Patterson, C W Brice, R A Dougal, D Kovuri Conclusions will be deduced that the small induction machine will eventually lose its place as the drive of choice in small applications, and be relegated to niche applications. It will further be concluded that this displacement can be justified on cost alone, with dramatic efficiency increases being simply fortuitous additional benefits. 9

10 Content OM PETROMAKS PM TEKNOLOGI ASYNKRON V.S PERMANENT MAGNET MASKIN LONG STEP-OUT, MODELLERING OG KONTROLL PERMANENT MAGNET MASKIN I SUBSEA APPLIKASJONER POWER ELECTRONICS DOWNHOLE Long Step-out work in progress, not concluded. LONG STEP-OUT, MODELLERING OG KONTROLL Notice! This is an ongoingactivity, and to be consideredas workin progress, and not concluded. 10

11 PM-motor and Vector Control PM-motors, the variable speedmotor of the future. Bedre virkningsgrad enn IM over hele turtallsområdet. Er enklere å styre med VectorControl enn IM, da en har info om rotorfluksen allerede i fra null turtall. -> Enklere å få til uten posisjonssensor / enkoder. IM og PM på Long stepout Likt for IMog PM på Long stepout Samme problemer med: Kabelrefleksjoner, kabelresonanser Spenningsfall på kabel (Lavere virkningsgrad ηog cosϕfor IMgir mer tap og spenningsfall enn PM) Metning av trafo ved lav frekvens / turtall gir ulineær impedans Forskjell PM: Høyere startmoment IM: Bedre dynamisk egenskap. Større elektrisk treghetsmoment i rotor. 11

12 Long stepout Problem ved Long stepout: Har ikke info om motorstrømvektor og rotorposisjon Har ikke posisjonssensor. Kun strøm ut fra omformer. (Som ikke er lik motorstrøm) Hvis en ikke kompenserer korrekt for kabel/trafo/filter impedans kan en bomme med strømvektoren slik at en ikke får riktig moment -> Motoren kan kippe β s ω α r s + u s β - s is β θ α s + s s is α us α - + i rd u rd u rq i rq β r Modeling Løsning: Modellere kabel/trafo/filter slik at en får en presis modell. Kompensere for impedans i kabel/trafo/filter. -> Presis estimering av motorstrøm -> Elektrisk moment for å styre motoren. Exact π-equivalent model: U c2 cosh( γ l) Zb sinh( γ l) ( ) ( ) Uc 1 = Ic2 Zb sinh γ l cosh γ l Ic 1 Distributed cable model: 12

13 Scalar Control ScalarControl (V/f-control) In Standard Drive for Control of Induction Machines Open-loop control Simple, primitive Scalar Control less dynamic than Vector Control. Keep the stator-flux constant up to rated voltage and speed. No need for precise measurement and estimation of motorcurrent m e Fra venstre: f,u = 0.2 s s f s,u s = 0.4 f s,u s = 0.6 f,u = 0.8 s s f s,u s = 1.0 f s =1.2, u s = 1.0 f =1.4, u = 1.0 s s f s =1.6, u s = n r s Compensation for r s voltage drop at low frequencies. u s =ψ s f x + s Compensate for voltage drop in cables and transformers as well Feasible for IM and Long step out 2 2 s Vector Control Vector Control In Standard Drive. More complex control. (Transforms 3-fase current to vector) For both IM and PM-Machines. Better dynamic properties than ScalarControl Requires precise estimation of motor-flux, i.e. precise impedance-model. Requires high bandwidth in cable / umbilical for precise estimation of current-vector. α r θ α s s s dψs Us = R s Is + dt r r dψ r Ur = R r Ir + dt s r β s s + us β - s is β r r r r β r s s is α us α - r i α u α - i β r u β r r 13

14 Control of PM-Machine Summary, control of PM-Machine: Scalar Control : Challenge: Stabililty during load variations Solution: Special designed rotor with improved dynamic behavior/ properties. Vector Control : Challenge: Stablilty during load variations Requires precise estimation of impedances during all frequencies, temperatures and failure-modi. Solution: Precise modeling of impedances in model. Temperature compensation of model. Special designed rotor with improved dynamic behavior/ properties. PMSM control of linear motor Model: Linear motor model 20kW / 250Hz / 2kV Cable 3-10km LC-filter Dynamical load model Challenge: More complex to control than a rotating machine. (Start Stop Cycle) High dynamic requirements. Questions: Is Scalar Control, (open-loop) or Vector Control (sensorless) preferable? Are special adaptations to the control necessary or is standard solutions applicable? Can a transformer be used to increase voltage? 14

15 PMSM control of linear motor Vector Control, (sensorless control) was implemented in the model. -> Vector Control is feasible. -> Very dependent on the estimated values of resistance and inductance in the system. A simulation including a transformer between Inverter and motor voltages the inverter and cable was also performed > This is also feasible. 1 Sensorless control implies : Custom control for the motor Or customisation and tuning of Standard drive. voltage [p.u.] time [s] uid uiq umd umq PMSM control with long step outs - Status Control method during development: More complex models due to nonlinear impedances in cable and transformers Comparing different cable-models Initial work on special designed rotor with improved dynamic behavior/ properties. A laboratory setup are to be developed and tested. Control strategy (-ies) will be described and system simulation to be performed, and tested and verified. 15

16 Subsea VSD enables PM-technology enables Integrated motor-pump solutions Motors with passive rotor: FSPM & SRM Subsea VSD Induction motors (Aker, Framo) PM from DDS (now FMC) PM from SM&partner PM from SM&partner for long step outs Content OM PETROMAKS PM TEKNOLOGI ASYNKRON V.S PERMANENT MAGNET MASKIN LONG STEP-OUT, MODELLERING OG KONTROLL PERMANENT MAGNET MASKIN I SUBSEA APPLIKASJONER POWER ELECTRONICS DOWNHOLE 16

17 PM technology enabling new solutions PM technology enabling new solutions in Subsea Oil & Gas Large air gap machines Reliable operation in harsh conditions, HTHP-machines/drives (High Temp. High Pressure) Replacing existing IM Subsurface Valves (SSV) Drive progressive cavity pumps (PCP) Drive electrical submersible Pumps (ESP) Electrical Drilling (ED) Downhole oil / water separator (DOWS) Downhole gas compressor (DGC) Downhole generators (DG) Well tractor (WT) Flux - Switching PM motor, FSPM Robust construction PM magnet and winding on the stator Only steel on the rotor High torque density Suitable for high torque, low speed application

18 Badger SmartMotor Delivery Complete drive systems for down-hole applications In deep wells temperature C High pressure bars Limited space Channel PM design Unique axial channel design in the stator. Transportation of: rock cuttings, cooling liquid, oil. Brushless Gearless High efficiency : 95% High torque Temperature 125 C Example application: Downhole drilling Drive PCPs Downhole generator

19 Submerged designs Propulsion RRM Rim Thruster Tidal Atlantis. 1 MW / 3,3 kv / 17 tonn Complete Power Train Converter Transformer Switch gear Control system Submerged designs Tidal Flumill PowerTower tidal concept Complete Power Train Converter Transformer Switch gear Control system Tidal Nautricity CoRMaT Contra rotating tidal generator Complete Power Train Converter Transformer Switch gear Control system 19

20 Submerged designs AUV Hugin Machine and Drive Mapping the seabed 4500m NFR MAROFF Program Submerged Propulsion system for high-speed boats Electric motor integrated into the pod. Content OM PETROMAKS PM TEKNOLOGI ASYNKRON V.S PERMANENT MAGNET MASKIN LONG STEP-OUT, MODELLERING OG KONTROLL PERMANENT MAGNET MASKIN I SUBSEA APPLIKASJONER POWER ELECTRONICS DOWNHOLE 20

21 High Temp Power Electronic Packaging NFR FUNDED BUP Project Scope Research on packaging for reliable operation of high temperature power stage Goals Develop HT powerstage SiC solutions for kw power range Test and provethe solutions Strategic focus Develop state of the art solutions for HT power conversion systems Challenges High ambient temperatures and pressure High power(losses) on confirmed places Lifetimeat elevated temperatures. Halves at 10C increase. Arrhenius:

22 Silicone Carbide semiconductor Silicone Carbide semiconductor properties: SiC3 times higherband gap thansi -> Higher temperatures possible, Ti=900⁰C. Higher break down voltage -> times betterfor SiC/GaNthanSi -> Thinner component Lower on-resisitance -> Redused loss High saturated drift velocity -> Faster On / Off -> Lower switching losses Higher thermal conductivity -> Better heat dissipation Summary HT Power Electronics Fordelene med SiCkontra konvensjonell Si er store og vil føre til at SiCvil ta over for Si i krevende HT-applikasjoner. Kompakthet Pris: SiC 3 x Si Omliggende struktur blir mindre, og billigere Kan gå fra aktiv kjøling til passiv kjøling. -> På sikt kan SiCerstatte Si også i konvensjonell applikasjoner

23 Thank you! Inge Nordsteien SmartMotor AS Mob: