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According to the U.S. Energy Information Administration, in the period from 2005 to 2015 the share of oil produced on oil platforms was on average 30% of global production (Fig. 1). The German company Statista expects this trend to continue until 2025.
Figure 1 - Ratio of onshore and offshore oil production
A key element in the oil production process on offshore platforms is the equipment that ensures the technological operation of the submersible unit, specifically the frequency drive and related transformers (step-down and step-up transformers). The equipment has high standards, such as:
- low input and output THD;
- rust resistance;
- minimum dimensions;
- minimum weight;
- reliability;
- fire protection;
- non-stop operation;
- wide range of connectable motors;
- easy and quick setup when handling the equipment;
- equipment autonomy operation in case of emergency situations; and
- easy and fast equipment maintenance.
Triol Corporation offers a solution to meet a wide range of challenges that the offshore platform environment requires of its equipment.
Triol E-Cabinet is a specialized compact solution combining in minimal dimensions a step-down phase-shift transformer (SDT), a frequency drive, and an output step-up transformer (SUT). The solution ensures reliable and durable operation of the equipment due to unique technical solutions (Fig. 2, 3).
Figure 2 - Exterior of the Triol E-Cabinet
Figure 3 - Basic elements of the Triol E-Cabinet
Low input THDi is achieved by using a phase-shifting input transformer, which can be 12, 18 or 24 pulse circuit, and it can minimize the influence of the harmonics generated by the frequency drive on the power grid. This is important to save energy and reduce the risk of overheating the supply generator windings.
The low output THDu is achieved by using a sine filter output, which provides the THDu ˂ 5% and protects the motor windings from overheating. It also prevents the premature aging of the insulation.
The equipment is designed to operate in harsh offshore platform environments, where the shell and external elements are exposed to effects such as: salt spray, sulfides, carbon oxides, nitrogen oxides, etc. In order to protect the electronics and internal components and to ensure the operation of the product throughout its lifetime, the E-Cabinet enclosure is made of AISI 316L stainless steel with an additional double layer coating, all external fasteners are stainless steel, and the sealing rubber is made of components resistant to harsh environments.
Every millimeter counts in the minimum space on the platform due to the configuration in two levels and the double-sided maintenance of the low-voltage unit. The E-Cabinet takes up only 5.8 m2 of space for a 1000 kVA capacity.
Figure 4 - Dimensions of the E-Cabinet-1000-4-1.47/5-12-1-0101 in mm
With the limitations on oil platforms related to the lifting capacity of cranes as well as the load-bearing capacity of the platforms, the issue of product weight has a key role.
The E-Cabinet design has two modules, which are divided into a first level and a second level.
a) b)
Figure 5 - External modules of the E-Cabinet:
a) “First level” of the configuration;
b) “Second level” of the configuration.
In this case, the first level includes step-down and step-up transformers, which are mounted as separate modules when being assembled on the site.
Figure 6 - Installation of the step-down transformer
The second level is a cooling system, where fans and a heat exchanger unit are located.
This module system allows one:
- to perform the installation on platforms with crane capacity up to 5 tons;
- to get the equipment with minimum weight, as the frame is not a giant to lift the product assembled;
- to simplify the external piping (E-Cabinet: SDT - Motor, classic system: SDT - VSD - SUT - Motor); and
- to replace both individual modules and individual elements in a module.
High humidity, precipitation and wind gusts make reliable protection of the product’s internal components an urgent issue. For this reason, the E-Cabinet is designed according to NEMA 250, IEC 60529 and IP66. Inside the enclosure is a humidity control and removal system, which guarantees protection against wetness and condensation. Also, the design ensures stable operation of the product in wind blasts up to 33 m/s.
Oil platforms are equipped with a centralized fire extinguishing system, which, according to the feedback signals from the equipment, can determine how to respond to the current emergency situation.
The E-Cabinet is equipped with smoke and arc protection sensors, signals from which are transmitted to the fire extinguishing system.
Figure 7 - Fire and arc protection scheme
E-Cabinet also includes dry-type transformers, which reduces the risk of fire compared to oil transformers.
The cost of work performed on platforms is higher than the cost of similar work onshore, so offshore platform equipment is subject to higher requirements for smooth and trouble-free operation.
The E-Cabinet includes the following systems to meet these requirements:
7.1 Waterproofing
The system automatically turns on at a certain percentage of humidity in the air and turns off when the permissible level of humidity inside the equipment is reached, which protects the electronics from operating in a humid environment.
7.2 Control of the transformers, IGBT modules and rectifier modules temperature
The transformer’s temperature is monitored by four temperature sensors (thermocouples), three sensors installed in the coils and one in the core of each of the transformers (input and output).
The temperature of the IGBT modules is monitored with data from the temperature sensors built into the module.
The temperature of the rectifier modules is monitored by temperature sensors installed in the unit design at the direct contact area with the modules.
Information from the sensors goes to the UMKA07 controller. The controller has the ability to set the overheat protection to prevent failure of the components and timely response on deviation from the normal operation of the equipment.
7.3. Monitoring the fans’ operation
The software allows one to determine the efficiency of the fans and signal when a fan’s efficiency decreases.
All data on the equipment operation status can be displayed in the customer’s automated control system, which allows one to operate the well without the continuous location of service engineers on the platform.
Figure 8 - External connections compartment
The built-in step-up transformer, with a wide range of tappings from 1,500 V to 5,000 V, enables the E-Cabinet to be used across the entire life cycle of a well, from using high-rate pumps at the start of production to switching to low-rate pumps at the end of the well life cycle.
The E-Cabinet is controlled and configured by the UMKA07 controller. The touch screen and menu structure make menu navigation easy and fast, and the already developed equipment configuration scripts minimize the time for the commissioning of the equipment.
Figure 9 - The UMKA07 controller
The E-Cabinet is equipped with an uninterruptible power supply that allows you to maintain control system performance for up to 6 hours, that is, in case of brakes with the power grid security, and it ensures the system will continue to operate and transmit data to the control panel.
Since E-Cabinet is a complete Triol product, from the manufacture of the frequency drive, transformers and software, to commissioning and service support, it allows you to coordinate all operations for installation, maintenance, and operation without possible delays, rather than when different organizations handle the supply of equipment, installation and commissioning.
