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Advantages of the
Variable Frequency Generator (VFG)
Worldwide Patent Pending
Presented By:
Juergen Schulz, Canadian Advanced Inc.
Paper Authored By:
Andy Limanowka, Canadian Advanced Inc.
Dana Pettigrew, Nexen International Petroleum
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What is a VFG
VARIABLE FREQUENCY GENERATOR (VFG)
Power Generator that varies Frequency and Voltage
output
Operates 30-70 Hz, 400-5000 Volts
For use with ESPs & other Variable Torque Loads
requiring variable speed
Eliminates Variable Speed Drive and Transformer
Developed by: Canadian Advanced Inc.
With Nexen International & Finning Canada (Caterpillar)
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How the VFG works
Reduced Speed Start
Reduced Voltage Start
Control Module controls:
Voltage, Current & Hz (RPM)
Diesel or Natural Gas Engine
with Governor
Motor Protection
SCADA/Communication
Power
Generator
Generator
Control/
Motor
Protection
Well
E
S
P
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Start-up traces (40Hz Ramp Start)
Ramp Start
Nominal full load Volt 3480V@60Hz
Nominal full load Amps 90A@60Hz
2sec for system stabilizations
inrush current 2.4 x full load current
0
500
1000
1500
2000
2500
3000
3 4 5 6 7 8 9 10 11 12 13 14 15
TIME [s]
V
O
L
T
S
0
20
40
60
80
100
120
140
160
180
200
A
M
P
S
Gen Volts Gen Current
3508 CAT; 12000 BPD pump and 644HP/3480V/117A motor
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Advantages of VFG
Lower Capital & Maintenance Cost
More Efficient System, less Diesel fuel
Smaller Engines required to Drive Large
ESPs
No Harmonics, spikes or mirroring
Increase Production
Easy to Use Fully Integrated System
Touch Screen Operation
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VFG Advantages
Improved Run Times
Voltage / Current Optimization
Hard Starting Advancements
Recoverable Asset (Compared to High Line)
Smaller Foot Print-Offshore Applications
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System Comparison
Power
Generator
Variable
Speed
Drive
Load
Filter
Step-Up
Transformer
Power
Generator
Generator
Control/
Motor
Protection
Typical Variable Speed Drive System
Variable Frequency Generator System (Less Equipment)
Typical Switchboard System
Power
Line
Switch
board
Step-Up
Transformer
ESP
ESP
ESP
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Lower Capital / Maintenance cost
Engine Matched to Full Load of ESP
Low frequency Soft Start-up
No Need to Oversize Engine
VFG = 2.5 X Nameplate Current
Switchboard = 6-8 X Nameplate Current
Eliminates VFD & Transformer Capital Cost
Eliminates VFD Maintenance Cost
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Capital cost comparison
Capital Cost Comparison, 3512 CAT 900 ekW
Engine
&
Generator
Engine
&
Generator
VFG
Controller
VFD
&
Step-up
Transformer
Traditional VFD VFG System
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Maintenance cost comparison
Maintance Cost Comparison, 3512 CAT 900 ekW
Engine
&
Generator
Engine
&
Generator
VFD
&
Step-up
Transformer
VFG
Controller
Traditional VFD VFG
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Fuel cost comparison
Fuel Cost Comparison, 3512 CAT 900 ekW
VFG
Fuel
Consumption
Traditional
VFD
Fuel
Consumption
Traditional VFD VFG
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Output Waveform VFD vs VFG
Typical VFD Output Waveform - Unfiltered
Typical VFG Output Waveform
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Improved Run Times
Soft starts reduce shaft stress
Cable runs cooler longer life
Motor runs cooler longer life
No voltage spikes ideal sine wave w/o any filter
RESULTS: Longer ESP Electric and Mechanical System
Life Reduced Electrical Losses
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Increased Production (Heijah 49)
Improve Efficiency by 5-10% Less Heat!
VFG eliminates Heat and Turns to Oil Production
Example for Maximum of 3508 CAT Diesel Generator, 562 Series
CKC12000, 650 hp ESP
VFG System
Maximum Frequency = 63 Hz
Gross Fluid = 12,400 bbl/day
Net Oil (90%WCT)=1240 bbl/day
Traditional VFD & Transformer
Maximum Frequency = 58 Hz
Gross Fluid = 11,600 bbl/day
Net Oil (90%WCT) =1160 bbl/day
Production increase of 80 bbl/day of oil
At $ 65/bbl addl revenue of $ 5.200 per day
Increase of annual revenue of over $ 1,8 Mio.
Return of initial CAPEX in less than 3 months
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Increased Production (Qataban 11)
0
1000
2000
3000
4000
5000
6000
T
D
H
,

f
t
0 5000 10000 15000 20000 25000
Liquid + Gas Rate, Bbl/D
CLift 562 KC16000 / 86 Stgs / 57.0 Hz
Pump Performance (TDH @ Design)
Q11 VFG TEST.sp7
Reg: Nexen Inc. - Nexen Inc.
Pump Curve , Case 1 Well System Curve , Case 1, (Truncated)
Pump Curve , Case 2 Well System Curve , Case 2, (Truncated)
Min-Max Optimum Rate
On a VSD at 114 Amps and 57.0 Hz, 18,250 bfpd RED SOLID LINE
On a VFG at 114 Amps and 59.0 Hz, 19,550 bfpd BLUE DASHED LINE
VFG measured benefit of an extra 1,300 bfpd for a 7.1% increase.
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VFG
Entire unit prepared for shipment
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VFG
Control panel during testing
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VFG
Canadian Nexen Yemen (Heijah 49)
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VFG
Touch-pad controls
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VFG
Touch-pad controls
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VFG
Touch-pad controls
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When to use a VFG
Every time a Generator is used on an ESP
Temporary or Permanent Installation
Portable Well Testing
Areas of Power Quality Problems
Weak or Insufficient Supply Power
Other Applications PCP, Beam Pump, Ships, Fans, etc.
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Questions
For more information or pricing contact:
Juergen Schulz or Sid Degen
CANADIAN ADVANCED INC.
CANADIAN ADVANCED INC.
5307-72A AVENUE
EDMONTON, ALBERTA, T6B 2J1
PHONE: 780-469-0770
FAX: 780-450-4592
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Thank you for your attention