MULTIPLE VARIABLE SPEED DRIVE UNIT ON A COMPRESSION SHAFT LINE
20240364242 · 2024-10-31
Inventors
- Niccolò SPOLVERI (Firenze, IT)
- Daniele SGRÒ (Firenze, IT)
- Michele FRATTONI (Firenze, IT)
- Valentina NARDI (Firenze, IT)
Cpc classification
International classification
Abstract
A drive unit for driving a load, like a centrifugal compressor, a pump, or the like, comprising a driving shaft connected to the load to be driven. The drive unit comprises a plurality of electric motors connected to the driving shaft and a plurality of variable frequency drives electrically connected to the power grid used to feed each electric motor.
Claims
1. A drive for driving a load, such as a centrifugal compressor, a pump, or the like, the drive unit comprising: a driving shaft, coupleable with the load to be driven; a plurality of electric motors, wherein each electric motor is mechanically coupled with each other series to the driving shaft, to drive the load; and a plurality of variable frequency drives, each one electrically coupled with a relevant electric motor; capable of adjusting the torque and/or the angular speed of the electric motor it is connected to, wherein the variable frequency drives, cause, by their operation, the generation of torque harmonics other than the mean torque value, and current harmonic components on a power grid other than a fundamental current component; and, a plurality of isolation transformers each one coupled with a variable frequency drive and to the power grid; wherein the electric motors and the isolation transformers of the drive unit are configured to reduce the torque harmonics other than the mean torque value and/or the current harmonics components other than the fundamental current component.
2. The drive unit of claim 1, wherein: a first electric motor mechanically coupled with the driving shaft, to drive the load; a first variable frequency drive, coupled with the first electric motor capable of adjusting the torque and/or the angular speed of the first electric motor on the driving shaft; a first isolation transformer of the plurality of isolation transformers coupled with the first variable frequency drive and to the power grid; a second electric motor of the plurality of electric motors is mechanically coupled with the driving shaft, to drive the load; a second variable frequency drive, coupled with the second electric motor, capable of adjusting the torque and/or the angular speed of the second electric motor on the driving shaft; and, a second isolation transformer coupled with the second variable frequency drive and to the power grid.
3. The drive unit of claim 2, wherein one or more torque harmonics of the second motor are phase-shifted with respect to the respective torque harmonics of the first motor, to reduce the overall torque harmonics acting on the driving shaft.
4. The drive unit according to claim 1, wherein each electric motor comprises a stator, wherein each stator has a plurality of windings; and, wherein the stator windings of each electric motor are radially physically shifted by a predetermined displacement angle-+9 with respect to the stator windings of a reference electric motor to reduce the overall torque harmonics acting on the driving shaft.
5. The drive unit of claim 4, wherein the first electric motor comprises a stator, wherein the stator of the first electric motor has a plurality of windings; wherein the second electric motor comprises a stator; wherein the stator has a plurality of windings; and, wherein the windings of the stator of the second electric motor are shifted of predetermined displacement angle with respect to the windings of the stator of the first electric motor, to reduce the overall torque harmonics acting on the driving shaft.
6. The driving unit of claim 5, wherein the first electric motor is a three-phase type and the stator has three windings, and, wherein the second electric motor is a three-phase type and the stator has three windings.
7. The driving unit of claim 4, wherein the predetermined shifted displacement angle of each stator relative to the stator of a reference electric motor is set to suppress or reduce one or more torque harmonics, to reduce possible mechanical excitations on the driving shaft.
8. The drive unit according to claim 1, wherein each electric motor comprises a rotor; wherein each rotor of each electric motor is mechanically connected to the driving shaft and has a predetermined physical angular displacement with respect to the rotors of the other electric motors.
9. The drive unit of claim 8, wherein the first electric motor comprises a rotor, mechanically connected to the driving shaft; wherein the second electric motor comprises a rotor, mechanically connected to the driving shaft, and, wherein the rotor of the second electric motor has a predetermined physical angular displacement with respect to the rotor of the first electric motor.
10. The drive unit of claim 9, wherein the predetermined displacement angle is set to suppress or reduce one or more torque harmonics, two reduce possible mechanical excitations on the driving shaft.
11. The driving unit of claim 1, wherein each isolation transformer comprises: a primary winding, connected to a common point of the power grid; and, a secondary winding, connected to the relevant variable frequency drive; wherein the primary winding of the isolation transformers is connectable to the power grid at the same point of common coupling; and, wherein the primary windings or the secondary windings of the plurality of isolation transformers are arranged with different vector groups to reduce the current harmonics components injected into the power grid.
12. The driving unit of claim 11, wherein the first isolation transformer has a primary winding, connected to a common point of the power grid, and a secondary winding, connected to the first variable frequency drive; wherein the primary winding and the secondary winding of the first isolation transformer are connected in a Delta-Delta configuration; and, wherein the second isolation transformer has a primary winding, connected to a common point of the power grid, and a secondary winding, connected to the second variable frequency drive; wherein the primary winding and the secondary winding of the second isolation transformer are connected in a Delta-Wye configuration.
13. The driving unit of claim 1, wherein each one of the electric motors generates an equal torque.
14. The driving unit according to claim 1, comprising a control logic unit connected to at least one of the variable frequency drives, wherein the control logic unit is configured to control the power generated by the plurality of electric motors and transferred to the load; wherein the control logic unit is configured to provide the angular speed reference value to the first variable frequency drive; and, wherein the first variable frequency drive is capable of providing the torque reference value to the plurality of variable frequency drives, to maintain the required angular speed of the driving shaft.
15. The driving unit of claim 14, wherein the control logic unit is connected to the plurality of variable frequency drives.
16. The driving unit according to claim 14, wherein the control logic unit is configured to control the power generated by the plurality of electric motors and transferred to the load; and wherein the control logic unit is configured to provide torque reference value to the first variable frequency drive, and wherein the control logic unit is configured to provide torque reference value to the plurality of variable frequency drives, to maintain the required angular speed of the driving shaft.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] A more complete appreciation of the disclosed embodiments of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0015]
[0016]
[0017]
[0018]
[0019]
[0020]
[0021]
DETAILED DESCRIPTION OF EMBODIMENTS
[0022] In the field of oil and gas, it is generally required to drive the load, such as centrifugal compressors or pumps, which require high driving power. Nowadays electric motors are preferred devices for driving the load since no pollution is spread in the environment. To reach the required power to drive the above-mentioned loads, several electric motors are required, coupled with each other in series, to sum up the power they generate.
[0023] The electric motors are fed by Variable Frequency Drives, which introduce disturbing alternating torques components into the shaft line and/or disturbing current harmonics injected into the grid. According to the present disclosure, it is possible to arrange the electric motors between them and/or arrange voltage isolation transformers, to reduce the disturbing alternating components in such a way that they cancel each other. This has several benefits, including but not limited to, that of reducing, minimizing, and/or even eliminating undesired torsional vibrations on the driveshaft, thus reducing or avoiding mechanical problems to the operation of the drive unit. This also can have the benefit of extending the operational life of the driveshaft and/or of other components, such as couplings.
[0024] As used herein, a voltage isolation transformer is an electrical machine capable of transferring electrical power from a source of alternating current (AC) power to some equipment or device, while isolating the powered device from the power source for safety reasons. An isolation transformer changes the amplitude of the AC voltage and blocks transmission of the DC component in signals from one circuit to the other, allowing AC components to pass.
[0025] Isolation transformers can be electrically connected in several different schemes, depending on how the primary and secondary windings of the transformers are electrically connected. As better specified below, among the available connections there are the so-called Delta-Wye connection and Delta-Delta connection, which allow different voltage ratios and phase shifting between the primary winding and the secondary winding of the isolation transformers.
[0026] Referring now to the drawings,
[0027] According to the present disclosure, the load L is a centrifugal compressor. A centrifugal compressor is a rotating machine that achieves a pressure rise by adding kinetic energy/velocity to a fluid through an impeller. However, in other embodiments, the type and the number of the loads L may be different. More specifically, to remain in the oil and gas field, the load L can be, for instance, a pump for pumping oil through the pipeline.
[0028] According to the present disclosure, as can be appreciated referring to
[0029] In the present embodiment, each electric motor 31 and 32 is a three-phase type, which is quite diffused in the application. However, different types of electric motors can be considered.
[0030] Each one of the VFDs 41 and 42 supplies the respective electric motor 31 and 32, in order to adjust the torque T applied from the electric motor 31 and 32 to the driving shaft 2. More specifically, given the power absorbed by the load L and the angular speed of the driving shaft 2, a certain torque is requested by the load L and therefore each of the electric motors 31 and 32 have to generate a specific torque. The VFDs 41 and 42 then control the power supply of the relevant electric motor 31 and 32 for them to generate the right torque in order to drive the load L according to the required rotating speed a.
[0031] In the first embodiment of the drive unit 1 illustrated in
[0032] The control logic unit 5 can be embodied as a programmable microcontroller, a PLC, and the like. The control logic unit 5 can be manually programmed using any suitable programming technique and/or programming language, such as C++ and the like, to contain computer-readable instructions, that when executed by a computer processor, cause the computer processor to read the operating status of each VFD 41 and 42, for instance, as well as each electric motor 31 and 32, namely the power absorbed, the torque generated, the angular speed of the drive shaft 2.
[0033] The control unit 5 is then programmed to generate, in one embodiment, a first output signal to control the VFD 41 and a second output signal to control the VFD 42, to adjust the angular speed of each electric motor 31 or 32, to balance torque reference value T they generate. In this way, as better explained below, a cancellation of the torque harmonics (excluding the mean torque value) and the current harmonic components (excluding the fundamental current component) is allowed through the arrangement of the couplings of the electric motors 31, 32, and of isolation transformers, as better explained below.
[0034] Usually, the control logic unit 5 is embodied with a motherboard electrically connected to the VFD of the electric motor to control. The control logic unit 5 can be possibly placed even remotely with respect to the VFD equipment it is connected to.
[0035] The control logic unit 5, as mentioned, is operatively connected to the first VFD 41. In particular, the control logic unit 5 is capable of determining an angular speed reference value, or angular speed setpoint a, and transmitting the angular speed reference value to the first VFD 41. The two VFDs 41 and 42 exchange torque and speed data in order to maintain the angular speed reference value required by the control logic unit 5, properly distributing the torque T to be generated by both the electric motors 31 and 32, according the load L torque demand.
[0036] As also shown in
[0037] Also, and in general, the angular speed of the driving shaft 2 is determined by the load L, such as the compressor, where, depending on the operating regimes, a different angular speed is required. Therefore, based on the power required by the load L, the total torque required is set as well, and the control logic unit 5 adjusts indirectly the operation of the first electric motor 31 and therefore of the second electric motor 32 to possibly proportionally distribute the torque to be generated to drive the load L. If the torque generated by the first 31 and the second 32 electric motor is the same, the alternating torque components have the same amplitude, and, if properly shifted, they can be mutually canceled, as better specified below.
[0038] Continuing referring to
[0039] When each electric motor 31 and 32 is supplied by the relevant VFD 41 and 42, disturbing torque harmonics, namely the harmonics different from the mean torque value, can be introduced, and they can generate torsional vibrations on the driveshaft 2 possibly causing mechanical problems to the operation of the drive unit 1. As mentioned, above, when the torque generated by the first 31 and second electric motor is the same, the amplitude of the alternating torque components generated by each electric motor 31 and 32 has same amplitude.
[0040] The stators 311 and 321 of the first 31 and the second 32 electric motor, as mentioned above, have the windings designed to be phase-shifted of an angle above-called . In particular, the stator windings 311a, 311b, and 311c, of the first electric motor 31 are physically shifted with respect to the relevant stator windings 321a, 321b and 321c, of the second electric motor 32 of the above-mentioned predetermined displacement angle . More specifically, the stator windings 321a, 321b and 321c of the second 32 electric motor are radially (namely perpendicular to the driving shaft 2 length to which the electric motor 2 is coupled with) physically shifted by the above-mentioned displacement angle , with respect to the stator windings 311a, 311b, and 311c of the first electric motor 31.
[0041] Since the first electric motor 31 is three-phase, it comprises three-phase windings 311a, 311b, and 311c, which are arranged to have a predetermined physical angular displacement with respect to the three-phase windings 321a, 321b, and 321c of the second electric motor 32. According to the present disclosure, the angular displacement is 30, as in the case of six-phase windings electric motors. However, in some embodiments, different physical angular displacement can be used based on the specific application and motor construction technology.
[0042] In case the drive unit 1 comprises more than two motors, then there will be an angular displacement between each of subsequent electric motors series coupled with the driving shaft 2, properly calculated in order for reducing the alternating torque components.
[0043] Still referring to
[0044] As mentioned above, torques harmonics are generated by the use of VFDs 41 and 42. In particular, such harmonics are superimposed on the average torque T as oscillating torque, which can be an excitation for torsional resonance modes of, for instance, a train for an LNG application, leading the shaft line, namely the driving shaft 2, into possible vibration issues.
[0045] Considering that the electric motors 31 and 32 driven by the two VFDs 41 and 42 are coupled with the same driving shaft 2, the same two VFDs 41 and 42 will operate preferably at the same power level (i.e., the same torque distribution, which, as mentioned above, is the optimized solution for better distributing the power to be de-livered by the electric motors 31 and 32) and with the electric motor stators 311 and 321 configurations shown in
[0046] Specifically, in some embodiments, the arrangement of the two sets of three-phase windings 311a, 311b and 311c, and 321a, 321b, and 321c of the stators 311 and 321 of the two relevant electric motors 31 and 32 allows canceling the alternating torque components. Said alternating torque components, as mentioned above, are generated by the VFDs 41 and 42. More specifically, the phase shift of the windings of the stator 321 of the second electric motor 32 is designed for the phasors of the undesired harmonics to be 180 phase-shifted with respect to the phasor the same undesired harmonics generated by the VFD 41 of the first electric motor 32, so that they can cancel out each other.
[0047] In addition, through the operation of the control logic unit 5, an optimization of the drive unit 1 operation is achieved since having two motors they can generate the same torque so that the cancellation of alternate torques is maximized. The same thing applies to the cancellation of current harmonics components injected into the power grid through the phase shift of the isolation transformer windings, as better specified below, where current harmonic components are those other than a fundamental current component set a 50 Hz or 60 Hz, depending on the grid G and the electric network.
[0048] Referring to
[0049] Also in this embodiment, the first 31 and the second 32 electric motors are mechanically coupled with the driving shaft 2, which is mechanically coupled with the load L.
[0050] In this second embodiment, the torque T or the power and the angular speed control is directly performed by the control logic unit 5, which is coupled, as mentioned above, with both the VFDs 41 and 42.
[0051] In this embodiment, the VFDs 41 and 42 are not directly in communication with each other. In particular, the control logic unit 5 is configured to determine the angular speed reference value and a torque reference value or torque setpoint T, to maintain the angular speed on the driving shaft 2, distributing the torque T to be generated between both the electric motors 31 and 32.
[0052] Furthermore, the control logic unit 5 is configured and programmed, as mentioned above, to transmit the angular speed reference value to the first VFD 41 and the torque reference value T to the second VFD 42 so as to control the two VFDs 41 and 42 in speed and/or torque respectively. In this way, being the angular speed desired on the driving shaft 2 set, the control logic unit 5 allows controlling of the two electric motors 31 and 32, by means of the first 41 and the second 42 VFDs, distributing the overall torque T required to generate the required power to be transmitted to the load L.
[0053] The operation of the drive unit 1 of the second embodiment of
[0054] The drive unit 1 of the second embodiment illustrated in
[0055] Therefore, in both the first embodiment as shown in
[0056] In some embodiment, the control logic unit 5 is also configured to control the power generated by the electric motors 31, 32 and transferred to the load L. The control logic unit 5 is then configured to provide a torque reference value T to the first variable frequency drive 41, and a torque reference value T to the variable frequency drive 42, to maintain the required angular speed of the driving shaft 2.
[0057] Referring to
[0058] The drive unit 1 also comprises two isolation transformers, one for each VFD 41 and 42, in particular, a first 61 and a second 62 isolation transformer. Specifically. The first isolation transformer 61 is connected between the first VFD 41 and the power grid G, and the second isolation transformer 62 is connected between the second VFD 42 and the power grid G. Also, each isolation transformer 61 and 62 comprises primary windings, respectively indicated with the reference numbers 611 and 621, and secondary windings, respectively indicated with the reference numbers 612 and 622.
[0059] The two isolation transformers 61 and 62 are capable of transferring electrical power from the power grid G to the VFDs 41 and 42 while isolating the same VFDs 41 and 42 from the power grid G.
[0060] The primary windings 611 and 621 of the first 61 and second 62 isolation transformers of each VFD 41 and 42 are connected to the grid G at the same point of common coupling, as shown in
[0061] For example, in a three-phase power distribution system, the 5th and 7th harmonics are the predominant ones and usually cause distortion and heating problems. The cancellation of these current harmonic components generated by each VFDs 41 and 42 can be achieved (but not limited to this configuration) by arranging the vector groups of the isolation transformers 61 and 62 in a first configuration or Delta-Delta configuration and a second configuration or Delta-Wye configuration respectively, as better shown in
[0062] In particular, the Delta-Delta configuration of the first isolation transformer 61, causes a 0 phase shift of the current, while the Delta-Wye configuration of the second isolation transformer 62 causes 300 current phase shifting of the current that feeds the second VFD 42.
[0063] The 5th harmonic in the Delta-Wye transformer 62 is phase shifted by 5 times 300 and so it has a 1500 phase shift. In addition, the 5th harmonic is a negative sequence harmonics, so it is in the opposite direction of the fundamental that is 300 phase shift in the opposite direction, resulting in a total 1800 phase shift. In this way, the 5th harmonic generated by the two VSDs systems will have a phase shift of 1800 with respect to each other, causing the cancellation of this harmonic component.
[0064] Similarly, the 7th harmonic in the Delta-Wye second transformer 62 is phase shifted by 7 times 300 and so it has a 2100 phase shift. The 7th harmonic is a positive sequence harmonic, so the relative sifting with the fundamental is again 180.
[0065] The cancellation of the above-mentioned harmonics can be visualized in
[0066] In this way, the drive unit 1 according to the third embodiment illustrated in
[0067] Other connections of the primary winding 611 and 621 and of the secondary windings 612 and 622 of the first 61 and the second 62 isolation transformers can be foreseen for canceling the undesired current harmonics.
[0068] As mentioned above, the electric motors 31 and 32, driven by the two VFDs 41 and 42, are connected to the same driving shaft 2, the two VFDs 41 and 42 will operate preferably at the same power level, thus maximizing the harmonic cancellation effects at the point of common coupling, since the harmonic components will have the same amplitude. In principle, the same effect of harmonic cancellation could be achieved by two independent VFDs 41 and 42 connected to the same point of common coupling, but sizing and operating conditions of independent VFDs 41 and 42 are typ-ically driven by process requirements of the driven machine (e.g., centrifugal compressors), and it is unlikely that these VFDs 41 and 42 can operate continuously at the same level of power maximizing the harmonic cancellation.
[0069] Referring to
[0070] Therefore, the effect of the torque harmonics reduction (namely the harmonics different from the mean torque value) is achieved in this embodiment maintaining the same arrangement of the electric motor stator windings, as it is schematically shown in
[0071] The operation of the fourth embodiment of the drive unit 1 is the same as the third embodiment of
[0072] Referring now to
[0073] At the same time, The VFDs 41 and 42 are supplied respectively by the transformers 61 and 62. Since the three-phase transformer 61 primary and secondary windings are connected in Delta-Delta connection, with phase-shift of the VFD 41 (the one supplying the first electric motor 31) current supply equal to 0, while the three-phase transformer 62 primary and secondary windings are connected in Delta-Wye connection, with phase-shift of the other VFD 42 (the one supplying the second electric motor 32) current supply equal to 30 in the embodiment shown, the fifth and the seventh current harmonics cancel each other at the grid G.
[0074] While aspects of the invention have been described in terms of various specific embodiments, it will be apparent to those of ordinary skill in the art that many modifications, changes, and omissions are possible without departing from the spirit and scope of the claims. In addition, unless specified otherwise herein, the order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments.
[0075] Reference has been made in detail to embodiments of the disclosure, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the disclosure, not limitation of the disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope or spirit of the disclosure. Reference throughout the specification to one embodiment or an embodiment or some embodiments means that the particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrase in one embodiment or in an embodiment or in some embodiments in various places throughout the specification is not necessarily referring to the same embodiment(s). Further, the particular features, structures or characteristics may be combined in any suitable man-ner in one or more embodiments.
[0076] When elements of various embodiments are introduced, the articles a, an, the, and said are intended to mean that there are one or more of the elements. The terms comprising, including, and having are intended to be inclusive and mean that there may be additional elements other than the listed elements.