STARTING LARGE SYNCHRONOUS MOTORS IN WEAK POWER SYSTEMS

Copyright Material IEEE

Paper No. PCIC-2013-14

Kurt LeDoux Paul Visser Dwight Hulin Hien Nguyen

Member, IEEE Member, IEEE Member, IEEE Member, IEEE
Toshiba International Corp Consultant to ExxonMobil ExxonMobil Corp Toshiba International Corp
13131 W. Little York Dr. 800 Bell St 396 W. Greens Rd 13131 W. Little York Dr.
Houston, TX 77041 Houston, TX 77002 Houston, TX 77067 Houston, TX 77041
[email protected] [email protected] [email protected] [email protected]

Abstract –Utility company standards for power quality are original circuits for the remaining in-service equipment and
making it difficult for industrial users to start large induction lighting.
and synchronous motors due to high inrush current. This
paper will present a large oil company’s challenges starting A. Utility Constraints
large motors driven by the utility company in a relatively
weak power system in East Texas while not violating the During Front End Engineering Design (FEED), it was
Utility company’s standards. A workable solution is an air discovered that the Utility had the following constraints for
cooled pulse width modulated (PWM) voltage source the proposed 138kV substation:
variable frequency drive (VFD) system designed to start
multiple large horsepower, medium voltage synchronous 1) Limited available short circuit current: Calculated
motors without any measurable voltage flicker. Various to be 7,459A three phase @138kV which would
combinations of motor design (induction vs. synchronous) & affect the large motor (8.1 kHP to 17.5 kHP)
starting methods are reviewed and final design schematic starting ability;
diagrams are documented. Challenges encountered during
the design & start-up are described and solutions with final 2) Strict voltage flicker requirements: Requested to
performance details are provided. limit voltage flicker (dimming of lights resulting
from voltage drops) to 1-1/2%. This rule limited
Index Terms — motor starting, weak power systems, the ability to start the large compressor motors
adjustable speed drive, variable frequency drive, variable without special starting methods;
speed drive, VFD, synchronous motor 3) Limited available transmission line capacity to the
facility: 63MW at 90% power factor (per the utility
I. INTRODUCTION contract) without a major rebuild of the existing
138 kV transmission lines. Note that the total plant
A large Oil and Gas Company undertook a major upgrade demand load is currently over 60 MW and rising @
of a 1940’s vintage gas plant in East Texas installing four 99% power factor.
15 kV electric driven centrifugal compressors ranging from
8,100 to 17,500 HP. The objective of the project was to In summary, the Utility did not have a “stiff” system but did
both increase the capacity of the plant and replace obsolete have very stringent flicker requirements. A “stiff” system is
& high maintenance large (over 5,000 HP) existing gas more immune to flicker during high current inrush when
engine driven compressors. Additionally, eight new 5kV starting large motors. The project had a significant
compressors were installed including all requisite 480V challenge to start the loaded compressor motors and
ancillary and lighting system loads. Electrical demand maintain power quality standards imposed by the Utility.
increased over fifteen fold from less than 4 MW to about 60
MW with over 65% of that total attributable to the four new II. ALTERNATIVES & FINAL DESIGN
15 kV centrifugal compressors. Lower anticipated life cycle
operating costs (investment vs. maintenance and up time) A. Motor Starting Alternatives Considered
pointed to electric in lieu of gas drivers for the new
compressors. It was desired to start the four compressors Multiple motor starting alternatives were considered to
loaded or in recycle to eliminate emissions associated with address the voltage flicker limits. Some options were
blowing down (unloading) the compressors. Compressor considered only in passing and others were investigated
speed turn down was not required for this installation. The more thoroughly as follows:
existing plant electrical distribution system was upgraded 1) Auxiliary Starting Motors (Diesel or electric): One
and expanded with a new 138 kV substation and all of the option considered was to install “pony” motors to
associated 15 kV, 5 kV, & 480V electrical infrastructure bring large motors up to partial speed before
(switchgear, MCC, cables, and tray). transferring to the normal bus. This option was
Upon project completion, there was essentially a new quickly discounted by inspection due to the
electrical distribution system retaining only a fraction of the excessive field equipment requirements,

978-1-4673-5110-2/13/$31.00 ©2013 IEEE

 complexities with the required clutch arrangement, effective for reducing voltage flicker than the RVSS
and overall reliability. soft start method described above. Said another
way, the RVAT produces more torque per unit line
2) Switched Starting Capacitors: Installation of large amps than the RVSS. This is because a
banks of switched starting capacitors common to transformer is used to reduce voltage to the motor.
all motors on the main 15 kV switchgear bus was A transformer transforms the voltage while
considered only in passing as a viable option. conserving kVAs; whereas, other series type
Capacitors would be switched in and out with starters (reactor, RVSS) drop voltage and
vacuum breakers to correct the very low power therefore absorb kVAs. The impact to the motor is
factor of a motor during starting acceleration. This similar between the RVAT and RVSS.
option was discounted due to the potential for Consequently the RVAT was not considered after
electrical system resonance issues, arcing during the RVSS starting study showed that excessive
switching operations, risk of self-excitation of other motor heating would be encountered during
motors on the bus, and overall system protection starting.
issues.
6) Reactor Starting: Reactor starting was not
3) Reduced Voltage Solid State (RVSS) Soft Start considered even though it is simpler than RVAT or
Dedicated to each Motor: Significant time was capacitor starting and without the system
invested in evaluating the alternative of using solid resonance issues associated with capacitor
state reduced voltage starters as this was the starting. As described above, reactor (in series)
initial Concept Select recommendation. A Soft starting provides poor starting torque and there
Start manufacturer performed unloaded motor were concerns with overall power system stability
starting analyses for both large induction and during the transition to full voltage (i.e. bypass
synchronous motors. If the compressors had been reactor). For large motors of the Project’s size,
loaded (i.e. not vented), the starting calculations large reactors would have been required that may
would have indicated higher inrush current and/or result in power system disturbances. This starting
increased acceleration time. The analysis results method has the additional issue of excessive
for the 14,000 HP synchronous motor were as motor heating common to low voltage starting
follows: methods.
a) RVSS Soft Start: 375% FLA for 23.0 sec. 7) Voltage Source PWM Starting Variable Frequency
acceleration time and equivalent locked rotor Drive (VFD): Inherently, the VFD starting method
time of 6.5 sec; results in the highest (100%) torque per unit line
b) Across the Line Start: 460% FLA for 4.3 sec. current. Several design options were considered
acceleration time and equivalent locked rotor using large VFD(s), either dedicated and sized for
time of 3.6 sec. each motor or one common and switched between
motors. The final design recommendation was a
To summarize, installation of a soft start system shared/ common single large starting VFD coupled
would only reduce the starting current by with a 15 kV switching scheme that proved to be
approximately 20% while increasing the the lowest cost and technically acceptable option.
acceleration time by over 400% for synchronous This solution builds upon a similar paper submitted
motors. Similar results would be anticipated for to the IEEE PCIC 2010 which documents the
induction motors. The marginal reduction in capability of a Voltage Source VFD to start motors
starting current would not have reduced the without exceeding motor full load amps (1).
voltage flicker to the required 1-1/2% and the
extended acceleration time at the higher starting The other alternatives investigated only partially
current would result in unacceptable rotor heating. corrected for current inrush and the associated
Accordingly, this alternative was finally discarded. resulting voltage flicker or potentially had
significant system concerns. Table 1 below
4) Load Commutated Inverter (LCI): LCI systems provides a qualitative summary of the various
have been available for many years and have starting methods described above.
been used for large synchronous motor control.
This option was not considered due to a number of
complexities. Primarily, position sensor feedback
was needed for starting that would have required
additional hardware on the motor. The rectifier
section of the LCI system has a high harmonic
content and low starting power factor that would
have required additional studies for power line
quality to ensure compliance with the flicker
limitations.
5) Reduced Voltage Auto Transformer (RVAT): Auto
transformer starting methods can be more
 TABLE I tank to ensure non-conductivity. This is not an issue for air
COMPARISONS OF STARTING METHODS cooled technology.
Method Torque Flicker System Motor Cost/
Resonance Restarts Sim- Previous experience with starting VFD’s had shown that a
plicity motor can be started unloaded with a VFD rated at only
Across the Good Poor None One N/A 25% of the motor HP rating. Available air cooled VFD’s are
Line Start well within that range as the largest motor for this
Pony Good Good None Multiple High application was 17.5 KHP. In order to minimize unloading
Motors requirements (venting of compressors), a 60% or 10 KHP
Starting Good Good Poor One Low air cooled VFD was specified.
Capacitor
Reactor Poor Fair Poor One Low Also, a “start duty only” VFD allows savings associated with
RVSS Poor Fair None One Fair climate control The control house was specified with an
RVAT Fair Good None One Fair HVAC system sized only for the ambient temperature &
PWM VFD Best None None* Multiple High humidity plus the no load heat losses from the VFD input
LCI VFD Best None Fair Multiple High transformer. The full load VFD thermal losses were not
*With Sine Filter considered for the HVAC design even though they can be
substantial (4% or 300 kW at full load). However, the VFD
B. Synchronous versus Induction Motors is only fully loaded for less than one minute during the start
cycle; accordingly, at least ten (10) consecutive large motor
Prior to starting system design, the type of motor to be starts can be made without an unacceptable temperature
utilized had to be determined, induction or synchronous. rise in the building. This fact was borne out during
Induction motors are simpler, lower in cost, and easier to commissioning and startup. At the User request, a
control; synchronous motors are marginally more efficient redundant outside air exhaust fan was provided in the VFD
and provide reactive power (VARs) to improve system wide building should the air conditioning system fail to keep up
power factor. with the VFD heat load. To date, this feature has never
The use of synchronous motors was selected in lieu of been utilized.
induction motors even though they are appreciably higher in
initial cost and require a more complicated starting system
design. However the selection of the synchronous motors III. APPLICATION CHALLENGES
was justified by the 1% improvement of efficiency compared
to induction motors. Additionally, once transferred to the The End User did impose a number of special technical,
power line, synchronous motors allowed for improvement of testing, and project execution requirements upon the Drive
the overall plant power factor (PF) thus increasing the Vendor which did complicate the design, testing, and
available real power on the current limited Utility execution of this project
transmission lines. The Utility limited the load to 63MW A. Technical Specifications
based upon a 90% PF; by improving the PF (the plant is
currently operating at 99% PF), the project would be able to A combination of User Operations philosophy, cost
add an additional 7.0 MW load and stay within the capacity considerations, and machinery design requirements
of the existing transmission lines. dictated that the Drive Vendor provide the following
deliverables:
C. Final Design Selected
1) Redundancy/Backup: The User recognized that
After evaluating all of the considered alternatives, the the selection of one VFD for starting four motors
project recommended a single/common starting VFD meant that that one VFD was a single failure point
coupled to four (4) 12.47 kV synchronous motor that could result in total plant shutdown.
compressor drivers. This combination addressed voltage Redundancy in the design was requested of the
flicker concerns, reliability requirements, lowest operating VFD vendor. The vendor supplied a drive that
(kWH energy) costs, and extended motor life/maintenance allowed for 60% output capacity even if a rectifier,
reductions. This was not necessarily the lowest cost initial transformer, or output phase failed which could still
investment (CapEx) solution and a premium was paid for start the compressors by additional unloading.
this scheme versus some of the other alternatives This required dual transformers in parallel and
investigated. However, it was determined that the benefits parallel output phases. Once the motors are
far outweighed the additional costs and potential risks. This running, the drive can be isolated for repair.
system would result in the lowest long term operating and
maintenance costs (OpEx). 2) Test Mode: The User required a one button self
test of the VFD system to ensure that the VFD
Only air cooled VFDs were considered as air cooled units would be available and operational when called
have lower complexity (i.e.no hoses, pump seals, water to upon. Since the VFD is for starting duty only, it
water heat exchangers, outdoor heat exchangers, or a would be idle/ offline and unpowered for more than
deionization tank) and subsequent higher reliability than 99.99% of the year. Activation of the self test
liquid cooled VFDs. After a long period (up to three performs the following offline functions while the
months) of inactivity, most water cooled drives require 15 kV motors are running normally:
significant wait time to pump water through the deionization
 a) Close the preselected 12.47 kV switchgear frequency, voltage output from the transformer and
feeder breaker to the VFD; motor break-away torque performance is very
poor. To obtain proper performance, vacuum
b) Close the integral VFD feeder breaker to circuit breakers were installed in the output to
energize the input transformer and power bypass the transformer during motor acceleration
cells; from 0 to 20 Hz and then insert the transformer
c) Power up the VFD cooling fans; from 20 to 60Hz. This stepped approach requires
the drive to switch between two different drive
d) Energize the power cells; V/Hz settings to maintain the motor’s fixed
e) Perform self test of the VFD controller; 12.47kV to 60 Hz ratio.

f) Issue failure alarm to operator should any


portion of this test fail.

g) This test does not check the operation of any
parts of the system that would conflict with  '5,9(&211(&7(':,7+
operating equipment; accordingly, the motor 67(38375$16)250(5

breakers and synchronization scheme is not
tested. Neither is the output transformer 

02725.,/292/76
bypass scheme tested as that requires feed

back from a motor.

3) Drive Inrush: To reduce the 1200% power up
inrush current of the drive internal input  &/26('75$16,7,21
transformer, a current limiting reactor with shorting 
%<3$66
contactor was utilized to limit the inrush to 75% of
drive full load current rating. 

4) Drive Output Transformer: Motor size is large, and  23(175$16,67,21

&+$1*(29(5
most commercially available VFD designs are 
limited to 4.16kV, 6.0kV, or 7.2 kV applications. In
this instance, the project team and compressor 
vendor had already determined that 12.47kV was  '5,9(',5(&7/<&211(&7('
the most suitable voltage for the motors due to the 7202725
existing power system infrastructure and the motor
size. Accordingly, a step up transformer was 
required for the drive design to obtain the proper
motor voltage. '5,9(287387,1+(57=
5) Sine Filter: A sine filter consisting of an inductor Fig. 1 Two Stage Acceleration
and capacitor was required on the drive output for
the following reasons:
a) To reduce detrimental effects of output 8) Application Concerns: The compressor selected
transformer: Since a transformer can was a high speed centrifugal unit that required a
exacerbate ringing and resonance surges speed increaser gear box. On a four pole
from a drive artificial voltage (DC pulses to synchronous motor, the rotor could rotate up to 90̊
simulate a sine wave current), that may either forward or backward to get in synchronous
damage motor insulation (2). position. However, reverse operation would
damage the compressor. A ratchet could be
b) To limit liability: Since the motor supplier was installed, but this requires mechanical servicing
a different vendor from the VFD supplier. and adds complexity. Without the use of
6) Excitation System: The motor starts synchronized encoders, the VFD determines the exact rotor
with drive output frequency and at unity power position by measuring the stator transient voltage
factor. The motor rotor needs excitation before the during rotor magnetization and adjusting the drive
drive starts. The VFD outputs a control signal to voltage at startup to ensure only forward rotation.
the exciter controller as part of the control scheme B. Interface Coordination and System Responsibility
and upon transfer to across the line, it hands off
control to the exciter to maintain VAR or power The User assigned system responsibility to the VFD
factor control. manufacturer. However, the 15kV switchgear was
purchased directly by the User and the 12.47 kV motors
7) Output Transformer Response at Low Frequency: were purchased by the compressor packager which is
A drive output transformer does not have linear typical (mechanical/machinery issues drive that decision).
response from 0 to 60 Hz (simply put, a
transformer cannot step up DC voltage). At low
The VFD manufacturer proved to be the optimum choice for thyristor controller starter output. Additional equipment
system responsibility for the following reasons: added to the low voltage VFD included a sine wave output
filter, VAR and power factor controller, and a PLC for
1) Provided the most critical and complex control of the synchronous motor power factor after the
components of the system (VFD with drive has transferred the motor to the normal power line.
synchronizing logic to the Utility, breaker switching
logic PLC, and synchronous motor exciter Testing of the electrical system components individually and
controller in addition to the VFD building); together in a string test proved to be very important in
identifying and resolving what could have been a very
2) Provided design guidance and one-line serious problem in the factory before field installation.
requirements to the User to obtain bids from
switchgear vendors; D. Site Acceptance Test (SAT) Events
3) The only entity willing and technically able to Once all equipment was installed in the field with
provide a complete string test utilizing both his compressors and testing had begun, four minor
provided equipment and representative switchgear unanticipated issues occurred.
& synchronous motor to prove the total system
during the Factory Acceptance Test (FAT); 1) Exciter Controller: During the check out of the VFD and
motor, the motor was stopped while running on power
4) Participated in the switchgear vendor’s FAT after line. During coast down of the motor, the capacitors on
installation of the VFD Vendor’s switching logic the DC bus of the new design low voltage exciter failed
PLC in the switchgear building to prove PLC dramatically. This would happen even if the exciter
control of the 15 kV breakers. controller had no power. Exciter winding voltage would
not decay as normally expected and would actually
Accordingly, the end User issued three separate purchase increase.
orders from different vendors for (1) switchgear/power
building, (2) VFD,VFD Building, exciter controllers, & Referring to Fig. 2 below, the exciter circuit was
Switching Logic PLC, and (3) compressors/motors. designed without isolation contactors as originally
Meetings were held with all parties and drawings when configured. During non-powered coast down of the
released were shared to ensure equipment and controls motor, the capacitors (B) in the sine wave filter on the
compatibility. The VFD vendor developed and low voltage VFD exciter controller were in resonance
manufactured the drive, purchased and programmed the with the motor exciter windings (A). The resulting AC
User specified Breaker Switching Logic (BSL) PLC, and voltage (C) would go to high levels exceeding the VFD
purchased a commercially available dedicated synchronous capacitor rating (D). Voltages on the exciter are
motor AC exciter controller from a third party. normally 420VAC or less, but were documented over
700VAC exceeding the limits of the motor exciter
C. Factory Acceptance Test (FAT) Events winding insulation.
In keeping with the User’s “system responsibility” approach, The sine wave filter capacitors (B) were removed from
the VFD vendor was required to functionally “string test” the the VFD exciter and the resonance problem
full system. This included not only his equipment but also disappeared. However, harmonics from the VFD
representative switchgear and synchronous motor to be based exciter controller (2KHz PWM) output became
utilized in the field. During the User specified Factory unacceptably high and the motor exciter manufacturer
Acceptance (FAT) string testing all of the major components required that the sine filter capacitors be retained.
(VFD, switching logic, switchgear, and exciter controller) Surge arrestors were tried without success (continued
worked together to start the synchronous motor to the to experience unacceptable voltage spikes). The final
User’s satisfaction. However, the exciter controller failed solution was both simple and inexpensive; an output
multiple times with circuit board damage. The failure contactor was added to instantaneously isolate the
occurred during transition/switching from the the VFD/motor exciter controller from the motor whenever the motor
period (i.e. 0- 20 Hz) to the VFD/output transformer/motor was tripped.
period (i.e. 20- 60 Hz). This result was completely
repeatable (all four exciter controllers were damaged) and it
was assumed that a surge was occurring in the motor ,62/$7,21&217$&725$''('
exciter winding. When the exciter controller manufacturer
was unable to determine the failure cause or offer a
solution, that exciter controller was abandoned and a &
different exciter controller manufacturer was selected. $
' 527
The new exciter controller design (one required for each (;&,7

motor) used a commercially available low voltage VFD (by

main VFD vendor) with modified software. Normally this %
product provides variable voltage and frequency with a fixed
(;&,7(532:(5'(9,&(6&+(0$7,&
V/Hz ratio. The software was modified to maintain the
frequency fixed at 60HZ with an ouput infinitely adjustable
up to 460V. This simulates the same performance of a Fig. 2 Exciter Controller to Motor Interface
2) Power Factor Control Handoff: During the start
sequence, the VFD maintains the Power Factor (pf) at
1.0 via the Exciter Controller. However, upon
completion of the motor start sequence, the VFD was
to hand off pf set point control to the DCS to permit the
plant DCS operator to maintain overall plant pf. That
was a mistake; it was one interface not assigned under
the VFD Vendor’s “system responsibility” mandate.
The DCS output was missing subsequently driving the
pf to extremely lagging (close to -0-) and tripping the
motor on a pf fault. The DCS was removed from the
control circuit. Upon completion of the starting
sequence, pf set point control was handed over to the
exciter controller PLC which was reprogrammed to only
accept manually entered pf values between 1.0 and 0.8
leading.
3) Potential Transformer Location: The manufacturer of
the VFD had installed a 5kV PT (potential transformer)
for feedback on the drive output as part of the original
design. When the drive was directly connected without
the step up transformer accelerating the 12.47kV motor
to 20 HZ @ 4kV, the drive v/HZ relationship was not
compatible with the PT and it overheated. PT’s are
designed for full voltage at 60 Hz, not extended periods
of 20 Hz at full voltage required for testing and
commissioning. The PT wiring was relocated to the
primary of the output transformer circuit so that it only Fig. 3 Starting VFD System: Example for two Motors
operated above 20 Hz and then only for 2 minutes
before reaching 60 Hz.. Please reference Fig. 1 Two Stage Acceleration and Fig. 3
Starting VFD System Schematic above for an explanation
4) Relay Settings: An independent 25 relay (synchronism of the Motor Startup sequence described below. This
check) used for permissive to transfer to line was set at sequence can be monitored on the Breaker Switching Logic
too tight of a tolerance and created nuisance transfer (BSL) PLC HMI.
failures on some of the motors. The problem appeared
to be on the motor with larger torque variances. It was 1) Assuming Motor M1 must be started, Operator in
difficult to troubleshoot because it is not a latching field pushes the start button on selected
device and is independent of the VFD diagnostics. compressor control panel which only operates if
multiple permissives including “VFD Ready” is
E. Final Observations and Performance of the Package received from BSL PLC;
The VFD method of starting limits motor starting current 2) BSL PLC closes VFD feeder breaker 52-A1 and
inrush to much less than 100%; in fact during the four (4) integral VFD input transformer soft start breaker to
minute starting sequence, the motor starting current energize VFD cells and start VFD cooling fans;
typically never exceeded 40% over the full speed range
since the compressors were started either fully unloaded 3) BSL PLC closes motor starting breaker 52-A3,
(for the largest 17.5 kHP nitrogen compressor) or only output transformer Bypass Breaker 52-V2, and
partially loaded for the rest. Hydrocarbon compressors ensures that Normal Bus Breaker 52-A2 and
were in recycle and not blown down for starting. This Output Transformer Breaker 52-V1 are open;
compares with about 300-375% inrush using a reduced
4) VFD controller takes control and ramps motor from
voltage soft start.
0 to 20 Hz (33% of full speed); approximately 2
minutes are required up to this point;
5) At 20 Hz, the BSL PLC performs open transition
switching of the output transformer bypass scheme
by opening 52-V2 and then closing 52-V1;
6) Motor speed coasts down to about 15 Hz and VFD
Controller “catches” motor and ramps motor from
15 Hz to 60 Hz;
7) Upon reaching 60 Hz (full speed) at rated voltage,
the drive microprocessor located compares the
voltage, frequency, and phase angle of the
Utility/Normal Bus with that of the VFD output and
 makes corrections to the VFD output as restarts. This design of one single VFD with limited
necessary; redundancy for starting multiple motors balances capital
investment with system performance. It allows a motor to
8) When the Normal and VFD starting buses are start with the most available torque with the least impact to
synchronized and receives independent the electrical system.
confirmation form the “25 Sync Check Relay”, the
VFD controller directs the BSL PLC to initiate a This innovative design installed in deep East Texas
closed transition transfer by closing Normal Bus combines the use of the following:
Breaker 52-A2 and then opening Starting Breaker
Bus Breaker 52-A3. A total of 4 minutes time is 1) Starting duty drive with a rating below the motor
typical from initial start command to transfer. voltage and current rating.

9) VFD remains energized for 30 minutes during 2) Multiple differently sized motors with different
which time Step#s 1 & 2 are bypassed and the protection settings and multiplexed breaker
VFD is immediately available to start another controls.
motor by going to the Step# 3 breakers for the 3) Synchronous motor with associated individual
following motor (i.e. 52-B2 & 52-B3). excitation controllers.
10) There is only a marginal temperature rise in the 4) On line uncoupled test mode for confirming VFD
VFD building during this 4 minute starting availability.
sequence.
As a result, this starting system has been performing as
This VFD starting method completely eliminated any designed consistently starting up each motor without any
potential for voltage flicker. Additional benefits of this failed starts or need for electrician assistance.
starting system were complete elimination of all motor and
coupling stresses as well as motor heating concerns during V. ACKNOWLEDGEMENTS
starts; in fact, the Max Starts/Hour feature in the motor
protection relays for the four VFD started motors was turned Matt Colosino owner of Crescent Power Systems with
off. Compressors were started multiple times per hour locations based in New Orleans and Houston was
during the commissioning and startup period with no rotor instrumental in bringing parties together for a successful
heating concerns. implementation.
These advantages provided by VFD starting over other Takashi Morishita, Toshiaki Oka, Mike Daskalos and Mark
starting methods reduced the commissioning time on the Rayner with Toshiba International Corporation were key
compressors; no starting delays were required for cooling design engineers for the VFD system and exciter package.
time for the motors during the multiple shutdowns and
restarts that occurred during testing of the compressor
VI. REFERENCES
controls and surge protection. There was never any wait
time between starts required for the motor to cool down.
[1] Kurt Ledoux and Frank Haydock, “New Technology
A single/common starting VFD was the most cost effective Assists the Design of Outdoor Rated Medium Voltage
solution versus dedicated starting VFD’s. The cost for four Drives”Paper T-00 PCIC in Toronto September, 2010, pages
dedicated VFD’s, one per compressor, far outweighed the 1-3.
additional investment required in switchgear and controls.
The VFD was sized to about 60% (10,000 HP) of the largest [2] Bill Pelton and Kurt LeDoux, “Performance Testing of a
motor knowing that if it could start the largest 17.5 kHP Sine Wave ASD in Submersible Pumping Applications”
motor, all of the other compressors would definitely start. In presented at the Gulf Coast Section Electric Submersible
fact, selection of sizing was over conservative on the VFD Pump Workshop held in Houston, TX April, 2002, pages 4-
as the compressor models showed that only 25% (4,400 11.
HP) of the largest motor horsepower was needed to start
any compressor fully unloaded. The larger 10 kHP VFD VII. VITA
was selected in order to start some of the smaller methane
gas compressors partially loaded to minimize any venting. Kurt LeDoux graduated from DeVry Institute of
The largest compressor was for nitrogen for which venting Technology with a BSEET degree in 1978 and started his
is not a concern (air is 78% nitrogen). career with Reliance Electric as a Service Engineer on Drive
Systems. He moved to Toshiba in 1982 and has held various
IV. CONCLUSIONS drive related positions in manufacturing, service and repair,
engineering, and quality control. He has authored many
Starting large motors has always been a challenge for technical papers, most regarding voltage stress issues using
multiple reasons. There are more constraints for the design drives with long motor cables and step up transformers for
engineer than ever before: emissions requiring loaded the Society of Petroleum Engineers Electric Submersible
starts, limited utility capacity, and voltage flicker Pump Workshop. He is presently still at Toshiba working as
requirements. VFD technology is improving and is a viable Product Manager for Medium Voltage Drives.
alternative for the industrial user to mitigate the constraints
without reduction of motor life while allowing multiple
 Paul W. Visser graduated from Texas A&M University in
1969 with separate BS degrees in both Electrical Engineering
and Nuclear Engineering. Upon graduation, he went to work
with Humble Oil & Refining Company (now ExxonMobil)
performing various electrical, controls, and even drilling &
workover engineering assignments onshore & offshore both
in the US and on loan to Saudi Aramco. He retired from
ExxonMobil and is now an independent Consulting Engineer.
He originally became a student member of IEEE in 1968 and
has been a Member of IEEE since 1986. Mr. Visser is a
registered professional engineer in the state of Texas.

J. Dwight Hulin earned a BSEE degree from Texas A&I

University (Kingsville, TX) in 1982. He joined Exxon Pipeline
Company immediately after graduation as a design engineer
in the computer and communications group and then in the
electrical group designing power and automated controls for
pipeline facilities. In 1994 he transferred to Exxon Production
which subsequently became ExxonMobil Production where
he has continued serving as the Electrical Technical Lead for
the US Operations. Mr. Hulin has been an IEEE member for
34 years. He has co-authored and presented a technical
paper on distance protection schemes at the 2007 IAS
Conference. Mr. Hulin is a registered professional engineer
in the great state of Texas.

Hien Nguyen graduated in 1982 with a BSEE degree from

Kansas State University and has held positions at Western
Electric and General Electric (GE) before starting at Toshiba
in 1988 where he now works as a Design Engineer and PLC
programmer. Mr. Nguyen received a Masters in Electrical
Engineering from Prairie View A&M and is registered as a
professional engineer in Texas.