VARIATORS SA V YASKAWA

BACK SPIN CONTROL WITH VDF

YASKAWA F7

“Guando Petrobras Colombia Limited field tests”

Version 2.00
Rev. 3 27/08/09
VARIATORS SA

PROBLEM DESCRIPTION
■ All oil extraction pumps with PCP (progressive cavity
pump) system take the form of communicating vessels
with different pressures at the same depth. When the drive
that drives the pump motor is turned off, the fluid level in
the tubing and in the annulus tries to reach the same
horizontal line or the static level of the fluid. This also
occurs when the drive presents some type of failure
caused by disturbances in the electrical distribution
system.

■ Voltage dips, phase losses or power outages can cause

significant loss of production in PCP pumps. Loss of PCP
control caused by power problems results in back spin
(reverse rotation of the pump) as fluid drains through the
production tubing.
VARIATORS SA V YASKAWA

PROBLEM DESCRIPTION

■ The back spin time can take minutes or even hours

depending on the specifications of the pump, additionally, a
greater depth produces a longer back spin time.

■ Production losses can be more than double the back spin

time, since the fluid must reach the surface again for the
pump to start producing. For this reason the event must be
measured based on the sum of the two times .
VARIATORS SA V YASKAWA

SOLUTION ALTERNATIVES

Based on the Yaskawa F7 drive,

two alternatives are presented for
control:

1. Software alternative.

2. Alternative for speed search

(requires devices for managing
regenerative energy).
VARIATORS SA
1. BACK CONTROL SOFTWARE
SPIN
The back spin control software is a CASE Software
(Custom Application Software Environment) and must be
installed on each device

Functions used:

1. Automatic restarts
2. Dwell Frequency
3. Dwell torque limit
VARIATORS SA V YASKAWA

1. BACK CONTROL SOFTWARE

SPIN
1. Automatic restarts:

This feature allows the drive to automatically restore

pump operation after failure events such as long (greater
than 4 sec.) or short (less than 4 sec.) power outages,
momentary overloads, over voltages, phase losses in the
entrance, among others.
VARIATORS SA

1. BACK CONTROL SOFTWARE

SPIN
1. Automatic restarts:

Related parameters:
• L5-01= Number of restarts
Allows you to adjust the desired number of restarts.

• P3-01= Time between restarts

Allows you to adjust the time in minutes that the drive will wait before resetting the fault.

• P3-02= Restart count clear time

Allows you to adjust the time that must elapse after a successful start to clear the
restart count.
VARIATORS SA V YASKAWA

1. BACK CONTROL SOFTWARE

SPIN
1. Automatic restarts:
run
command
Restart counter is desred

Drive cannot restart because fault condition is

present - restart counter is incremented and
inverter waits for F3-01 time again
VARIATORS SA
1. BACK CONTROL SOFTWARE
SPIN
2. Dwell Frequency:

This function allows the drive to send an output frequency

of 0.5 Hz (lower than the motor slip frequency) for an
adjustable time to the motor just before starting the
acceleration ramp, in order to monitor and reduce power
stored in the load.
VARIATORS SA V YASKAWA

1. BACK CONTROL SOFTWARE

SPIN
2. Dwell Frequency:

Related parameters:
• B6-01= Dwell frequency at startup
Allows you to adjust the desired frequency during the Dwell function

• B6-02= Dwell frequency time at startup

Allows you to set the time in seconds during which the Dwell frequency will be sent to
the motor at startup.
VARIATORS SA

1. BACK CONTROL SOFTWARE

SPIN
3. Dwell torque limit:

Related parameters:
• P1-05= Dwell torque limit
It allows you to adjust the level of torque that must be present in the load during the
time set in P1-06 in which the drive will make the decision to start forward.
• P1-06=Dwell torque detection time
Allows you to adjust the time in seconds during which the load torque must remain
below the level set in P1-05 to make the decision to start forward.
VARIATORS SA

1. BACK CONTROL SOFTWARE

SPIN
 VARIATORS SA V YASKAWA
Feb 10 2009
CONTROL SOFTWARE DEVELOPMENT
See. 119274

BACK SPIN
• Inhibition of low
torque detection after
restart

Feb 29 2008
Ver. 119273

• Modification of the • Restart functionality • Modification of the • Modification of high

recommended settings in over torque fault restart functionality in and low pressure
for torque control case of over torque faults with
parameters L7-06, L7- failure independent delay for
07 and N2-01 • Stuck pump failure each fault
• Sequence and • Review of texts in
reference by Spanish
communications and
terminals

Jan 9 2009 Feb 24 2009

Ver. 119273 Feb 16 See. 119276
2009
See.
VARIATORS SA V YASKAWA
VARIATORS SA V YASKAWA

2. BACK SPIN CONTROL BY

SPEED SEARCH
The speed search function is a function included in the
PCP software that allows you to detect the direction of
rotation and speed of the engine just before starting
the engine, control it and bring it to the direction of
rotation and operating speed.

Function and necessary equipment:

1. Speed search
2. Regenerative unit
VARIATORS SA V YASKAWA

2. BACK SPIN CONTROL BY

SPEED SEARCH
VARIATORS SA V YASKAWA

Energy Savings = P m - P reg

Braking
resistance RC5

Heat 777
Motor Power: Ｐｍ
Regenerative Power: Ｐｒｅｇ
VARIATORS SA V YASKAWA

TESTS PERFORMED

Tests of the two Back Spin control systems were

carried out in wells GUA 113, GUA 67 and GUA 21 in
the Guando field operated by Petrobras, located in
the department of Tolima, Colombia.
These tests were carried out in the months of
January to October 2008.
VARIATORS SA V YASKAWA

TEST #1 GUANDO 113

■ Pump characteristics:

Pump Depth: 3255 feet

Rod: 1" SR, GRADE "D" SUCKER
ROD, w/SH CPLG & CENTR
VDF: F7U4037 for 75 amps HD 50 HP
Engine: - 58 amps, 1190 rpm 297rpm
Pump speed:
Tests carried out on January 24,
2008.
VARIATORS SA V YASKAWA

TEST #1 GUANDO 113

■ Operating conditions

Production as of 4/02/08
BFDP: 1230
BOPD: 241
Operating Speed: 251rpm
Output reference torque: 47,1 %.
Back Spin Time: 32 minutes.
Recovery time: 28 minutes
VARIATORS SA

TEST #1 GUANDO 113

■ Result
ORIGINAL SOFTWARE SOLUTION
WELL BACK SPIN T. FLUID TOTAL BACK SPIN T. FLUID TOTAL
TIME CONTRIBUTION TIME TIME CONTRIBUTION TIME

GUA 113 32 min 28 min 1 hour 6 min 35 sec 6 min 45 sec 13 min 20
sec

Software operation

Graph
VARIATORS SA V YASKAWA
TEST #2 GUANDO 67

■ Pump Features:

3617 feet
Pump Depth: 1" SR, ROD –COROD SER6
Rod: F7U4045 for 91 amps HD 50 Hp – 58
VDF: amps, 1190 rpm
Engine : 297rpm
Pump speed: Tests carried out September 30 -
October 2, 2008
VARIATORS SA V YASKAWA
TEST #2 GUANDO 67

■ Pump operating conditions:

Production as of 09/20/08
BFDP:
BOPD: 446
Operating Speed: 201
Output reference torque: 190rpm
Back Spin Time: 68 %.
Recovery time: 4.5 hours
approx.
1.5 hours
VARIATORS SA

TEST #2 GUANDO 67
■ Result
ORIGINAL SOFTWARE SOLUTION SOLUTION BY SPEED SEARCH
T. OF T. OF T. OF
WELL
T. BACK CONTRIB T. BACK CONTRIB T. BACK CONTRIB
T. TOTAL T. TOTAL T. TOTAL
SPIN UTION SPIN UTION SPIN UTION
OF FLUID OF FLUID OF FLUID
1 min 37 1 min 5 2 min 42 1min 30
GUA 67 4.5 hours 1.5 hours 6 hours 1 min 30 sec
sec sec sec sec

Software operation Operation with search

speed

Graph Vide Graph Vide

o o
VARIATORS SA V YASKAWA

TEST #3 GUANDO 21

■ Pump characteristics:

Pump Depth: 3208 feet

Rod: 1" SR, ROD –COROD SER 6
VDF: F7U4037 for 75 amps HD 75 Hp –
Engine: 86 amps, 1190 rpm 297rpm
Pump speed: Tests carried out October 8, 2008
VARIATORS SA

TEST #3 GUANDO 21

■ Pump operating conditions:

Production as of 09/18/08
BFDP: 953
BOPD: 565
Operating Speed: 290 rpm
Output reference torque: 60%.
Back Spin Time: 13 min. 27 sec.
Recovery time: 9 min 19 sec.
VARIATORS SA

TEST #3 GUANDO 21
■ Result
ORIGINAL SOFTWARE SOLUTION SOLUTION BY SPEED SEARCH
T. OF
WELL T. FLUID T. FLUID
T. BACK CONTRIB T. BACK T. BACK
T. TOTAL CONTRIB T. TOTAL CONTRIB T. TOTAL
SPIN UTION SPIN SPIN
UTION UTION
OF FLUID
13 min 9 min 19 22 min 4 min 50 2 min 4 6 min 54 1 min 25 1 min 55
GUA 21 30 sec
27 sec sec 46 sec sec sec sec sec sec

Operation with search

Software operation
speed

Graph Vide Graph Vide

o o
VARIATORS SA

TEST #4 GUANDO 45

■ Pump Features:

VDF: F7U4045 for 91 amps ND

Engine: 75 Hp – 86 amps, 1190 rpm
Pump speed: 297rpm
Tests carried out June 9, 2009
VARIATORS SA V YASKAWA

TEST #3 GUANDO 45

■ Pump operating conditions:

Operating Speed: 250 rpm

Output reference torque: 44%.
Back Spin Time: 16 min. 50 sec.
Recovery time: 10 min 2 sec.
VARIATORS SA

TEST #4 GUANDO 45

■ Result
ORIGINAL SOLUTION BY SPEED SEARCH
WELL TIME T. FLUID
TOTAL BACK SPIN T. FLUID
FROM CONTRIBUTIO TOTAL TIME
TIME TIME CONTRIBUTION
BACK N
SPIN
GUA 45 16 min 10 minutes 26 min 1 min 2 sec 1 min 10 sec 2 min 10 sec

Operation with
Speed Search

Graph
VARIATORS SA

TEST #5 GUANDO 108

■ Pump Features:

VDF: F7U4045 for 91 amps ND

Engine: 75 Hp – 86 amps, 1190 rpm
Pump speed: 297rpm
Tests carried out June 11, 2009
VARIATORS SA

TEST #5 GUANDO 108

■ Pump operating conditions:

Operating Speed: 231 rpm

Output reference torque: 45%.
Back Spin Time: 19 min. 30 sec.
Recovery time: 11 min 2 sec.
VARIATORS SA

TEST #5 GUANDO 108

■ Result
ORIGINAL SOLUTION BY SPEED SEARCH
WELL TIME T. FLUID
TOTAL BACK SPIN T. FLUID
FROM CONTRIBUTIO TOTAL TIME
TIME TIME CONTRIBUTION
BACK N
SPIN
GUA 45 19 min 11 min 30 min 1 min 8 sec 1min 2 min 8 sec

Operation with
Speed Search

Graph
VARIATORS SA V YASKAWA
SUMMARY OF RESULTS
ORIGINAL SOFTWARE SOLUTION SOLUTION BY SPEED SEARCH

WELL T. OF T. OF
T. BACK CONTRIB T. BACK T. FLUID T. BACK CONTRIB
T. TOTAL T. TOTAL T. TOTAL
SPIN UTION SPIN CONTRIB SPIN UTION
OF FLUID UTION OF FLUID
6 min 6 min 13 min
GUA 113 32 min 28 min 1 hour - - -
35 sec 45 sec 20 sec
1.5 1 min 1 min 2 min 1min
GUA 67 4.5 hours 6 hours 1 min 30 sec
hours 37 sec 5 sec 42 sec 30 sec
13 min 9 min 22 min 4 min 2 min 6 min 1 min 1 min
GUA 21 30 sec
27 sec 19 sec 46 sec 50 sec 4 sec 54 sec 25 sec 55 sec

16 min 10 26 min 1 min 1 min 2 min

GUA 45 - - -
50 sec minutes 50 sec 10 sec 2 sec 12 sec

19 min 11 min 30 min 1 min 2 min

GUA 108 - - - 1 min
30 sec 2 sec 32 sec 8 sec 8 sec
VARIATORS SA

RESULTS WITH SOFTWARE

■ Conclusions:
■ The drive must be sized based on the current in heavy duty.
■ The time spent controlling back spin depends on the operating
conditions of the well.
■ To guarantee the proper functioning of the back spin control
software, the motor variator assembly and the rod torque
protections, dynamic self-adjustment must be performed.
■ The reduction in non-productive time of the pump in a failure event
is on average 82.34%.
VARIATORS SA

SEARCH RESULTS
SPEED
■ Conclusions:
■ The drive can be sized based on current in heavy duty or normal
duty.
■ The time spent controlling back spin is less than the software
alternative, but it also depends on the operating conditions of the
well.
■ To guarantee the proper functioning of the torque and motor
protections during the speed search, dynamic self-adjustment
must be performed.
■ The reduction in non-productive time of the pump in a failure event
is on average 95.45%.
VARIATORS SA V YASKAWA

END OF THE PRESENTATION