In order to meet the needs of oil and gas exploration enterprises for clean, economic and highly reliable production under the background of carbon neutralization, a new electricity-replace-oil driving device based on the variable frequency speed regulation of two megawatt alternating current asynchronous motors was designed. Based on the modularization idea, the split modular box structure for high-voltage transformer and low-voltage transmission was designed,which improved the convenience of dispatch and use of the electricity-replace-oil driving device. The high-voltage transformer module was adopted the twelve-pulse rectifier transformer, which realized that only the transformer cost increased by 25% under the premise of no significant increase in the inverter cost, so as to greatly save the reactive power compensation cost. Especially in the high-power drilling section where the proportion of on-site electricity consumption was low, the measured power factor of the device was over 0.95. Aiming at the problem of unbalanced load in the dual-motor cooperative control, a PLC (programmable logic controller) control system based on the master-slave control structure was designed, and the speed matching control was combined with the converter droop control to control the motor speed deviation within 10%; at the same time, the designed control system could support the multi-place operation and remote monitoring of field data, which improved the reliability of the electricity-replace-oil driving device. The test run results showed that the designed electricity-replace-oil driving device could meet the actual engineering needs; compared with the traditional diesel driving device, it could save cost by 52% and reduce the carbon dioxide (CO2) emission by 27% per month. The designed device has certain practical value in the field of energy conservation in oil and gas exploration.
Chun-lin WANG,Chang LIU,Hua YANG,Hong QIN,Guo-zhu CHEN. System design and analysis of electricity-replace-oil driving device for oil and gas exploration. Chin J Eng Design, 2022, 29(2): 220-230.
Fig.1 Overall structure of transmission system of oil and gas exploration site
Fig.2 Electrical system structure of new electricity-replace-oil driving device
Fig.3 Electrical system structure of traditional electricity-replace-oil driving device
谐波次数
谐波含量/%
传统电代油驱动装置 新型电代油驱动装置
5
20
0
7
14
0
11
9
9
13
8
8
17
6
0
19
5
0
Table 1Comparison of theoretical harmonic content of different electricity-replace-oil driving devices
Fig.4 Relationship between measured power factor and apparent power of new electricity-replace-oil driving device under a certain drilling condition
Fig.5 Three-dimensional structure of high-voltage transformer module
Fig.6 Three-dimensional structure of low-voltage transmission module
Fig.7 Strain nephogram of box base of low-voltage transmission module
参数
数值
极对数
3
绝缘等级
200
额定电压/V
600
额定频率/Hz
50.5
额定功率/kW
1 200
额定转速/(r/min)
1 000
工作转速/(r/min)
0~2 599
恒转矩转速/(r/min)
100~1 000
恒功转速/(r/min)
1 000~1 680
Table 2Parameters of three-phase alternating current asynchronous motor
Fig.8 Vector control speed regulation principle of motor in new electricity-replace-oil driving device
Fig.9 Mechanical characteristic curve of three-phase alternating current asynchronous motor
Fig.10 Droop control block diagram of motor in new electricity-replace-oil driving device
Fig.11 Paraller control flow of new electricity-replace-oil driving device
Fig.12 Shutdown control flow of new electricity-replace-oil driving device during parallel operation
Fig.13 Dual-motor cooperative control flow of new electricity-replace-oil driving device
Fig.14 Hardware structure block diagram of control system of new electricity-replace-oil driving device
Fig.15 Placement site of motor and operation cabinet on the motor side
Fig.16 Block diagram of PLC control program design for new electricity-replace-oil driving device
Fig.17 Human computer interaction interface of new electricity-replace-oil driving device during parallel operation under a certain actual working condition
Fig.18 Remote monitoring and data sharing scheme for operation status of new electricity-replace-oil driving device
Fig.19 Dynamic monitoring interface of active power of high-voltage transformer module total meter
设备
设备使用成本
能源使用成本
设备成本/万元
使用寿命/a
月使用成本/万元
单价/(元/L)
月消耗量/L
月平均使用成本/万元
柴油驱动装置
480
15
2.70
6.40
5.10×105
326.40
Table 3Cost analysis of diesel driving device
设备部件
设备使用成本
能源使用成本
设备成本/
万元
使用寿命/
a
月使用成本/
万元
单价/
(元/kWh)
月消耗量/
kWh
月平均使用成本/
万元
高低压开关柜
15
10
0.13
0.80
1.93×106
154.40
双路十二脉整流变压器
40
15
0.22
高压变电模块箱体
15
15
0.08
交流变频器（含制动电阻）
163
10
1.32
500 kVar无功补偿装置
25
10
0.21
PLC控制系统
10
10
0.08
空调
15
10
0.13
低压传动模块箱体
15
15
0.08
三相交流异步电动机
80
15
0.44
Table 4Cost analysis of new electricity-replace-oil driving device
主要动力设备
指标
量值
1 200 kW柴油发动机
燃油消耗率
283.7 g/kWh
10 kV/3 150 kVA双路十二脉整流变压器
效率
98.5%
600 V/1200 kW交流变频器
效率
98.5%
YDZJ-20DDf型液耦
效率
96.0%
600 V/1 200 kW三相交流异步电动机
效率
96.0%
Table 5Energy efficiency parameters of main power equipment of oil and gas exploration driving device
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