ifea kurs 26. mai 2011 testing av undervanns mechanical loss tests ... • norsok r-001...

Copyright Framo Engineering AS 2009

Audun Magne Askeland

IFEA kurs 26. Mai 2011Testing av undervanns kraftsystem


Testing av undervanns kraftsystem



• Electrical components in power chain

– Motor

– Penetrator

– Connector

– SubseaTransformer

– Umbilical

– Topside transformer

– Frequency converter



• Subsea Motor

– Gas or liquid filled

– Induction or permanent magnet motor



• Motor testing

– Qualification

• Material compatibility

• Ageing tests (temperature/pressure)

• Pressure withstand testing

– Type tests

• Electrical type tests according to IEC 60034

• Mechanical loss tests

• No-load tests

• Heat run with correct cooling system

• Load tests at variable speed with correct cooling system



• Motor testing

– FAT

• Electrical tests (IEC 60034)

• No-load tests

• Load tests (performance mapping)



Framo oil filled motors during performance test in water brakes

Horisontal Vertical



Motor performance logging



• Motor Penetrator

– Qualification (Parts of TD 0153 used)

• Material compatibility

• Ageing tests

• Pressure testing both ways

• Hyperbaric tests (cycle testing)

• Thermal testing (temp rise and cycling)

• Electrical testing (HV, IR, PD, CR)

• Mechanical tests (pull/bend/drop/vibration)

• Flooded tests (one barrier towards sea removed)


• Typical standards for penetrator qualification• ASTM D 877 Dielectric Break Down testing of Dielectric Fluids

• API-6A Hydrostatic Body Test

• API-17D Verification Test Requirements

• ASME VIII Div 2 Boiler and Pressure Vessel Code , Div 2

• PD 5500 Specification for Unfired Fusion Welded Pressure Vessels.

• STATOIL TD0153 “Specification for HV Wet and Dry Mateable Connector Assemblies

• NACE –MR0175 Sulphide Stress Corrosion Cracking Resistant Metallic Materials for Oil Field

Development (Applicable to all seawater exposed metallic surfaces)

• IEC-60502-2 Power cables with extruded insulation and their accessories for rated voltages from 1 kV up to 30 kV. Part 2: Cables for rated voltages from 6 kV (Um = 7,2kV) up to 30 kV (Um = 36 kV). (see also definition of standard voltage levels)

• IEC-60502-4 Power cables with extruded insulation and their accessories for rated voltages from 1 kV up to 30 kV. Part 4: Test requirements on accessories for cables with rated voltages from 6 kV (Um = 7,2 kV) up to 30 kV (Um= 36 kV)

• IEC 60270 Pd Measurements

• IEC 60287 Calculation of continuous current rating of cables

• IEC 60060-1 HV test Techniques Part 1 General Definitions and Test Requirements

• IEC 61442-1 Test Methods for Accessories for Cables for rated Voltages from 6 kV to 30 kV

• IEC 60228 Conductors of Insulated Cables

• NORSOK M-001 Design Principles, Materials Selection.

• NORSOK E-001 Electrical Systems

• NORSOK R-001 Mechanical Equipment




• Penetrator (motor or transformer)

– FAT

• Internal to External Pressure Test

• External to Internal Pressure Test

• Combined Differential Pressure Test

• IR Test

• HV Test

• PD Test

• Oven-dry

• Dye Penetrant Test

• Batch Helium Leak Test



Vibration testing of penetrator


• Transformer standards:– IEEE C57.12.90

– IEEE C57.12.00

– IEC 60076

These only cover the active part, not the complete subsea transformer.




• Subsea Transformer qualification

– Compatibility tests

– Hyperbaric pressure test of windings

– Pressure compensation tests



• Subsea Transformer Type tests

– Impulse test

– Heat run

– Partial discharge test


• Subsea Transformer Routine test

– Measurement of winding resistance

– Measurement of ratio and check of vector group

– Measurement of no load losses

– Measurement of load losses

– Applied high voltage test HV

– Applied high voltage test LV

– Induced voltage test

– Helium leak test

– Pressure test




Winding pressure tesing



Final testing of SS transformer


• Connectors

– Qualification covered by Statoil TD 0153

– Customer specifications



• Connector FAT

– Contact Resistance Test (CR)

– Insulation Resistance Test (IR)

– High Voltage (HV) Withstand Test

– Partial Discharge (PD) Test

– Shell Continuity Test

– Screen Continuity Test

– Mate / De-Mate Bench Test

– Hydrostatic Testing (Make and break in water)

– Helium Leak Test




Example of long time

test at elevated temperature



Umbilical:


• Electrical power cable qualification elements

– Power cable as per IEC 60502

– Water blocking

– Gas blocking

– Factory joint


Umbilical


• FAT

– Electrical tests before terminations

– Electrical tests after terminations

High voltage (HV), Partial discharge (PD), Insulation

resistance (IR), continuity resistance (CR), Time

Domain Reflectometry (TDR)


Umbilical


Tests after final installation

• HV test (IEC 60502)– Tests after installation are made, if required, when the installation of the cable and its

accessories has been completed.

– A d.c. voltage equal to 4 Uo shall be applied for 15 min.

– As an alternative, and by agreement between the contractor and purchaser, an a.c. voltage test at power frequency, in accordance with items a) or b) below, can be used:

• a) test for 5 min with the phase-to-phase voltage of the system applied between the conductor and the metallic screen;

• b) test for 24 h with the normal operating voltage of the system.

• TDR test

• CR test

• IR test


Umbilical


• Topside transformer

– Qualification/type tests

• Standard IEC or IEEE tests

• Core boost test

• Any Ex-certification tests (temp rise)



• Frequency converter

– Qualification

• Software capability to operate on long cable (and with transformers)

• Start-up capability



BasicDriveModule

M

Umbilical

Hang off

Filter

Jumper

Supplysystem

Subsea

Topside

Dry Mate

Step-up

Wet Mate

Wet Mate

SS transf.

Input tr.

BDM

CDM

M

Main Umbilical

Hang off

Filter

Jumper

Supplysystem


Different drive system topologies

give different system test

requirements.

System Integration Testing (SIT) or Extended FAT (EFAT)



Lf=3.6 mH

Cf=11.5 F Ci=1.40 F Co=0.93 F

R=1.86-2.02

R=1.86-2.02

R=1.86-2.02

MotorCable modelFilter

L=2.27mH

L=2.27mH

L=2.27mH

Lf=3.6 mH

Lf=3.6 mH Rs=0.425

Rs=0.425

Rs=0.425

Lm=0.28H Lr=6.7mH

Rr=25.3

Rr=25.3

Rr=25.3

Ls=9.39mH

Ls=9.39mH

Ls=9.39mH

VSD cells

Norma5000Power analyzer

Typical test setup for power system test



How advanced cable simulator is needed?

Lenght, converter type, amount of skin effect and cost are main inputs

to evaluation

Real cable vs two π-elements



Typical cable simulator components



Cable simulators can be

large….



System testing:

A lot of data to evaluate. What are the acceptance criteria's agreed with

end client??



Remote access to test data a benefit.


• Summary/lessons learned

– Qualifications always take longer time and are more expensive than at first glance.

– Qualified is a relative word….

– FAT is in many cases not suitable to pick up faults that a qualification test would

– Standards are many, and interpretations are even more.

– System tests at full power with all components is vital, ref. point about FAT.

– Water depth is not the main challenge.


ifea kurs 26. mai 2011 testing av undervanns mechanical loss tests ... • norsok r-001...

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