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Injection Station Automation System

Injection Station Automation System is used to control horizontal pump units (HPU) equipped with electric motors with a power of up to 1,000 kVA and supply voltage of 0.4 to 0.6 kV for the injection of process fluid into formation.

Components

The system consists of the RUMB KSU-06 Controller and additional modules installed on a DIN rail and designed to receive signals from sensors and other equipment of an injection station, generate control signals and protect the electronic components of the automation system against high-voltage spikes. The composition of the system is defined after the technical specifications for the system are agreed.

Functionality:

  • controlling and monitoring the condition of HPU and injection stations;
  • control of HPU by means of a contactor, variable frequency drive or soft starter;
  • protection of HPU parts against abnormal operating conditions;
  • control of a booster pump station;
  • monitoring the condition of the thrust chamber;
  • control of the oil pump and fan of the thrust chamber;
  • monitoring the condition of the multiplying gear;
  • control of the multiplier fan;
  • monitoring the pressure in the hydraulic system of the injection station;
Injection Station Automation System
  • fluid metering at the injection station inlet;
  • fluid metering at different lines at the injection station outlet;
  • controlling and monitoring the condition of motor operated valves at the injection station inlet and outlet;
  • monitoring the presence of supply voltage on the incoming feeders of the injection station when automatic load transfer to a backup feeder is provided;
  • monitoring the condition of the built-in protection cell of the high-voltage motor of HPU;
  • monitoring the condition of a gas detection system;
  • monitoring the condition of a fire detection and fighting system;
  • operating history storage in a nonvolatile memory;
  • periodic operation of HPU with predetermined running and idling time periods;
  • periodic operation of HPU with predetermined absolute starting and stopping times;
  • halt due to pressure sensor readings;
  • energy-use metering;
  • establishing different access levels for personnel by means of proximity access identifiers;
  • software update in the field by means of the RUMB UPI-06 Data Transfer Device;
  • control of the heater of the modular injection station;
  • control of the fan of the modular injection station;
  • control of the separate cooling fan of the main centrifugal pump motor of the HPU (HPUM);
  • control of the VSD heater;
  • control of the VSD fan;
  • emergency shutdown of all equipment controlled by the switchboard when the EMERGENCY SHUTDOWN button is pressed on the safety post;
  • HPU motor shutdown on an interlock signal from another HPU switchboard when its high or low temperature protection or gas detection system in a small modular injection station is tripped;
  • injected water metering using the flow meter data for the current and last day, month and year as well as total injected water since the last manual reset of the statistic;
  • manual adjustment of the voltage-frequency relation (U/f curve) by points for a reliable HPU start in difficult conditions, improving power efficiency and reducing the HPUM temperature;
  • maintaining a set flow rate of the HPU by means of the VSD and flow meter;
  • maintaining a set discharge pressure of the HPU by means of the VSD and discharge pressure sensor.
  • If a variable speed drive is installed:

    • smooth acceleration and deceleration of the HPU;
    • manual regulation of the motor power supply frequency;
    • automatic maintenance of a selected process parameter (for instance, the pump discharge pressure) at a set level by means of a built-in PID regulator.

    Monitored Parameters:

    • apparent power consumption;
    • active power consumption;
    • line currents of the motor;
    • line-to-neutral supply voltages;
    • line-to-line supply voltages;
    • average line-to-neutral voltage;
    • ESP motor load as a percentage of the rated load;
    • power factor (cos );
    • line-to-neutral supply voltage imbalance;
    • motor line current imbalance;
    • motor backspin speed while coasting;
    • motor power supply frequency;
    • motor speed;
    • motor torque;
    • power consumption;
    • pressure drop on the trunk-line inlet filter;
    • suction pressure of the booster pump station;
    • suction pressure of the HPU;
    • discharge pressure of the HPU;
    • suction temperature of the HPU;
    • HPUM vibration (vibration speed);
    • HPUM stator temperature;
    • temperature of the housing of centrifugal (main) pump of the HPU (CP HPU);
    • HPU delivery rate (flow rate);
    • oil temperature in the thrust chamber;
    • oil pressure in the thrust chamber;
    • oil pressure in the multiplying gear;
    • gas content in the air (hydrogen sulfide);
    • air temperature in the modular injection station;
    • temperature of the VSD/soft starter;
    • temperature of the front and rear bearings of the HPU motor;
    • temperature of the front and rear bearings of the CP HPU;
    • temperature of the front and rear bearings of the booster pump station motor;
    • temperature of the front and rear bearings of the booster pump station;
    • condition of the fire alarm system and shutdown on the FIRE signal;
    • condition of the 6 kV relay protection cell and shutdown on its signal prohibiting operation.

    Protection against abnormal operating conditions:

    • underload protection;
    • overload protection;
    • current imbalance protection;
    • overcurrent protection;
    • power supply overvoltage protection;
    • power supply undervoltage protection;
    • voltage imbalance protection;
    • incorrect phase sequence protection;
    • loss-of-phase protection;
    • backspin protection;
    • protection against an unauthorized door opening;
    • protection against discharge overpressure;
    • protection against discharge underpressure;
    • protection against suction overpressure;
    • protection against suction underpressure;
    • protection against high temperature at suction;
    • protection against low temperature at suction;
    • protection against high flow rate of the HPU;
    • protection against low flow rate of the HPU;
    • protection against low pressure in the multiplying gear;
    • protection against high temperature of the multiplying gear;
    • protection against low pressure in the thrust chamber;
    • protection against high pressure in the thrust chamber ;
    • protection against high temperature in the thrust chamber;
    • protection against high vibration;
    • protection against high temperature of the HPU motor stator;
    • protection against high temperature of the 1st bearing of the HPU motor;
    • protection against high temperature of the 2nd bearing of the HPU motor;
    • protection against high temperature of the of the CP HPU;
    • protection against high temperature of the 1st bearing of the CP HPU;
    • protection against high temperature of the 2nd bearing of the CP HPU;
    • protection against high temperature in the modular injection station;
    • protection against low temperature in the modular injection station;
    • protection against high gas content;
    • protection triggered by a signal from fire protection system;
    • protection triggered by a signal from the 6 kV motor protection cell;
    • protection against high temperature of the 1st bearing of the booster pump station;
    • protection against high temperature of the 2nd bearing of the booster pump station;
    • protection against high temperature of the 1st bearing of the booster pump station motor;
    • protection against high temperature of the 2nd bearing of the booster pump station motor;
    • protection against underpressure at the booster pump station suction ;
    • protection against overpressure at the booster pump station suction ;
    • protection against loss of communication (with a VSD, soft starter, flow meter, current inlet module or digital input/output module as well as 4-20 mA loop disconnection);
    • protection triggered by an interlock signal from another HPU switchboard when its high or low temperature protection or gas detection system in a small modular injection station is tripped.