Transforming offshore oil production

05 September, 2024

That’s why WEG was asked to support the project. The manufacturer was called upon during the Belbazem project’s Front-End Engineering Design (FEED) stage. Here, the project's engineering, procurement, and construction (EPC) companies come together to plan and identify the proper operational design and technology, with input from global experts in the field. They also proactively assess potential challenges or risks upfront, preventing expensive changes in the later phases of development 

“WEG was delighted to support the Belbazem development project’s EPCs during the FEED stage”, explains Ahmed ElShayal, WEG global O&G Regional Business Manager — Middle East. “This meant we were able to contribute to the development of the project from its earliest, conceptual stages with our expertise and crucial technology.

“Based on those early discussions, it was decided to transition away from the use of a conventional low voltage (LV) drives solution to operate and control the ESPs. Instead, it was decided that a better choice would be to use WEG’s MV VSDs to suit the project circumstances.”

While LV drives are more advantageous in certain settings, there were several advantages of using MV VSDs over LV drives systems at Belbazem. MV systems would prove more efficient, support a smaller footprint because they are compact and lighter —specially if MVW01 G2 drives with an integrated transformer, mentioned below, are used — and tend to produce fewer disruptive harmonics. Moreover, MV voltage systems experience lower voltage drop over long distances and can accommodate the longer cable runs that are so essential for powering ESPs — without experiencing excessive voltage drop or requiring additional compensation measures.

In the end, MV VSDs were recommended as the “crucial technology” for the Belbazem offshore block — 15 units in total. Specifically, WEG recommended its second-generation MVW01 G2 drives that feature advanced components, deliver higher power output, greater reliability and significant energy efficiency gains. 

The MVW01’s advanced components include Voltage Source Inverter (VSI) technology, which takes the energy from a power source and converts it into a form that can be used by different devices, with Neutral Point Clamp (NPC) multilevel power topology, which helps efficiently use and manage different voltage levels. These technologies combine with 6.5 kV High Voltage Insulated Gate Bipolar Transistors (HV IGBTs) that amplify, regulate, convert or turn high-voltage currents on or off rapidly.

The second generation MVW01 G2 — as recommended for use in the Belbazem project — offers enhanced power output and reliability while retaining the same footprint. This improvement in performance is attributed to the use of the latest HV IGBTs with a larger safe operating area and higher short circuit capability. The drive's power capacity ranges from 500 to 22,500 HP (400 to 16,000 kW), with voltage ratings from 2.3 kV to 6.9 kV and an output frequency of up to 120 Hz.

“The MVW01 G2 is versatile, finding applications in various industrial settings including compressors, pumps, fans, conveyors and grinding mills”, explains ElShayal. “The unit’s design, which combines the optimum number of power and control components, results in the highest efficiency design on the market. “The operator interface is designed for familiarity and ease of use, mirroring that of WEG’s LV VSD product line. By coordinating with ESP suppliers, it was possible for WEG to ensure seamless integration of the entire system.”