Shenzhen IPC Co., Ltd. Lifulin

Abstract: This paper mainly presents the application of IPC PUS to Beam Pumper of HuoShaoShan，The core controller of IPC-PUS series control system use pumping unit dedicated control program and digital feedback technology and it can automatically run by setting in advance. The whole system has a bypass function ,its control scheme reliable performance and simple operation and high efficiency for energy- saving.Taking HuoShaoShan oil field as an example，this paper analyzes its application and provides IPC-PUS series control system in the pumping unit system optimal application promotion scheme.

Key words: beam pumper IPC-PUS control system energy feedback

1. Introduction

Energy is the foundation of modern industrial life, and petroleum is still the main energy source for industry. With the rapid development of China's economy, my country's oil consumption has increased significantly, and international oil prices are also constantly fluctuating. Energy industries such as oil and natural gas have become more and more important in the country's economic industry, which has extensively affected my country's economic development. Effectively controlling the key technical links in the production process, improving the work efficiency of oil and gas production, reducing energy consumption, and improving the overall informationization of the oil field are the current development trends of oil extraction operations.

The core technology of the IPC pumping unit intelligent control cabinet (PUS) comes from Canada. It is designed by the Albert Oilfield Design Institute according to the special working conditions of the oilfield pumping unit and is produced and applied by Smart Chip in the United States. PUS adopts special control program for pumping unit and digital feedback technology, and is equipped with power frequency bypass and reserved communication interface. The design of the system meets the requirements of oilfield production, greatly improves the oil production process, and has significant energy-saving effects. It has been listed as the preferred product for promotion and application by major oilfield units.

2. Application analysis of pumping units in Huoshaoshan Oilfield

The Huoshaoshan Oilfield in Xinjiang is a fractured low-permeability sandstone reservoir, and its exploration and development has entered the middle and late stages. The beam pumping unit is generally used in Huoshaoshan Oilfield, and the pumping unit system used generally has low efficiency and high energy consumption. In the actual production process, the fluid supply capacity of the oil production well changes at any time, and the operating parameters of the pumping system need to be adjusted in a timely and reasonable manner. Among them, the adjustment of the stroke rate of the pumping unit is particularly important. Generally, the stroke frequency is adjusted by replacing the motor pulley, and the stroke frequency of the pumping unit is generally only three or five gears, which results in a decrease in oil extraction efficiency and an increase in energy consumption.

In order to improve the oil extraction operation process, reduce energy consumption, increase efficiency, and enhance the intelligence of the pumping unit system, a system upgrade and transformation plan came into being. The system is mainly composed of a kowtow machine, an intelligent control cabinet, an electric motor, and a sensor. The sensor collects the position information of the pumping unit to provide a basis for judging the position of the donkey head of the pumping unit. The intelligent control cabinet controls the pumping unit, and the electric motor is connected to the control cabinet to drive the pumping unit to operate at the required stroke times.

The well site provides 380V/50HZ input AC power. According to the different load of the oil well, the power of the electric motor equipped with the pumping unit of each well site in Huo Shaoshan Oilfield will be different. This article only uses the Huo 12 well as an example for analysis.

3, program analysis

The main parameters of the Huo 12 well motor are shown in the table below.

Table 1

Main parameters of pumping unit motor for Huo 12 well

Taking into account the large temperature difference between winter and summer in Xinjiang, the lowest temperature on site in winter may reach -40°C, and the highest temperature on the surface in summer may reach 80°C. The electrical components in the cabinet are all considered for derating. Based on this, the following control cabinets are equipped.

Form 2

Parameters of Intelligent Control Cabinet of Pumping Unit

In order to adapt to the strong wind and sand that comes at any time, the cabinet structure is designed with strict dust protection, as shown in the figure below.

Figure 1 Intelligent control cabinet of PUS pumping unit and double-layer sand-proof structure

During normal operation, the pumping unit adopts the intelligent control mode. When the pumping unit fails in this mode, it can be bypassed to the power frequency channel to ensure the normal operation of the oil well during maintenance.

Fourth, analysis of on-site application effects

Install the wellsite frequency conversion control cabinet according to the working condition control requirements, check the internal and external wiring of the cabinet according to the standard procedures, and conduct on-site debugging of the intelligent control cabinet. IPC-PUS can complete the test task excellently.

According to the relevant parts in SY/T5264-2006 "Test and Calculation Method of Energy Consumption of Oilfield Production System", SY/T6422 "Determination of Energy Saving Effect of Energy-saving Products in Petroleum Enterprises", according to the requirements of the standard, use advanced 3169-20 electric energy comprehensive tester and SGH2000-1 pumping well tester, the Oilfield Energy Conservation Testing Center conducts on-site comparison tests between this well and other standard wells. The following is the detection data of the fire 12 part.

Table 3 Operating data of part 12 of the fire

It can be seen from the above table that the Huo 12 well has reduced the overall power consumption on the basis of reducing the unit consumption of liquid production. Not only that, the use of the PUS oilfield special intelligent control cabinet has improved the efficiency of the pumping unit system. Under field test conditions, through comparative tests, the active power saving rate of the oil well is 32.7%. , The power factor is also greatly improved.

Through testing the PUS control cabinet in other oil wells, the energy-saving effect is satisfactory. Through testing, the average active power saving rate of oil wells is 27.3%~37.3%, and the power saving effect varies from well to well. In addition, the average system efficiency of oil wells has increased by 8%.

The PUS intelligent control cabinet is easy to use and operate, and is highly adaptable to the on-site environment. It has maintained zero-fault operation since the well, which greatly improved the use of technology and operating costs.

5. Advantages of IPC-PUS pumping unit intelligent control cabinet

The IPC-PUS series pumping unit intelligent control cabinet is specially designed according to the working conditions of the pumping unit and has its own advantages.

⑴ Adopt digital feedback technology, more energy saving. Because the operating conditions of beam pumping units are not constant speed conditions, their operating conditions are: upstroke and downstroke. If the counterweight is unbalanced, the electric motor is in a state of frequent and deep power generation and electric alternation. Ordinary frequency conversion cabinets and energy-saving devices used in pumping units are generally connected to an external braking unit and braking resistor, which consumes the power generated during the downward process of the pumping unit on the braking resistor. IPC-PUS adopts the internationally leading digital feedback technology to feed the electric energy from the motor back to the original grid to obtain energy saving effect. The IPC-PUS series of intelligent control cabinets for pumping units save 15-25% more energy than ordinary general-purpose inverter cabinets. The heat loss is less than 3% of resistance braking.

⑵ The performance and quality are super high. IPC-PUS adopts well-known brands in the industry from contactors to relays, from electrolytic capacitors to control chips, with super high performance and quality, and is completely designed and configured for the harsh environment of the oil field.

⑶ The special application program for pumping unit is adopted, but the display is clear, the operation is simple, and it is suitable for direct debugging by ordinary oil producers without manual and operation manual.

⑷ According to the pertinent design of the operating conditions of the kowtow machine, the stroke frequency can be directly displayed and adjusted, and the optimal stroke frequency of the upper and lower strokes can be adjusted according to the single well operating conditions, and a fully automatic control scheme can be designed based on this.

⑸ Provide automatic operation of up and down strokes. The position of the donkey head of the pumping unit is detected by the sensor, and the control cabinet will run according to the preset up and down strokes.

⑹ Built-in input filter device, full noise filtering, low harmonic content, voltage distortion rate is generally below 3%.

In addition, the use of PUS series control cabinet will have the following basic advantages.

⑴ The stroke frequency of the pumping unit can be adjusted arbitrarily to improve the efficiency of the pumping unit system and increase the liquid production. In the initial oil wells, because the oil wells have just been exploited, the oil reserves are large. In order to improve the efficiency of oil extraction, we can increase the stroke order of the pumping unit, and its oil production will increase accordingly. However, in the middle and late stages of oil well collection, due to the reduction of the original fluid reserve in the well and the insufficient fluid supply, we adopted the control method of lowering the stroke rate of the pumping unit and selecting the high-speed and low-low control methods. The pumping can be dynamically adjusted according to the full load of the pump. The stroke rate of the oil machine increases the pump full coefficient and displacement coefficient to achieve a more energy-saving and increased production operation effect.

⑵ Improve the power factor of the network side. When the original motor is directly driven by industrial frequency, the power factor is about 0.81 at full load, and the actual operating power factor is much lower than 0.7. After adopting the PUS intelligent control system, the power factor on the power supply side can even be increased to more than 0.9, and the reactive power can be greatly reduced without a reactive power compensation device, meeting the requirements of the power grid, and further saving the operating cost of upstream equipment.

⑶ Equipment operation and maintenance costs are reduced. After adopting the PUS intelligent control system, the motor can be soft-started, and the current does not exceed 1.2 times the rated current of the motor when starting, without any impact on the power grid. When the load rate is low, adjust the stroke rate, the main equipment and the corresponding auxiliary equipment such as bearings, etc. wear less than before, the maintenance cycle can be lengthened, the maintenance cost is reduced, and the equipment operating life is extended.

⑷ Integrated electrical protection is added. Compared with the original system, the PUS intelligent control system has multiple protection functions such as over-current, short-circuit, over-voltage, under-voltage, and temperature rise, which can better protect the motor.

⑸ Improve the level of automation to provide the underlying guarantee for the digital construction of oilfields. Directly through the PUS intelligent control system to dynamically adjust the speed of the pumping unit, the stroke rate of the pumping unit can be steplessly adjusted, and it is convenient to realize remote centralized monitoring and easy to detect the operating status of the equipment.

6, concluding remarks

Shenzhen IPC Co., Ltd. IPC-PUS series of intelligent control cabinets for pumping units play an important role in the energy-saving transformation of oilfields due to its superior performance. The long-term operation of the well site is affected by front-line employees. The high praise, the stepless speed regulation brought by it greatly reduces the intensity and time of the on-site stroke adjustment, and its energy feedback function optimizes energy saving. With the promotion of oilfield digitization and informatization, the IPC-PUS series of pumping unit intelligent control cabinets will surely play an increasingly important role in the energy-saving transformation of pumping units.

References

IPC-PUS Pumping Unit Intelligent Control Cabinet User Manual.