Automatic Tail Balancing Intelligent Energy-Saving System for Pumping Unit

Innovative production enhancement and energy saving solutions

Automatic Tail Balancing Intelligent Energy-Saving System for Pumping Unit

Intelligent upgrade, energy saving and consumption reduction

01 Overview

Currently, most oil fields have entered the middle and late stages of development. With continuous increase in water cut of crude oil, oil reservoir pressure and dynamic liquid level of oil wells have gradually declined. To maintain stable crude oil production, that is, crude oil production does not decrease with increase in water cut, the liquid production volume must be increased, correspondingly raising oil production cost. Therefore, pumping units are required to meet requirements of “deep pumping and large displacement” for liquid extraction, and feature low energy consumption and high reliability, necessitating the adoption of energy-efficient pumping units. However, the mainstream pumping units in use are still conventional beam pumping units, completing more than 80% of the oil extraction tasks. If these pumping units are equipped with intelligent energy-saving systems, it will bring considerable economic benefits to the oilfield.

Cloud service management mode
Schematic diagram of energy-saving device of automatic tail balancing intelligent pumping unit

02 Structure

Automatic tail balancing intelligent energy-saving system for pumping unit is composed of motorized balance adjustment module, digital control cabinet, sensors and so on.

Automatic Tail Balancing Intelligent Energy-Saving Device for Pumping Unit

  • Motorized balance adjustment module: Motorized balance adjustment module is core technique with manual and automatic functions.It can adjust torque and counterbalance moment of pumping unit according to balance degree, achieve stepless speed regulation, achieve automatic balancing within a range of 50% to 100% of rated load.
  • Digital control cabinet
  • Data acquisition module: It achieve real-time data acquisition of load, current, power, wellhead pressure, etc., for logical operations and intelligent control.
  • Data display module: It displays stroke frequency and balance degree of pumping unit in real-time.
  • Fixed frequency control: It provides protection functions such as start, stop, overcurrent, overload, and phase loss.
  • Variable frequency control: It adjusts stroke frequency of pumping unit, achieves soft start of electric motor and multiple protection functions, and automatically switch to fixed frequency in case of fault.
  • Communication module: It includes data transmission.
  • Sensors: It realizes real-time acquisition of loads, displacements, and electrical parameters.
  • Motorized balance adjustment module
  • Digital control cabinet
  • Sensors

Safety monitoring equipment mainly utilizes image monitoring, data fault acquistion and automatic alarm systems.

  • Image Monitoring: monitor well site operation conditions.
  • Fault Data Collection: monitor pumping unit operation and alarm automaticly.

The data transmission from well site to management center is primarily achieved through the 3G/4G mobile networks or oilfield communication networks.

  • 3G/4G Mobile Networks
  • Oilfield Network

Intelligent and energy-saving modification system for pumping unit is equipped with a remote management platform, which can collect work diagrams, loads, strokes, stroke frequencies, currents, voltages, electrical parameters, etc. in real-time. It can achieve remote operation and management through snapshotting and timed photography of well site equipment and personnel.

  • Real-Time Data Collection: Dynamometer cards, load, stroke length, stroke rate, and electrical parameters.
  • Image Monitoring: Oversees wellsite equipment and personnel activities.
  • Remote Operation Management: the duty personnel can remotely control the operation of the pumping unit.

03 Advantages

Field application

Reduce operating costs

Our intelligent energy-saving system greatly reduces burden and cost of manpower, equipment, and vehicle usage caused by on-site balance and stroke adjustment operations. Operating expenses will be reduced by approximately 90%, significantly reducing oil production costs, eliminating manual on-site start-stop, saving time, labor, and vehicle usage.

Save investment costs

Pumping units achieve soft start and overload protection with intelligent energy-saving equipment, reducing startup inertia loads, decreasing wellsite grid capacity by 30%, reducing investments in oilfield grid line construction and capacity expansion fees paid to power departments.

Boost oil production

It contributes to boost crude oil production especially for water-driven reservoirs.

Extend lifespan of pumping unit

Pumping units can automatically adjust parameters with intelligent energy-saving equipment, ensuring smooth operation and lighter loads. This extends lifespan and maintenance interval of pumping unit, pumping rods, oil pumps, and packing boxes, increasing effective production time.

Cloud management platform

The improvement of digitization, automation, remote control, and intelligence levels facilitates optimization of labor organization within oilfield companies, transforming on-site monitoring into well patrols, further elevating management efficiency and reducing labor intensity.

04 Project Case

05 FAQ

This device dynamically adjusts the torque of the balance weight through the electric balance adjustment module to achieve the best balance state of the pumping unit under different loads and reduce the ineffective power consumption. At the same time, the frequency conversion control function in the digital intelligent control cabinet can adjust the stroke of the pumping unit according to the actual demand, further optimize the energy consumption, so as to achieve energy saving.

The electric balance adjustment module is used in combination with the sensor and the control cabinet. The sensor receives the data signal, and then the control cabinet decides and issues the command. Finally, the electric balance adjustment module reduces the power loss and improves the pumping efficiency.

The remote monitoring platform collects power diagram, load, stroke,, current, voltage and other data in real time, monitors well site equipment and personnel activities through images, and realizes remote operation management of pumping units. The duty personnel can remotely adjust the parameters of the pumping unit, monitor the equipment status, respond to the fault alarm in time, and improve the operation and maintenance efficiency.

Safety monitoring equipment through image monitoring and data fault acquisition, real-time monitoring of the well site environment and pumping unit operating status, once detected abnormal conditions, such as equipment failure or unsafe behavior, will automatically alarm, notify the management personnel, effectively prevent accidents, ensure the safe operation of pumping units.

The data transmission channel adopts 3G/4G mobile network or oilfield communication private network to ensure the security and stability of data transmission. Even in remote fields, it can maintain a stable connection to the remote monitoring platform to transmit pumping unit operation data in real time, enabling efficient data analysis and decision making.

Quick response and reliable service are available.

Get Solution