Industrial application of a linear drive system in a pump testing facility

Abstract

Low oil prices push the demand for efficient oil and gas production, especially in mature fields. Reducing the costs of artificial lift systems by increasing efficiency is mandatory for extending meantime between failure, economic limit and increasing recovery factor. To achieve these goals, the Pump Testing Facility was established in Leoben for low risk, low cost, and high-performance testing of new technologies including various artificial lift systems. Montanuniversitaet Leoben constructed this facility to overcome the enormous field testing costs and to speed up innovation. The initial objective of the Pump Testing Facility was to test and optimize sucker rod pumps. Due to the inflexibility of the standard surface pump jack, an industrial linear drive system is selected as a prime mover for the down hole pumping system. The highly sophisticated control unit of the AC drive is able to describe, on one hand, the same motion profile as a standard pump jack. On the other hand, it is even more powerful because of its ability to perform any required motion profile. The AC linear drive system is in addition equipped with a powerful monitoring system that allows quick data recording and analysis. This paper summarizes concept and capabilities of this unique testing facility, its performance, and planned applications, demonstrating advantages towards conventional developments and testing. The case studies have already shown that the employed AC linear drive system can be applied in the field as well, making this kind of artificial lift system cheaper, smarter and more flexible. As an integral part of the chair's research programs, new technologies, self-development, and patents will be tested before being applied in fields, using the AC linear drive system. In close cooperation with the industry, this pump testing facility will be expanded to cover more special operational modes and events that may occur in the field.