Efficiency Of Pumping Unit Research Articles

Using frequency regulation to improve the energy efficiency of pumping units in switching circuits with a water tower

The development of the water supply system for small settlements involves the use of frequency converters and specialized control algorithms capable of maintaining the pressure level established in the network within certain limits. The implementation of one of the standard schemes involves decommissioning a water tower, which, on the one hand, allows reducing the cost of its maintenance, on the other hand, if the pump fails, the water tower provides a certain supply of water to the consumer, which increases the overall uptime. The paper considers the potential for increasing the energy efficiency of a water supply system when operating well pumps on a water tower through the use of frequency converters. The study has analyzed the operating conditions of more than 300 wells. This has made it possible to establish that most pumps have overestimated pressure values when lifting water into the tower (median excess of about 30 m). For the wells under study, optimization of the operating modes of the pumping units has revealed energy saving potential of up to 50 % by reducing excess pressure and up to 2.0 % due to a reduction in starting power at the moment of engine acceleration. An assessment of the energy saving potential based on similarity theory emphasizes that when the pump motor speed is reduced, it is important to take into account the reduction in its performance, which is a significant limitation in the design of automated control systems. The study results confirm the significant theoretical and practical potential of using frequency converters to improve the efficiency of water supply systems without the need to mothball water towers. The research provides a basis for further developments in the field of optimization and automation of water supply systems in order to achieve high energy efficiency.

Research on efficiency simulation model of pumping stations based on data-driven methods

The operational efficiency error of a pumping station unit is affected by several factors, resulting in a large error between the theoretical and actual pumping efficiencies. To solve the problem of accurately simulating the operating efficiency of the pumping station unit, this study conducted research on efficiency simulation models of pumping based on data-driven from three aspects: ①model algorithm, ②feature input and ③response output. In this study, eight machine learning models were introduced to establish pumping unit efficiency simulation models and they were compared with the traditional polynomial regression models, and the models with better performance were selected. Then the experiment proposed using “upstream water level + downstream water level” (UWL + DWL) instead of the traditional “head” (H) as feature input to train the models, and discussed the effects on efficiency simulation accuracy with direct fitting efficiency and fitting power then calculate the efficiency through formula. An example analysis was carried out using the historical data of eight units at Pizhou Station and Suining 2nd Station on the East Line of the South-to-North Water Diversion Project. The experimental results show that ① among all methods, the models based on Gaussian Process Regression (GPR) has the most accurate in ERMS, EMA, R², and EMI indicators, R² is close to 0.92. ②After UWL + DWL was used to train the models, all the test set indicators of the GPR models improved, and the EMA indicator decreased from an average of 0.39–0.26 %. ③ The study found that the fitting efficiency directly is better than the calculation efficiency after fitting the power, but the R² of fitting the power is better than the efficiency, which may provide another idea for the optimal goal of economic operation of pumping stations. ④ On the whole, trainning the GPR models with UWL + DWL to simulate efficiency has the highest precision, for example the EMA and EMI indicators of No.4 unit in Pizhou station can be reduced from 16.49 % and 20.40–0.18 % and 1.55 % respectively. The research results have practical significance and can provide strong support for the economical operation of pump stations.

Ключевые направления и мировые практики повышения эффективности и надежности водоснабжения

The article reviews modern research and practical developments in the field of increasing the efficiency and reliability of water supply systems. The analysis covers both the micro level, which includes optimizing the opera-tion of individual components of the system, and the macro level, related to the management and optimization of the water supply system as a whole. Particular attention is paid to improving the efficiency of pumping units, leaks and pressure losses management, as well as water treatment processes optimization. At the macro level, the article presents a review of strategies for the optimal distribution of water between water intakes, a study of the zones of water intakes influence on the hydraulic network, dynamic pressure planning and power consump-tion management of pumping stations. The importance of monitoring and diagnostics systems for increasing the reliability of water supply systems is emphasized. Key areas of research and current problems are identified, and promising approaches to improving the management of urban water supply systems are proposed

A Hybrid Prediction Model for Pumping Well System Efficiency Based on Stacking Integration Strategy

The current prediction model for the system efficiency of pumping units primarily relies on a mechanistic approach. However, this approach incorporates numerous unnecessary factors, thereby, increasing the cost associated with predictions. With the improvement of the oil field database, the available information is increasing. Some scholars propose a prediction model based on a single neural network, however, such models face challenges in effectively capturing complex data, resulting in lower prediction accuracy and limited resistance to interference. To solve the above problems, the study proposes a novel stacking integrated learning prediction model, which incorporates fivefold cross‐validation. First, the magnitude of the correlation coefficient was quantified using the Pearson correlation coefficient. Second, the impact and predictive features were normalized. Final, convolutional neural network (CNN), recurrent neural network (RNN), Long Short‐Term Memory network (LSTM), gated recurrent unit (GRU), and transformer are used as the base models, and fully connected neural network (FNN) is used as the metamodel. Each base model was trained by fivefold cross‐validation, and the predicted values of each fold were stacked by rows. Next, the predicted values of each base model are stacked by columns as input variables to the metamodel and metamodel learning is performed, and the stacking integrated learning prediction model based on fivefold crossover validation is established. To validate the accuracy of the model, we selected 5,000 actual well parameters, including 26 impact features and one predictive feature, for comparative analysis. This analysis presents the maximum percentage reduction in mean square error (MSE), mean absolute error (MAE), and root‐mean‐square error (RMSE) of our proposed integrated learning model concerning a single neural network prediction model as 28.26%, 24.40%, and 15.66%, respectively. The maximum percentage improvement in R2 is 17.74%. It shows that our proposed integrated learning prediction model has high prediction accuracy.

Mining of non-metallic mineral deposits in the context of Ukraine’s reconstruction in the war and post-war periods

Purpose. The research purpose is to study the conditions for mining deposits of metamorphic and igneous origin to produce crushed stone products in conditions of limited electricity supply. Methods. The research uses an integrated approach, including data analysis on quarry field spatial dimensions and the overburden rock thickness, which provides the basis for identifying deposits into basic groups. For the identified groups of deposits, taking into account the hydrological characteristics of non-metallic deposits and their parameters, patterns have been determined that characterize the change in the normative atmospheric precipitation inflow, based on the quarry field area and the change in the specific costs for water drainage depending on the studied quarry field type. Based on data on technical characteristics of mobile and semi-stationary units and aggregates, the parameters of physical-mechanical properties of granites and diorites, technical-technological solutions for the formation of complexes for processing raw materials for the production of crushed stone products are proposed. Findings. Problems arising during mining operations under conditions of limited electricity supply, which is caused by mass attacks on Ukraine’s energy infrastructure, have been revealed. A systematization of deposits of igneous and metamorphic origin for mining of rock building materials, which are the basis for the production of crushed stone products, has been developed. The rates of water inflow into the mined-out space depending on the quarry field spatial parameters and the depth of mining operations have been studied. Technological schemes of the apparatuses of a complex for processing raw materials for production of crushed stone products and the apparatuses of a complex for processing siftings are proposed. Originality. Dependences of possible water inflow into the mined-out space of the quarry and change in energy consumption for water drainage have been determined, taking into account the accepted classification criteria, namely the quarry field spatial dimensions, the overburden rock thickness and the quarry depth. Practical implications. The obtained data on the possible water inflow into the mined-out space of the quarry and change in energy consumption for water drainage make it possible to assess the efficiency of pumping units. The proposed technical-technological solutions on formation of complexes for processing raw materials to produce crushed stone products have been developed in accordance with the fundamental provisions of the Law of Ukraine “On approval of the National program for the development of the mineral resource base of Ukraine for the period up to 2030”.

OPTIMIZATION OF OPERATION MODES OF THE PLUNGER PUMP OF THE FORMATION PRESSURE MAINTENANCE SYSTEM

The efficiency of pumping equipment in the context of continuous growth in electricity prices is a priority for any oil and gas production department (OGPD). The pumping stations of the reservoir pressure maintenance system are the main consumers of electricity in the OGPD. The efficiency of pumping units, as a rule, is reduced primarily to the value of their efficiency, and the criterion for the efficiency of the injection system is usually the consumption of electrical energy per unit volume of pumped liquid. At the same time, they often focus only on maintaining high pump efficiency, which optimizes pump operation, but does not take into account the impact of collectors on electricity costs.Typically, the PPD pump station will inject service water into several directions. The purpose of the studies is to find optimal modes of pumping by pumps of a pump station in several directions, which ensure minimum electric power consumption for injection. The presented article presents the calculation of the cost of pumping by one plunger (volume) pump into two directions during laminar movement of liquid in the pipeline. Injection volumes for each area are specified. Three options are considered: separate injection in each direction (1), parallel injection in both directions simultaneously until the ordered volume is injected in one of the directions, after which this direction is blocked and injection in the other direction (2), and parallel injection in both directions simultaneously with «pressed» one direction, so that the injection of the ordered volumes is completed simultaneously (3).The performed calculations showed that the useful operation of the pump performed during simultaneous pumping of some volumes of liquid (modes 2 and 3) in two different directions of the same system is the same and significantly less compared to the operation of the pump performed to fill one of these directions during separate pumping (mode 1). The maximum effect is achieved with equal injection volumes in each direction and the same reservoirs. In this case, the useful operation of the pump for simultaneous injection (mode 2 and 3) is half as much as for separate injection (mode 1).

The use of Universal (Control) Characteristics of Vane Blowers for an Objective Assessment of the Energy Efficiency of Pumping Systems

This article describes the methodology for assessing the energy efficiency of pumping systems equipped with a variable electric drive and operating with variable load, which was elaborated by the authors of the article. The analysis of traditional methods of recalculating the characteristics of the efficiency of pumping units when changing the frequency of rotation of the impeller using the formulas of theories of hydrodynamic similarity of blade blowers is presented. It is shown that in the derivation of the similarity formulas assumptions were made, which were not fully confirmed later when testing operating pumps. An algorithm and a technique developed by the authors are presented that allow one to read the actual values of the efficiency from the pre-digitized universal characteristics of vane blowers The results of comparison of efficiency values calculated by different methods are presented.

Comparative Analysis of the Overall Efficiency of a Hydraulic Pump Unit with and without a Separate Pre-Charging System

The overall efficiency and energy consumption problem in hydraulic power pack units with and without an additional pre-charging system was analyzed in this paper. A theoretical mathematical model was developed for calculating energy losses in both pump unit structures. To verify the theoretical relationships, a laboratory test stand was built, upon which the results of calculating the overall efficiency were compared with the results of the laboratory tests. Universal diagrams of the overall efficiency dependence as a function of pressure load and geometric adjustment of the main pump’s working volume were created for the case of a particular hydraulic pump unit without and with a pre-charging system. Based on this, discussions were carried out on whether and the way in which the additionally pre-charging system affects the parameters of the overall efficiency characteristics of the researched pump unit. Additionally, the dependence of the optimal pressure load and the maximum overall efficiency of the pump unit on the geometric adjustment of the main pump’s working volume was analyzed. It was shown that the pre-charging system affects the increase in the optimal pressure load at which the most favorable operating conditions, in terms of energy consumption, are obtained for the researched hydraulic pump unit.

Reducing vibration of pumping units of reclamation systems

The article presents the results of scientific research on the operation of pumping equipment at reclamation pumping stations. In pumping stations, more and more attention is being paid to measures to maintain the reliability and efficiency of pumping units and reduce the negative impact of factors of various origins. One of the most significant factors affecting the service life of the equipment is the increased vibration of the pumping unit. According to the analysis of failures of pumping equipment at pumping stations in Uzbekistan for 2010-2021, more than 40% of the pump stops occurred due to increased vibration. The most common cause of vibration of pumping equipment is waterjet and cavitation wear of the impeller, destruction of seals, wear, and temperature rise of the bearing. The greatest vibration occurs when the equipment is operated in heavy and non-optimal modes. As a result of the generalization of the research results, active methods and means of reducing the vibration of pumping units were identified.

Estimation of energy efficiency potential of electric drive pumping units in steady operating modes

According to the results of studies of steady operation modes of electric pumping units of Ukrainian oil pumping stations, have been identified the main reasons of efficiency decrease of their performance during operation. It is determined that the normative documents regulating the efficient operation of pumping units of the main oil pipelines of Ukraine need to be improved. The assessment of energy efficiency potential of the main pumping unit on the example of pump НМ-3600-230 with synchronous electric drive СТД-2500-2 is carried out and the main ways to increase the efficiency of electricity use at oil pumping stations of main oil pipelines are analyzed. A complex mathematical-graphic model of a centrifugal pump and a synchronous electric motor is used to determine the parameters of the process of energy consumption and energy use of hydraulic and electrical subsystems of the pump unit, which allowed to take into account possible changes in equipment characteristics and modes of operation. The value of the relative specific consumption of electricity for pumping of working fluid for regulated and unregulated electric drive based on a complex electro-hydraulic model of the main pump was calculated, which allowed to promptly recalculate the characteristics of the centrifugal pump and electric motor taking into account their technical condition and to determine the potential of the pumping unit. It is determined that an effective way to reduce energy consumption by main pumping units is applying of a controlled electric drive at oil pumping stations, but the feasibility of such a measure requires additional technical and economical calculations. It is determined that to increase the efficiency of pumping units is necessary to avoid low flow-duty modes, to form maps of main oil pipelines in a way to ensure optimal in terms of energy efficiency operation modes of electro-hydraulic equipment of oil pumping stations and to change operation mode of pump and motor in terms of their technical condition.

Main control factors affecting mechanical oil recovery efficiency in complex blocks identified using the improved k-means algorithm.

The system efficiency of pumping units in the middle and late stages of oil recovery is characterized by several factors, complex data and poor regulation. Further, the main control factors that affect system efficiency in different blocks vary greatly; therefore, it is necessary to obtain the block characteristics to effectively improve system efficiency. The k-means algorithm is simple and efficient, but it assumes that all factors have the same amount of influence on the output value. This cannot reflect the obvious difference in the influence of several factors in the block on the efficiency. Moreover, the algorithm is sensitive to the selection of the initial cluster centre point, so each calculation result that reflects the efficiency characteristics of the block system cannot be unified. To solve the aforementioned problems affecting the k-means algorithm, the correlation coefficient of all the factors was first calculated, followed by extracting the system efficiency of the positive and negative indicators of standardization. Next, the moisture value was calculated to obtain the weight of each factor used as a coefficient to calculate the Euclidean distance. Finally, the initial centre point selection of the k-means algorithm problem was solved by combining the dbscan and weighted k-means algorithm. Taking an oil production block in the Daqing Oilfield as the research object, the k-means and improved algorithm are used to analyse the main control factors influencing mechanical production efficiency. The clustering results of the two algorithms have the characteristics of overlapping blocks, but the improved algorithm’s clustering findings are as follows: this block features motor utilization, pump efficiency and daily fluid production, which are positively correlated with system efficiency. Further, low-efficiency wells are characterized by the fact that the pump diameter, power consumption, water content, daily fluid production, oil pressure and casing pressure are significantly lower than the block average; high-efficiency wells are characterized by pump depths lower than the block average. For this block, it is possible to reduce the depth of the lower pump and increase the water-injection effect to increase the output under conditions of meeting the submergence degree, which can effectively improve the system efficiency.

COMPARATIVE ANALYSIS OF CALCULATION METHODS FOR CENTRIFUGAL PUMPS TAKING INTO ACCOUNT LIQUID VISCOSITY IN ESTIMATING EFFICIENCY

In the main oil transport system of Russia, at present, the main indicator of the energy efficiency of the oil pipeline operation is the cost of electricity for pumping, while the main part of the cost of electricity falls on the drive of pumping units. To predict these energy costs, it is necessary to be guided by the planned pumping modes, as well as the actual parameters of the technical condition of the pumps, which directly depend on the actual efficiency of the mainline and booster pumping units. The planned pumping modes are known in advance, and it is not difficult to calculate the required amount of electricity. However, the actual cost of pumping can significantly exceed the planned value, since the actual efficiency of pumping units can be quite noticeably different from the rated values. Thus, an adequate assessment of the actual value of the efficiency of pumping units, and, first of all, of the main main-line pumps as the most energy-intensive equipment, is an urgent and difficult task that depends on a number of factors. The authors compared two methods for recalculating the passport values of the efficiency of main-line pumps: the method described in State Standard 6134-2007 «Dynamic Pumps. Test Methods» and method of N.Z. Aitova and L.G. Kolpakov. Comparison of the calculated values of the efficiency of pumps with the actual values of the efficiency of industrial pumps, which were determined by the actual values of the oil flow rate, pressure at the discharge and suction nozzles of the pump, the power consumption of the engine from the network was made. As a result, it was concluded that N.Z. Aitova and L.G. Kolpakov method, taking into account the speed coefficient, gives more reliable results of the efficiency assessment, which is confirmed by the actual data.

Ways to reduce hydraulic losses in multistage centrifugal pumping equipment for mining and oil-producing industries

Purpose. To study hydraulic losses in pumping units during pumping and transportation of liquids, to develop the design and technology solutions to improve the energy efficiency of centrifugal pumps in the mining and oil-producing industries. Methodology. In the theoretical and experimental analysis of hydraulic losses during the transportation of liquids, the hydraulics and experimental analysis methods were used. Findings. As a result of the research carried out, a new design scheme of a multistage centrifugal pump has been developed, providing a coaxial arrangement of impellers, which allows reducing hydraulic losses in pump elements and increasing the energy efficiency of pumping units. Originality. Based on the analysis of existing designs of multistage blowers of axial and centrifugal types, the distribution of hydraulic losses in the elements of a centrifugal blower with coaxial impellers is considered. Experimental dependences on the establishment of pressure flow and power characteristics are presented. Based on the accounting of hydraulic losses, the energy efficiency of the design of the pumping unit with the coaxial arrangement of the impellers was assessed. Practical value. The new design of a centrifugal pump with coaxial impellers reduces hydraulic losses by more than 23% compared to traditional designs of centrifugal pumps. The results of the work can be used by design, research, and industrial organizations engaged in the design and operation of pumping equipment.

Разработка стенда для исследования гидравлических характеристик проточной части безвального совмещенного насоса-электродвигателя

The stages of creating a brand new shaftless pump unit are considered; including its flow part efficiency tests. The development is aimed at reducing losses caused by design features of existing pumps. A reliable and relatively inexpensive way to choose the optimal design of a pump unit is to perform large scale models tests. The key criterion of the test bench efficiency is the precise determination of the monitored parameters and their characteristics. The authors analyzed the structure of centrifugal pump losses and identified ways to improve the efficiency of pumping units. Principles of testing new pumps were formulated. The main components of the testing equipment are given. The main parameters that allow estimating the efficiency of the hydraulic part of a designed shaftless pump are defined, on the basis of which bench technical solutions are developed. A delivery component sketch is proposed, a flow diagram of a test bench is developed, and the criteria of measured parameters are defined.

Efficient evaluation model of beam pumping unit based on principal component regression analysis.

The beam pumping unit is widely used in oil fields as an oil extraction machine. However, due to its structural characteristics and the changing conditions of underground reservoirs, there are many factors affecting the efficiency of the beam pumping unit. How to quickly and accurately reflect the inefficient factors, and whether the efficiency of the pumping unit is reasonable, it is an urgent problem to be solved. In this article, we propose a pumping unit efficiency evaluation model consisting of the scoring model and the predictive model. The scoring model reflects the inefficient factors, and the predictive model judges whether the efficiency of the pumping unit is reasonable. Finally, the actual production data of the oilfield were used to verify the effectiveness of the method.

Substantiation of parameters of the energy-efficient water outflow scheme of underground mine using energy of hydro-flows

The purpose of the study is development of a structural scheme of mining-engineering system designed to ensure energy performance of the mine water outflow system. The article reveals the need for research aimed at improving the energy efficiency of the water outflow system by comparing the dynamics of electrical energy consumption and commercial output volume at the mining industry enterprises. A brief overview of the global experience in compensation for growth of electric energy consumption under more difficult mining conditions and mining depth due to the use of innovative technological solutions in the mine water outflow system is given. Scientific novelty of the research is the use of energy, which is bypassed to the underlying horizons of the underground mine, of technological and natural waters to improve efficiency of pumping units by using boost pressure and automated processes of cleaning hydraulic flows from sludge deposits, as well as to reduce the overall operational costs in the water outflow system. The energy-efficient scheme of mine water outflow system that increases energy efficiency of a mining enterprise is substantiated.

Повышение энергоэффективности насосных установок нефтеперерабатывающей отрасли

Повышение энергоэффективности насосных установок нефтеперерабатывающей отрасли

Low-Dimensional Modeling of a Pumping Unit to Cope With Multiphase Flow

Pumping unit efficiency is highly disturbed by the presence of gas influx reducing the productivity and inducing unpredictable system response due to the change of its intrinsic properties such as the natural frequency. A poor estimation of those properties may affect the on-field crew and system safety as well as the production rate. The purpose of this paper is to construct a hydromechanical model describing the coupled multiphase flow-pumping unit system dynamics and to develop a procedure to control the pumping speed for safety assurance and oil production maximization. A coupled mechanical-multiphase flow model capturing the interplay between the gas void fraction (GVF) and the driving harmonic force of the pumping unit is developed. Specifically, the predicted downhole pressure is used to determine the sucker rod effective load. Consequently, a reduced-order model, capturing the dynamics of the sucker rod, is used to estimate the saddle bearings axial displacements which are function of polished rod loading. An error-driven adaptation using the difference between presumed bearing displacement with known GVF and the predicted bearing displacement from the proposed multiphysics model is employed to estimate the unknown downhole GVF. The obtained results prove that the adaptation allows an accurate evaluation of the pumped fluid's GVF, thereby circumventing the need for a costly and inaccurate measurement of the two-phase flow gas fraction. Based on this estimation, a control strategy is then proposed to regulate the pump speed while avoiding the resonance frequency of the sucker-rod system.

Kinematic Parameters Of Rotary Transmission With Hydraulic Cylinders

The issue of designing drives, which provide low frequency (max. 1 rotation per minute) rotation with a big moment (min 1 MN m) of large technical bodies utilized in restricted spaces, is a complex and contradictory one. The drives of geokhod propeller, rotor actuators of tunneling machines with overload protection, as well as actuators of other machinery meeting aforementioned requirements are examples of such machines. The paper considers mathematical model developed by the authors which determines the relation of design factors of transmission tooled with hydraulic cylinders to kinematic parameters of output element movement. The paper also provides description of methods to determine pumping unit efficiency for rotary transmission tooled with hydraulic cylinders.

Determination of Kinematic Parameters of Rotary Transmission Tooled with Hydraulic Cylinders

The paper considers mathematical model developed by the authors which determines the relation of design factors of transmission tooled with hydraulic cylinders to kinematic parameters of output element movement. The paper also provides description of methods to determine pumping unit efficiency for rotary transmission tooled with hydraulic cylinders.