Oil Pumping Unit Research Articles

Highly hard modified Novikov gears for special purpose drive gearboxes

A comparison of the technical and economic characteristics of the drive gearbox of oil pumping units with different versions of modified Novikov gears with thermally improved and highly hard teeth is considered. The advantages of the latter are shown. Keywords: Novikov gearing, thermally improved teeth, highly hard teeth, contact endurance, bending endurance, technical and economic characteristics of the gearbox. vkorotkin@sfedu.ru

A novel method for trajectory recognition and working condition diagnosis of sucker rod pumping systems based on high-resolution representation learning

The pumping unit is the most important lifting equipment in the rod pumping system, which transmits ground power to the downhole pump through its sucker rod. Trajectory identification of the rod pumping system can be used to study the motion law of the pumping unit, and it is the basis for the design of the pumping parameters and the analysis of the working conditions. Most of the studies on the dynamics of the pumping unit are to discuss the simple harmonic motion of the suspension point or the motion of the crank-slider in the ideal state, which is quite different from the actual situation. In this paper, a key point detection method for oil pumping units based on high-resolution representation learning is proposed. The model adopts a multi-resolution parallel network, which connects multiple network branches with different resolutions in parallel. Then it performs multi-stage processing on the input pumping unit images and outputs the predicted Gaussian heatmaps of key points to realize the trajectory recognition of the pumping unit. Different from the traditional series convolutional network structure, which needs to recover high resolution from low resolution, the parallel structure of this model is able to maintain the high resolution of the backbone network and thus the learned representations are more accurate in spatial location. This method is also experimentally verified and compared with the latest convolutional network structure. The results show that the model accuracy of the high-resolution representation learning method is more than 6% higher than that of the comparison methods. In addition, the results of this model can be used to judge the balance of the pumping unit, automatically calculate the maximum stroke and polished rod stroke, and have guiding significance for the working condition diagnosis of the rod pumping system.

INVESTIGATION OF THE INFLUENCE OF GEAR ERRORS ON THE PERFORMANCE OF THE ROCKING MACHINE GEARBOX

This article presents the results of a study of the influence of gear manufacturing errors on the smooth operation of the reducer of the mechanical drive of the oil pumping unit based on a specially developed 3D modeling technique for the formation of kinematic error. This technique consists in constructing a three-dimensional solid-state model of a gear transmission with specified primary errors of the wheels and subsequent modeling of the gear engagement operation. Models of gears are obtained as a result of modeling the tooth-cutting process. This makes it possible to include manufacturing errors in the gear models caused by various technological reasons, such as, for example, fluctuations in the chain links of the machine, the beating of the cutting tool and the workpiece, errors in the cutting edges of the tool, errors in the installation of cutting tools, etc. The simulated graphs of the kinematic error of gears consisting of wheels are given, which contain the main manufacturing errors affecting the smooth operation of the reducer of pumping unit (errors in the lateral profile of the teeth, the error of the gearing step). Keywords: pumping unit, reducer, errors, working capacity.

AUTOMATION OF CONTROL OF ROOM DEEP OIL PUMP USINGTRACE MODE SCADA SYSTEMS

The issues of automation of technological processes are relevant for all industries. The article discusses the issues of automating the control of the operation of oil pumping units widely used in oil production using the TRACE MODE SCADA system from AdAstrA Research Group.
 
 To control the operation of a sucker rod pump of an oil pumping unit, the use of dynamometers is widespread in world practice. Technically, it is easier to carry out a more generalized control of the operation of an oil pumping unit using a wattmetergram, which displays the dependence of the active power consumed by the drive on time or the position of the polished rod. The results of power measurements are transmitted via communication channels to the computer of the SCADA system. Further, preliminary processing of the results of the control of the wattmeter diagram and the calculation of parameters characterizing the operation of the oil pumping unit are performed.
 
 At the stage of data preprocessing, noise filtering is performed using TRACE MODE tools that provide data exchange with MS Excel, MS Access, MS Visual Basic packages. The use of moving average, median filtering, and B-splines methods for this is considered. It is shown that cubic B-splines are an effective method of analytical description and graphical representation of experimental data, reducing the total mean square of the error. The use of splines in comparison with the polynomial approximation gives a slightly better approximation. The results of filtering and calculations by means of the SCADA system are displayed on the dispatcher’s monitor, archived, documented, etc. Thus, the related software products SCADA TRACE MODE and MS allow you to effectively implement complex data processing algorithms.

Optimization of Sucker Rod Pump Operations Using Parallel Systems

With the exploitation of oil, oil pumping units are facing with the challenges such as low efficiency, increased mining difficulties and old infrastructures. The requirement of digital construction on oilfields is emerging, especially to these sucker sod pump (SRP) units built in last century. In this article, to facilitate the intelligent development of SRP systems, the concept of the parallel digital sucker rod pump systems (PDSRPS) was presented first, and their optimization framework was designed to efficiently improve the design and balance by data interactions. The real oil pump systems were integrated with their customized digital twins to establish the cyber-physical systems. The adaptive optimization on pumping processes was continuously developing with the interaction between physical pump units and their digital versions. The feasibility of the proposed framework has been demonstrated through the computational experiments on conventional beam-pumping units.

Energy Efficient Control by the Group of Oil Pumping Stations Operation

This work is devoted to intensification of the power efficiency of computerized systems of con-trol by the pumping units group of oil pumping stations of the main lines. The criterion of the energy efficiency is a minimum total energy loss. The goal set can be reached by the develop-ment of algorithms of the energy efficient control. The most important scientific result based on the identification of the mathematical models of the objects controlled is the efficient algorithm for controlling the group of oil pumping units. It allows determining in real time the operation modes of separate pumping units, upon which the total energy losses will be minimal. The sig-nificance of the results obtained consists in the energy losses decrease across the main oil pipe-line during the combined control by the pumping units groups. Their practical significance con-sists in decreasing the cost of oil transportation at the expense of decreasing the energy con-sumed by the pumping units. The main stages of plotting the modes maps were presented of the efficient operation of the pumping units based on the definition of the necessary rotation fre-quencies and positions of the regulating valves. Experimentally was performed the analysis of the operation modes of the pumping unit using different methods for productivity regulation, and their comparative energy efficiency was shown. The experimental data extrapolation was carried out, and, on its basis, the possible economic effect was determined brought by the use of the energy-conserving systems of the controlling the group of pumping systems.

Modification of Gearing for Improving Technical and Economic Characteristics of Drive Gearboxes in Oil Pumping Units

Modification of Gearing for Improving Technical and Economic Characteristics of Drive Gearboxes in Oil Pumping Units

Justification and selection of design parameters of the eccentric gear mechanism of the piston lubrication and filling unit for the mining machines maintenance

Piston pumps are widely used in the lubrication systems of mining machines. When carrying out technical maintenance (MOT), including lubrication and filling works, at the site of operation of mining machines due to the remoteness from repair shops and warehouses of fuels and lubricants (FAL), mobile repair shops (MRS), maintenance units (MU) and mechanized filling units (MFU) are used. The specificity of carrying out maintenance is to create conditions for the supply of oils, working fluids and lubricants to the corresponding systems of mining machines for their refueling. Existing piston pumps and pumping units, as a rule, are single-flow, and the piston is driven by a crank mechanism driven from the engine through a worm gear. The emergence of unique, hydraulic, low-mobility mining machines in open pit mining required a significant increase in the power of the MU and MFU oil pumping units, primarily for greases. However, the traditional design of the drive design of a crank-type piston pump unit at a power of over 80 kW does not allow achieving the specified operating time, it is accompanied by intensive wear of the drive elements and increased dynamics during operation. In addition, it is necessary to apply various designs of pumping units for the supply of liquid and grease lubricants. Thus, it is necessary to develop new circuit solutions for pumping units of the crank type, to improve mobile refueling facilities with a modernized design of the pump unit drive of the mobile lubrication and filling station MRS.

Fracture analysis of a pulley shaft for the linear motor oil pumping unit in western oilfield of China

The main objective of the present study is to investigate the fatigue failure in the pulley shaft of the linear motor pumping unit after 25 months of service in the western oilfield of China. In order to analyze the fracture mechanism systematically, different testing methods, including the microstructure observation, fluorescent magnetic powder detector, direct-reading spectrometer, material testing machine, pendulum impact testing machine and Brinell hardness test, are applied in the present study. The obtained results showed that under the action of a cyclic load, the fracture of the pulley shaft appears mainly because of the multi-source fatigue. Meanwhile, it is found that quality of the base material highly affects the impact energy, hardness, and resultant microstructure. Besides, it is demonstrated that fatigue cracks originate from the heat-affected zone of the outer surface of the pulley shaft. Then, these cracks grow simultaneously under the action of the cyclic load. When cracks reach the intersections, the brittle fracture occurs finally. In addition, efficient precautions were provided to avoid fracture.

Development of a stand for researching electric drives of pumping units

In the modern oil industry, the vast majority of oil production units are represented by sucker rod pumping units, driven mainly by asynchronous electric motors without using any monitoring, control and regulation means. Studies carried out on such installations show their low energy efficiency and reliability. Therefore, the issue of developing complex electric drives of a new generation based on the use of synchronous valve electric motors is relevant allowing to significantly increase the energy efficiency and reliability of both individual installations and to ensure the creation of "smart" oil field control systems. The paper discusses new technical solutions of the experimental stand which makes it possible to study the energy characteristics of electric drives based on asynchronous and synchronous valve electric motors, as well as allowing to create conditions as close as possible to real field conditions with imitation of the operation of an oil pumping unit of a sucker rod pumping unit. In modern test equipment systems, devices are often used to create a mechanical load on the shaft of the electric motor under study. The system proposed and implemented as such a device is "a frequency converter - load asynchronous electric motor", which has been tested on a stand and has proven to be the best in comparison with traditional circuits using DC motors. But using of a load asynchronous electric motor as part of the test stand has revealed a number of disadvantages: overheating of the electric motor operating in the opposing mode, low accuracy of creating the load torque and the speed of the system's response. The problem of overheating of the load electric motor has been solved by transferring the frequency converter to the direct torque control mode, while a significant decrease in the motor current and stabilization of the temperature regime have been detected. The low accuracy and response speed of the system have been increased by introducing feedback and a PID controller into the stand control system.

Control measuring and information system of the experimental stand

Modern trends in the development of technology are based on the need for experimental studies of the equipment being developed in laboratory conditions with the maximum approximation of the operating modes to real ones. Such studies are impossible without the development of specialized stands with test automation systems. Automation of processes involves the organization of measuring channels as part of a stand using analog-to-digital conversion (ADC), digital-to-analog conversion (DAC), digital-todigital conversion (DDC) and the development of a hardware-software complex (HSC) based on high-speed computing devices. As part of the project to create new high-tech equipment, the specialists of FSBEI HE “KSPEU” and JSC “ChEAZ” developed and created an experimental stand designed to verify and confirm the correctness of the selected structural and circuit solutions used in the design of a synchronous valve electric motor (SVEM) and rod control station borehole pumping unit (RC SBPU). The object of experimental research was the prototype and prototype electric drives of oil pumping units, as well as their components: SVEM and RC SBPU. The article discusses the ways of organizing the measuring and control channels of the measuring and information system of the experimental bench, which allows to study samples of synchronous valve motors and control stations of the sucker rod pump unit in the regimes that are as close as possible to real field conditions simulating the operation of the oil pumping unit of the sucker rod pump unit. Thus, in the experimental stand, analog, discrete and digital control and control channels are implemented.

Adaptability Analysis and Optimization of Oil Well Energy Saving Motor

Motor is the core energy consumption node of mechanical mining system, and also the key point of energy saving potential of mechanical mining system. At present, there are two main problems in the use of matching motor of mechanical oil production system: one is that the types of oil well motor are complex and the performance index is uneven; the other is that the oil well working conditions are complex and diverse, and there is no basis for motor selection.In view of the above problems, in order to reduce the power consumption of high energy consumption motor, improve the rationality and scientificity of oil well energy-saving motor selection and matching work, effectively improve the operation efficiency of mechanical production system and reduce energy consumption, the adaptability of oil well energy-saving motor is carried out. Taking the energy-saving motor of oil pumping unit as the research object, through no-load, locked rotor, pumping unit simulated load, field calibration and other testing means This paper evaluates the comprehensive quality of the energy-saving motor of oil well from the systematic point of view, and studies the optimization method of the matching between the energy-saving motor and the pumping unit.

REDUCTION OF THE TENSION OF MODIFIED TEETH OF NOVIKOV GEARING IN THE THREE-STEP GEARBOX Ц3НШ-450-40 DRIVE OF OIL PUMPING UNIT

The article is devoted to the actual topic – reduce the tension of the modified teeth of Novikov gearing drive gearbox of widely used oil pumping unit for oil production in order to increase the resource of their work and load-bearing capacity. As the object is considered a typical three-stage gearbox model Ц3НШ-450-40, produced by the plant “Izhneftemash” (Izhevsk). Gearbox is equipped with Novikov gearing with the basic rack profile according to GOST 15023–76. It is shown that the use of the proposed longitudinal modification of the working surfaces of the teeth in combination with an increase in gear module provides a very significant effect on reducing effective contact and bending stresses, on increase the load-bearing capacity and service life of the gearbox in comparison with the serial version currently produced by the domestic industry. The research is based on the results of solving the spatial contact problem of the stress-strain state of a tooth, as well as modeling the real multipoint engagement of Novikov gearing taking into account the technological errors of manufacture and assembly of gears. Recommendations on the implementation of the longitudinal modification of the teeth are given and it is shown that there are no technological difficulties. The effect achieved at different stages of the gearbox is: to reduce tooth stresses from 1.75 to 2.54 times, to increase the load-bearing capacity of the gearbox from 2.81 to 4.1 times, to increase the service life of the gearbox by an order of magnitude. In the future, the research outlined is supposed to spread to other models of gearboxes produced oil pumping units.

The use of a digital controller in the loading system of the test bench to improve the accuracy of simulating the modes of oil pumping units

Modern trends in the development of technologies are based on the need to conduct experimental studies of the developed equipment in laboratory conditions with the maximum approximation of operating modes to real ones. Such studies are impossible without the development of specialized stands with test automation systems. In modern test equipment systems, devices are often used to create a mechanical load on the shaft of the electric motor under study. As such a device, a system of frequency converter load asynchronous electric motor has been proposed and implemented, which has been tested at the test bench and has proven itself from the best side in comparison with traditional circuits using DC motors.

Analysis of the development of electric drives for oil rocking machines by the results of patent search

Object. The object of research is the modernization of the drives of oil pumping units through the use of synchronous motors and adaptive control systems. Field of application: electrical equipment for oil pumping units.The purpose of the work is to identify inventions in the field of electric drives based on Russian highly efficient synchronous motors for oil pumping machines, to determine the advantages and disadvantages of modern developments in this field.Methods. This analysis will reveal the strengths of the drive being developed and most competitively present them. An important point is, and checking the possibility of patenting in this area, i.e. check for patent purity.Results. As a result of the study, the most significant inventions (based on the patent analysis of the Russian Federation) were identified in the field of sucker rod pump control stations, dynamometry, and wattmetry, which are presented in the work, they provide a brief overview, provide basic information and novelty.Conclusion. A literature review showed that the issues of control stations for sucker rod pumps, dynamometry, wattmetry, and the development of synchronous electric motors are rather deeply covered, on the other hand, the literature does not sufficiently reflect the problems of frequency regulation of synchronous motors, as well as the capabilities of intelligent control stations that would allow increase the level of oil production, optimize the technological process, significantly reduce the influence of the “human” factor improve production safetyThus, the need to create a competitive electric drive for oil pumping machines is the use of “smart” control systems that will regulate the operation of the well due to adaptive (based on automatic analysis of dynamograms and wattmetergrams) private regulation.

Tribology Performance of Surface Texturing Plunger.

Plunger pumps are widely used in oil pumping units around the world. The water content of the wellbore is increasing along with the development progress, so the lubricating capacity of the well fluids between the plunger and barrel is decreasing correspondingly. Commonly, the substrate material of the plunger and barrel are stainless steel, and the plunger surface is usually covered with nickel-based coating. Therefore, the performance of the plunger and barrel has been affected due to poor lubrication and eccentric wear. Non-smooth surfaces have been proven to improve the tribology performance in many cases. A surface texturing plunger covered with specific dimples has been prepared by using laser surface texturing technology. The morphology of the surface texturing plunger was characterized and analyzed. The tribology performance of surface texturing plunger samples was tested using standard friction and wear test machines with oil and water lubrication, respectively. The results indicated that surface texturing could effectively reduce the coefficient of friction, and the wear resistance of the surface textured samples has been improved to some extent.

Fracture analysis of a connecting rod for oil pumping unit in China western oilfield

The connecting rod of the pumping unit is fracture after 95 days' service in China western oilfield. The failure causes were analyzed by macroscopic fracture morphology, fluorescence magnetic particle detector, impact testing machine, direct-reading spectrometer, optical microscope(OM), scanning electron microscopy(SEM), energy dispersive spectrometer(EDS) in this paper. The direct cause of the fracture of the sample is the fatigue fracture of the connecting rod under the action of cyclic load, and the fundamental cause of the fatigue fracture of the sample is the material quality itself, including the impact energy of sample varies greatly, the substandard chemical composition of the material, the heterogeneity of the microstructure, the coarse grain, the influence of inclusion.The fracture process of the sample was as follows: under cyclic load, the root of the thread formed a fatigue crack source, and then the crack expanded from slow and fast fatigue, and finally under cyclic load, the crack expanded further until brittle fracture.

Research on Intelligent Energy-saving Algorithm of Oil Pumping Based on BP Neural Network

In order to enhance the international competitiveness of China’s oilfields, this paper reduces the phenomenon of high energy consumption in low-permeability oilfields, reduce electricity costs, increase oil production, and improve oilfield efficiency. In this paper, an intelligent energy-saving algorithm based on BP neural network is proposed for continuous oil recovery. This algorithm analyzes the main influencing factors of oil production and collects sample data from two aspects of oil production and electricity consumption cost. The BP neural network model with single hidden layer is constructed. The number of hidden layer neurons is determined. The output of oil and the unit speed of oil pumping are predicted, and combined with the time-sharing electricity price to adjust the times of oil pumping unit time to reduce the cost of electricity. The experimental results show that the proposed intelligent pumping energy-saving algorithm effectively improves the pumping efficiency, can save the electricity cost to a certain extent, realizes the intelligent control of pumping unit, and makes the oil field achieve high production and efficiency.

Increasing the Useful Life and Load-Bearing Capacity of the Drives of Oil Pumping Units

The possibility of increasing the useful life and load-bearing capacity of the gearboxes of oil pumping units is considered. Models of double-stage Ts2NSh-450-40 and Ts2NSh450-28 and triple-stage Ts3NSh-450-40 and Ts3NSh-450-28 gearboxes (Izhneftemash) with Novikov gearing were selected as the subjects of the study. An increase in the selected indicators may be achieved by increasing the gear module while maintaining the overall dimensions of the factory housing of the gearboxes constant. The study is based on simulating the solution of a three-dimensional contact problem of the stress-strain state of the teeth with real multipoint engagement of the Novikov gearing. The computational effect is seen in a 1.45 to 1.74-fold increase in the load-bearing capacity of the gearbox and two- to four-fold increase in its useful life.

Study of the Hamming Network Efficiency for the Sucker-Rod Oil Pumping Unit Status Identification

Процес нафтовидобутку нафти потребує проведення постійного моніторингу роботи обладнання свердловин. Одним з найдієвіших методів оперативного контролю роботи штангових глибинних насосів є отримання інформації від давача зусилля в полірованому штоці або давача струму привідного двигуна верстата-гойдалки. У багатьох випадках завчасне розпізнавання неполадок і здійснення профілактичного ремонту дають змогу уникати великих матеріальних витрат. У зв’язку з цим актуальними є дослідження, пов’язані з розробленням систем діагно- стики та створення на їхній основі автоматизованих систем керування ШГПУ. Розглянуто підхід до вирішення завдання прогнозування технічного стану штангових глибинних насосів з використанням нейромережевих технологій. Як нейронну мережу використано модифіковану мережу Хопфілда – мережу Хемінга. Для неї створено алгоритм ідентифікації стану ШГПУ, завдяки якому результатом розпізнавання є не сам зразок, а тільки його номер. У результаті прискорюється робота мережі і витрачаються менші обчислювальні ресурси та пам’ять. Для тестування працездатності запропонованого алгоритму розпізнавання створено лабораторний стенд, який імітує роботу системи діагностики стану ШГПУ. Отримані експериментальні результати показали, що система ідентифікації на основі мережі Хемінга може в реальному часі та з мінімальними похибками розпізнавати поточний стан глибиннопомпового обладнання.