Pump Unit Research Articles

Advanced Exergy Assessment of an Air Source Heat Pump Unit

Conventional exergy-based analysis methods are used for evaluating the performance of the energy conversation systems. Conventional exergy-based analyses identify the sources, amounts, and reasons of irreversibilities (exergy destructions), costs and environmental effects, and provide a general direction for improvement. However, interactions between system components (endogenous/exogenous) and technical limitations (avoidable/unavoidable) cannot be identified with any conventional analysis. Hence, the real potential for improvement and optimization strategies can be misguided. Advanced exergy based analysis seeks to overcome this limitation. An air source heat pump unit was assessed applying conventional and advanced exergy analysis approaches respectively. Avoidable/unavoidable and endogenous/exogenous exergy destructions, modified exergy efficiencies and modified exergy losses ratios were calculated for every single component of the system. The results showed that while the evaporator and condenser efficiencies could be upgraded via constructional enhancements to the overall system and other system components, internal operating conditions were mainly responsible of the inefficiencies regarding with the compressor. The analysis demonstrated that while it was possible to improve evaporator and condenser efficiency by making constructive enhancements to whole system design, the efficiency of the compressor was mainly determined by the internal conditions in which the compressor operated.

Identification of the energy-efficient operation mode of the electric submersible pump installation in the periodic mode

ABSTRACT Reducing the power consumption of oil production wells is one of the important directions of oil industry development in the context of transition of many fields to the late stages of operation. At the same time, there is often a need to limit hydrocarbon production, which is often accomplished by shutting down wells completely. In this paper, the authors propose an approach to improve the energy efficiency of the electric centrifugal pump unit through the use of periodic operation mode, which allows to reduce the specific power consumption of the electric centrifugal pump unit. Also, this mode can be considered as a way to regulate the well flow rate. According to the results of calculations it was obtained that the reduction of specific power consumption of the unit when operating at nominal frequency can reach 5% relative to the continuous mode of operation. An assessment was made of the effect of reducing the frequency of the supply voltage in a periodic mode on the parameters of the operation of the installation and it was found that the well flow rate increased by 1.43% with a reduction in specific power consumption by 1.64%.

The use of energy management ISO 50001 to increase the effectiveness of water treatment plants: An application study on the Zai water treatment plant

This study sought to determine the impact of implementing the energy management system ISO 50001 on the Zai Water Treatment Plant's energy efficiency performance and demonstrate how this implementation affected the cost and rate of energy consumption. The proposed study model contained three dependent variables—energy consumption, energy efficiency, and the cost of energy consumption. It also contained an independent variable—the energy management system ISO 50001. All these variables were used to develop various questions to help accomplish the study's goals. Planning was done by selecting pumping stations, selecting the most energy-consuming type of pump, and finally, choosing a pump maintenance project to improve energy performance. The researcher used the case of the Zai water pumping station as an example where the ISO 50001 energy management system was applied along with the stages of the Deming Cycle of management. Four pumping units from the Zai water pumping station served as the research sample for the study.•Find the impact of implementing the ISO 50001 energy management system on the energy efficiency performance of the Zai water treatment plant.•The effects of implementing ISO 50001 energy management system on cost and energy consumption at the Zai water treatment plant.•What effect does the ISO 50001 energy management system affect the Zai Water Treatment Plant's energy efficiency?After applying the ISO 50001 energy management system, several conclusions were drawn. Energy costs and consumption rates in the pumping units dropped while the energy efficiency in the chosen pumping units increased.

The influence of production factors on the formation of the health of workers in the production of synthetic rubbers, preventive measures

The petrochemical industry, which includes, along with the production of basic chemicals for the production of rubber, occupies one of the leading places in terms of potential chemical hazards to the health of workers. The high prevalence of CNID among workers of petrochemical industries is an important socio-economic problem. The issues of reducing the incidence of chronic non-communicable diseases, including those related to working conditions, the protection and preservation of the health of workers in petrochemical industries dictate the need to develop preventive measures. The aim of the study was to study the prevalence of chronic non-communicable diseases in synthetic rubber production workers. Clinical and hygienic studies have been carried out in the production of synthetic rubber. Harmful production factors were assessed at 80 workplaces based on the materials of a special assessment of working conditions and production control data. The health status of 674 employees was studied according to the results of periodic medical examinations. The surveyed workers were represented by apparatchiks (33.2 %), locksmiths for the repair of technological equipment (12.8 %), machinists of pumping and compressor units (10.7 %), locksmiths of KIP and A (9.1 %). A number of clinical and laboratory, functional research methods have been used to assess the state of health. At the workplaces of the production of synthetic rubber, an adverse effect of chemicals on the worker’s body in combination with industrial noise, the severity of labor and microclimate in certain working areas has been established. The working conditions of employees of the main professions are assigned to the third class of the first-second degrees of harmfulness (classes 3.1–3.2). It was found that there were 17.3 % of practically healthy individuals. Among the identified chronic non-communicable diseases, the leading place was occupied by diseases of the musculoskeletal system (31.1 %), disorders of the autonomic nervous system (28.7 %), myopia (22.0 %), hypertension (12.2 %) hearing impairment (10.3 %). When evaluating the results of biochemical blood tests, the most pronounced changes were found in the indicators of lipid metabolism. Excess values of total cholesterol were detected in 40.9 % of employees. A complex of therapeutic and preventive measures has been developed aimed at reducing the risk of the formation of chronic non-communicable diseases, including measures of primary and secondary prevention.

OSNR enhancement of Rayleigh-assisted Brillouin-Raman fiber laser via double pass configuration.

We propose and demonstrate a 10 GHz spacing multi-wavelength Brillouin-Raman fiber laser (MBRFL) with wide bandwidth and an outstanding optical signal-to-noise ratio (OSNR). This is achieved by utilizing loop mirror at one end of the laser cavity through a symmetrical bi-directional Raman pumping scheme. The setup is arranged in a double pass configuration by employing different lengths of dispersion compensating fibers (DCF). The attainment of MBRFL with outstanding performance necessitates the optimization of Raman pump power, Brillouin pump wavelength, and DCF length. By employing an 11 km DCF, when setting the Brillouin pump wavelength at 1531.4 nm, 504 Stoke lines are produced with a channel spacing of 0.08 nm. All the counted laser lines have less than a 1-dB peak amplitude variation and are spread across a 40.4 nm bandwidth that covers from 1531.4 to 1571.8 nm wavelength. In this case, the Raman pump power is fixed at 900 mW which results in average OSNR and Stokes peak amplitude level of 28 dB and -7 dBm respectively. To date, this is the simplest cavity design with the widest bandwidth and flattest spectrum together with outstanding OSNR attained in 10 GHz spacing multi-wavelength fiber lasers that incorporate a single low-power Raman pump unit.

Research on the Soft-Sensing Method of Indicator Diagram of Beam Pumping Unit.

An accurate calculation of the indicator diagram of a pumping unit is the key factor in analyzing the performance of an oilfield production and operation and in preparing and optimizing an oilfield development plan. Aiming at the problems of the poor stability of the conventional load-displacement sensor method and the wave equation method, owing to the influence of an alternating load on the force sensor and the difficulty in measuring the crank angle using the electrical parameter method, a new soft sensing method employing the input electrical parameters of the motor and the beam inclination has been proposed to obtain the indicator diagram. At first, this method is established based on the beam angle of the pumping unit, which is easily measured using the suspension point displacement mathematics calculation model and the torque factor. Subsequently, the electric motor input parameters, the parameters of the four-bar linkage, and the relationship between the polished rod load have been established. Finally, the motor and the beam angle of the measured electrical parameters have been substituted into the calculation of the suspension point displacement and load value and pull in accordance with the guidelines to eliminate the singularity mutation values. After processing the measured data through a Butterworth filter, the indicator diagram is obtained. The results of the engineering experiment and application show that the average relative error of the method is less than 3.95%, and the maximum relative error remains within 2% for 6 months, which verifies the stability of the soft sensing method.

Study on Impeller Optimization and Operation Method of Variable Speed Centrifugal Pump with Large Flow and Wide Head Variation

The benefits of variable speed centrifugal pumps include high stability, a broad operating range, and adjustable input power. In water distribution systems, the pump units are increasingly using variable speed technology. The energy-saving features and operational stability of the pump station are directly impacted by the hydraulic performance and the operation strategy. In this study, CFD numerical analysis and model tests were adopted to design and evaluate the hydraulic performance of the variable speed centrifugal pump with large flow and wide head variation in Liyuzhou Pump Station. Under the premise of ensuring the wide head variation, the optimized centrifugal pump met the requirements of hump margin and efficiency in the high head zone and the cavitation margin in the low head zone. The test results demonstrated that the operational range of the variable speed centrifugal pump was successfully widened by reasonable hydraulic parameters selection and impeller optimization. The safe and efficient operational range of the variable speed unit was determined by means of taking the performance requirements of the pump’s maximum input shaft power, cavitation characteristics and pressure fluctuation into consideration. The scientific and reasonable operational path to meet the various operation needs was also investigated and determined for the pump station’s actual operation needs. A high efficiency, safe operation, and a simplified control logic were achieved by using the operational path, which makes it a reasonable potential guide for hydraulic design and operational optimization of variable speed centrifugal pumps with large flow and wide head range.

Optimizing the selection and combined operation of multiple air-source heat pumps for sustainable heating systems

A common concern is that air-source heat pumps (ASHP) perform poorly when operating at partial load. This issue arises due to the disparity between the unit's heating capacity and the actual heating load of the building. This work introduces a new, generally applicable method to determine the optimal combination of air-source heat pump units and provides an optimum unit selection scheme. It proposes two definitions: the average unit load rate throughout heating season (ALR) and the comprehensive nominal heating capacity throughout heating season (Qao), and develops a formula to intuitively demonstrate how different unit selection schemes affect the ASHPs’ performance on an annual basis. The results of the final calculations demonstrate that the best performance is achieved by selecting five units with varying nominal heating capacity. Compared to conventional selection schemes with the identical units for their nominal heating capacity, the average unit load rate throughout entire heating season rises from 81% to more than 95%, and the yearly average coefficient of performance (COP) rises by 6%.

Design and Experimental Study of 50 kW Ocean Thermal Energy Conversion Test Platform Based on Organic Rankine Cycle

In recent years, clean and renewable energy sources have received much attention to balance the contradiction between resource needs and environmental sustainability. Among them, ocean thermal energy conversion (OTEC), which consists of surface warm seawater and deep cold seawater, can rely on thermal cycling to generate electricity and has great potential in alleviating the energy crisis. In this paper, the design and experiment study of a 50 kW OTEC platform is proposed. Thermodynamic modeling, calculation, optimization, and engineering calibration of the system were carried out, and the thermal efficiency reached 2.63% to meet the power generation demand. Experiments were also carried out by using a heat pump unit to simulate hot and cold seawater environments, and data on the stable operation of the system were obtained, with the grid-connected power reaching 47.5 kW and a thermal efficiency of 2.46%. The accuracy of the design scheme is verified, and the theoretical basis and data support are provided for the practical development and application of ocean thermal energy conversion.

Development of a distributed group control strategy for pumping well groups connected by multisource DC microgrids

Due to the alternating loads on pumping units and the integration of new energy sources, multisource DC microgrid pumping unit well groups experience increased fluctuations in voltage and power as well as superimposed peak and valley values. This work presents a distributed control strategy for pumping unit well groups on a multisource DC microgrid based on the weighted moving average algorithm. A centralized control program is implanted in the RTU of the single-well controller of each pumping unit, and communication with each well is realized via SCADA and multicast communication, resulting in a distributed well group system. The real-time power values of the pumping well group are calculated by grouping the power values, and each group is weighted using the total power fluctuation threshold of the well group as the control target. Then, a weighted moving average algorithm is used to predict the next power value and form a table of predicted real-time power spectra. According to the power values in the community power spectrum table, the inverter frequency is proportionally adjusted downwards to reach the power peak before deceleration; after the power peak is crossed, the frequency is increased in the same way to reach the power valley before acceleration. Finally, the peak and valley power values of the bus system level off and further learn to reach the set impulse; ultimately, a stable impulse is formed. In laboratory testing and field application in the Shengli Oilfield XIN-11 block, the group control software module effectively suppressed the active power peak and valley values and voltage fluctuations of the bus system, the active power fluctuation rate range decreased by more than 70%, and the DC bus voltage fluctuation range decreased by more than 80%; moreover, the active power decreased by approximately 6% without additional hardware costs.

OPTIMIZATION OF COMPRESSOR STATION LOADING AT VARIABLE COSTS OF TRANSPORTED GAS

During the operation of the gas pipeline system of the Russian Federation, a significant share of natural gas is consumed for the own needs of compressor stations of main gas pipelines.According to Gazprom's reporting, the share of natural gas for technological and fuel needs reaches 7 % of the production volume. The inefficient use of natural gas can be reduced by energy saving measures implementation.Energy saving issues are important not only for Gazprom PJSC, but also for the country's economy as a whole. The highest priority of the «Energy Strategy of Russia for the Period up to 2035» and «The Concept of Energy Saving and Energy Efficiency Improvement of Gazprom PJSC» is the maximal realization of all available energy saving potential.Saving of energy resources can be achieved by organization of their efficient con-sumption, the use of innovative energy-saving technologies and equipment, reduction of losses and gas consumption for the own needs of compressor stations.The article presents the results of the analysis of the parameters of natural gas pumping through the Chelyabinsk – Petrovsk main gas pipeline on the 112–292 km section operated by Gazprom Transgaz Ufa LLC.It has been established that the monthly unevenness of the gas supply through the gas pipeline under consideration varies from 0.062 to 0.195. As a result, in many modes, the compressor station, regardless of any possible schemes for switching on gas pumping units, does not allow the planned gas pumping mode to be ensured without bypassing part of the gas through the recirculation circuit of the station.One of the solutions to this problem is the installation of a recirculating valve, which allows to provide the required volume of gas flow through the recirculation line, while providing an economical mode of operation of the compressor station.

Thermal performance and energy flow analysis of a PV/T coupled ground source heat pump system

Ground source heat pump (GSHP) system in cold regions will lead to a decrease in soil source temperature over the years after a long period of operation, and if no timely measures are taken, the system performance will get worse and worse, and even face the risk of shut down. The PV/T (photovoltaic/thermal) is an integrated energy supply system that can both improve the efficiency of solar energy utilization and weaken the soil temperature imbalance. In this paper, the thermal performance and year-round energy flow of the system are analyzed by the simulation model, and the effects of different soil thermal storage control strategies on the thermal storage performance in the transition season are explored. The results show that the coefficient of performance of the heat pump unit can reach 3.99 and 3.96 in the heating and cooling periods. The soil temperature only increases by 0.09 °C and 0.11 °C compared with the initial temperature after five and ten years of long-term system operation, respectively. In addition, after a comprehensive comparison of the thermal storage performance of different control strategies in the transition season, this study found that the temperature difference control strategy was superior to the time control strategy. Ultimately, the annual energy supply of the simulation system produces an additional 391.8 kWh of electricity in addition to meeting the energy demand for cooling, heating and power supply of the building, which realizes the zero-energy operation of the building.

FUZZY CONTROL OF POWER CONSUMPTION OF ELECTROMECHANICAL EQUIPMENT OF THE MAIN DRAINAGE COMPLEX AT IRON ORE MINE

The paper presents a fuzzy control system for the consumption of electric power by pumps of the main drainage complex of a mine based on the Mamdani fuzzy inference algorithm. The proposed system has a structure with two inputs, such as water inflow and electricity cost, and one output, the power of pumping units. The choice of the Mamdani method for building a fuzzy system is due to the fact that all these inputs and outputs are subject to preliminary expert evaluation. All quantities are fuzzificated by smooth membership functions - Gaussian and sigmoid. The input values of the system are represented by linguistic variables, each of which includes five fuzzy sets that define the membership in the very low, low, medium, high, and very high levels of the corresponding input value. The output of the system contains ten fuzzy sets. During the fuzzification, it was assumed that in order to avoid overloading the pump motors, only one option is considered: their operation at maximum power when there is a very high level of mine water inflow during heavy rains or for other reasons. In all other cases, the operation of at least one of the pumps with the highest permissible power is excluded. A base of 25 fuzzy rules was formed. When defining the rules, it is assumed that in all cases when there is a high water inflow into the mine, all three pumps must be put into operation, regardless of the electricity cost in force in the current period of time. This set of rules is of the highest importance due to the need to prevent flooding of the mine. For other values of water inflow, the output power consumption of drainage pumping units depends on the current cost. This set of rules has a lower priority. We simulated the operation of the dewatering pumping system with and without a fuzzy power consumption control system. The test signal for the "water inflow" input was represented as a random variable with a normal distribution. The test signal for the "electricity cost" input was formed on the basis of real data on the price determined by the operator for the day ahead market for 12/24/2023. It was found that the use of a fuzzy system can reduce the cost of purchasing electricity by 1.24% per day. It should also be noted that the economic effect is achieved not by reducing the level of power consumption, but by rationalizing the operation of the drainage complex, which ensures maximum groundwater drainage performance when the cost of electricity is high, and minimum when it is low.

IMPROVING THE RELIABILITY AND ENERGY EFFICIENCY OF GAS AIR COOLING DEVICES BY USING A REPAIR AND RECOVERY COMPOUND

Over the last two decades, different gas transportation companies has placed significant emphasis on the issues of energy efficiency and energy conservation. The allocation of electrical energy for the operation of air-cooling mechanisms for gas in a compressor station equipped with gas turbine pumping units ranges from 22% to 48%. The primary aim of this study is to improve the durability of the bearings in the electric motor of the gas air cooling device. This will be achieved by investigating various approaches to reduce friction. The objective will be accomplished by the use of advanced surface technology with enhanced strength properties. The use of the Repair and Recovery Compound (RRC) inside the lubrication system or its direct application onto the friction pairs' surface is contingent upon the unique characteristics and design of the particular unit undergoing treatment. The objects undergoing processing included the use of specialist lubricants. The items in question are primarily the ball bearings that are located inside the drive electric motors of air-cooling fans used in gas compressor stations. The results obtained from the study examining the effectiveness of using serpentine-based compositions on electric motor bearings demonstrate a noticeable impact on the outermost layers of the metal surfaces that come into contact. This impact enables beneficial modifications in the operating characteristics of the device. The effectiveness of repair and restoration chemicals mostly depends on the manufacturer responsible for their creation. A comprehensive economic assessment is essential when choosing a compound for the processing of rubbing components in equipment. This assessment should include several factors such as the cost of the compound, processing expenditures, and the time necessary for cost recuperation. Keywords: gas air cooling devices, bearings, reliability, energy efficiency, energy saving, repair and recovery compound.

Association rules mining for long uptime sucker rod pumping units

The uptime of sucker rod pumping units (SRPUs) varies significantly due to differences in geological reservoir conditions, as well as design and operation parameters of the SRPUs. Conventional approaches encounter challenges in accurately quantifying the intricate interplay of these factors with uptime. This study investigates the application of association rules mining in exploring reliable measures in long uptime SRPUs. We create an uptime dataset for 5789 sucker rod pumping wells with 16 features encompassing reservoir conditions, production characteristics, SRPUs design, operational settings, and uptime. A novel algorithm is proposed to mine association rules between uptime and other features, yielding over 1,000,000 rules. These rules reveal relationships and impacts on long uptime. By following these rules, adjustments can be made to improve the uptime of SRPUs through alterations in design and operational parameters. Two case studies were presented to illustrate that by adjusting the design and operational parameters of SRPUs based on the association rules, the probability of improved operational performance can be increased by 30 % and 8 % respectively. This study explores the association rules of long uptime SRPUs from a data-driven paradigm, providing scientific guidance for subsequent oil well design. The research methodology is also valuable for other mechanical equipment.

ТЕПЛОМАССООБМЕННЫЕ ПРОЦЕССЫ В ИСПАРИТЕЛЬНОМ БЛОКЕ ВОЗДУШНОГО ТЕПЛОВОГО НАСОСА

Heat pump installations and the possibility of their application in engineering systems are considered. This allows expanding significantly the possibilities of using renewable energy sources, as well as waste heat from various technological processes in engineering systems for creating a microclimate. Air heat pumps are the most promising, but their use in regions with a cold climate is limited due to condensation of moisture vapors on the cooling line of the evaporation unit with subsequent formation of ice, which reduces the efficiency of the installation. In this paper, an upgraded evaporative unit of an air heat pump with a MOVEBIT ice removal system is considered. Taking into account the design of the heat exchanger, which includes a magnetostrictive radiator unit, the influence of heat and mass transfer processes in the evaporation unit on the efficiency of the heat pump unit in a wide range of outdoor temperatures is considered. A criterion equation has been obtained for calculating the heat transfer coefficient in the evaporation unit depending on the hydrodynamic conditions of the process and the thermophysical parameters of the air environment. This equation allows to calculate the heating capacity and cooling capacity. In addition, to determine the coefficient of energy transformation of a heat pump installation at all stages of the life cycle of engineering systems. The dependence of the influence of temperature and relative humidity on the kinetics of ice formation is obtained. This provide calculation the operating time of the installation between the cycles of switching on the radiator to destroy the ice. Based on the research results, computer programs have been developed for controlling the main thermal parameters of an air heat pump with a MOVEBIT system and an electrical part of a magnetostrictive radiator in a wide temperature range.

INCREASED RELIABILITY OF ELECTRIC CENTRIFUGAL PUMPING UNITS

Electric submersible pumping units are used for production in high-yield oil wells. Since existing pumping units come in different types depending on the complexity of the design and well conditions, a clear and responsible decision must be made in terms of reliability. In the article, in connection with the widespread use of electric submersible pumping units at oil fields, the methods of solving the issue of ensuring the performance of the equipment, namely, achieving reliability and control of technical condition in the conditions of its operation are considered. In relation to regional oilfields the well efficiency indicators were determined and a comparative analysis is presented. The analysis allows to study the problems of failures of wells equipped with submersible pumps with low service life. The aim of the study is to improve the reliability of the electric centrifugal pump during operation.

Improving the rod well pumpfor production of watered oil from deep wells

At the moment, the bulk of the total reserves of well oil fields in Kazakhstan are developed using sucker rod pumping units at a late stage of development. Experience in operating sucker rod pumping units has shown that the problem of rod chain failure in the form of breakage and rupture is still relevant today, given that the production of medium-high water oil during well operation significantly increases corrosion processes and applied loads. This article discusses methods for analyzing and optimizing the method of oil production using sucker rod pumping units. Methods used to prevent corrosion of metal structures under the influence of mineralized water are shown.

Application of digital technologies in the management of oil well pumping systems in oil extraction

In recent years, one of the trends in oil well production has been the continuous growth of interest in intelligent monitoring and control systems for mechanized well assets. This is attributed, on one hand, to the increasing number of oil fields worldwide reaching maturity and the development of new challenging reservoirs (in terms of viscosity, water cut, and sand production). On the other hand, it is driven by the necessity to enhance the economic efficiency of oil production, including cost reduction and minimizing losses. The emergence of «smart» oil production technologies, such as programmable drives for well pumps, also contributes significantly to addressing these issues. Their application allows for increased reliability and lifespan of pump equipment, reduced well downtime and failures, prevention of negative scenarios during oil production, and facilitates the visualization of parameters in a user-friendly manner. Despite the widespread use of digital technologies in the oil and gas industry, there is still significant potential for further digitization to expand operations for enhanced safety and productivity. This article presents the experience of creating and testing such a control station for screw pump units at an oil field.

The Analysis of Operation Modes of Variable Speed Pump Units with Different Circuits of Turbomachine Connection

The scientific novelty of the proposed article lies in the development of the theory of analysis of the operation modes of group pump units operating on a long pipeline network with back pressure. This was achieved by creating electric equivalent circuits of group pump units based on the method of electrohydraulic analogy. Such equivalent circuits take into account pumps’ connection circuits, the configuration of the pipeline network, and the method of regulating technological parameters. A method for determining the characteristics of pump units with series and parallel connection is proposed. The dependences of the power consumed by the pump units on the change in the frequency of rotation of the adjustable pump are obtained for various parameters of the hydraulic network. This makes it possible to determine the limits of energy-efficient regulation of pump discharge. Analytical expressions for determining the lower limit of the pump rotation frequency for various circuits of turbo mechanism connection and various numbers of pumps operating simultaneously on a pipeline network with back pressure are proposed. The necessary range of adjustment of the pump rotation frequency with different circuits for turbo mechanism connection and different numbers of hydraulic machines operating at the same time is determined. The analysis of the obtained modes of pump units is performed and the possibility of expanding the controlled properties of the group electric drive systems of turbomachines when changing the direction of the rotation frequency and reversing the liquid in the event of an emergency situation is shown.