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Variable frequency drive for sucker rod pumps & progressive cavity pumps with surface motors

THE IRZ-400 SERIES VFDs control, protect, verify parameters, and regulate rotation frequency of SRP or PCP systems arranged with surface three-phase induction or permanent magnet motors.

Building up, displaying, and analyzing calculated dyno charts

Main feature of the smart VFD is that user can build up calculated dynamometer chart without dynamograph or other sensor mounted on moving parts of the pump system.

Using VFD, customer is able to CONSTANTLY MONITORING operation of the pumping equipment, as well as pump fill factor and well production rate.


Adjustable graphic presentation of any parameter on the drive’s display or a PC


Load curve drawing without a dynamograph

Defining dynamic level

  • Dynamic level is defined according to the actual or calculated dyno graphs
  • Dynamic level defining based the difference between top and bottom plunger pressure (based on the rated loads)
  • Annulus pressure gauge can be used to increase defining accuracy
  • The dynamic level data can be used in optimization algorithms as well as SRP protection

Effect

  • Maximizing well production rate due to:
    • smart control algorithms
    • minimization of emergency shutdowns
  • Increase of MTBF via diagnostics and protection of downhole pump equipment
  • Reduction of maintenance costs due to:
    • adjusting reciprocating rate without replacing the pulleys
    • automatic selection of pump operation mode
    • continuous automatic control of the dyno chart
  • Energy saving up to 40% due to:
    • elimination of generator mode
    • optimization of reciprocating cycle
    • stop/slow-down in case of pump-off and other emergencies
  • Continuous automated real-time analysis allowing registering work parameters and detecting potential causes of loss of efficiency

Features

  • Smart control algorithms for automatic well production optimization
  • Service modes for variety of production scenarios, including start with stuck motor
  • RS232/RS485 interfaces
  • Digital & analog inputs
  • Compatible with SCADA systems
  • Radio link for data transmission (GPRS)
  • Graphic screen
  • Colored light indicators
  • Archive downloading on USB drive
  • Software update without motor shutdown using a USB drive
  • Data retention in case of power interruptions
  • Easy setup, quick start menu
  • Reduction of hits of the plunger over fluid
  • Capability to adjust reciprocating motion at different speed

Functions

  • Monitoring pump system parameters:
    • measuring pump fill, flow rate (at any moment of pump operation), downhole and ground equipment loads, voltage and current imbalances, load factor, power factor, power consumption, and failure free operation time
    • building up and analyzing surface and downhole dyno charts
  • Automatic control of well operation based on:
    • pump fill
    • operation timer
    • well operation schedule
    • two-term (proportionaldifferential) controller (to maintain constant pump fill)
  • Pump-off control
  • Smooth start/stop and regulation of motor rotation frequency
  • Automatic restart
  • Data display

Protections

  • Protection in case of faults in the pump system:
    • pump starvation
    • belt and rod twisting
    • current overload/underload in any phase
    • phase currents imbalance
    • unallowable well-head pressure
    • short circuit
    • abnormal parameters reported by the DH monitoring system
  • Protection in case of faults in the power supply system:
    • overvoltage
    • low voltage
    • phase voltages imbalance
    • wrong phase sequencing
ParameterValue
Supply voltage 275…475 V (380 +25%-25%V), 340…550 V (480 +15%-30%)
Power range of electric motor to be connected 5—75 kW
Range of regulated rotation frequencies 0.5—100 Hz (resolution 0.1)
Relative error of current, voltage and rotation frequency measurement and time setting 2%
Enclosure protection class IP54/IP66
Operating temperatures -60…+50 °С (-76…122 °F)

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Variable frequency drive for sucker rod pumps & progressive cavity pumps with surface motors

The IRZ-400 Series VFDs control, protect, verify parameters, and regulate rotation frequency of SRP or PCP systems arranged with surface three-phase induction or permanent magnet motors.

Technologies

  • In-House Design
  • Highly-skilled professionals
  • Full Cycle Production
  • Quality Management System
  • Testing and control
  • Warehouse facilities