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

THE IRZ-400 SERIES VFDs ensure control, protection, checkout of parameters, and rotation frequency regulation of a sucker rod pump or PCP system equipped with a surface three-phase induction or permanent magnet motor.

Generation, display, and analysis of calculated dynamometer charts

The main feature of the smart VFD is that the user can build up a calculated dynamometer chart without using a dynamograph or other sensors to be mounted on moving parts of the pump system.

With the help of VFD, the user can CONSTANTLY MONITOR the 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

Calculation of dynamic level

  • Dynamic level is calculated according to actual or calculated dynamometer chart
  • The calculation of dynamic level is based on the difference between upper and lower plunger pressure (based on the calculated loads)
  • To increase the accuracy of calculation, an annulus pressure sensor can be used
  • The dynamic level can be used in optimization algorithms and for protection of sucker rod pump systems

Effect

  • Maximizing well production rate due to:
    • smart control algorithms
    • minimization of emergency shutdowns
  • Increase of time between overhauls by means of diagnostics and protection of subsurface pump equipment
  • Reduction of maintenance costs due to:
    • change of swinging speed without replacing the pulleys
    • automatic selection of pump operation mode
    • continuous automatic control of the dynamometer chart
  • Energy saving up to 40% due to:
    • elimination of the generator mode
    • optimization of swinging 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
  • History download to a 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 regulate beam up & down motion at different speeds

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
    • Taking and analysis of surface and in-depth dynamometer 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 breakage
    • 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

Technical specification

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 ensure control, protection, checkout of parameters, and rotation frequency regulation of a sucker rod pump or PCP system equipped with a surface three-phase induction or permanent magnet motor

Technologies

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