Perm Polytechnics have developed “smart” pumps for oil workers

Scientists from Perm National Research Polytechnic University (PNRPU) have developed "smart" pumps for oil production that dynamically adjust the operating speed, reducing equipment wear and energy costs. Traditional sucker rod pumping units operate at a constant speed, which causes uneven movement of the rod column, leads to vibrations, increased wear of parts and excessive energy consumption.

The new control technology allows adapting the pump speed in each pumping cycle according to pre-calculated laws of motion that take into account the mechanics of the unit. To do this, the scientists created software and a control system that optimizes the operation of the electric motor, reducing peak loads and vibrations. The method is based on a digital twin of the pump - a computer model that, based on real data on the voltages and currents of the motor, determines the optimal suspension point of the rod column without using additional measuring equipment. This allows for smooth changes in the electric motor speed and significantly reduces wear on parts, as well as saves up to 15-20% of electricity, commented Evgeny Solodkiy, Associate Professor of the Department of Microprocessor Automation Tools at PNRPU, PhD (Note: E. Solodkiy defended his dissertation on the topic of "Control of a Sucker Rod Well Pumping Unit for Oil Production with Observers of Technological Process State Variables").

The system has already been successfully tested in a virtual engineering environment, confirming its high efficiency in increasing equipment reliability and reducing loads. Pilot field tests are planned for the near future. The technology can be integrated into modern pumping stations, which will extend the service life of pumps, reduce energy costs and reduce the risk of accidents associated with rod breaks. This development makes a significant contribution to ensuring sustainable and uninterrupted oil production, where every downtime is costly