Oil derrick transforming into a tree, symbolizing efficiency and sustainability.

Maximize Oil Production: Smart Strategies for Electric Sucker Rod Pump Efficiency

"Discover innovative methods to boost the efficiency of electric drives in sucker rod pumps, reducing energy consumption and optimizing oil production economics."


Sucker rod pumps (SRPs) are the unsung heroes of the oil production world. Globally, around 40% of oil wells utilize SRP units, contributing to about 20% of the world’s oil production. In places like the U.S. and Canada, SRPs are a staple for extracting oil. But as energy costs fluctuate and environmental concerns grow, the need to optimize these systems becomes increasingly vital.

While electric centrifugal pumps have gained traction in recent years, SRP units remain relevant because of their high efficiency and lower power consumption, especially when using non-explosion-proof electric motors. However, these pumps often operate under challenging conditions, including high gas factors, corrosion, and the presence of paraffin and sand, which can impact their performance and energy use.

This article delves into practical methods for boosting the energy efficiency of SRP electric drives. By understanding the intricacies of these systems, oil production companies can significantly reduce energy consumption and lower operational costs.

Understanding the Structure and Challenges of SRP Units

Oil derrick transforming into a tree, symbolizing efficiency and sustainability.

An SRP unit comprises both surface and submersible subsystems. The surface components include a control station, electric motor (EM), gearbox, crank mechanism, and walking beam. The submersible subsystem consists of a rod column and the SRP itself. Often, low-speed three-phase asynchronous EMs, operating at 0.4 kV and less than 55 kW, drive these units. These motors, known for their increased starting torque, belong to series like AIR and 5A. Many older, less efficient models, such as AOP and AO2, are still in operation, highlighting a key area for potential upgrades.

SRP electric drives often suffer from poor energy characteristics due to their operating modes. Cyclic loading and a large power reserve for start-up result in the EM frequently running underloaded. This, coupled with the energy losses from multiple intermediate elements between the EM and the pump, significantly decreases overall efficiency. Starting the SRP unit, especially in cold conditions, requires a substantial power supply, further exacerbating the issue of underloaded operation and reduced efficiency and power factor.

Here are some common factors contributing to energy inefficiency:
  • Cyclic loading patterns specific to SRP technology.
  • Oversized motors running under capacity.
  • Energy loss via intermediate components.
  • Challenges during system startup.
The numerous intermediate elements—V-belt drives, gearboxes, crank mechanisms, walking beams, and rod columns—convert the motor's rapid rotation into the slow, reciprocating motion needed for the rod column. While newer SRP drive mechanisms like chain, hydraulic, and linear drives offer better energy transfer, many operational oil wells still rely on older sucker rod pumps due to economic constraints. This creates an opportunity for targeted improvements that can yield significant energy savings without requiring a complete overhaul of existing infrastructure.

Practical Steps for Boosting Efficiency

Improving the energy efficiency of electric SRP drives is not just an operational imperative but also an economic and environmental one. By adopting a strategic approach that addresses cyclic loading, motor sizing, counterbalancing, and operational adjustments, oil production companies can achieve significant cost savings and reduce their environmental footprint. Implementing these changes requires a commitment to understanding the specific conditions of each oil well and tailoring solutions accordingly. This proactive approach can transform SRP units from energy-intensive systems into models of efficiency and sustainability.

About this Article -

This article was crafted using a human-AI hybrid and collaborative approach. AI assisted our team with initial drafting, research insights, identifying key questions, and image generation. Our human editors guided topic selection, defined the angle, structured the content, ensured factual accuracy and relevance, refined the tone, and conducted thorough editing to deliver helpful, high-quality information.See our About page for more information.

This article is based on research published under:

DOI-LINK: 10.1109/icepds.2018.8571642, Alternate LINK

Title: Ways Of Increase Energy Efficiency Of Electric Drives Sucker Rod Pump For Oil Production

Journal: 2018 X International Conference on Electrical Power Drive Systems (ICEPDS)

Publisher: IEEE

Authors: Marat Khakimyanov, Fanur Khusainov

Published: 2018-10-01

Everything You Need To Know

1

What are the main components of a sucker rod pump unit, and why is it important to understand them?

Sucker rod pumps utilize both surface and submersible subsystems. The surface components include a control station, electric motor, gearbox, crank mechanism, and walking beam. The submersible subsystem consists of a rod column and the sucker rod pump itself. Understanding these components is crucial for identifying areas where efficiency can be improved.

2

What are the primary factors that lead to energy inefficiency in electric sucker rod pump drives?

Several factors contribute to energy inefficiency in electric sucker rod pump drives. These include cyclic loading patterns, oversized motors running under capacity, energy loss via intermediate components like V-belt drives and gearboxes, and challenges during system startup, especially in cold conditions. Addressing these issues is key to improving overall efficiency.

3

Why are sucker rod pumps still used despite the rise of electric centrifugal pumps?

While electric centrifugal pumps are used, sucker rod pump units remain relevant because of their high efficiency and lower power consumption, especially when paired with non-explosion-proof electric motors. The initial investment versus production expectation determines whether a electric centrifugal pump or sucker rod pump is more appropriate.

4

How do newer sucker rod pump drive mechanisms compare to older systems, and what are the implications for existing oil wells?

Newer sucker rod pump drive mechanisms, such as chain, hydraulic, and linear drives, offer better energy transfer compared to older systems. However, many operational oil wells still rely on older sucker rod pumps due to economic constraints. Targeted improvements to these older systems can yield significant energy savings without requiring a complete infrastructure overhaul.

5

What strategic approaches can be used to improve the energy efficiency of electric sucker rod pump drives, and what are the potential benefits?

Improving the energy efficiency of electric sucker rod pump drives involves adopting a strategic approach that addresses cyclic loading, motor sizing, counterbalancing, and operational adjustments. This proactive approach can transform sucker rod pump units from energy-intensive systems into models of efficiency and sustainability, leading to significant cost savings and a reduced environmental footprint. Successfully executing will involve understanding the specific conditions of each oil well and tailoring solutions accordingly.

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