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Control Station SHERP-6000

Various sucker rod pumping units control station SHERP-6000 based on frequency

inverters (electric drives) series REN2N

Power 5,5...75 kW

Application

Sucker-rod pumping unit operator station series SHERP-6000 is designed to control the drive motor of the pumping unit, automatically adjusting the operating mode and protecting the drive and processing equipment of the sucker-rod pumping unit.

Sphere of application

Oil companies utilize oil-sucker rod pumping units in to support pumping units.

Advantages:

  • Maximizes (appropriate) the increase in oil production. This is ensured by increasing the filling of the plunger with formation fluid to the maximum level, which is achieved by the automatic generation of optimal law of variation of the frequency of oscillation within a cycle.  When the frequency of oscillation is automatically installed the well's delivery rate is increased by 5,6%. As a result, the fill factor reaches 75,90% against the existing 40,50%.
  • Eliminates accidents from occurring in surface and well equipment.  Availability of accurate real-time operating information on the performance of the equipment allows for quick reaction to avoid the excess load on the walking beam, failure in operation of the sucker rod, failure of the sucker rod at the bottom of the column, changing the dynamic fluid level in the annulus, occurrence of paraffin plugs in the oil well tubing and to protect the driving equipment from any emergency situations.
  • Extends the life of well mechanical equipment by automatically reducing the dynamic component and limiting the total load on the walking beam. Thereby eliminating many potential accidents at each start-up and self starting of the motor, and during start-up commissioning.
  • Reduction in energy consumption up to 40% or more by increasing the overall efficiency of the sucker-rod pumping unit while increasing the fill factor of the pump.  Complete absence of reactive power consumption from the mains at any load on the motor, which, also eliminates the use of cosine condenser battery compensation.
  • Simplification and reduction of maintenance and repair work of oil producers of the down-hole equipment due to:

- Significant simplification of installation and commissioning works.

- Significant reduction in the need for surveys.

- Sharp decrease in the workload to control and configure the operating modes during operation of the sucker-rod pumping unit, while the well is operating with a stop operating equipment.

- Eliminates need for regular inspection when the data link is installed in REN2N providing a total reduction in operating costs up to 30.50 %.

  • Any level of automation - from the most simple (for one well) to the organization of oil-field automated process control system via radio.
  • For the first time in the technology of oil production - the possibility of improving the quality of economic, technological and operational characteristics of enterprises using the sucker rod pumping units.

Functionality

  • Soft start up of the pumping unit drive motor with programmable acceleration time.
  • Smooth shock-free self-starting with a programmable delay time after loss of voltage.
  • Stepless change in the number of swings of pumping unit in the automatic and manual mode from 0 to 200% of the nominal number of swings.
  • Automatic self-tuning mode of pumping with maximum plunger pump filling.
  • Speed control rod movement of the drill string from cycle to cycle, and within the loop of any given law of motion.
  • Automatic stabilization of the dynamic level of the well.
  • Automatic limit of dynamic forces in the pumping unit and sucker-rod drill string.
  • Highly customizable control (limiting) of load on walking beam.
  • The possibility of implementing an automatic control system of every sucker-rod pumping unit, closed on any technological parameter (or their combination).
  • Possibility of an accurate balance of the crank-balancer mechanism of pumping unit.
  • Possibility of remote control operation mode of sucker-rod pumping unit.
  • Provision of energy saving features.
  • Increasing energy efficiency of driven equipment (increase of cosj).
  • Possibility of installing an electric motor of any type (including high-speed, with high slip).
  • Opportunity to significantly reduce the installed capacity of the installed motor.
  • Increasing the functionality of the control station by installing a process variable sensors and changing software.

Protective functions

Sucker-rod pumping unit control station SHERP-6000 has the widest range of protective functions:

  • Maximum current protection.
  • Short circuit protection in load.
  • Protection from termination/phase imbalance of supply voltage.
  • Protection against overheating of the motor and control station.
  • Protection against breakage or slippage of belts.
  • Protection against excess pressure in the through flowline.
  • Protection against reduction gear jamming.
  • Protection from the brink of suspension rod.
  • Protection from the sucker rod breakage, including the bottom of the drill string.
  • Protection from failure in operation of the sucker rod.
  • Protection from unacceptable reduction of the dynamic level.

 Diagnostic capabilities

While the sucker-rod pumping unit SHERP-6000 is in operation the following information is available about the condition and operation of the sucker-rod pumping unit to the control station:

  • State of sucker-rod pumping unit (working/not working).
  • Frequency (cycle time) swing.
  • Current of the pumping unit motor.
  • Pumping unit motor power.
  • Energy consumption for a given period.
  • Torque rate of crankshaft.
  • Current load on walking beam (dynamometer).
  • Efficiency of pump and volume efficiency.
  • Current supply of sucker rod pumps (estimated).
  • Definition of pumping unit imbalance (unbalance factor).

Optionally data transmission channel can be set in SCHERP-6000 (wired or wireless channel). In this case it is possible to use SCHERP-6000 as a low-level control system that makes all the information available to remote users.

Communications capabilities

The input signals:

  • Discrete 0..24 V, galvanically separated - 8 pcs.
  • Analog 0(4)..±20 mА, 0..±10 V, galvanically separated - 2 pcs.

The output signals:

  • Discrete 0..24 V, galvanically separated - 4 pcs.
  • Analog 0(4)..±20 mА, 0..±10 В, galvanically separated - 2 pcs.

Digital signals:

  • RS232, standard СОМ-port, galvanically separated ? 2 channels.
  • RS485, шинная реализация, galvanically separated ? 3 channels, interface Modbus RTU.
  • CAN (optional).

Technical features SHERP-6000

  • Rated capacity of SHERP-6000 ? 5.5, 7.5, 11, 15, 22, 37, 55 и 75 kW.
  • Nominal input voltages ~ 3´380В, 50 (60) Hz.
  • Tolerance of input voltage amplitude from -25%Uн to +15%Uн.
  • Tolerance of input voltage frequency from -5 Hz to +10 Hz.
  • Output voltage - three-phase, variable, 3´(0..380)V; 0..100 Hz.
  • Multiplicity of permissible overload output current - 2´Iн.
  • The form of output current is sinusoidal.
  • The minimum efficiency - 0.97.
  • The minimum input power factor - 0.96.
  • Operating mode - long-term behavior, nonstop run.
  • Control algorith of the drive motor - vector control.
  • A group of mechanical stress according to GOST 17516.1-90 - М2, М6.
  • The design concept according to GOST 14254-80 - a sealed enclosure IP54.
  • Climate performance according to GOST 15150-69 - U, UХL, ХL, Т.
  • Placement category according to GOST ГОСТ 15150-69 - 1

Design features

The control station SHERP-6000 is designed in the form of an enclosure of single floor accommodation.

Enclosure SHERP-6000 is divided into two separate compartments - switching and power.

In the switching compartment contactor and power switching devices are located, also the current limiting reactor (if necessary).

In the power compartment the frequency inverter, control system and climate control module are located. Structurally, the components of the power compartment are designed in the form of removable modules. During replacement of the modules of the power compartment the pumping unit motor can operate in an unregulated mode with manual control, performing all the functions of a standard unregulated control unit.

Connection points for organic sensors and wired connections to the control system are located at the bottom of the patch bay.

Controls of SCHERP-6000 (buttons, connectors to the PC, connectors for diagnostic equipment) and alarm (indicator lamps) are located on the outer part of the power compartment door.

Overall and mounting dimensions

SHERP-6000

5.5, 7.5, 11 kW

15, 22, 37 kW

55, 75 kW

Height, mm

1550

1800

2060

Length, mm

800

800

900

Depth, mm

480

540

620

Delivery, installation, commissioning

The package includes:

  • Enclosure SHERP-6000 of the appropriate dimension-type.
  • Position pickup of rotor and crank; dynamo graph (1 pcs. for a set 10-20 pcs.).
  • Portable control device (1 pcs. for a set 10-20 pcs.).
  • A set of software for the platform Windows.
  • Documentation set SHERP-6000; Repair kit (in consultation with the customer).

The process of assembling SCHERP-6000 is similar to that of a standard control unit without electric drive. The process of setting up is automated - is performed automatically by means of the control station before commissioning for 10-15 minutes. In case of failure of the power module or the control system, replacement by a new module can be done in 20-30 minutes by unskilled personnel.