Sectional Variable Frequency and Voltage Regulation Control Strategy for Energy Saving in Beam Pumping Motor Systems

Despite the fact that the energy losses in the beam pumping motor systems (BPMS) utilized in oil fields represent a monumental challenge industrially, very few studies discussed the feasibility and applicability of a universal energy saving technology for such industry. This study proposes a sectional control strategy integrating variable frequency (VF) with voltage regulation (VR) based on the mechanical load characteristics of the BPMS. Main merits of the proposed strategy are as follows: 1) controlling horse-head acceleration through VF, and indirectly weakening the inertia torque of polished rod load, thereby reducing the power consumption during the up-stroke; and 2) based on monitoring load conditions in real time, auto-tracking VR is adopted to optimize the online efficiency of the system. The proposed strategy utilized the adaptive fuzzy logic control to alternate between VF and VR modes. The proposed energy saving strategy was applied to a CYJ10 BPMS driven via a 37-kW induction motor in simulation and experimental environments. Results revealed that the effectiveness of the proposed strategy to improve the load balance effects through better utilization of the counterbalance during the heavy-loading conditions in up-stroke. Furthermore, the energy consumption is reduced via the auto-tracking of VR under light-loading conditions during the down-stroke. Moreover, the energy saving ratio is more than 10% under different dynamic liquid levels and counter weights. The effectiveness of the proposed strategy is verified through comparing the calculated results with the measured data for a standard oil rig, and the generality is verified as well.