Beam Pump Drive Control System Solution

Common beam pumping units, often referred to as "nodding donkeys," are the traditional oil extraction equipment widely used in oilfields. Typically driven directly by standard AC asynchronous motors, their crankshafts with counterweights pull the sucker rods to drive downhole pumps in a fixed cycle of up-and-down reciprocating motion, lifting oil from the wellbore to the surface. Within each stroke, the motor operates in different modes: during the upward stroke, it draws energy from the grid to run as a motor; during the downward stroke, the load becomes potential (due to gravity and sub-surface pressure), causing the motor to act as a generator, converting mechanical energy back into electricity and feeding it into the grid. Common specifications for these units range from 2 tons to 8 tons and 10 tons, with motor power varying based on pumping depth, typically ranging from 18.5kW kW up to 110 kW. The traditional transmission method uses an asynchronous motor, pulley wheel, and reducer. The motor transmits torque via a belt to the reducer, which then drives the entire beam to oscillate repeatedly around its balance point through a crank-connecting rod mechanism. The intermediate transmission components and mechanical wear are key factors limiting system lifting efficiency. Additionally, the annual maintenance cost for reducers and belts is high; for example, a 22 kW system costs approximately 1 ten thousand yuan per year. This setup also risks unplanned downtime, leading to greater losses. Furthermore, the regenerative energy generated during the downward stroke cannot be effectively recovered in traditional systems; excess energy dissipates as heat. This solution establishes a four-layer drive and control architecture: Information Layer, Control Layer, Drive Layer, and Execution Layer. - **Information Layer:** Utilizes Wolong Shunzhi Cloud IoT modules to enable production visualization, remote monitoring, and debugging, supporting interaction via both mobile apps and web interfaces. - **Control Layer:** Handles information exchange between DCS and PLC systems, fully configured and tested for seamless communication parameters, ensuring ease of use and peace of mind. - **Drive Layer:** Employs the WD200 series high-performance vector inverters and energy feedback units. This enables energy regeneration + vector control, energy recycling, S-curve smooth starting, and precise speed/torque control, while offering abundant expansion communication and I/O resources. - **Execution Layer:** Uses TYCP5 series low-speed permanent magnet synchronous motors for direct drive, replacing the reducer, belt, and asynchronous motor. This simplifies procurement and maintenance, reduces failure rates, and achieves energy savings and emission reductions. The TYCP5 low-speed direct-drive permanent magnet motor covers frame sizes 180~560, rated power 1.1~900 kW, and rated speed 25~500 r/min. Rated voltage supports 380 V and 660 V. It meets Energy Efficiency Level 1. Standard duty cycle is S1 (S2, S3, etc., available). Mounting options include V1 (B3, etc., available). Insulation class is F (H class available). Protection rating is IP55 (IP56, IP65, IP66, etc., available). Cooling methods include IC410 and IC70W (IC418, IC416, IC71W, etc., available). The housing is made of cast iron or steel plate. Bearings use grease lubrication with filling/draining devices. Optional PT100 or PTC protection devices are available. Frame size, power, speed, and voltage can be customized per customer requirements. The WD200 series represents the next generation of high-performance general-purpose inverters. Featuring advanced motor control algorithms, they offer optimal matching with motors and support asynchronous, permanent magnet synchronous, and synchronous reluctance motors. Key features include high reliability, performance, scalability, multi-drive capability, and easy cabinet assembly. Available in power ranges from 0.75kW to 1000kW, these inverters support four power supply types. They feature a unified platform design for synchronous, asynchronous, and reluctance motor drives. Closed-loop and torque control functions are integrated into general models for diverse industrial applications. Support includes common DC bus applications and four-quadrant operation for high energy efficiency. Communication protocols supported include PROFIBUS-DP, PROFINET, Ethernet, EtherCAT, CANopen, and Modbus. The control panel offers parameter storage and upload/download capabilities for convenient debugging and backup. Optional features include: built-in braking units for models 0.75kW to 22 kW; optional built-in braking units for 30 kW to 160 kW models; optional external braking units for models above 160 kW; and optional built-in DC reactors for models 30 kW and above. Models above 710 kW are custom-built, with options determined by specific customer needs. System advantages span five areas: 1. **Energy Efficient & High Performance:** Motors meet National Grade 1 Energy Efficiency standards. Eliminating unnecessary transmission equipment reduces reduction losses, achieving energy savings of 15%~40%. 2. **Reliable Performance:** High-strength motor materials and premium quality components ensure stable operation. 3. **Intelligent:** Features real-time monitoring, timely alerts, and intelligent control. 4. **Easy Maintenance:** Direct connection between the motor and equipment removes redundant transmission structures, reducing failures and approaching zero maintenance. 5. **Powerful Functionality:** Meets diverse operational conditions and application scenarios. **Drive Efficiency Improvement and Energy Cost Analysis** (based on a 22 kW shaft power system): - **Permanent Magnet Direct-Drive System:** Motor actual efficiency 0.94, inverter efficiency 0.98, total transmission efficiency 92.12%, total input power 23.7kW, annual energy consumption 187704kWh. - **Traditional Drive System:** Motor actual efficiency 0.90, reducer efficiency 0.90, total transmission efficiency 81%, total input power 27 kW, annual energy consumption 213840kWh. Based on 330 working days per year, 24 hours per day, and an average industrial electricity price of 0.7 yuan/kWh, adopting the permanent magnet synchronous direct-drive system with energy feedback saves approximately 2.9 ten thousand yuan in total operating costs annually (excluding the value of electricity fed back to the grid) compared to traditional solutions. Removing the reducer also minimizes unplanned downtime, preventing further losses. The energy feedback unit transforms the system's power flow from two-quadrant to four-quadrant, allowing bidirectional energy flow between the grid and the load. Excess energy is no longer dissipated solely as heat but is significantly recycled. The amount of energy fed back depends on the nodding donkey's balance rate and operating conditions, requiring on-site assessment. **Application Case:** A Wolong inverter plus energy feedback unit control scheme has been applied to oilfield pumping units at an oil production plant. The installation includes 400 pumping units with powers of 37/55/75 kW. The selected inverters are from the WD200 series, and the energy feedback units are from the WD230 series. When selecting inverters, a higher power rating than the motor is recommended to provide sufficient system margin. The system operates stably with significant energy-saving effects, creating substantial economic benefits for enterprises and suitable for oilfields in various environments.

Use Cases:Beam pumping units, walking beam pumps, and other oilfield extraction equipment for various oilfield environments (commonly available in 2 ton, 8 ton, and 10 ton capacities; paired motor power ranges from 18.5 to 110 kW).