Pumping Unit Out-of-Balance Correction via Current Transformers
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Solution Overview
Problem
Reciprocating pump systems, such as sucker rod pump systems, face challenges in maintaining optimal balance due to changing rod loads, leading to increased energy consumption and reduced operational life, as existing methods require opening high voltage electrical cabinets to measure out-of-balance conditions.
Innovation Solution
A method and system that monitor operating parameters using sensing equipment to determine out-of-balance conditions and implement corrections to counterbalance parameters and stroke parameters, allowing for real-time adjustments without the need to access high voltage components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If electrical meters are installed across motor terminals to measure out-of-balance conditions, then measurement capability is improved, but device complexity and safety risks increase due to requiring high voltage electrical cabinet access
Solution Approach 1:
The patent uses current transformers as intermediary devices that can measure motor current without direct electrical connection to high voltage terminals. These transformers act as mediators between the measurement system and the motor, allowing accurate out-of-balance detection while eliminating the need to open high voltage electrical cabinets, thus resolving the contradiction between measurement capability and device complexity/safety
2Loss of energy
If counterbalance weights are manually adjusted to correct out-of-balance conditions, then energy consumption is reduced, but productivity and operational efficiency decrease due to required shutdowns and manual intervention
Solution Approach 1:
The system continuously monitors motor current and calculates out-of-balance conditions in real-time, providing feedback that triggers automatic counterbalance weight adjustment. This closed-loop feedback mechanism eliminates the need for manual intervention and shutdowns, allowing the system to maintain optimal energy efficiency while maximizing productivity through continuous operation
Solution Approach 2:
The pumping unit performs self-adjustment of counterbalance weights based on real-time monitoring and automatic control algorithms. The system serves itself by detecting out-of-balance conditions and automatically adjusting weights without requiring external manual intervention, thereby maintaining energy efficiency while preserving operational continuity and productivity
3Duration of action of moving object
If out-of-balance conditions are allowed to persist, then operational continuity is maintained, but component life and system reliability deteriorate due to increased energy consumption and suboptimal operation
Solution Approach 1:
The system dynamically adjusts counterbalance weights in real-time based on changing operating conditions and detected out-of-balance states. This dynamic adjustment capability allows the system to maintain optimal performance and component life across varying operational scenarios without requiring shutdowns, thereby simultaneously preserving both operational continuity and component reliability
Data Source
AI summary
A system and method handles one or more pumping units in an out-of-balance condition. Sensing equipment monitors operating parameters related to balance of each of the one or more pumping units. Processing equipment determines the out-of-balance condition in at least one of the one or more pumping units based on the monitored operating parameters. A first correction to a counterbalance parameter of the at least one pumping unit can be calculated, such as a new position or weight of the counterbalance, so the out-of-balance condition can be corrected by implementing the new position or weight at the at least one pumping unit. A second correction to a stroke parameter of the at least one pumping unit can be calculated, such as a new stroke rate or pattern, so operation of the pumping unit can be maintained despite the out-of-balance condition.