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Ovak Technologies Case Studies Oil Well Pump Control System

Oil Well Pump Control System

Ovak Technologies
Oil Well Pump Control System
Oil Well Pump Control System
Oil Well Pump Control System
Oil Well Pump Control System
Equipment & Machinery
Process Control & Optimization (PCO)
Other frequency

Naftamatika was looking to develop an oil well pump control system which could optimize oil well operation using only sensors installed on surface equipment.

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Naftamatika offers modern, efficient, proven solutions for producing oil wells.

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The Naftamatika WellSim rod pump controller is highly effective, with hardware specifications far exceeding all modern analogue pump controllers. Ovak Technologies developed the software upon technical specification of Naftamatika company. The Naftamatika WellSim controller, based on the NI SingleBoard RIO platform, was programmed using the LabVIEW Real-Time Module and LabVIEW FPGA Module. LabVIEW was chosen because it is easy to use and significantly faster to develop a complicated application with a user-friendly GUI. LabVIEW provides a platform to easily develop and change algorithms. In addition to rod pump control functions, the Naftamatika WellSim controls and monitors the whole system. It provides a complete well simulation based on data obtained from the single universal integrated load and position sensors. This approach is very useful in monitoring well parameters and provides ample opportunities for real-time downhole equipment diagnostics. Such a system is necessary due to oil reserve exhaustion, high cost electric power, and the desire for oil companies to lower the cost of well maintenance and increase labor efficiency. Using the controller, the user can manage the well in manual or automatic mode. Automatic control uses an improved algorithm based on this well model, which is how we achieve the highest accuracy, parameter calculation stability, and maximum pumping unit operating reliability. The controller supports the Modbus Remote Terminal Unit protocol and interacts with XSPOC and other supervisory control and data acquisition (SCADA) systems. An accelerometer in a weatherproof enclosure takes accurate position measurements on the polished rod (not the modeled position). Internal electronics provide signal conditioning necessary for accurate data acquisition. The load cell sensor is mounted on polished rod. The sensor works on Wheatstone bridge principle with a temperature compensation. Load measurement accuracy is 0.25 percent, and load measurements range from 0 to 22,500 kg/50,000 lb. Technology Deployed: Hardware components - NI Single-Board RIO Software components - LabVIEW Developer Suite - LabVIEW Real-Time Module - LabVIEW FPGA Module - Modbus Library for LabVIEW

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Equipment Status, Fill Levels Of Containers, Oil Level, Process Parameters, Temperature
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Increased Well Production Efficiency - By maintaining optimal formation pressure and continuous operation at minimal speeds (for wells that should not be shut down)

Reduced Maintenance Costs - By reducing equipment failure and remote access

Optimised Production Capacity - By tapping on the comprehensive data-sets available from all oil wells from the entire oil field using the WellSim system.

35% energy saving in comparison with a pumpoff controller

Total profit from installation of WellSim control stations at 6 wells will be $170,000 after 1 year.

Payback period is 0.23 year.

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