Intelligent Operation and Maintenance of Pumping Units

 Intelligent Operation and Maintenance of Pumping Units

In the battle to stabilize production in heavy oil blocks, the efficiency improvement of pumping units runs through the entire production process. The company strictly implements the management standard of "one well, one policy", equips the pumping units of high water-content wells with variable frequency speed regulation devices, and installs the automatic cleaning system of pumping unit rods for well groups with serious wax deposition. Especially in the S48 block, through the implementation of "pumping unitPumping Unit health level management", 32 old pumping units that have been in service for more than 8 years have been included in the key transformation plan, and the traditional drive system has been replaced with magnetic levitation motors. The daily power saving of a single pumping unit has reached 85 kWh.

In terms of intelligent operation and maintenance of pumping units, the company has built an Internet of Things platform covering 236 pumping units, and real-time collection of 12 key parameters including indicator diagrams and load curves. With the help of the "digital twin + expert diagnosis" model, the operation and maintenance team successfully compressed the downtime of pumping unit failures to 4.2 hours per unit per year, which is 37% lower than the industry average. At present, the SVES team is accelerating the testing and application of the AI early warning system for oil pumps, and plans to achieve intelligent prediction and autonomous optimization of the operating status of the oil pumps in the entire oil field in the second quarter.

In the development process of heavy oil blocks, the performance and efficiency of the pumping unit as a key production equipment directly affect the production efficiency and economic benefits of the oil field. In order to cope with complex reservoir conditions such as high water content and high wax content, the company has taken a series of targeted measures. In high-water-content wells, by installing a variable frequency speed control device, the pumping unit can automatically adjust the operating frequency according to the production dynamics of the oil well, thereby optimizing the pumping process, improving pump efficiency and reducing energy consumption. In the well group with serious wax deposition, the application of the automatic cleaning system for the light rod effectively solves the problem of wax adhesion to the light rod of the pumping unit, reduces the wear of the light rod, prolongs the service life of the equipment, and also reduces the risk of production interruption caused by wax blockage.

In the S48 block, the company pays special attention to the health management of the pumping unit. By evaluating the health level of the pumping unit, 32 old pumping units with a service time of more than 8 years were listed as the focus of transformation. After years of operation, these pumping units generally have problems such as aging equipment, high energy consumption, and high failure rate. To this end, the company adopted advanced magnetic levitation motor technology to replace the traditional drive system. The magnetic levitation motor has the advantages of non-contact, wear-free, high efficiency, and low noise, which can significantly improve the operating efficiency and reliability of the pumping unit. After the transformation, the daily power saving of a single pumping unit reached 85 kWh, which not only reduced production costs, but also reduced carbon emissions, in line with the requirements of green development.

In the field of intelligent operation and maintenance, the company actively explores and applies new technologies to improve the management level and operation efficiency of pumping units. The company has built an Internet of Things platform covering 236 pumping units, realizing real-time collection and monitoring of key parameters of the pumping units. These parameters include indicator diagrams, load curves, motor current, voltage, power, etc. Through big data analysis and artificial intelligence algorithms, the operating status of the pumping unit can be monitored in real time, and potential fault hazards can be discovered in advance. With the help of the "digital twin + expert diagnosis" mode, the operation and maintenance team can quickly and accurately diagnose and handle pumping unit failures. Digital twin technology creates a virtual model of the pumping unit to achieve real-time simulation and optimized control of the equipment. The expert diagnosis team uses years of experience and expertise to conduct in-depth analysis of the collected data to provide a scientific basis for the operation and maintenance of the pumping unit. Through this model, the company has successfully reduced the downtime of the pumping unit to 4.2 hours per unit per year, which is 37% lower than the industry average.

At present, the SVES team is accelerating the testing and application of the AI early warning system for oil pumps. The system uses artificial intelligence algorithms to analyze the operating data of the pumping unit in real time, which can predict possible failures of the pump in advance and issue early warning information in time. This will provide operation and maintenance personnel with sufficient time for preventive maintenance and avoid production interruptions caused by sudden failures. In addition, the system also has an autonomous optimization function, which can automatically adjust the operating parameters of the pumping unit according to the production dynamics of the oil well, and realize intelligent prediction and autonomous optimization of the operating status of the oil pump in the entire oil field. The company plans to complete the full promotion and application of the system in the second quarter, which will greatly improve the intelligence level and production efficiency of the oil field.

In the future development of oil fields, the intelligence and efficiency of pumping units will become an important development direction. The company will continue to increase investment in technological innovation and equipment transformation, and continuously improve the performance and efficiency of pumping units. At the same time, through the application of intelligent operation and maintenance systems, it will further optimize the production management of oil fields, reduce production costs, and improve economic benefits. With the continuous emergence and application of new technologies, pumping units will play a more important role in oil field development, providing a strong guarantee for achieving stable, high-yield and sustainable development of oil fields.