Orbital’s Advantage Over Legacy Equipment
Variable Frequency Drive (VFD)
SentinAL vs. VFD
|Cost||Baseline||<50% of VFD|
|Power Density||Baseline||100× VFD|
|Environmental||Requires Enclosure||Harsh Environments|
|Torque Dampening||Control Required||Intrinsic|
|Retrofit||Requires Site Updates||Easily Retrofit|
SentinAL vs. VFD Installation Cost Breakdown
|Lufkin Sam Unit with hp conventional rod pump||100 HP VFD||100 HP SentinAL ASD|
|Electrical 2-man crew w/service truck for 11-hour day = $2,000||2.5 days - $5500||.8 days = $1600|
|Elictrical consultant for a day = $ 1000||1.5 days -$1500||NA - $0|
|Electrical 2-man crew w/service truck = $200 per hour (commissioning)||8 hours - $1600||NA - $0|
|Programmer for programming and Scad = $450 per hour (commissioning)||8 Hours = $3600||6 Hours = $2700|
|Commissioner day rate = $1500||1 day = $1500||1 day = $1500|
|Total Cost for Installation and Commissioning||$13,700||$5,800|
Variable speed benefits are proven… We just do it better!!
Upstream Oil & Gas and Rod Pump ASDs
As oil production declines, various methods of artificial lift are used to lift oil from the well. Rod Pump Units (sucker rod pumps or beam pumps) is one of the most popular methods, with more than 80% of the active oil wells in the US using some form of rod lift. A Rod Pump Unit (RPU) converts the rotational motion of the prime mover (electric or fuel driven motor) into a vertical reciprocating motion that allows a positive displacement pump and sucker rods to pull fluid up from the well.
RPUs are designed to operate at a fixed speed or stroke rate. Operators set the pump speed with the goal to match the production rate of the pump with the inflow from the reservoir. This is manpower intensive process that requires several visits to the wellsite to ensure the pump rate is set correctly. In an ideal world, this process would occur on a continuous basis but limitations with time and costs, operators try to schedule this on a regular basis.
Once the inflow of the well drops below the production rate of the pump, the pump will not be full on every stroke. Partial fillage creates inefficient pumping as it wastes the power of the pump and can damage downhole equipment due to a phenomenon call fluid pound. In most situations, the operator will manage the pump production rate by using a timer or Pump Off Control sensor. These techniques will stop the pump, allow the well to fill and after a set period of time, the pump will restart and drain the well. This method will improve fillage but result in higher power costs due to inrush currents and will not maximize production.
The use of a variable speed drive (VSD) can overcome many of the issues associated with matching pump rate with declining oil well inflow. A VSD along with surface measurements can be used to automatically match the stroke rate of the pump to the inflow of the well. It has been shown in multiple technical papers that a VSD can increase production by 5% to 10% while potentially lowering electrical costs by up to 50%.
Orbital Traction’s SentinAL is a simple mechanical adjustable speed drive (ASD) and controls package that will maximize oil production by autonomously managing RPU Stroke rate. In addition to the proven benefits of VSDs, the SentinAL will have additional benefits: