Application of ABB frequency converter in oilfield water injection pump

Oilfield water injection is a crucial and effective strategy for maintaining high and stable production in many oil fields across China. The process involves concentrating the dispersed oil within the reservoir to be extracted through oil wells. Daqing Oilfield, being a fault block oilfield, presents unique challenges as each block has a limited water injection area, requiring frequent adjustments in water injection volume based on changing production conditions. Most water injection stations face issues where the rated flow rate of the system does not match the actual flow, leading to inefficiencies. Given the high pressure and large volumes of water involved, the motors used for water injection are typically high-power units that operate under high energy consumption for extended periods. To address these challenges, variable frequency speed control devices are implemented to regulate the speed of the water injection pumps, enabling flexible control over the water injection flow. This method significantly contributes to energy savings and operational efficiency. Traditionally, oilfield high-pressure water injection systems have relied on gate valves to control flow and pressure. However, prolonged low-displacement operation is discouraged due to risks such as temperature rise, cavitation, and mechanical failure. In the past, this led to excessive reflow operations, which increased energy consumption and caused significant waste in oil fields. In the original system design, two injection pumps were commonly used. Without frequency conversion, the main energy loss came from throttling at the control valves. To optimize energy use, it's essential to consider factors like mixing volume, reduce water pressure, and minimize the pressure difference across injection wells. The principle behind the frequency conversion system lies in the fact that the actual flow rate of the water injection pump is often lower than its rated capacity, offering considerable potential for energy savings. The system uses feedback pressure signals from a transmitter, comparing them with preset values in the inverter. A PID controller then automatically adjusts the frequency to maintain the desired pressure. These parameters are transmitted to a computer workstation via internal communication protocols, allowing real-time monitoring and control of system pressure, motor speed, voltage, and current. This enables fully automated, energy-efficient operation. Compared to the traditional control system, the frequency conversion approach offers several advantages. It simplifies operation by eliminating the need for manual valve adjustments, reducing labor intensity and improving work efficiency. The system starts with a low-frequency acceleration, resulting in reduced noise and less stress on the power grid. Additionally, the system employs a one-to-two control mode, using feedback from pressure transmitters to create a closed-loop system. When pressure exceeds the set value, the first motor switches to power frequency while the second operates in variable frequency, maintaining consistent pressure and reducing reactive power consumption. In contrast, the conventional power frequency control requires manual operation, making it time-consuming and error-prone. The motor speed is fixed, and when pressure exceeds the required level, the inlet valve must be manually adjusted, leading to unnecessary energy waste. By implementing frequency conversion, the system can adapt to varying conditions, allowing the pump to operate efficiently at both high and low flow rates and pressures. The outlet valve remains fully open, minimizing differential pressure and saving energy. This also reduces valve maintenance, enhances automation, lowers system noise, improves working conditions, and decreases labor demand. Overall, frequency conversion not only saves energy but also improves system performance, ensuring smooth and stable operation while increasing operational efficiency.

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