Sensorless Pump Off Control

A Game-Changing Idea: the sensorless pump off controller (SPOC)
SPOC Software → Sensorless Pump Off Control
Sensorless Pump Off Control image

A Game-Changing Idea: the sensorless pump off controller (SPOC)

Improving production while lowering lifting costs, that’s the ultimate goal that every oil and gas producer is aiming for. And that’s exactly what the Sensorless Pump Off Controller does: SPOC helps you pull more product from the ground while lowering your costs. It works on oil, gas and CBM gas wells; it’s even an improvement over wells with traditional pump off controllers.

SPOC will work on beam pump, progressive cavity pump and electric submersible pump applications. The software resides in the SPOC Automation drive and requires no external sensors, wires, load cells or other field devices that fail over time. SPOC uses technology that analyzes the motor’s rotor relationship to the stator to determine the load and position. As with traditional pump off controllers, pump off is determined when the load is reduced at specific positions.

With SPOC, you can establish high load limits and adjust intra-stroke speeds to maintain those limits. Unlike traditional pump off controllers, SPOC gives you text messages on the VFD keypad showing problems such as pump off, parted rod, leaking valve, high load and minimum load, even shutting down if conditions warrant. All this data is available via ModBus RTU as read and write values. SPOC allows you to monitor, control and fine-tune the drive/pump off controller at the well site or by using telemetry and SCADA systems.

Increased Production

  • SPOC varies the strokes-per-minute (Beam Pumps) or speed (PCP & ESPs) to match the well productivity. Eliminating downtime reduces pressure on the reservoir, allowing more flow into the well.
  • In heavy oil, SPOC automatically varies the strokes to reduce rod float and increases up stroke to maximize production.
  • SPOC adjusts strokes-per-minute to compensate for well productivity.

Lower Energy Consumption

  • Traditional pump off controllers run at a higher speed and then shut down. SPOC varies the speed within each stroke to reduce mechanical stress and cut electrical consumption.
  • Reduces energy consumption by 10 to 15 percent over traditional pump off controllers.
  • Some customers have reduced energy consumption by 30 to 35 percent over wells without pump off controllers.
  • IronHorse drives with SPOC reduce peak demand charges because SPOC varies its strokes or speed to match production, eliminates the need to shut down and reduces the overall motor speed.
  • The IronHorse drive package with SPOC can slow the motor to preset minimum speeds, or you can choose to shut the unit down. Speed reduction, combined with overall efficiency gains, reduces the demand for energy.

Lower Capital Cost

  • Can be installed in less than 25 percent of the time needed for traditional pump off controllers.
  • Requires no external sensors (load cells, prox switches, etc.) that fail over time.
  • Increases the entire system’s efficiency. When our engineers review your application, in many cases we can reduce motor, cable and transformer size.
  • IronHorse drives with SPOC will replace the standard pump panel and requires no additional field sensors or equipment.

Fewer Mechanical Failures

  • Decreases speed during peak mechanical loads in each stroke (on beam pumps) by as much as 50 percent.
  • Since the pump runs at an overall slower speed, it suffers less wear and fatigue over time.
  • Does not shut down during pump off, but rather slows down; this prevents sand, iron sulfide, etc. from falling back onto the plunger.

SPOC Automation gives you far more for far less than traditional pump off controllers

  • IronHorse & Subduer VFDs with SPOC can potentially increase production from each well.
  • Reduces your energy usage and cost by up to 35 percent.
  • Because it has no external sensors, hardware or load cells, it is far more reliable.
  • Reduces mechanical down time and repair cost.
  • When a problem occurs in the well, you typically know the exact nature of the problem and the solution – sooner.

Help is at Hand: Customer Service is an inherent part of every product we manufacture. Whether you need application expertise or emergency help in the field when there is a problem, our professional field engineers are here to solve your issues fast before, during and after installation.

vfd, variable frequency drive

TESTIMONIAL

Dealing with the people at SPOC has been fantastic. You don’t feel like you’re left alone with the technology. It’s been like no other support we’ve ever had with any other company.

- Mike Bair, Owner, Black Gold Pump & Supply

ADDITIONAL FEATURES

WiseGuy VFD Interface

WiseGuy can tell you everything you need to know about your well

WiseGuy VFD Interface: WiseGuy can tell you everything you need to know about your well

The WiseGuy™ series of drive interface products is our latest innovation in drive technology. The days of needing a specialist around to change speeds, get the amps, production data, run time or other information you need from your drives are over.

WiseGuy can tell you everything you need to know about your well. And the touch screen technology and oil-field terminology make it simple to use. WiseGuy interface is the most user-friendly on the market.

Smart. Intuitive. Easy. These are the most common words customers use to describe the WiseGuy. If you know industry terminology like “SPM” (Strokes per Minute), “Pump Run Time” (“Real Time Run Time”), and “Number of Pump Offs,” you can program the drives. It’s really that easy.

WiseGuy VFD interfaces are available for a host of drive applications. Here are a few of the application packages available from SPOC Automation:

  • IronHorse Beam Pump Drives
  • Subduer ESP Drives
  • Roto-Armor PC Pump Drives
  • SPOC (Sensorless Pump Off Controller)
  • HPS Injection Pump Drives
  • Compressor Drives
  • Marine Application Drives
  • Custom developed products are available

WiseGuy VFD interfaces come in standard keypad and logic control versions. It can help you make decisions that will keep your equipment running at peak performance and production.

For more information about upgrading your SPOC Automation VFD package with our WiseGuy VFD interface products, please consult our sales or support staff.

Harmonics

Our low-harmonic drives keep you running reliably, efficiently and in compliance

Harmonics: Our low-harmonic drives keep you running reliably, efficiently and in compliance

Harmonic drive compliance becomes more critical every day. At SPOC, we focus on the entire system, providing low-harmonic drives to ensure that you continue running reliably, efficiently and in compliance of IEEE519 and EN-6100-3-2.

We can perform studies for new or existing systems, as well as harmonic measurements to help you get a baseline of your current power quality. Using harmonic modeling tools, we can help you evaluate different scenarios and supply you with the right products that will help you run in compliance with the harmonic standards, with the highest reliability and at the right cost.

We manufacture every type of low harmonics drive, using the latest technology available.  Everything we do is tailored to your needs.

The Active Front End VFD is SPOC’s recommended approach for minimizing harmonics in fields where all lifting is done using variable speed drives. This technology is electronically based, not magnetically based. It meets the IEEE519 under every scenario and all loading conditions, regardless of voltage imbalance or source impedance. It is so advanced it can actually correct for low-voltage conditions from marginal systems and correct power factor within the electrical system, saving you money. We have years of experience in Active Front End Drives, and can do systems from 1HP to 2000HP at 480V.

Well Optix

SPOC's SCADA package gives you better data and more control over your wells

Well Optix: SPOC's SCADA package gives you better data and more control over your wells

Well Optix is our SCADA package designed to perform remote monitoring, historical data acquisition, while also controlling artificial lift and other oil and gas field applications. Well Optix gives you actionable production data that can enhance your profitability. It’s powerful, yet simple to use, allowing you to remotely make changes depending on well conditions, maximizing your uptime. In addition, we have experienced field engineers on staff who can help guide you should problems at the well arise.

Well Optix can:

  • Trend production optimization data on your well 24/7
  • Make well data available instantly from any internet connected device
  • Make production notes about significant events, keep current logs on well equipment and set email or text alerts to notify you when conditions hit your specified thresholds.

Learn more about Well Optix