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.
- 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.