Turbo Trac's Technology:
Industrial - Oil Well Pumps
Industrial - Oil Well Pumps
Most operating oil wells in North America are "stripper" wells. In these wells there is little or no pressure that forces the oil up as in the proverbial "gusher"
seen in the beginning of the 20th century. Consequently, it takes energy to pump the oil out of the ground. Because of the nature of these wells, the pump
needs to be stopped and restarted several times daily. Each start-up requires a high horsepower and torque, though the need is only during start-up and after
the start-up the horsepower and torque need drops substantially. This start-up demand requires a relatively large electric motor and results in substantial
electric bills to the oil well operator. The use of Turbo Trac technology in this application will allow for improved efficiency.
seen in the beginning of the 20th century. Consequently, it takes energy to pump the oil out of the ground. Because of the nature of these wells, the pump
needs to be stopped and restarted several times daily. Each start-up requires a high horsepower and torque, though the need is only during start-up and after
the start-up the horsepower and torque need drops substantially. This start-up demand requires a relatively large electric motor and results in substantial
electric bills to the oil well operator. The use of Turbo Trac technology in this application will allow for improved efficiency.
A pumping unit operating at 100% efficiency (theoretical) will require 0.132 kwh/bbl/1000 ft. (calculated). Current efficient pumping unit designs are capable
of performing at 0.20 kwh/bbl/1000 ft. This represents overall energy efficiency of up to 66%.
of performing at 0.20 kwh/bbl/1000 ft. This represents overall energy efficiency of up to 66%.
Typical pumping operations are considerably less efficient, however, and vary widely in performance. For example, a number of 10,000 ft. wells surveyed
in West Texas ranged in performance from 0.271 kwh/bbl/1000 ft. to 0.424 kwh/bbl/1000 ft. Annual electricity costs on these wells ranges from $3000.00 to
$5000.00. Several 4700 ft. stripper wells surveyed in West Texas ranged in performance up to 0.81 kwh/bbl/1000 ft. with annual electricity costs ranging
from $1500 to $2000.00.
in West Texas ranged in performance from 0.271 kwh/bbl/1000 ft. to 0.424 kwh/bbl/1000 ft. Annual electricity costs on these wells ranges from $3000.00 to
$5000.00. Several 4700 ft. stripper wells surveyed in West Texas ranged in performance up to 0.81 kwh/bbl/1000 ft. with annual electricity costs ranging
from $1500 to $2000.00.
Fundamentally, there are three (3) aspects of a typical pumping operation where efficiency can almost always be improved:
1) Motor operation;
2) Power factor;
3) Pumping (lifting) operation.
2) Power factor;
3) Pumping (lifting) operation.
Various existing technologies and strategies can be employed to improve unit efficiency:
¨ Replace the typical NEMA D (high slip) motor with a premium efficiency NEMA B motor. This can yield 10 - 15% savings, but starting loads are
sometimes problematic with NEMA B motors, so they are not often used.
sometimes problematic with NEMA B motors, so they are not often used.
¨ Install variable frequency power supply to vary motor speed and limit peak torque. This can yield 10 -12% savings but such installations are
expensive and are seldom used.
expensive and are seldom used.
¨ Install glass fiber sucker rods in place of steel rods to reduce weight and power requirements. This can yield savings up to 30% and is widely used.
(This is compatible with and can be used with the Turbo-Trac System.)
(This is compatible with and can be used with the Turbo-Trac System.)
¨ Install slow-down pump off control to optimize pump fill and minimize pump "hammer". Unspecified savings. (Almost all pumping units already
use on-off pump off controls, but not the slow-down type.)
use on-off pump off controls, but not the slow-down type.)
¨ Install Power Factor correction capacitors. When optimized, can yield more than 10% savings, but are seldom used and cannot be fully optimized
because of the severe motor load fluctuation on typical units.
because of the severe motor load fluctuation on typical units.
¨ Adjust stuffing box to minimize polish rod friction.
¨ Change to correct motor size when an oversized motor is in use.
Any pumping unit must be well balanced and relatively efficient in order to perform at 0.20 kwh/bbl/1000 ft. (66% efficient). In fact, none of the
existing technologies, even in combination, can provide all of the possible efficiency improvements for pumping units and only rarely can enable a
pumping unit to achieve or exceed 66% efficiency. However, the Turbo-Trac Ratio Variator System can improve efficiency in all three of the above
aspects and can likely achieve up to 80% total efficiency by doing the following:
existing technologies, even in combination, can provide all of the possible efficiency improvements for pumping units and only rarely can enable a
pumping unit to achieve or exceed 66% efficiency. However, the Turbo-Trac Ratio Variator System can improve efficiency in all three of the above
aspects and can likely achieve up to 80% total efficiency by doing the following:
1. Changing the motor load from a fluctuating load to a steady load which allows the motor to be more efficient. Plus, by reducing peak loads, this
also facilitates a 30% reduction in motor size and enables the use of a premium efficiency motor. A premium efficiency motor at steady load will
yield 95% efficiency. Typical motor efficiency, with fluctuating loads, is no more than 80%. Hence, this will provide at least 18 - 20% improvement
in efficiency.
also facilitates a 30% reduction in motor size and enables the use of a premium efficiency motor. A premium efficiency motor at steady load will
yield 95% efficiency. Typical motor efficiency, with fluctuating loads, is no more than 80%. Hence, this will provide at least 18 - 20% improvement
in efficiency.
2. Making the motor load steady will enable the optimum use of correcting capacitors to bring the Power Factor to unity. This will produce an
additional 10% improvement in electric efficiency.
additional 10% improvement in electric efficiency.
3. Slowing the mid-stroke speed to steady the motor load will also reduce back pressure at the stuffing box and in surface piping and will reduce
suction pressure at the pump. This will produce an additional 5 - 10% improvement in efficiency.
suction pressure at the pump. This will produce an additional 5 - 10% improvement in efficiency.
4. Increasing the end-of-stroke speed to steady the motor load will also optimize the strokes per minute (SPM) rate without proportionate increase
in power usage.
in power usage.
5. Keeping the SPM rate slow during near pump-off conditions will reduce pump "hammer" and pump wear.
6. When entire oil field leases are equipped with Turbo-Trac Systems, the monthly demand charge also may be reduced by 10 - 15%.
The Turbo-Trac System, offered in combination with a correctly sized premium efficiency motor, can be the only efficiency improvement system
capable of providing, in one package, all of the feasible improvements for pumping units. Economically priced, Turbo Trac can dominate the market.
capable of providing, in one package, all of the feasible improvements for pumping units. Economically priced, Turbo Trac can dominate the market.
| Turbo Trac’s business is to commercialize its continuously and infinitely variable mechanical transmission (CIVT) system while establishing its core competency as a technology leader in high torque, traction-type CIVT systems for transportation and industrial markets. Turbo Trac will be the developer, assembler and supplier of its core, patented technology to selected strategic partners in targeted, energy-inefficient, niche segments of transportation and industrial markets. |
