In the past decade, the evolution of AC drive technology—from low-capacity systems to high-capacity ones, and from basic open-loop configurations to advanced closed-loop setups—has brought significant benefits to society. These systems are now widely used in various applications, especially in controlling the speed of AC motors, which were once difficult to regulate. In the past, adjusting the speed of AC machines was a challenge, both from an operational and energy-saving perspective.
Similarly, submersible pumps, which serve as power units for deep-well oil extraction, have also benefited greatly from variable frequency speed control technology. Whether driven by process requirements or energy efficiency needs, this technology offers substantial advantages. However, earlier technical solutions were not ideal, limiting its widespread use. The current technology employed by the company is among the most advanced globally, offering promising prospects for future development.
The best transmission solution for submersible pump variable frequency technology lies in its ability to optimize performance. Submersible pumps are multi-stage centrifugal pumps designed for underground operation, typically working in harsh environments at depths of 2 to 3 kilometers. They are subjected to high temperatures and corrosive conditions, yet they have become increasingly popular due to their high efficiency. Their power ranges from 55 to 75 kW, and because of the depth of oil wells, the voltage is usually set at around 1000 volts to minimize line losses. This medium voltage level balances efficiency and insulation challenges.
Common issues with existing systems include high starting currents that can cause system overpressure and damage to insulation. Additionally, changes in geological conditions often lead to excessive pump pressure, shortening the lifespan of the equipment and increasing maintenance costs. To address these problems, implementing variable frequency speed control is the most effective approach.
The benefits of using AC variable frequency drives are numerous. First, the soft-start function reduces inrush current and back EMF, minimizing the risk of insulation damage. Second, the system maintains a higher power factor, especially under light loads, significantly reducing reactive power and saving energy. Third, it allows for precise regulation of pump speed based on well conditions, improving efficiency and reducing failure rates. Finally, it enables closed-loop control of pressure and temperature, enhancing automation and optimizing production across different types of oil wells.
Comparing previous frequency control schemes, the traditional approach using general-purpose inverters involves step-down and step-up transformers, but this leads to bulky designs and inefficiencies. Another method uses low-voltage inverters to achieve medium-voltage conversion, but it results in poor output waveforms and high dv/dt, causing insulation issues and high costs.
The company’s medium-voltage inverter solutions offer superior performance. The first option is a 1140V medium-voltage inverter using diode-clamped three-level technology, which improves waveform quality and reduces insulation stress. The second option is a 6000V and above inverter that uses a transformer-isolated, series-connected power unit design, offering greater flexibility and reliability.
The company's medium-voltage inverter is optimized for different grid voltages and is designed to deliver high performance at a competitive cost. While foreign products focus on 1140–10,000V systems, the company’s solution stands out for its simplicity, mature components, and excellent value for money. With its ability to reduce harmonics and provide clean input/output, this technology is well-suited for oil field submersible pump applications and has a strong potential for future growth.
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