Researchers from Perm Polytechnic have developed an efficient method to reduce fluid flow irregularities, ensuring the reliable operation of piston pumps and minimizing downtime in oil and gas equipment. This was reported by the university’s press service.

In oil extraction, special pumps are actively used to retrieve hydrocarbons from wells and maintain reservoir pressure. These pumps operate using a piston that moves back and forth to transport oil or water. Often, multiple pumps must be installed at a single well to increase the volume of fluid being pumped. However, variations in piston speeds can lead to uneven fluid flow, resulting in pressure pulsations and fluctuations. These issues may cause failures in pipelines and other equipment.

The researchers at Perm Polytechnic have developed an innovative method to mitigate these irregularities, improving the reliability of piston pump operation and reducing downtime in oil and gas systems. A patent (No. 2833229) has been issued for this invention, which was developed as part of the Priority 2030 strategic academic leadership program.

Various procedures, such as hydraulic fracturing, are used to enhance oil recovery. This process involves injecting fluid into a reservoir to create additional fractures in rock formations. The effective implementation of this technology requires multiple piston pumps operating simultaneously to provide high pressure and large fluid volumes. Typically, between four and twelve pumps are used, though in some cases, even more may be needed. This is particularly relevant for horizontal wells, which are becoming increasingly popular due to their extended reach and the significant effort required to pump fluid throughout their length.

One of the key challenges in piston pump operation is the irregularity in fluid delivery. Differences in piston speeds create pressure fluctuations and pulsations, which negatively impact the injection process and may lead to failures that reduce the efficiency and reliability of equipment. Existing solutions allow for the simultaneous use of only two pumps, which is not always effective, or require additional devices that complicate the pump's design, increasing its size and cost.

Experts at Perm Polytechnic have developed a unique technology that ensures the synchronized operation of two or more piston pumps. The core idea involves a pre-calculated phase shift in the rotating shaft positions. This shift is determined in advance and regulated by a special control unit. The shaft is a key component of a piston pump’s design, transmitting rotation to other elements.

In their research, scientists examined a system with three piston pumps but noted that the method could be applied to any number of pumps.

“The technology ensures that each pump has its own drive motor. The shafts within the pumps are connected to the shafts of the electric motors. The core innovation involves the installation of additional sensors that measure the position and speed of shaft rotation. The control unit processes this sensor data and maintains the predefined phase shift between shafts. If the pump operation is disrupted, the control unit detects it through sensor feedback and promptly adjusts the rotation speeds to restore the required phase shift,” explained V. Kartavtsev, Assistant and Engineer at the Department of Mining Electromechanics, PNRPU.

“The advantage of our technology lies in its ability to quickly and effectively reduce fluid flow irregularities in multi-pump systems. If one pump is temporarily taken offline—for example, due to a motor failure—our method ensures the stable operation of the remaining pumps,” added A. Muravsky, Associate Professor at the Department of Mining Electromechanics, PNRPU, and Ph.D. in Technical Sciences.

The developed technology allows for continuous regulation and maintenance of low fluid flow irregularities in multi-pump systems used in the oil and gas industry.

Author: A. Shevchenko