Lex – Solution for SRP power saving up to 35% in complicated wells operation

Solution for SRP power saving up to 35% in complicated wells operation

The sucker rod pump with the asynchronous motor and V-belt transmission is still the standard lift method at most wells worldwide. However, the low efficiency of the asynchronous motor and power loss that accompanies torque transmission in the V-belt system result in high overall power consumption. Our optimized power-saving solution, which replaces the asynchronous motor with the SynchroGear™ permanent magnet motor (PMM) technology, allows to cut down energy costs by more than 1/3.

Solution for SRP power saving up to 35% in complicated wells operation

About 75% of artificial lifters worldwide use the sucker rod pump with the V-belt transmission and Asynchronous Motor. This system is simple and easy to service, yet it is low inefficient, quite unreliable in design, and has limited controllability.

In the sucker rod pump, the rods connected to the horsehead, which moves up and down through the crank-and-rod system being induced by the gearbox torque, drive the submersible cavity pump. In its turn, the asynchronous motor drives the gearbox via the V-belt gear, and that is precisely where the maximum power loss occurs. The torque transmission from the asynchronous motor to the gearbox shaft comes with excess demand energy and a mutual risk of failure because of the impossibility of promptly responding to emergent complications.

Since the creation and introduction of the sucker rod pump, no fundamental improvements have been made last 70 years. 

We have reconsidered the torque gear transmission and sucker rod pump operation to create an innovatively new solution, the SynchroGearTM technology with its highly efficient PMM and a smart control station instead of the asynchronous motor with V-belt gear.

The PMM saves power by reducing the electric and magnetic losses to gain overall efficiency.

We mount the stator on the gearbox body and put the rotor on its intake shaft so the motor directly transmits the torque to the gearbox. This solution allows eliminating the low-efficiency V-belt gear with an asynchronous motor.

The control station reacts to any change of current capacity during motor operation and adapts the pumping rate and lag to the existing conditions of the well. In case of emergency, it can completely shut down the pump automatically under a preset program.

The SynchroGearTM technology implementation leads to the power saving up to 35%, evens out the submersible plunger pump operation, and decreases downtime due to V-belt drive.

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Drive for Sucker Rod Pumps (SynchroGear™)

Drive for Sucker Rod Pumps (SynchroGear™)

SynchroGear™ technology is a drive for sucker rod pumps with up to 98% efficiency. The system integrates power-efficient Universal Permanent Magnet (PM) Motor and smart Variable Speed Drive. Сonventional V-Belt Transmission is not applicable.

Universal Permanent Magnet Motors

Universal Permanent Magnet Motors

We develop and continually improve Lex Universal Permanent Magnet Motor (Universal PMM) technology, an alternative way to provide rotational energy for electrical submersible, screw or sucker rod pumps. Lex features a product range of Lex UPMM from 85 to 12,000 rpm operating speeds, high efficiency up to 95%, operational flexibility, lower motor heating rise, stable operation at any frequencies, and high-temperature environments up to 392 °F (200 °C).