抽油机变频节能及测控技术研发
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摘要
游梁式抽油机是目前油田使用最为广泛的采油设备,但实际应用中,存在着“大马拉小车”、能耗高、效率低等缺点,此外,抽油机电机还存在不同程度的“倒发电”现象,进一步降低了整机效率。根据各油井汲油需要,系统需采用变速箱调速,此调速方法灵活性差,在一定程度上降低了抽油机的泵效。鉴于此,本课题研发了一套抽油机专用变频节能装置,旨在节能增效。
该装置采用交-直-交变频主电路,整流部分采用二极管不可控整流,逆变单元使用IGBT或功率集成模块IPM。整套装置通过独特设计的继电接触控制线路,可实现变频/工频运行的自动切换。控制系统以dsPIC30F4011型DSC(Digital Signal Controller)作为控制核心,采用SPWM控制技术实现电机的变频调速,其构成主要包括:DSC控制单元、基于STC单片机控制的键盘显示单元、检测与保护单元、功率模块驱动单元、和开关电源等。系统设计中,DSC和STC单片机各司其能,通过串行通讯协调工作,整个系统能够实现电机变频软启停,根据负载率的不同可进行自动节能控制调整,根据汲油速度需要,可方便实现变频调速,同时还可实现上下冲程的变频运行。
针对电机“倒发电”引起的直流侧电压抬升问题,系统设有专门的耗能处理电路,同时控制系统还配置有直流侧电压监测和电机侧稳压控制环节。大量的实验调试结果表明,整套装置功能完善,运行安全可靠,节能效果明显。
At present, beam pumping unit is the most widely used oil field equipment. In practical application, there are many problems, For example,“big horse hauling small cart”, high energy-consuming, low efficiency. Besides that, the motor of pumping unit has different levels of regenerating electricity, which further reduces the efficiency of machine. According to the needs of draining oil, the system requires transmission to adjust speed, which has poor flexibility and to some extent reduces the pump efficiency in some pumping unit. In view of this, the paper researches and develops a kind of frequency conversion control system for beam pumping unit in order to save energy and improve efficiency.
The system uses AC-DC-AC frequency conversion main circuit with uncontrollable rectifier diode and inverter unit based on IGBT or power integrated modules IPM. The system can realize the automatic switching between frequency and frequency conversion through a complete control circuit of relay contacts which is specially designed. The control system based on dsPIC30F4011 digital signal controller adopts SPWM control technology to achieve motor VVVF. The control system mainly includes DSC control unit, keyboard and display unit which is controlled by STC MCU, detection and protection unit, power module-driving unit, switching power supply and so on. In system’s design, DSC and STC microcontroller perform their own function separately and coordinate each other through serial communication. The whole system can achieve soft start and stop of variable frequency. According to the differences of load, it can automatically adjust the control to save energy. According to the needs of draining oil, not only can the system change operating frequency at any time but also achieve different frequency operation between up and down stroke.
For the uplift of DC side voltage resulted from regenerating electricity, the equipment has special energy-consuming circuit, while the control system is equipped with the monitor of DC side voltage and the regulator control of motor side. Experiments show that the whole equipment has perfect function, safe and reliable operation, and obvious energy-saving effect.
该装置采用交-直-交变频主电路,整流部分采用二极管不可控整流,逆变单元使用IGBT或功率集成模块IPM。整套装置通过独特设计的继电接触控制线路,可实现变频/工频运行的自动切换。控制系统以dsPIC30F4011型DSC(Digital Signal Controller)作为控制核心,采用SPWM控制技术实现电机的变频调速,其构成主要包括:DSC控制单元、基于STC单片机控制的键盘显示单元、检测与保护单元、功率模块驱动单元、和开关电源等。系统设计中,DSC和STC单片机各司其能,通过串行通讯协调工作,整个系统能够实现电机变频软启停,根据负载率的不同可进行自动节能控制调整,根据汲油速度需要,可方便实现变频调速,同时还可实现上下冲程的变频运行。
针对电机“倒发电”引起的直流侧电压抬升问题,系统设有专门的耗能处理电路,同时控制系统还配置有直流侧电压监测和电机侧稳压控制环节。大量的实验调试结果表明,整套装置功能完善,运行安全可靠,节能效果明显。
At present, beam pumping unit is the most widely used oil field equipment. In practical application, there are many problems, For example,“big horse hauling small cart”, high energy-consuming, low efficiency. Besides that, the motor of pumping unit has different levels of regenerating electricity, which further reduces the efficiency of machine. According to the needs of draining oil, the system requires transmission to adjust speed, which has poor flexibility and to some extent reduces the pump efficiency in some pumping unit. In view of this, the paper researches and develops a kind of frequency conversion control system for beam pumping unit in order to save energy and improve efficiency.
The system uses AC-DC-AC frequency conversion main circuit with uncontrollable rectifier diode and inverter unit based on IGBT or power integrated modules IPM. The system can realize the automatic switching between frequency and frequency conversion through a complete control circuit of relay contacts which is specially designed. The control system based on dsPIC30F4011 digital signal controller adopts SPWM control technology to achieve motor VVVF. The control system mainly includes DSC control unit, keyboard and display unit which is controlled by STC MCU, detection and protection unit, power module-driving unit, switching power supply and so on. In system’s design, DSC and STC microcontroller perform their own function separately and coordinate each other through serial communication. The whole system can achieve soft start and stop of variable frequency. According to the differences of load, it can automatically adjust the control to save energy. According to the needs of draining oil, not only can the system change operating frequency at any time but also achieve different frequency operation between up and down stroke.
For the uplift of DC side voltage resulted from regenerating electricity, the equipment has special energy-consuming circuit, while the control system is equipped with the monitor of DC side voltage and the regulator control of motor side. Experiments show that the whole equipment has perfect function, safe and reliable operation, and obvious energy-saving effect.
引文
[1]张学鲁,季祥云,罗仁全.游梁式抽油机技术与应用.北京:石油工业出版社,2001
[2]陈宪侃,叶利平,谷玉洪.抽油机采油技术.北京:石油工业出版社,2004
[3]武卫丽,焦培林.抽油机节能技术研究综述.重庆科技学院学报(自然科学版),2009,11(4):111-113
[4]白连平,马文忠.关于游梁抽油机用电动机节能的讨论[J].石油机械,1999,27(3):41-44
[5]高月民,尹传庆.抽油机的调速节能控制理论探讨与实践.电气应用,2009,28(8):50-54
[6] Rusong Wu,ShashiB.Dewan,Gordon R.Slemon.Analysis of an AC–to-DC Voltage Source Converter Using PWM with Phase and Amplitude Control.IEEE Trans.on Industry Applications,1991,27(2):355-364
[7]曲刚,孙永兴.抽油机智能化变频控制系统的应用.陕西师范大学学报(自然科学版),2005,33(专辑):231-233
[8]李华德.交流调速控制系统.北京:电子工业出版社,2003
[9]陈伯时,陈敏逊.交流调速系统.北京:机械工业出版社,1998
[10]蔡士齐.感应电动机传动和变频器应用技术.北京:机械工业出版社,2008
[11]石新春,杨京燕,王毅.电力电子技术.北京:中国电力出版社,2006
[12]张润和.电力电子技术及应用.北京:北京大学出版社,2008
[13]张加胜,张磊.电力电子技术.东营:石油大学出版社,2004
[14]王兆安,黄俊.电力电子技术.北京:机械工业出版社,2000
[15]孙涵芳. Intel 16位单片机.北京:北京航空航天大学出版社,1999
[16]刘和平. TMS320LF240x DSP结构、原理及应用.北京:北京航空航天大学出版社,2002
[17]何礼高. dsPIC30F电机与电源系列数字信号控制器原理与应用.北京:北京航空航天大学出版社,2007
[18]刘和平. dsPIC通用数字信号控制器原理及应用—基于dsPIC30F系列.北京:北京航空航天大学出版社,2007
[19] Microchip Technology Inc. dsPIC30F Enhanced Flash 16-bit Digital Signal ControllersMotor Control and Power Conversion Family. Microchip Technology Inc. DS70082D-, 2003.
[20] Microchip Technology Inc. dsPIC30F4011/4012 Enhanced Flash 16-bit Digital Signal Controller. Microchip Technology Inc. DS70135B-, 2004.
[21]宏晶科技. STC12C5410系列1T 8051单片机中文指南.
[22] Robert W.Erickson,Dragan Maksimovic. Fundamentals of Power Electronics (Second Edition). Springer, 2004
[23]刘胜利.现代高频开关电源实用技术.北京:电子工业出版社,2001
[24]杨小晨,王欣.高精度线性光耦HCNR200/201及其应用.仪器仪表用户,2003(10):41-42
[25]谭颖琦,范大鹏,陶溢.基于线性光耦HCNR200的DSP采集电路设计与实现.电测与仪表,总第43卷486期,2006年第6期:46-48
[26]张宝生,王念春.基于高线性模拟光耦器件HCNR200的模拟量隔离板.仪表技术,2005(5):59-60
[27]董传岱,于云华.数字电子技术.东营:石油大学出版社,2001
[28]刘润华,刘立山.模拟电子技术.东营:石油大学出版社,2001
[29]赵来军,刘刚.智能化抽油系统.西安石油学院学报(自然科学版),2001年第16卷第1期:50-54
[30] Dunham C L. Supervisory Control of Beam Pumping Wells [J]. SPE 16216
[31] Dunham C L, Andersan S R. The generalized Computer-Assisted system: A Comprehensive computer system for day-to-day oilfield operation [J]. SPE 20366
[32]徐甫荣.变频器在抽油机上应用的若干问题探讨[J].电气传动自动化,2004,26(2):4-8
[33]郑一力,殷晔,冯海峰. Protel 99SE电路设计与制版入门与提高.北京:人民邮电出版社,2008
[34]徐煜明,韩雁.单片机原理及接口技术.北京:电子工业出版社,2005
[35]李朝青.单片机原理及串行外设接口技术.北京:北京航空航天大学出版社,2008
[36]徐新民.单片机原理与应用.杭州:浙江大学出版社,2006
[37]高拓微电子技术有限公司. ICD2系列说明书.
[38] Microchip Technology Inc. dsPIC30F Family Reference Manual. MicrochipTechnology Inc. DS70046B,○C 2003.
[39] Microchip Technology Inc. dsPIC30F Family Reference Manual. Microchip Technology Inc. DS70046C_CN,○C 2005.
[40] Microchip Technology Inc. dsPIC30F Programmer’s Reference Manual. Microchip Technology Inc. DS70030E-, 2003.
[41] Steve Bowling. An Introduction to AC Induction Motor Control Using the dsPIC30F MCU. Microchip Technology Inc. DS00984A-, 2005.
[42] Hrushikesh (Rishi) Vasuki. In-Circuit Debugging Interface Options with dsPIC DSC. Microchip Technology Inc. DS93003A-, 2005.
[43] Microchip Technology Inc. MPLAB○R ASM30, MPLAB○R LINK30 AND UTILITIES USER’S GUIDE. Microchip Technology Inc. DS51317D-, 2004.
[44]贾庆忠,刘永善. dsPIC30F数字信号控制器高速串口设计.微计算机信息(测控自动化),2007,23(6-1):24-26
[45]丁宝东.基于DSP的游梁式抽油机变频控制系统研究.[硕士学位论文].东营:中国石油大学(华东),2007
[46]林瑞光.电机与拖动基础.杭州:浙江大学出版社,2002
[2]陈宪侃,叶利平,谷玉洪.抽油机采油技术.北京:石油工业出版社,2004
[3]武卫丽,焦培林.抽油机节能技术研究综述.重庆科技学院学报(自然科学版),2009,11(4):111-113
[4]白连平,马文忠.关于游梁抽油机用电动机节能的讨论[J].石油机械,1999,27(3):41-44
[5]高月民,尹传庆.抽油机的调速节能控制理论探讨与实践.电气应用,2009,28(8):50-54
[6] Rusong Wu,ShashiB.Dewan,Gordon R.Slemon.Analysis of an AC–to-DC Voltage Source Converter Using PWM with Phase and Amplitude Control.IEEE Trans.on Industry Applications,1991,27(2):355-364
[7]曲刚,孙永兴.抽油机智能化变频控制系统的应用.陕西师范大学学报(自然科学版),2005,33(专辑):231-233
[8]李华德.交流调速控制系统.北京:电子工业出版社,2003
[9]陈伯时,陈敏逊.交流调速系统.北京:机械工业出版社,1998
[10]蔡士齐.感应电动机传动和变频器应用技术.北京:机械工业出版社,2008
[11]石新春,杨京燕,王毅.电力电子技术.北京:中国电力出版社,2006
[12]张润和.电力电子技术及应用.北京:北京大学出版社,2008
[13]张加胜,张磊.电力电子技术.东营:石油大学出版社,2004
[14]王兆安,黄俊.电力电子技术.北京:机械工业出版社,2000
[15]孙涵芳. Intel 16位单片机.北京:北京航空航天大学出版社,1999
[16]刘和平. TMS320LF240x DSP结构、原理及应用.北京:北京航空航天大学出版社,2002
[17]何礼高. dsPIC30F电机与电源系列数字信号控制器原理与应用.北京:北京航空航天大学出版社,2007
[18]刘和平. dsPIC通用数字信号控制器原理及应用—基于dsPIC30F系列.北京:北京航空航天大学出版社,2007
[19] Microchip Technology Inc. dsPIC30F Enhanced Flash 16-bit Digital Signal ControllersMotor Control and Power Conversion Family. Microchip Technology Inc. DS70082D-, 2003.
[20] Microchip Technology Inc. dsPIC30F4011/4012 Enhanced Flash 16-bit Digital Signal Controller. Microchip Technology Inc. DS70135B-, 2004.
[21]宏晶科技. STC12C5410系列1T 8051单片机中文指南.
[22] Robert W.Erickson,Dragan Maksimovic. Fundamentals of Power Electronics (Second Edition). Springer, 2004
[23]刘胜利.现代高频开关电源实用技术.北京:电子工业出版社,2001
[24]杨小晨,王欣.高精度线性光耦HCNR200/201及其应用.仪器仪表用户,2003(10):41-42
[25]谭颖琦,范大鹏,陶溢.基于线性光耦HCNR200的DSP采集电路设计与实现.电测与仪表,总第43卷486期,2006年第6期:46-48
[26]张宝生,王念春.基于高线性模拟光耦器件HCNR200的模拟量隔离板.仪表技术,2005(5):59-60
[27]董传岱,于云华.数字电子技术.东营:石油大学出版社,2001
[28]刘润华,刘立山.模拟电子技术.东营:石油大学出版社,2001
[29]赵来军,刘刚.智能化抽油系统.西安石油学院学报(自然科学版),2001年第16卷第1期:50-54
[30] Dunham C L. Supervisory Control of Beam Pumping Wells [J]. SPE 16216
[31] Dunham C L, Andersan S R. The generalized Computer-Assisted system: A Comprehensive computer system for day-to-day oilfield operation [J]. SPE 20366
[32]徐甫荣.变频器在抽油机上应用的若干问题探讨[J].电气传动自动化,2004,26(2):4-8
[33]郑一力,殷晔,冯海峰. Protel 99SE电路设计与制版入门与提高.北京:人民邮电出版社,2008
[34]徐煜明,韩雁.单片机原理及接口技术.北京:电子工业出版社,2005
[35]李朝青.单片机原理及串行外设接口技术.北京:北京航空航天大学出版社,2008
[36]徐新民.单片机原理与应用.杭州:浙江大学出版社,2006
[37]高拓微电子技术有限公司. ICD2系列说明书.
[38] Microchip Technology Inc. dsPIC30F Family Reference Manual. MicrochipTechnology Inc. DS70046B,○C 2003.
[39] Microchip Technology Inc. dsPIC30F Family Reference Manual. Microchip Technology Inc. DS70046C_CN,○C 2005.
[40] Microchip Technology Inc. dsPIC30F Programmer’s Reference Manual. Microchip Technology Inc. DS70030E-, 2003.
[41] Steve Bowling. An Introduction to AC Induction Motor Control Using the dsPIC30F MCU. Microchip Technology Inc. DS00984A-, 2005.
[42] Hrushikesh (Rishi) Vasuki. In-Circuit Debugging Interface Options with dsPIC DSC. Microchip Technology Inc. DS93003A-, 2005.
[43] Microchip Technology Inc. MPLAB○R ASM30, MPLAB○R LINK30 AND UTILITIES USER’S GUIDE. Microchip Technology Inc. DS51317D-, 2004.
[44]贾庆忠,刘永善. dsPIC30F数字信号控制器高速串口设计.微计算机信息(测控自动化),2007,23(6-1):24-26
[45]丁宝东.基于DSP的游梁式抽油机变频控制系统研究.[硕士学位论文].东营:中国石油大学(华东),2007
[46]林瑞光.电机与拖动基础.杭州:浙江大学出版社,2002