· Hydraulic brake PCP solution

1.Research and development background
In order to overcome the drive equipment belt drive slip，safety hazard of mechanical ratchet brake，direct drive PCP of motor has the safety hidden danger of rod reversal ，a new type of PCP ground drive device, hydraulic brake PCP, was developed.

2. Hydraulic brake PCP
2.1 Design concept ：The high efficiency plane drive reducer uses the lever principle to realize the torque amplification.
2.2 Operating principle ：The motor is used to drive the plane reducer directly to drive the rod rotation.


ⅰ.The hydraulic braking technology is combined with the working principle of automobile ABS, which USES 20MPa hydraulic pump and special distribution valve to control hydraulic calipers, so as to achieve the goal of releasing the elastic torque of the driving rod slowly and regularly.
ⅱ.The reverse torque can be reset to zero and the safety hidden danger is eliminated.
ⅲ.The distributing valve realizes the intermittent control of torque release by adjusting the spring adjusting device .
ⅳ.The hydraulic drive mechanism is set in the gear box, which is soaked in the engine oil, so as to ensure the lubrication of the bearing, achieve the purpose of reliable power transmission and safe braking.
2.3 Product features
2.3.1 Efficient planar transmission reducer of reduction ratio is greater than 15, matching motor is small, high output torque, stable performance, wide range of speed ratio, wide applicable scope, can adapt to the needs of different PCP performance.

2.3.2 Planar circular arc gear relative to the bevel gears of simple structure, low cost, wide range of speed ratio, wide applicable scope, speed reducer based on lever principle of work, its essence for input torque amplifier. The maximum output speed can reach 300 RPM.

2.3.3 The motor is connected directly, the belt is cancelled, the safety hidden danger is eliminated.

2.3.4 The protection measures of mechanical seal under high pressure are increased. This technology eliminates the hidden danger of the liquid being produced into the gear box, and makes the mechanical seal in use have the function of self-repairing, so as to extend the service life of the mechanical seal.


3.Comparison of equipment performance parameters
3.1 Transformer capacity：
When the speed is 100r/min and the output torque reaches 382N. M, the matching motor power of the two driving devices is shown in the figure. Similarly, the matching capacity of the transformer is different.

3.2 Dc motor is used in direct drive device
When the speed is 100r/min and the output torque reaches 900n.m, the matching motor power of the two driving devices is shown in the figure. It can be seen that the matching power of dc drive device is small when using dc motor.

3.3 Operating torque of the actuator
When the speed is 100r/min and the output torque reaches 573 and 859.5N.m respectively, the matching motor power of the two driving devices is shown in the figure. This comparison is based on the working torque of the drive device. 







4.Examples of application
4.1 In December, 2014, 21 - oblique 504 Wells, to field test of hydraulic brake PCP driven equipment, running two years later, in September 2016 and choice and west inclined 21-504 similar conditions of south 1-20 - inclined P044, high 154-44, north 1 - butyl 25 - E46 three pumping Wells, and west 21-504 energy saving effect test, test results are as follows:

Conclusion: the average daily power saving per well is 130.1 KWH. The active power saving rate was 40.7%. The consumption of liquid energy decreased by 1.468 KWH.
4.2 In September 2016, 100 PCP wells and 100 pumping Wells with similar working conditions were selected for the comparison test of energy consumption (this data is from DAQING oil production plant database).

Conclusion:
ⅰ.Compared with the same type of pumping unit, the active power saving rate of the second generation PCP is 36.81. The active power saving rate of hydraulic brake PCP is 40.7.
ⅱ.Compared with similar pumping units, the second generation PCP drive equipment has an average daily power saving of 99.12 KWH; The average daily energy saving of oil and gas production equipment of hydraulic brake PCP is 130.1 KWH.

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