TorqDriveTM - Newest Advantage product tops the industry
Advantage’s revolutionary new TorqDriveTM 450/1000 PC pump top drive motor virtually eliminates all the inconveniences and problems associated with conventional PC pump top drive arrangements. The industry’s first variable-speed permanent magnet motor designed for PC pump top drives, it does away with hydraulic pumps, hydraulic motors, gearboxes and belt drives. And importantly, there’s no need for a hydraulic or mechanical brake to counteract backspin in case the well trips.
The TorqDriveTM 450/1000 PC pump top drive weighs only 733 kg. This is lighter than a similarly powered conventional PC pump top drive which includes the weight of the sheaves, gearbox, frame and electric motor. Further, the TorqDriveTM design is concentric with the rod string so you do not have the overhung weight and moment caused by a side mounted motor as is the case with conventional PC pump top drives.
Power needs are three-phase 460 VAC and 100 amperes. With a nearly flat 1,000 ft-lbs continuous and 1,400 ft-lbs breakaway torque curve at speeds ranging from 30 to 450 rpm, the speed is infinitely variable from the drive control cabinet. At start up, there’s no need for the huge inrush of current to start the motor as is the case for a typical induction motor. It draws power as it needs it; so the power requirement comes up gradually instead of peaking at the front end and coming back down.
The TorqDrive TM 450/1000 excels in efficiency. Because it does away with drive belts and gears, efficiency at the polish rod is 97.4% at 1,000 ft-lbs torque at 430 rpm; compared with from 50 to 70% for conventional PC pump top drive systems.
The braking system is revolutionary for PC pump top drives. The TorqDriveTM employs a failsafe regenerative braking system that meets regulatory requirements and eliminates the need for mechanical add-ons. The braking system engages automatically whenever the power is lost, dissipating the stored energy in the fluid column in load bank resistors. If for any reason that system should fail, the electric motor itself is designed to backspin safely at over ten times its rated speed. Maintenance requirements are minimal. Semiannual cleaning of the air filters in the drive cabinet and replacement of the oil in the thrust bearing housing once every 3 years are the only scheduled maintenance requirements. The upper bearing is sealed requiring no maintenance and the thrust bearing housing is filled with biodegradable synthetic oil (Panolin Synthetic VG22).
A further advantage is the electric motor’s very low noise level compared with conventional systems. At 10 metres the noise level is just 60 decibels—quieter than a normal conversation. This compares with around 72 db at the same distance with other systems. Low noise levels are becoming an increasingly important consideration especially where wells are close to residential areas. The TorqDriveTM 450/1000 can be controlled remotely. For remote controlling and monitoring, it is fully SCADA configurable.
Preliminary installation test results have shown a reduction in power consumption of 7.4 kW – 32.6 kW down to 25.2 kW, when a conventional PC pump top drive was replaced with a TorqDriveTM. This translates into an energy cost savings of $6,500 per year @ $0.10/kW-hr. And its carbon footprint is good to the environment: based on the calculator at www.carbonify.com, this equates to a reduction in greenhouse gas emissions of approximately 50 tons per year.
First in their class for Electric Motors, PC Pumps and Top Drive Motors
