Purpose:

To measure the percentage of regenerative power put back onto the grid when using the LUFKIN REGEN™ on a rod pumping system.

Testing:

Dranetz power meter installed at site to measure and record the total power used and the total regenerative power.

Results

REGEN™ drive regenerates 11.9% of total power used to the power grid versus wasting as heat through dynamic braking resistors.
Summary
Average Strokes per minute
(SPM)
Torque imbalance Up/Down Stroke Consumed energy
(kWh)
Re-Generated energy
(kWh)
Re-Generated energy
%
5.67 balanced 1978.8 236.1 11.9%
Insights
Annualized Consumption
(kWh)
Annualized Re-Generated energy
(kWh)
456,000¹ 58,8002

Test Details

Evaluation Timeline

Sept. 2022

Pumping Unit

LUFKIN 2560-500-320 Stroke Length 320 in

Runtime

Pumping units runs 100% during evaluation period

Input Power

460 VAC Wye

REGEN™ Drive

150 hp, 180 amp output

Motor Data

150 HP NEMA D

Motor Torque Monitoring

Indication of the electrical balance on the pumping unit. Motor Torque plot shows balanced pumping unit during test period indicating that regenerative energy was not due to improperly balanced unit.

LUFKIN Well Manager™ 2.0 REGEN™ Variable Speed Drive

Conserving Energy – Improving your ESG impact

The Power of Conserving Energy. Improving Technology

REGEN’s advanced engineering combines proven LUFKIN Well Manager™ (LWM) 2.0 technology for well diagnostics Variable Speed Drive (VSD) capabilities for pump speed regulation, and Active Front End (AFE) technology to regenerate clean power when overhauling loads occur. The REGEN™ control system eliminates dynamic braking systems by returning usable energy back to the grid. REGEN™ is exceptionally efficient when multiple loads connect to a single power meter.

The Responsible Choice

REGEN is the right choice when the local power grid requires clean power (IEEE-519 compliant), braking resistors are troublesome and you want to reduce your carbon footprint.

 

1 Annualized daily total input power usage (kWh) = 1250kWh * 365

2 Annualized regenerated Energy (kWh) = 456,000 kWh * 11.9%

3 Natural Gas fueled power plants: 58800 kWh * 0.915 lbs CO₂ per kWh = 53,508lbs = 26.8 tons

4 Coal fueled power plants: 58800 kWh * 2.235 lbs CO₂ per kWh = 131,124 lbs = 65.6 tons

5 EIA (9/24/2022): https://www.eia.gov/tools/faqs/faq.php?id=74&t=11#:~: text=In%202020%2C%20total%20U.S. %20electricity,CO2%20emissions%20per%20kW

6,7,8,9 State Electricity Cost (9/24/2022): https://www.eia.gov/electricity/state/
The potential electrical energy saving cost per well per year does not consider energy credits.