Control station WellSim

The WellSim control station is designed for oil production automation and integrates a complete set of modules for control and protection of sucker rod pump systems, including both power and control sections.

At the heart of the system is the WellSim Rod Pump Controller, which continuously analyzes data from connected sensors and equipment. Using advanced mathematical modeling of the well, the controller:

• Generates surface and downhole dynagraph cards
• Calculates key operating parameters of the well and pumping equipment
• Determines optimal pump operation strategies in real time

These intelligent algorithms help operators:

• Increase oil production by 2–4%
• Reduce energy consumption by up to 67% (depending on well conditions)
• Extend equipment lifetime and reduce failure frequency

The WellSim Control Station combines advanced pump control with a robust electrical protection system for the pumping unit. Key protection features include:

• Motor protection based on allowable voltage limits
• Phase sequence and phase symmetry monitoring
• Phase imbalance protection
• Short-circuit protection
• Emergency shutdown in case of faults
• Automatic and manual control modes
• Energy consumption monitoring and data storage
• Detection of leakage currents and insulation damage

Configurations equipped with a Variable Frequency Drive (VFD) provide the most advanced level of rod pump control. The VFD enables the controller to dynamically regulate motor speed, delivering several key operational advantages:

• Soft motor start (especially important at low temperatures)
• Dynamic speed adjustment depending on load conditions
• Slowing down at peak loads and accelerating during low-load periods
• Maintaining optimal pump fillage through motor speed control
• Speed variation during a pumping cycle to optimize plunger movement
• Stable low-speed operation to improve efficiency of depleted wells

WellSim Control Stations can be supplied in various cabinet designs, including vandal-resistant enclosures, modular cabinets, monoblock designs Systems can also be equipped with ergonomic and operational options such as:

• Internal cabinet lighting
• Customizable manual control panels
• Analog instruments (ammeters, voltmeters)
• Energy meters and other auxiliary equipment

These flexible configurations allow the system to be adapted for different field environments, operational requirements, and customer preferences.