Oil & Gas Well Pad Modernization Produces Significant Energy Savings with Regenerative Drives

Legacy Technology Unable to Support Future Growth 

DSI, an electrical-integration firm and system integrator in the Rockwell Automation PartnerNetwork™, identified a critical issue for one of their customers. A well-known global energy company faced the challenge of aging infrastructure that was creating inefficiencies that then led to financial drains. On top of that, the company was thinking about ways to reduce their carbon footprint in support of their ESG commitment. The local utility was also struggling to bring more capacity online, underscoring the company’s need to reduce energy consumption.

The company saw an opportunity to modernize their technology on the well pad to improve operational efficiency and sustainability. They wanted a solution that would reduce energy waste, lower operating costs, and improve long-term reliability across its field sites.

Specifically, many of the company’s motor control assets, particularly the PowerFlex® 700 variable frequency drives (VFDs) used in pump rod applications, had been in operation for over a decade. These older drives relied on dynamic braking resistors (DBRs), which released excess energy by dissipating it as heat. Newer drive technology offered an opportunity to rethink the design and reduce energy loss.

The company turned to a partner for help. DSI had the expertise and strong relationship with Rockwell Automation to achieve the outcomes that would support the company in maintaining their status as a leader in the energy sector for years to come.

Implementing and Scaling Regeneration Drives

DSI worked closely with Rockwell Automation to explore a new solution. After evaluating different technologies, DSI recommended the PowerFlex® 755TR drive, known for its energy regeneration capabilities. Unlike the older system, this drive recycled excess energy back into the system rather than wasting it through DBRs. DSI President Casey Johnston says, “We didn’t want to look elsewhere because nobody else had this regen drive fully developed. Rockwell Automation leads the game right now in this active front-end regen drive, so it was an easy pick for us.”

The implementation began with a pilot project at three wells in the company’s North Dakota location. Rockwell Automation field engineers and DSI worked together to install and optimize the system. For about a year, the team monitored key performance data, such as power consumption, energy regeneration levels, and efficiency gains. This rigorous testing phase allowed them to fine-tune parameters and optimize performance before launching a broader deployment. 

Beyond energy efficiency, the new solution also introduced an unexpected benefit. Now, carbon credits could be captured due to reduced energy waste, further aligning with the company’s sustainability objectives and supporting future growth. 

The company also benefitted from the PowerFlex 755TR drive’s ability to tune out mechanical resonances of the pump automatically with adaptive control.  Plus, better speed and torque accuracy improved reporting on well performance.