Researchers from PNIPU and Novomet-Perm have developed a virtual testing system for oil pumps. This digital platform simulates the performance of both submersible and surface pumps, allowing engineers to predict critical operational issues such as cavitation, abrasive wear, and bearing stress.
The software requires input data including well characteristics, fluid composition, and pump blueprints to generate a 3D model. It provides detailed visual reports on potential wear and structural stress, enabling engineers to optimize designs and operating modes before physical manufacturing.
Validation tests confirmed that the system achieves high accuracy, with a relative error margin of 3–4% compared to physical testing. This allows companies to move approximately 90% of testing procedures into a digital environment, reducing the need for expensive physical prototypes.
The transition to virtual testing replaces 10–15 cycles of physical trials, each lasting about two weeks and consuming significant energy. The implementation is expected to save tens of millions of rubles by minimizing the destruction of metal prototypes and lowering production costs.