Hydraulic Drive for Deep Well Rod Pump - Dubai Sea … · Hydraulic Drive for Deep Well Rod Pump...
Transcript of Hydraulic Drive for Deep Well Rod Pump - Dubai Sea … · Hydraulic Drive for Deep Well Rod Pump...
Hydraulic Drive for Deep Well Rod Pump(HDDWRP) “GEYSER”
DUBAI SEA BREEZE
Production facilities
HDDWRP “GEYSER” design
Major units of a hydraulic drive:
1.Supporting frame
2.Hydraulic cylinder
3.Block-box (shelter)
4.Pumping station
5.Electronic control system
Cable box on standsGravel and foundation
Road slabs
Wellhead equipment
Supporting frame(Ladder is not shown)
Hoses
Shelter
Removable panel
Supporting frames
Frame mounted on wellhead fittings
Dome-shaped frame on 4 legs
and ground plate
Dome-shaped frame with 3 legs
and base shoes
Supporting frame special configurations
Frame for drives with stroke length up to 6 m
Telescopic frame with service deck
Mounting methods
Mounted on reinforced concrete plate
Pile-supported
Block-box
Hydraulic system milestones
Hydraulic drive, 2009Hydraulic drive with adaptive pneumatic-
hydraulic recovery system
Hydraulic drive with electro hydraulic recovery
system
Cluster version
Pumping station
Frame with hydraulic cylinder - 1
Frame with hydraulic cylinder - 2
Application: on clusters with closely located wells
Limitations: distance between station and frame not more than 10 m.
Advantages:Cost reduction, improvement of energy
efficiency
“Light series” hydraulic drives “GEYSER”
“Light series” HDDWRP 60-3,5 (6,0) 80-3,5 (6,0)
Design modular, separate (hydraulic station is located in a separate block)
Counterbalancing Pneumatic or electro hydraulic
Maximum number of double strokes per minute:
at rod stroke up to 4,0 m
at rod stroke up to 6,0 m
up to 7
up to 3,5
up to 6
up to 3
Pumping station
Engine
Power, kW
Voltage, V
asynchronous
37
380
asynchronous
37 (45*)
380
Load on hydraulic cylinder rod, kN (t) 60 (6) 80 (8)
Working fluid – multigrade hydraulic oil AIMOL-M-Hydromax, Esso Unhivis, Shell Tellus
Overall dimensions of a shelter
length, mm
width (as per foundation and roof), mm
height, mm
3000
1900 (2100)
2400
Weight, kg:
Hydraulic station (without working fluid)
Hydraulic station with electronic control system in a shelter
Supporting frame with hydraulic cylinder
1200
2500
1500
1500
2800
1900
Mounting method Supporting frame is mounted on reinforced plates or piles
* Special configuration
“Heavy series” hydraulic drives “GEYSER”
* Special configuration
“heavy series” HDDWRP 120-4 (6,0) 160-4,0 (6,0) 200-6,0
Designmodular, separate (hydraulic station is located in a separate
block)
Counterbalancing pneumatic
Maximum number of double strokes per minute:
at rod stroke up to 4,0 m
at rod stroke up to 6,0 m
up to 7
up to 4,5
up to 5,5
up to 3,5 (7*)
up to 4,5
up to 3 (5,5*)
Pumping station
Engine
Power, kW
Voltage, V
asynchronous
37
380
asynchronous
37 (55*)
380
asynchronous
37 (55*)
380
Load on hydraulic cylinder rod, kN (t) 120 (12) 160 (16) 200 (20)
Working fluid – multigrade hydraulic oil AIMOL-M-Hydromax, Esso Unhivis, Shell Tellus
Overall dimensions of a shelter
length, mm
width (as per foundation and roof), mm
height, mm
3000
1900 (2100)
2400
Weight, kg:
Hydraulic station (without working fluid)
Hydraulic station with electronic control system in a shelter
Supporting frame with hydraulic cylinder
1200
2500
1500
1500
2800
1900
2000
4000
2500
Mounting method Supporting frame is mounted on reinforced plates or piles
Hydraulic drive “GEYSER”mobile version
Kamaz or Ural
Cross-road chassis
Electronic control system box
Operator console
Hydraulic tank
Hydraulic station
Hydraulic power cylinder
Telescopic boom Block
Wellhead equipment
Rope hanger
Technological boxes
Rotating platform
Hydraulic boom lift cylinder
Hydraulic pump connected through PTO
Back jack pads
Front jack pods
Hydraulic drive “GEYSER”container version
Installation requires:- Service crew – 2 workers- Specialized machinery – crane or truck-mounted loader craneInstallation time – approx. 3 hours
Service crew vehicle
HDDWRP “GEYSER”Container version
Truck-mounted loader crane
Hydraulic drive “GEYSER”container version
Pumping station and electronic control system are installed in 20-ft standard container. Supporting frame and hydraulic cylinder are placed inside the same
container in stowed position.
Pumping station
ECS box
Supporting frame
All configurations of HDDWRP “GEYSER” can be
adapted for container version. This modification is intended
for ease of transportation and installation.
Hydraulic cylinder
Hydraulic drive “GEYSER”mobile version
№ Parameter Value
1 Chassis
Triaxial, all-wheel drive,
cross-road Kamaz 43118
or Ural 4320
2 Approximate loaded weight, t 15..18
3Maximum wellhead rod stroke
length, m4
4 Maximum load in hanger center, t
4.1 Modification 1 8
4.2 Modification 2 12
5Number of double strokes per min
(at maximum rod stroke length)
Specified
in Technical Inquiry
(from 4 up to 6)
6Wellhead equipment and wellhead
rod typesAll types
7 Rod rotor installation capability Available
8 Stroke length rangeSteplessly
from 0,2 m up to 4,0 m
9 Hydraulic system volume, l 300
10 Control system Electronic
Functions and options:- Liquid crystal color display (LCD);- Load control and display at up stroke and down stroke;- Dynagraphs automatic reading;- Storage in controller memory of event log and up to 1000 dynagraphs;- Interface MODBUS-TCP, RS-232, RS-485, Ethernet;- Availability of automatic load capacity protection;- Availability of automatic hydraulic system temperature protection;- Real time clock;- Display on LCD of malfunction reasons;- Remote adjustment of stroke length;- Remote adjustment of double strokes number;- Display on LCD of double strokes number;- Automatic event logging;- Electronic control system of boom angle;- Capability of dynagraphs storage on USB-flash card;- Possibility of laptop PC and control system connection by USD + software;- Possibility of tablet PC and control system Bluetooth connection;- Well further equipping with CMD (echo meter + pressure transducer in a line)- Smart system of dynamic pressure level automatic control in annular space;- GSM-Module.
Hydraulic drive “GEYSER”, operating onassociated petroleum gas
Nomenclature:
1. Supporting frame with hydraulic cylinder;
2. Pump station with gas engine and electronic control system
Electronic control system
Cooler
Tank
Hydraulic system
Глушитель
Box
Gas engine with cooler
Pump
Gas preparing
block
Hydraulic drive “GEYSER”, operating onassociated petroleum gas
Standard version:
1 pump station – 1 wellCluster version:
1 pump station –
several wells
Limitation:
distance between
pump station and
wells no more 20 m
Hydraulic drive “GEYSER”, operating onassociated petroleum gas
Technical parameters of hydraulic drive “GEYSER”, operating in associated
petroleum gas in cluster version
№ Parameter Value
1 Number of wells up to 2
2 Load on hydraulic cylinder rod, kN (t) 8
3 Maximum wellhead rod stroke length, m 3,5 ( up to 6,0)
4 Number of double strokes per min (at maximum rod stroke length) 6 (up to 3 for 6,0 м stroke)
5 Gas engine Caterpillar G3304
6 Fuel associated petroleum gas*
7 Maximal brake power, kW 71
8 Type of wellhead fittings and stroke Any
9 Ability applying rod rotor Yes
10 Stroke length rangeSteplessly
from 0,2 m up to 3,5 m (6,0 m)
11 Volume of hydraulic system, l 300
12 Control system Electronic controller
* Parameters of gas preparing block depends on well and needs agreement
Evolution of Hydraulic cylinders
2009Hydraulic cylinder base version
2012Use of removable bush
to replace rod sealing set
2012Launching of hydraulic
cylinders production with rod stroke length up to 6 000 mm
and load on rod up to 20 tf
2013Internal drainage
introduced to hydraulics cylinder design
2012Use of stroke length
analog sensors
Evolution ofElectronic control system
Operation in automatic mode
Dynagraph plotting,telemetry data output,well CDM data transfer
Switch to industrial controllers
Database building for implementing of
“smart drives” operation
Implementing of drives
smart operation modes…
ECS scheme
21
Controller
CMD“GEYSER”
Data exchange module
GSM, УКВ
Radio-Ethernet
Satellite
Optic fiberServer
Well CMD
Base version
Option I: analysis of well data and operation modes automatic selection
Option II: telemetry data storage and
exchange
Data storage
In case of a sufficient data exchange channel capacity
there is a possibility to connect security systems
Communication channels
• USW
• GSM
• Satellite channel
• Optic fiber (routing along power transmission lines)
• PLC – data transfer on high-voltage power transmission lines
• Radio-ethernet with wireless routers
• Radio extenders for data transfer within cluster
• Bluetooth (tablet PC and smartphones for monitoring and managing)
Advantage:
• Any geographical location.
Disadvantages:
• High equipment cost;
• High user maintenance and traffic costs.
Satellite channel
CLUSTER OFFICE
User equipment
Advantages:
• Ease of installation;
• No ground relief limitations.
Disadvantages:
• Limited communication range: up to 10-20 km. without repeaters;
• Low data transfer speed: 10-100 kb/s.
PLC
CLUSTER OFFICE
User equipment
PTL (6-10 kW)
Advantages:• Ease of installation;• High data transfer speed: 1-300 Mb/s;• Communication range: up to 10-30 km.;• Low user equipment cost.Disadvantage:• Line-of-sigh distance required.
Radio-Ethernet
CLUSTER OFFICE
User equipment
2.3 – 2.6 GHz
Smart control system implementation
Single automatic drive
Cluster №923+ telemetry data transfer+ well equipping with CMD+ remote control
Cluster №8+ automatic choice of operation mode in accordance with parameters change+ remote stroke length change
Smart control system implementation
1 stageAutomatic operation mode implementation:
-Hydraulic drive parameters control-Automatic protection system implementation at emergency procedures-Automatic start-up
2 stageTelemetry transfer, well equipping with CMD:
-Dynagraph plotting-Data transfer-Remote monitoring-Remote control, SMS-notification-Well equipping with CMD
3 stageSmart operation mode implementation:-Remote stroke length change-Operation mode selection in accordance with wellhead CMD(echo meter, pressure transducer in a line, AGMU)
4 stageSmart operation mode implementation:
-Dynagraph analysis -Implementation of smart mode on the basis of dynagraphs-Special software “GEYSER-MONITOR” implementation
Wi-Fi
INTERNET
“GEYSER”
“GEYSER”
Beam pumping
unit
Electric
submersible
pump (ESP)
Automated
group measure
unit (AGMU)
Camera
Special software“GEYSER-MONITOR”
CLUSTER OfficeServer
Local users
Communication
channel
RF, PLC etc.
Remote users
System features
• Web – interface;
• Designed for HDDWRP “GEYSER” and
applicable well CMD;
• Self adjustment of user interface in accordance
with configuration of equipment connected;
• System coat is determined by the number of
equipment connected.
Special software“GEYSER-MONITOR”
HDDWRP “GEYSER” evolution
2009 - 2012
HDDWRP “GEYSER” advantages
1. Decrease in capital expenditures on wellhead area engineering
2. Minimization of terms and quantity of special equipment during mounting and commissioning work (less than 3 hours)
3. Increase in time before failures of underground equipment
4. Optimization of HDDWRP operation
5. Energy efficiency
6. Electronic systems of remote monitoring and control
7. Intellectualization of oil extraction process
Deep well rod pump performance optimization
1. Possibility of lifting and lowering
speed independent adjustment
2. Reduction in number of double
strokes and load on sucker-rod string
by increase in rod stroke length
3. Pump flow efficiency Increase
Application on wells with
asphaltic resinous paraffine sediments (ARPS)
Proposed solutions for ARPS problems
Smooth swinging of deep well rod pump by a hydraulic drive
Application of scrapers together with rod
rotor
Wel
lhea
d e
qu
ipm
ent
Energy efficiency increase
Spe
cifi
c e
ne
rgy
con
sum
pti
on
, kW
*h/m
3
RN-Yuganskneftegaz
Comparative analysis of beam pumping unit (BPU) and HDDWRP “GEYSER”
BPU-8
GEYSER80x3.5
Parameter / Model
Working parameters
Liquid
rate,
m3/day
Oil flow rate,
t/day
Daily energy
consumptio
n,
kW*h
Specific
energy
consumption,
kW*h/m3
Specific energy
consumption,
kW*h/t
Stoke
length,
m
Pumping
speed,
double
strokes/min
Load on
rod
(max),
tf
BPU-8 2,02 3,9 3,44 3 2,2 240 80,00 109,0909091
HDDWRP 80-3,5 "GEYSER"
with electric recovery system2,02 3,9 3,44 4 3 117,6 29,40 39,2
Energy efficiency increaseSp
eci
fic
en
erg
y co
nsu
mp
tio
n, k
W*h
/m3
Orenburgneft JSCComparative analysis of electrically driven centrifugal pump (EDCP)
and HDDWRP “GEYSER”well 2209 well 2268
EDCP
GEYSEREDCP
GEYSER
Parameter / ModelLiquid rate,
m3/day
Daily energy consumption,
kW*h
Specific energy
consumption, kW*h/m3
EDCP-44/2000
(well 2009)14 724,8 51,77
HDDWRP 120-4,0 "GEYSER"
(well 2009)12 504 42,00
EDCP-25/1900
(well 2268)12 616,8 51,40
HDDWRP 80-3,5 "GEYSER"
(well 2268)10 432 43,20
HDWRP upgrade
“NPP “PSM-Impex” ltd. upgrades of legacy hydraulic drives “GEYSER” in accordance with configuration data sheet
ECS upgrade including smart operation mode
Hydraulic system upgrade including hydraulic cylinder
HDDWRP “GEYSER” servicing
Principles of service organization:
1. Feedback with the manufacturer
2. Design maintenance during hydraulic drive life cycle
3. Service personnel training
4. Cost minimization on purchase of original spare parts in post-warranty period
5. Maintenance of original spare parts stock in warehouse
Requirements to service companies:
1. Meeting technical maintenance and service regulations in accordance with manufacturer requirements
2. Trained and certified personnel by all types of performed works
3. Availability of specialized tool set and devices (according to the checklist)
4. Required number of working crews presence in service region. Maximum incident response time is 6 hours
5. Existence of specialized machinery hire contracts
6. Organized warehouse of original spare parts for performing service and technical maintenance works
(according to the checklist)
7. Existence of own and leased areas and transport with all required equipment for performing works in
service region
Industrial safety behavior
1. Availability of permit documentation:
- Certificate of adequacy C-RU.AB75.B.00066
- Permit to use № РРС00-23886
2. System shutdown for reasons:
- high load on polished rod
- high pressure
- hydraulics fluid and engine overheating
- voltage variation and electrical imbalance
3. Use of incombustible thermoinsulation materials in a
block-box
4. Availability of automatic fire fighting system
Thank you for attention!
Dubai Sea Breeze (License #525341)Tel: +971 50 6565 243, +971 4 343 0680Dubai, Sheikh Zayed Road, Saeed Tower 2, Office #806P.O.Box 85546
E-mail: [email protected]