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: dubaiseabreeze@gmail.comwww.dubaiseabreeze.com