Wood Group ESP, Inc.Wood Group ESP, Inc.Surface Pumping Surface Pumping

SystemsSystemsNeil FerrierNeil Ferrier

Manager, Surface Pumping SystemsManager, Surface Pumping Systems

John HedgesJohn HedgesCanadian Regional Sales & Service ManagerCanadian Regional Sales & Service Manager

Jim Bedford – Waterflood Jim Bedford – Waterflood Authorized Distributor Authorized Distributor Alberta/SaskatchewanAlberta/Saskatchewan

Surface Pumping Systems (SPS)

Agenda

• Wood Group ESP – heritage & core business

• Surface Pumping System history• Alternative technology – context • Performance envelope• Applications• SPS design features• Sample installations

Wood Group is a leading international energy services company employing more than 13,000 people, and operating from bases in over 34 countries.

We provide knowledge and know-how services to add value to the oil and gas, and power industries.

Heritage

Heritage

Includes: Mustang EngineeringAlliance EngineeringJP KennyWG Production Services

WGESP HeritageInternational Locations

South America

Middle East

North America

U.K.

Saudi ArabiaOmanUAE

Kuwait

Central America

VenezuelaEcuador

ColombiaArgentina

Brazil

Guatemala

CanadaU.S.A.

Europe

Russia

MoscowKogalym

Africa

Germany

NigeriaEgypt

Algeria

Pacific Rim

SingaporeIndonesiaVietnam

Far EastIndia

JapanChina

Intake

Seal

Tubing

CheckValve

DrainValve

CasingPum p

M otor

Splice

Power Cable

W ELL HEA D

JUNCTIO NBO X

M O TO RC ON TR OLLER

TR ANSFO RM ERS

ESP Components

• Pump• Intake• Seal Section• Motor• Cable• Motor Controller• Transformers• Accessories

Typical ESP onshore

Surface Pumping Systems (SPS)

• First SPS installation 1989• Customer driven product development• Originally installations were Upstream

Oilfield applications, produced water injection. (disposal, waterflood, etc)

• Separate SPS group established 2001 to expand core business and diversify installation base to downstream & outside of Oilfield.

SPS History

• Centrifugal - Axially Split-Case

• Centrifugal - Ultra high speed

• Centrifugal - Canned Vertical Turbine

• PD positive displacementPlunger Pumps Triplex / Quintiplex

Alternative Technology Alternative Technology Summary Summary

Centrifugal – Axially Split Case Pump

Alternative technology - summary

Centrifugal – Axially Split Case Pump• Limitations

Lead-times typically 6 to 12 months Initial cost Custom engineered for a specific duty point Two high price Mechanical seals required, and

these can operate above suction pressure High degree of expertise required for

maintenance

Alternative technology - summary

Centrifugal – Ultra High Speed Pump

Alternative technology - summary

Centrifugal – Ultra High Speed Pump

• Limitations Initial cost High noise level Can be maintenance intensive & Expensive

Parts High degree of expertise required for

maintenance Custom engineered for a specific duty point

Alternative technology - summary

Centrifugal – Canned Vertical Turbine

Alternative technology - summary

Centrifugal – Canned Vertical Turbine• Limitations

Complex foundation work required Mechanical seal operates at discharge psi Motor bearings must handle pump thrust Initial cost Engineered for a specific duty point Crane required to carry-out repairs

Alternative technology - summary

Positive Displacement – Plunger pumps

Alternative technology - summary

Positive Displacement – Plunger pumps

Sump required just to collect and return leakage

Alternative technology - summary

Positive Displacement – Plunger pumps

Leakage sump potential for contamination

Crank case oil contamination

Alternative technology - summary

Positive Displacement – Plunger pumps• Limitations

Initial & Whole Life Cost Environmental –

• Leakage, Leakage collection & Disposal , Noise, Pulsation, Vibration

Maintenance required daily - even at remote sites Maintenance of additional equipment required

belts, pulsation dampers, oilers & etc. “Down” time vs. “up” time & time to carry-out

repairs

Alternative technology - summary

Advantages of SPS design Low initial & whole life cost Short lead-times Adaptable for changing duty conditions Minimal routine maintenance

• One low pressure mechanical seal• No gear reducers/increasers, v-belts, dampeners & etc

Low noise levels Environmentally friendly Ease of repair & replacement of components

Alternative technology - summary

Performance Envelope

Performance limits

• Suction Pressure: up to 3,000 psi

• Temperature: 250-300 F (standard configuration)

• Drive options: Electric Motors 100 to 1,000 hp (50/60 Hz.) Fixed or Variable Speed Engine Drive (Gas or Diesel)

Performance Envelope

• Injection; Waterflood, disposal & pressure maintenance

• Jet pump power fluid & hydraulics fluid • Transfer/pipeline booster• Gas services: NGL, LPG, Ethane,

Amine booster pumps• Liquid CO2 Booster• Condensate transfer

Applications

System components Motor

Vibration Switch

Flexible Coupling

Pumping element (ESP style)

Suction & Discharge Pressure Gaugeswitches

Skid

Thrust Chamber

Discharge Head

Suction Chamber

Pump Supports

SPS design features

Base

Adj. Nut & Shims

Comp. Nut, Slv. & Set Screw

2 pc. Ring

Head

Comp. Bearing Hsg.

Comp. TubeCritical Dimension

Fluid Dir.

Housing

Spacer

Diffuser

O’RingImpeller

Lower Diffuser

Tungsten Carbide BearingTungsten Carbide

Bearing

Shaft

Lower Bearing Hsg.

SPS design features

Pumping element

Pumping element Replaceable on site with minimal down-time Industry leading designs are highly efficient Corrosion resistant materials “Compression style” for abrasion resistance Mixed flow stages for high efficiency and

wear resistance Tungsten carbide bearings/sleeves available Various coatings & diffusion processes

available to meet application requirements

SPS design features

Viton O”RingMechanical Seal

Housing

Pump Adapter Plate

Monel Coupling

Viton O”Ring

Seal PlateMonel stub Shaft

SPS design features

Suction Chamber

SPS design features

Suction Chamber

SPS design features

Suction Chamber – “Front Pull-out” Cartridge

SPS design features

Mechanical Seal - “Front Pull-out”- Remove pipe spool piece- Move pump to access seal

from front of suction chamber

- Bearing housing remains in-situ

- No need to re-align motor coupling etc.

2 rolling jacks standard SPS tool kit

SPS design features

Mechanical Seal – options

- Leak Containment- Leak detection- Alarm &/or Shut-down

SPS design features

Suction Chamber Open free flowing area, for optimum suction

capability and seal life Silicone carbide mechanical seal faces Mech seal operates at suction pressure Stub shaft design for easy seal & shaft change-

out (thrust chamber exchange not required) Cartridge seal options API682 and most API610

flush & quench plans are available “Front pull out™” design allows seals to be

replaced without affecting alignment US Patent

Axial Thrust Ball BearingUp Thrust

Pre-Load Wave Spring

Viton O’Ring

Labyrinth Seal

Dual Axial Thrust Ball BearingsDown Thrust

Viton O’Ring

Lock Nut

Shaft

Housing

Oil Drain

Inspection Port

Oil Ring Retaining Bolt Plugs

Oil Rings

SPS design features Bearing Housing/Thrust Chamber

SPS design features Suction Chamber

Bearing Housing & Adapter

SPS design features Bearing Housing/Thrust Chamber

replaceable module - with minimal down-time Simple design with low number of moving parts Minimal routine maintenance (2000hr oil

change) 0.5 gal reservoir & Oil rings for low temp rise Labyrinth seals used to eliminate shaft wear Predictable bearings life. TC’s endurance tested,

minimum life for given pump/stage combination known

Machined Motor Adapter Plate

Provision for future Skid Extension(s)

30.5” Fixed Pipework, Pump & Thrust Chamber Height

Bolt-on Motor Jacking Blocks & ScrewsIntegral

Lifting lugs throughout

Rigid Frame for low vibration

SPS Design FeaturesEasily Modified Skid™ Design

Adapter Plate & Skid pre-drilled for all motor options

WG ESP – US Patent

SPS design features

Why Easily Modified Skid™??

Oil Decline Curve

Q % oil

Time - Years

Water Incline Curve

Time - Years

Q % Water

EMS™ Design

Traditional Skid

SPS design features

Easily Modified Skid™

Finite Element Analysis “F.E.A.” Comparison Old Skid vs. New

100hp700hp

SPS design features

Easily Modified Skid™

SPS design features

Easily Modified Skid™

Rigid design for smooth operation, ease of installation & start-up

Ability to change motor size without cutting metal or changing pipework height

Simple to add or subtract stages/pumps Skid re-usable for future applications US Patent

Systems are laser aligned at site

SPS design features

Systems are vibration tested at site

SPS design features

SP75 20-75 Hp Applications

SPS design features

Sample SPS Installations

South America

Middle East

North America

U.K.

OmanEgyptUAEKuwait

Central America

VenezuelaEcuadorArgentinaBrazil

Pemex – WTSV GoM Sealion: TOISA PiscesAker Langsten: Bourbon Opale

CanadaU.S.A. TexasOklahomaRockies

Europe Kazakhstan

Africa

TurkeyRomania

Cote D’IvoirePacific Rim

Indonesia

Far East

Japan

BP - Louisiana(Amine – Gas Treatment)

• Lean Amine 7700 bpd (225gpm) 1,000 psi discharge

• 200 hp TJ7500 – 32 stages

Warrior Gas - Hearne , Texas

• Lean Amine 7700 bpd (225gpm) 1,000 psi discharge

• 200 hp TJ7500 – 32 stages

Sample Installations

Apache, Snyder Texas

• 6,000 bpd (175gpm) – 1,500 psi• 250hp TE5500 – 71 Tefon® coated stages

Sample Installations

PDO (Shell) - Oman(Water Injection)

• 8,000 bpd (234gpm)- 4,600 psi (1,000 psi suction)

• 600hp TJ9000 – 92 stage

BP – Alaska (Jet Pump Power fluid)

• 12,000 bpd (350gpm)- 3,000 psi • 700hp TJ12000 – 80 stage

Ameriven - Venezuela(Pipeline Booster)

• Crude Oil 15000 bpd (440gpm) 500 psi discharge• 200 hp TM520A – 12 stages

BP, Louisiana

• 5,000 bpd (150gpm) – 1,000 psi• 60hp TE5500 – Amine

Sample Installations

Denbury, Jackson Dome MS

• C02 5500 bpd (160gpm) 1,600 psi (1,200psi suction)• 100hp TE7000 – 29 stages• API682 Double seal Plan 53 & Graphalloy Bearings

Sample Installations

Duke, Texas

• 1000 bpd (15gpm) – 800 psi• 20hp TD850 – Amine

Sample Installations

Wyoming Resources

Pumpkin Butte, Wyoming

• 1,000 bpd (29gpm) - 4,300 psi• 150hp TD1200 - 359 stage (floater)

Sample Installations

Wafra, Oman (PDO)

• 8,000 bpd (234gpm)- 4,600 psi (1,000 psi suction)

• 600hp TJ9000 – 92 stage

Sample Installations

Apache – Crane Texas

• 16,500bpd (482gpm)- 1,400psi• 600hp TJ20000 – 41 Teflon® coated stages

Sample Installations

Chevron/Simonette, Alberta

• 900 bpd (26gpm) - 4200 psi• 200 hp TD980 – 401 stage (Ryton Stages)

Sample Installations

PDVSA - Venezuela

• Jet pump Power Fluid 1700 bpd (50gpm) - 3300 psi

• 200 hp TE1500 – 136 stage

Sample Installations

Pemex - GoM “TIOSA Pisces”(Sea Water Injection & Oil Transfer)

• Injection Pumps – 5000bpd @ 3000 psi 500hp

• Export Pumps – 30,000bpd @ 500psi 350hp

Pemex - GoM “TIOSA Pisces”

• Injection Pumps – 5000bpd @ 3000 psi 500hp

• Export Pumps – 30,000bpd @ 500psi 350hp

Modec FPSO - Cote D’Ivoire(Sea Water Injection)

Modec, for CNR - FPSO “Baobab”

Modec FPSO - Cote D’Ivoire(Sea Water Injection)

100,000 Bpd 3000gpm @ 2500psi 6 x TM675 44st

Modec - FPSO

Surface Pumping Systems (SPS)