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)
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