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Electric Submersible Pumps for the Petroleum Industry

Wood group ESPThe ESP Specialists Submersible Pumps for the Petroleum IndustryElectric Submersible Pumps for the Petroleum IndustryA MESSAGE FROM THE PRESIDENT OF WOOD group ESPH eadquartered in Oklahoma City, Wood group ESP was established in 1983 as an esp equipmenttesting and service company. In 1992 we purchased a major Submersible pump manufacturingcompany that had been in business for over 30 years. Wood group ESP has since emerged as aleading manufacturer of Electric Submersible Pumps and control equipment. Our focus is on the pur-suit of innovation in the application of Petroleum Industry Electric Submersible and surface pump sys-tems. Our philosophy is to provide unparalleled service, quality cost-effective products and thetechnological advances to enhance group ESP introduced the application of field maintenance programs, equipment testing, wellperformance testing, performance-based contracts, radial-stabilized bearings, flame-spray corrosioncoating, gas separators and many more of the Industry s major recently developed high-efficiency Pumps and motors offer options for abrasion and corrosion-resistant materials, advanced downhole and surface monitoring capabilities and improved operatingtemperature.

Wood Group ESP The ESP Specialists™ www.woodgroup-esp.com Electric Submersible Pumps for the Petroleum Industry

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Transcription of Electric Submersible Pumps for the Petroleum Industry

1 Wood group ESPThe ESP Specialists Submersible Pumps for the Petroleum IndustryElectric Submersible Pumps for the Petroleum IndustryA MESSAGE FROM THE PRESIDENT OF WOOD group ESPH eadquartered in Oklahoma City, Wood group ESP was established in 1983 as an esp equipmenttesting and service company. In 1992 we purchased a major Submersible pump manufacturingcompany that had been in business for over 30 years. Wood group ESP has since emerged as aleading manufacturer of Electric Submersible Pumps and control equipment. Our focus is on the pur-suit of innovation in the application of Petroleum Industry Electric Submersible and surface pump sys-tems. Our philosophy is to provide unparalleled service, quality cost-effective products and thetechnological advances to enhance group ESP introduced the application of field maintenance programs, equipment testing, wellperformance testing, performance-based contracts, radial-stabilized bearings, flame-spray corrosioncoating, gas separators and many more of the Industry s major recently developed high-efficiency Pumps and motors offer options for abrasion and corrosion-resistant materials, advanced downhole and surface monitoring capabilities and improved operatingtemperature.

2 We have expanded booster and transfer pump applications with our SPS (SurfacePumping System). This versatile, low-maintenance product is an excellent alternative in applicationswhere high pressure movement of fluids is required. Operating under ISO 9001 certification, our pri-mary Technology and Manufacturing Center is located in Oklahoma City, USA. We now have Distrib-utive Manufacturing and Repair Centers located in key oil-producing regions worldwide and over 30sales and service centers within our 19 operating SmartArchitecture performance model demonstrates our commitment to reducing operatingcosts and maximizing production through the integration of an information to knowledge pro-activedecision making the Petroleum Industry , success is measured by performance. Routinely our customers ask us to testtheir wells, optimize ESP performance, service all their ESP equipment and provide and manage theirinventories.

3 Each month we deliver detailed performance reports on pull rates, surface and subsur-face activity, power consumption, production efficiencies and other key performance indicators. Wethen strive to improve performance the next call us a leading manufacturer of Electric Submersible Pumps . Others call us the best ESPservice supplier in the world. Operators all over the world continue to call us because they know we llimprove their operational BradyCEO and President3 SmartArchitecture Performance Model4 High-Efficiency Pumps5 Downhole Gas Compressors/Separators6 Seal Sections7 High-Efficiency Submersible Motors8 Controls and Communication10 Downhole Monitoring11 Power Cables12 Special Purpose Systems14 Field Services15 Equipment Testing Services16 Distributive Manufacturing and Equipment Repair17 Total Well Performance and Optimization18 Surface Pumping Systems20 Worldwide Sales and Service LocationsCONTENTSC omodoro, ArgentinaMaracaibo, VenezuelaJebel Ali, UAEM idland, TexasNisku, AlbertaDuri, IndonesiaOklahoma City, Oklahoma (facilities photo on back cover)

4 THE TOTAL PACKAGEWood group ESP designs andmanufactures artificial lift andsurface pumping systemsbased on a SmartArchitecturemodel, which consists of: Downhole and surface pumpsand assemblies Surface controls and commu-nication systems Data management and report-ing combined, these compo-nents provide operators a versa-tile information-to-knowledgemanagement tool that helpsthem optimize their oil fieldsand process Pumps were once consid-ered to be economic only inhigh-volume , Wood group ESP offerselectric Submersible Pumps ina wide capacity range from 70to 64,000 BFPD (barrels fluidper day). These include designsfor onshore and offshore appli-cations in casing sizes of larger to depths up to15,000 ft. With only the wellhead,and fixed or variable-speedcontroller visible at the surface,these ESP systems offer asmall footprint and low-profileoption for virtually all artificiallift applications.

5 Wood group ESP offers a fullarray of abrasion and corrosion-resistant pump equipment,power cables, fixed or variablespeed controllers, downholesensors, and data communica-tion and control panels. Thetypical application is to provideartificial lift for oil, water andbrine well production. The sys-tems can also be used for pipe-line booster service, waterfloodinjection, mine dewatering, fireprotection, irrigation, directinjection, cavern storage, com-mercial water systems, geo-thermal industrial applications,coal bed methane and gas MONITORING, CONTROLAND SYSTEM ANALYSISThe SmartArchitecture modelallows complete monitoring ofthe entire ESP system, localand remote data logging, aswell as control and interfacevia any Web-based Microsoft software program. Its versatiledesign capability facilitatesknowledge-based decisionmaking. Complete systemcontrol, data processing andanalysis is possible in real timefrom any computer anywherein the world.

6 The SmartArchi-tecture model is key to allow-ing proactive well or processsystem maintenance andimproving performance on acontinuous basis. It s like hav-ing an engineer on every or variable speed controllerDownhole ESP assembly including SmartGuard sensorVector Control System RTU programmable controller, data logger and communications interfaceeSmart data management, reporting and system control via laptop or portable data collectorData management, reporting and system control from operator's data center and/or Wood group eSmart data management centerSCADA or phone link to remote computer networkIncoming powerTransformersSurfaceProduction facilitiesSmartArchitecturePerformance ModelInformation-to-KnowledgeDecision MakingDownhole parameters monitored/controlledWellbore intake pressurePump discharge pressureWellbore fluid temperatureMotor oil or winding temperatureVibrationCurrent leakageSurface parameters monitored/controlledTubing pressureCasing pressureFlow rateChemical pump controlTank levelsPhase current/voltageRestartsRun/downtimePower consumptionPower qualityCathodic protection statusOther physical parametersData management,reports.

7 Trend analysisOnline controller setupAlarm code data/pagingException conditionsWell attributesPreconfigured reportsGraphical trendingPerformance analysis/historyWell optimization analysisIntegrated with other appsClient/server architectureWood group ESP5500 59th StreetOklahoma City, OK 73135 Tel 405-670-1431 Fax Performance Modelfluid, handle more gas andreduce the effects of sand andscaling. We have also designedour systems to have some ofthe highest efficiency and headper stage ratings of any in theirpump class Production rates from 70 to64,000 BFPD Operating depths up to15,000 ft High-efficiency stage design Abrasion and corrosionresistant materials Center tandem housings(radial or mixed flow, floateror compression) 100% factory tested to APIRP 112S standards ISO 9001 quality standards Monel-trim fasteners Optional coating and materialsWood group ESP s multistagecentrifugal Submersible pumpsconsist of a rotating impellerand a stationary diffuser thatcan be stacked in either floateror compression configurationsto meet the most demandingperformance impellersand diffusers are cast from aNiresist high-nickel iron con-taining destructive-resistantproperties.

8 For more severeenvironments optional radially-stabilized corrosion-resistantpump materials, including vari-ous stage coatings and borondiffusion hardening processes,are group ESP has intro-duced an array of high-effi-ciency, low-volume and high-volume Pumps . These pumpshave wider vane openings tohelp produce lower gravityRadial-flow centrifugal pumpMixed-flow centrifugal pumpSUBMERSIBLE PUMPSPump Normal SeriesOperating Range( )bbl/dm3/dTA250 to 40 to( )2800445TD70 to 11 to( )105001650TG1300 to 200 to( )67501100TE750 to 120 to( )195003100TH700 to 1100 to( )330005250TJ4000 to 632 to( )370005900TM12500 to 2000 to( )450007150TN22000 to 3500 to( )6400010200 HEAD CAPACITYPUMP ONLY EFFICIENCYHP MOTOR LOAD 30252015105100806040200 100% 80% 60% 40% 20% 0% HP Motor LoadPump Only Efficiency Headm ftbbl/d 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 m3/d 500 1000 1500 2000 2500 3000 3500 RECOMMENDED OPERATING RANGE Typical pump performance curve for a single-stage pump @ 3500 rpm High- and ultra-high-strengthshafts Wider vane openingsBenefits Up to 1500 horsepowerapplications Low operating costs Protection from H2S or corro-sives for extended run life Best-of-class inventory man-agement (flexible assembly,repairs and modifications)

9 Quality and workmanshipresults in fewer field failuresand extended run life International standard com-pliance for quality assurance Fewer stages and housingsrequired Wide-vane Pumps producelower-gravity fluid, handlemore gas and reduce solidsand scalingWood group ESP5500 59th StreetOklahoma City, OK 73135 Tel 405-670-1431 Fax PumpsThe intake section of a sub-mersible pump functions as asuction manifold, feeding thewell fluid to the pump. In stan-dard applications, an intakesection can be a simple inlethole adapter attached betweenthe seal section and the pumphousing. In applications withhigher gas/oil ratios (GOR) andlower bottom-hole pressures,the well fluid may contain sig-nificant amounts of free gas. A gas separator, designed toseparate free gas from the wellfluid before it enters the pump,replaces the intake section. The rotary gas separator, withthree abrasion-resistant bear-ings standard, comprises threedistinct stages.

10 In the first stage,a low NPSH (net positive suc-tion head) impeller is used toimpart energy to the fluid. In theseparation chamber, a spinningsteel rotor is used to generatecentrifugal forces to separatefluids based on density differ-ences. In the crossover section,the lighter density fluids areejected from the gas separatorto the well s annulus and heavierfluids are directed to the separators are designedwith special metallurgy andbearing systems to extend theiroperational lives in adversewell conditions. In applications where theamount of free gas cannot behandled efficiently by rotarygas separators, tandem rotarygas separators, a high-volumeXGVS separator or an XGC gas compressor can be XGVS uses a vortex sepa-ration chamber and the XGCsystem introduces a compres-sion chamber downstream fromthe tandem gas separators. Thecompression chamber allowsfree gas to be compressedback into the solution whilesimultaneously breaking largegas bubbles into an increasing-ly homogenized solution, whicha Submersible pump can han-dle without gas locking.