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

Shelter

Supporting frame Removable panel

Hoses

Road slabs

(Ladder is not shown)

Wellhead equipment

Gravel and foundation Cable box on stands

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 with

Hydraulic drive, 2009 adaptive pneumatic-

hydraulic recovery

system

Hydraulic drive with

electro hydraulic recovery

system

Cluster version

Frame with

hydraulic cylinder - 1

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

Frame with hydraulic

cylinder - 2

Pumping station

“Light series”

hydraulic drives “GEYSER”

“Light series” HDDWRP 60-3,5 (6,0) 80-3,5 (6,0)

modular, separate (hydraulic station is located in a separate block)

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

Pumping station

Engine Power, kW

Voltage, V

Load on hydraulic cylinder rod, kN (t)

up to 7 up to 3,5

asynchronous 37

380

60 (6)

up to 6 up to 3

asynchronous 37 (45*)

380

80 (8)

Working fluid –multigrade hydraulic oil

Overall dimensions of a shelter length, mm

width (as per foundation and roof), mm

height, mm

Weight, kg: Hydraulic station (without working fluid)

Hydraulic station with electronic control system in a shelter

Supporting frame with hydraulic cylinder

Mounting method

* Special configuration

AIMOL-M-Hydromax, Esso Unhivis, Shell Tellus

3000 1900 (2100)

2400

1200 1500 2500 2800

1500 1900

Supporting frame is mounted on reinforced plates or piles

“Heavy series”

hydraulic drives “GEYSER”

“heavy series”HDDWRP 120-4 (6,0) 160-4,0 (6,0) 200-6,0

modular, separate (hydraulic station is located in a separate Design

Counterbalancing

Maximum number of double strokes per minute: up to 7

at rod stroke up to 4,0 m up to 4,5

at rod stroke up to 6,0 m

Pumping station

Engineasynchronous Power, kW37

Voltage, V 380

Load on hydraulic cylinder rod, kN (t) 120 (12)

block)

pneumatic

up to 5,5 up to 4,5 up to 3,5 (7*) up to 3 (5,5*)

asynchronous asynchronous 37 (55*) 37 (55*)

380 380

160 (16) 200 (20)

Working fluid –multigrade hydraulic oil

Overall dimensions of a shelter length, mm

width (as per foundation and roof), mm

height, mm

Weight, kg: Hydraulic station (without working fluid)

Hydraulic station with electronic control system in a shelter

Supporting frame with hydraulic cylinder

Mounting method

* Special configuration

AIMOL-M-Hydromax, Esso Unhivis, Shell Tellus

3000 1900 (2100)

2400

1200 1500 2000 2500 2800 4000

1500 1900 2500

Supporting frame is mounted on reinforced plates or piles

Hydraulic drive “GEYSER”

mobile version

Telescopic boom

Cross-road chassis

Hydraulic power cylinder Kamaz or Ural Electronic control system box

Block

Operator console

Hydraulic station

Hydraulic tank

Hydraulic pump connected through PTO

Front jack pods

Hydraulic boom lift cylinder

Rotating platform

Rope hanger

Technological boxes

Wellhead equipment

Back jack pads

Hydraulic drive “GEYSER”

container version

Truck-mounted loader crane

HDDWRP“GEYSER”

Container version

Service crew vehicle

Installation requires: - Service crew –2 workers

- Specialized machinery –crane or truck-mounted

loader crane

Installation time –approx. 3 hours

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.

All configurations of

station

HDDWRP “GEYSER” can be

adapted for container version.

This modification is intended

for ease of transportation and

installation.

Supporting

frame

Hydraulic

cylinder

Hydraulic drive “GEYSER”

mobile version

№

1 Chassis

Parameter Value Functions and options:

Triaxial, all-wheel drive, - Liquid crystal color display (LCD);

cross-road Kamaz 43118 - Load control and display at up stroke and down stroke;

- Dynagraphs automatic reading; or Ural 4320

- Storage in controller memory of event log and up to 1000 2

3

4

Approximate loaded weight, t

Maximum wellhead rod stroke

length, m

Maximum load in hanger center, t

15..18

4

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; 4.2 Modification 2

Number of double strokes per min 5

(at maximum rod stroke length)

Wellhead equipment and wellhead 6

rod types

7 Rod rotor installation capability

8 Stroke length range

9 Hydraulic system volume, l

10 Control system

12 - Display on LCD of double strokes number;

Specified - Automatic event logging;

in Technical Inquiry - Electronic control system of boom angle;

(from 4 up to 6) - Capability of dynagraphs storage on USB-flash card;

- Possibility of laptop PC and control system connection by USD + All types

software; - Possibility of tablet PC and control system Bluetooth connection;

- Well further equipping with CMD (echo meter + pressure Available

transducer in a line) Steplessly

- Smart system of dynamic pressure level automatic control in

from 0,2 m up to 4,0 m annular space;

- GSM-Module. 300

Electronic

Hydraulic drive “GEYSER”, operating on

associated petroleum gas

Nomenclature:

1. Supporting frame with hydraulic cylinder;

2. Pump station with gas engine and electronic control system

Tank

Box

Electronic

Глушитель

Gas engine

with cooler

Pump

Gas

preparing

block

control

system

Cooler

Hydraulic system

Hydraulic drive “GEYSER”, operating on

associated petroleum gas

Standard version:

1 pump station–1 well

Cluster version:

1 pump station–

several wells

Limitation:

distance between

pump station and

wells no more 20 m

Hydraulic drive “GEYSER”, operating on

associated petroleum gas

Technical parameters of hydraulic drive “GEYSER”, operating in associated

petroleum gas in cluster version

№

1 Number of wells

Parameter Value

up to 2

Load on hydraulic cylinder rod, kN (t)

3

4

5

6

7

8

9

10

11

12

Maximum wellhead rod stroke length, m

Number of double strokes per min (at maximum rod stroke length)

Gas engine

Fuel

Maximal brake power, kW

Type of wellhead fittings and stroke

Ability applying rod rotor

Stroke length range

Volume of hydraulic system, l

Control system

3,5 ( up to 6,0)

6 (up to 3 for6,0 м stroke)

Caterpillar G3304

associated petroleum gas*

71

Any

Yes

Steplessly

from 0,2 m up to 3,5 m (6,0 m)

300

Electronic controller

* Parameters of gas preparing block depends on well and needs agreement

Evolution of

Hydraulic cylinders

2009

Hydraulic cylinder base version

2012

Launching of hydraulic

cylinders production with rod

2012

stroke length up to 6 000 mm

Use of stroke length

and load on rod up to 20 tf

analog sensors

2012

Use of removable bush

to replace rod sealing set

2013

Internal drainage

introduced to hydraulics

cylinder design

Evolution of

Electronic control system

Dynagraph plotting,

telemetry data output,

Operation in automatic mode

well CDM data transfer

Implementing

…

of drives

smart operation modes

Switch to industrial

controllers

Database building

for implementing of

“smart drives” operation

ECS scheme

Option I: analysis of well data and

operation modes automatic selection

Well CMD

GSM, УКВ

Satellite

Controller

CMD

“GEYSER”

exchange

module Optic fiber

Radio-Ethernet

Data storage

Server

Option II: telemetry

data storage and

Base version exchange

In case of a sufficient data exchange channel capacity

21

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)

Satellite channel

OFFICE

User equipment

Advantage:

•Any geographical location.

Disadvantages:

•High equipment cost;

•High user maintenance and traffic costs.

PLC

PTL (6-10 kW)

CLUSTER

User equipment

Advantages:

•Ease of installation;

•No ground relief limitations.

Disadvantages:

OFFICE

•Limited communication range: up to 10-20 km. without repeaters;

•Low data transfer speed: 10-100 kb/s.

Radio-Ethernet

2.3 –2.6 GHz

CLUSTER

User equipment

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.

OFFICE

Smart control system

implementation

Cluster№923

Single

+ telemetry data transfer

automatic drive

+ 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

3 stage

1 stage

Automatic operation mode implementation: -Hydraulic drive parameters control

-Automatic protection system implementation at

emergency procedures

-Automatic start-up

2 stage

Telemetry transfer, well equipping with CMD:

-Dynagraph plotting

-Data transfer

-Remote monitoring

-Remote control, SMS-notification

-Well equipping with CMD

Smart operation mode implementation:

-Remote stroke length change

-Operation mode selection in

accordance with wellhead CMD

(echo meter, pressure transducer in a

line, AGMU)

4 stage

Smart operation mode implementation: -Dynagraph analysis

-Implementation of smart mode on the

basis of dynagraphs

-Special software “GEYSER-MONITOR”

implementation

Special software

“GEYSER-MONITOR”

Office

CLUSTER

“GEYSER”

Communication channel

“GEYSER”

RF, PLC etc. Beam pumping

unit

Electric

submersible pump (ESP)

Automated

group measure unit (AGMU)

Camera

Server

Local users

Wi-Fi

INTERNET

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

Wellhead equipment

Application of scrapers

together with rod

rotor

Energy efficiency increase

RN-Yuganskneftegaz

Comparative analysis of beam pumping unit (BPU)

and HDDWRP “GEYSER”

GEYSER

80x3.5

BPU-8

Working parameters

Daily energy Liquid

Pumping Load on Oil flow rate, consumptio

Stoke Parameter / Model rate,

speed, rod t/day n,

length, m3/day

double (max), kW*h

m strokes/min tf

2

,

0

2

3

,

9 3,44 3 2,2 240 BPU-8 HDDWRP 80-3,5 "GEYSER"

2,02 3,9 3,44 4 3 117,6 with electric recovery system

Specific Specific energy

energy consumption,

consumption, kW*h/t

kW*h/m3

80,00 109,0909091

29,40 39,2

Energy efficiency increase

Orenburgneft JSC

Comparative analysis of electrically driven centrifugal pump (EDCP)

and HDDWRP “GEYSER”

well 2209

EDCP

EDCP

GEYSER

well 2268

GEYSER

Liquid rate,

Parameter / Model m3/day

EDCP-44/2000

14 (well 2009)

HDDWRP 120-4,0 "GEYSER"

12 (well 2009)

EDCP-25/1900

12 (well 2268)

HDDWRP 80-3,5 "GEYSER"

10

(well 2268) Daily energy consumption, kW*h

724,8

504

616,8

432

Specific energy consumption, kW*h/m3

51,77

42,00

51,40

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.

2.

3.

4.

5.

6.

7.

Meeting technical maintenance and service regulations in accordance with manufacturer requirements

Trained and certified personnel by all types of performed works

Availability of specialized tool set and devices (according to the checklist)

Required number of working crews presence in service region. Maximum incident response time is 6 hours

Existence of specialized machinery hire contracts

Organized warehouse of original spare parts for performing service and technical maintenance works

(according to the checklist)

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

Global Engineering

General Trading and Contracting Co.

جـلــوبـال الـهـنـدســـــيـة

للتجــارة العـامـة والمقـاوالت

P.O. Box. 2880 - Salmiya, 22029 - Kuwait, 9th Floor, Al-Shrooq Tower, Jaber Al-Mubarak Street, Sharq, Kuwait

Tel : +965 22476953/4, Fax : +965 22476955,