HUSITE EQUIPMENT & OILFIELD SERVICES COMPANY

Transcription

1 HUSITE EQUIPMENT & OILFIELD SERVICES COMPANY

2 For more information about Husite products please contact: 5940 MacLeod Place II, Suite 500 Calgary, AB T2H 2G4 Tel.: +1 (403) / Fax: +1 (587) info@flowlift.com

3 HUSITE ENGINEERING SYSTEM FOR OIL WELL RENOVATION SUCKER ROD PUMP TOWER AND OILFIELD SERVICES HUSITE EQUIPMENT & OILFIELD SERVICES COMPANY

4 HUSITE SUCKER ROD PUMP TOWER AND OILFIELD SERVICES Company Introduction...1~2 Basic Information Social Responsibility API Registration Husite Sucker Rod Pump Tower...2~14 Design Principles Structure Mechanical Components Motor Dual Sprocket, Chain,Counterweight, and Roller Drum Breaking System (Manual & Automatic) Automatic Transmission Heavy Duty Belt Power Supply Control Cabinent (PLC, Automatic Controls, and Soft Start) Specifications Model Selection Shipping Requirements Installation Operation Maintenance Oilfield Services & Equipment Supply...14~28 Well Analysis Well Renovation Equipment Supply Alternate Solution for Base Generator and Electrical Distribution System Wellhead Polished Rod Tubing Sucker Rods Pump Assembly and Gas Anchor Reference Material(Available Upon Request) QHSE Well Data Information Sheet Technical Comparisons 1st Generation SRP and 3rd Generation 2nd Generation SRP and 3rd Generation 3rd Generation SRP, PCP, and ESP

5 COMPANY INTRODUCTION Basic Information Established in 2007 with registered capital of 50 million RMB and assets of 230 million RMB, Husite (business registration number: ) is a joint venture between G.I.T. Holdings U.K. and Zhejiang Huaguang Complete Power Equipment Company. Located in the Binhai Economic and Technology Development Zone of Wenzhou, China, the company started to develop the third generation of the sucker rod pumps (SRP Tower), and completed the design in July 2010, and has submitted seven patents to Chinese patent authorities. In addition to the manufacture, supply, and the installation of the SRP Tower, our company also has a range oilfield services capabilities. In 2010 our company successfully installed a Husite designed SRP Tower System (including all above and below ground equipment) in a previously natural flowing well that had lost pressure and was only producing 50 barrels per day; after a detailed study of the field s other wells and the reservoir, and a field test of the system in which the production achieved over 600 barrels per day, the owner then executed a multi-well contract for the engineering, equipment supply, and maintenance for the HUSITE SUCKER ROD PUMP TOWER. Social Responsibility Having garnered the support of the Wenzhou city government for creating employment opportunities and also increasing foreign exchange revenue, Husite is devoted to identifying, creating, and nurturing economic benefits for our customers around the globe and their local constituents. Our products and projects adhere to the highest standards of mutual benefit, as well as protecting the environment and the people we work with. We honor the principles of conflict free engagement and increasing value for the communities that we operate in. 1

6 API Registration Husite has received from API the APIQR No for the ISO 9001:2008, the API Specification Q1 (Reg. Q1-1212), and the ISO/TS for the Design, Manufacture and Service of Tower Type Chain Belt Pumping Units. HUSITE SUCKER ROD PUMP TOWER Design Principles The electrically powered Husite SRP Tower is the main piece of equipment for an artificial lift system with vertical movement of between 4.5m to 8m, depending on the model and connects to a down-hole pump assembly via a polished rod and sucker rods to extract oil from underground wells by increasing pressure in the well with the advantage of not collapsing or being trapped by gas cap which allows liquid to flow through perforations in the well tubing, then into the down-hole pump assembly which on its upstroke creates a pressure differential that that allows the liquid in the pump assembly to flow upwards to the well head. Our machine represents the third generation of the SRP technology; the first generation being the donkey type pump jack that was first introduced in the U.S. over 100 years ago and is ubiquitous to oil fields around the world. The second generation was first developed in China and marketed internationally under a foreign trade name. It has over 10,000 units deployed worldwide and although the second generation model addressed certain problems with the traditional pump jack such as: Difficulty in dealing with deeper wells Unable to lift heavy and viscous oil High energy usage Many mechanical moving parts Large footprint Greater friction which leads to greater maintenance requirements Longer installation time Dangerous installationand maintenance 2

7 The second generations has several significant failings that the Husite third generation sucker rod pump has rectified in terms of structure, mechanical design, and functionality (for an in depth analysis of the comparison of the HUSITE SUCKER ROD PUMP TOWER and other types of SRP as well as other technologies, please refer to the Reference Material.) The new generation of long and slow stroke sucker rod pumps allow a greater amount of liquid to flow into the pump barrel over a longer period of time increasing production and the counterweight serves as a shock absorber for the entire system reducing the wear and tear of the system. These pumps have the following features: Operating depth: Up to 5000m Operating temperature: High (Over 100 C) Corrosion handling: Excellent Gas handling: Good Solids handling: Fair to good Fluid gravity (API): >8 Prime mover: Electric Servicing: Greatly reduced due to reduced SPMs and less friction within the entire system System efficiency: Above 78% Power: Saves 33-52% in power usage to the traditional pump jack Stroke Length: 4.5 to 8m Stroke/Minute: 4 (allowing for maximum barrel fillage) Load Capacity: 8 to 20+Mt 3

8 In addition to the above, the HUSITE SUCKER ROD PUMP TOWER has several unique innovations which distinguish it from second generation machines: Additional structural steel for operator safety, stability in windy and earthquake conditions; A dual set of sprockets with a dual mechanical reversing junction that redistributes the load on the chains, sprockets, roller bearings, and belt which significantly decreases friction and focused wear on one point; therefore increasing the lifetime of parts and the system as a whole; it also means less possible friction for the belt reducing the risk of rod breakage, as well as greater seal protection; Improved mechanical reversing unit for smoother movement and more stable movement resulting in increasing the lifetime of the stuffing box seal translating into less maintenance, continuous production, and reduced air pollution; Automatic transmission to adjust strokes per minute through PLC without any need to suffer any downtime due to need to stop the machine and to change the sprockets allowing greater production; Very little noise during operation All of our units are pre-assembled at the factory and thoroughly tested to insure every component of the system is operating correctly before shipment. The unit arrives at the well site in two parts, the structure and the base. Structure All models of the HUSITE SUCKER ROD PUMP TOWER are comprised of a concrete and steel base with a vertical steel structure frame consisting of four posts and two maintenance stands located above the middle of the vertical structure and at the top of the unit that is connected by three maintenance ladders that lead to the top of the tower which has a sheet steel housing for the rolling drum for the load belt. The back two steel beams connected with horizontal cross beams covered in sheet steel housing the dual set of sprockets, two sets of chains, load belt, and counterweight mechanisms which can be accessed in the front and back by steel doors. The vertical beams are one piece with the cross beam support structures all being arc welded to insure maximum support. The entire structure is divided into four levels within the four support beams and one level on the outside of the support beam on the back of the unit. 4

9 Inside support beams Level One: Level Two: Level Three: Level Four: Ground level Concrete base with reinforced steel frame Base with transmission system Located at first horizontal cross beams Access by ladder attached to outer face of horizontal cross beam Support for the electric motor Located between second and third support cross beam Access by ladder attached to inner face of mechanism housing Maintenance platform for chain and counterweight access panel Located at top horizontal cross beam Access by ladder on inner face of horizontal cross beams Maintenance platform for top roller and load belt with a steel safety guard rail On face of the mechanism housing between Level Two and Level Three there is a maintenance platform and double door panel to access the counterweight, the bottom of the chains, the lower sprockets, and junction mechanism. 1 Base 2 Braking System 3 Gear Reducer 4 Electric Motor 5 Structure 6 Rope Hanger 7 Counterweight Assembly 8 Control Box Main support, cross beams, transmission system are painted in blue and the base steel frame level three maintenance platform, the top safety guard rail, and housing for sprockets and drums housing are painted in red. Base The frame of the base is constructed of structural steel with reinforced steel on the inside of the frame that is filled with concrete which has been settled to allow for maximum strength and stability. 5

10 Mechanical Components Motor The HUSITE SUCKER ROD PUMP TOWER has five standard models that use a three phase brushless AC high efficiency motor of 18.5 kw to 75 kw depending on the size of the pumping unit with the TSCYJ model using the smaller motor and the TSCYJ using the larger motor. The electric motors are often installed to include an over capacity factor to prevent the under-powering of the pumping equipment which reduces the risk of the motor from failure due to overheating. In fields where three-phase power is not available, single-phase AC motors can be installed, but these motors cost more and operate less efficiently than three-phase motors having similar ratings. In case a customer makes a special request or after analysis, we may recommend a different sized motor, the selection of the motor size is based on preliminary estimates of the depth and size of the pump, speed of the pumping unit, and fluid properties, fluid level, viscosity, well deviation, and the quality of electric power, as well as friction in the pump, stuffing box, and pumping unit. Protective Features for the Motor Motor fuses, which are located between the motor control and the electric power and limit damage to the motor from electrical or mechanical problems; Air circuit breakers, which are used instead of fuses to protect the electrical distribution system in case the motor develops an electrical problem; Lightning arrestors, which protect the system against storm damage caused by lightning; Under-voltage relays, phase loss relays, thermal overload relays, and motor winding temperature sensors, which are used to stop the motor before any permanent damage is done; P u m p i n g u n i t m o v e m e n t activates vibration switches, which shut down the pumping unit motor if excessive vibration is detected, such vibrations tend to occur when sucker rods break. Controls for Motor Motors used for pumping units have two types of control devices: one that stops, starts, and controls the motor, and the other that protects the motor. Common control devices include: The Hand-Off-Auto Switch, which is used to shut off the motor or operate it in automatic or manual mode. In the hand position, the motor runs continuously, but does not override protection controls. In the off position, the motor stops and cannot start, but power is not shut off. In the automatic position, a programmer or time clock controls the motor. Pump-off controls usually function only when the switch is in auto-position. The Line Disconnect Switch, which cuts all electrical power to the motor and is used when maintenance is performed on the pumping unit. The Sequence-Restart Timer, which delays the simultaneous restarting of several motors. If a power failure occurs in the field, a severe voltage drop can result as many motors connected to the same power source try to simultaneously restart. This condition could potentially keep the motors from restarting or cause the unintended operation of other field safety control devices. The Programmer, which controls the running times of pumping units. If the pumping unit operates continuously, the pump may not fill completely on the upstroke. This pumped-off condition will cause fluid pounding as the pump strikes the top of the fluid column on the down-stroke. Such pounding causes shock loading of the sucker rods and pumping unit. Programmers optimize the pumping unit run time and reduce damage to the pumping system. 6

11 Dual Sprocket, Chain, Counterweight, and Roller Drum The HUSITE SRP TOWER has two sets of sprockets, when one faces the back of the unit one set of sprockets is on the right side of the mechanism housing and one on the left side. The sprockets of each set at the bottom of the housing are connected to the HUSITE AUTOMATIC TRANSMISSION SYSTEM through a junction which transfers the motion from the transmission system to the chains. Each set of the sprockets drives one set of chains, which transfer the motion to a counterweight which drives the belt up and down over the roller drum at the top of the machine. With the additional set of sprockets and chain, according to the inverse relationship of pressure and area, when pressure is distributed over a greater area which is the case when another sprocket is added, the friction on the sprockets, chains, and belt decreases greatly, thus increasing the lifetime of the machine and reducing maintenance. In addition, the smoother movement reduces the chance of vibration to the polished rod and down-hole equipment resulting in less chance of fatigue to sucker rods and also increasing the duration of the stuffing box seal and decreasing carbon emissions. Unlike the second generation type of SRP that only has a single set of sprockets, the HUSITE SRP TOWER does not require to be stopped when the strokes per minute (SPM) is adjusted from one SPM to a multiple SPM, but is controlled in the HUSITE AUTOMATIC TRANSMISSION SYSTEM through the PLC, thus reducing the downtime for the unit. The two set of chains are high fatigue resistant engineering class or conveyance chains that use heat treated side plates with through hardened pins and has been tested to withstand 100,000 hours of continuous use. The counterweight consists of a steel frame with bars weighing 16.9 kilos each. The roller drum is constructed of heavy duty steel with bearings on each side to allow the roller drum movement for the vertical movement of the belt. This is enclosed by the hood which can be opened for maintenance purposes and contains a safety strut. 7

12 HUSITE AUTOMATIC AND MANUAL BRAKING SYSTEM When facing the unit, the manual brake is located fifty centimeters above the base level of the unit and has a steel cover that opens d o w n w a r d s o n a b o t t o m h i n g e allowing access to a hand grip that when depressed allows the operator to pull the lever that is attached to the hydraulically controlled brake pad. T h e H U S I T E AUTOMATIC AND MANUAL BRAKING SYSTEM is activated through operation of the PLC or when the sensors that monitor the movement of the belt, transmission, or motor detect an irregularity in the operation and well head pressure exceeds a certain amount of PSI defined by the operator depend on the well and reservoir characterstion, the sensors then sends the relevant signals to the PLC to automatically shut down the system. HUSITE AUTOMATIC TRANSMISSION SYSTEM The transmission system uses a gear reducer to convert the high speed and low torque generated by the prime mover into the low speed and high torque required by the pumping unit. This new technology consumes 20% less energy than old transmission systems. The RPM of the Husite proprietary transmission system s gear varies according to electrical current adjustments controlled by signals transmitted from the PLC. The crank shaft of the gear is connected to a sheave/belt assembly that is driven by the electric motor. An oil reservoir continually lubricates the gear within an enclosed box. All of the operations of the transmission system are controlled through the PLC at the control box and requires little or no maintenance as it is a closed system with the RPM continually monitored through sensors that send the signals back to the PLC. Button Control Box Mounted beside the handbrake at the side of the unit, the control button box has a three position rotary switch with three positions from left to right: RESET, OFF, and ON. Below the rotary switch is a red color emergency stop button: Reset = automatically resets the electric brake On Off Heavy Duty Belt = to be pushed when the unit should start to operate = to be pushed when the unit should be shut down before applying the handbrake The steel reinforced heavy duty rubber conveyor belt that sustains the down-hole equipment load of the Husite SRP Tower has a standard width of 1000mm and thickness of 12mm that varies in length between 8.5 m to 12 m depending on the model that utilizes it. The belt is attached to the counterweight with fixing clamp, while the well side has a steel clasp with a fixture to attach the polished rod. 8

13 Power Supply Required Three Phase 380V50Hz (can be adjusted if required due to power supply available) HUSITE AUTOMATIC PLC SYSTEM Control Cabinet (PLC, Automatic Controls, and Soft Start) The control cabinet contains a Siemens PLC with touch panel and LCD display provides a unique combination of intelligent hardware controllers, communication systems, as well as the electrical control circuitry that ensures the HUSITE SRP TOWER motor can have a soft start. The PLC controls such functions as: Well site alarms and system diagnostics Selected pumping system alarms based on host analysis of well conditions Data storage and trending Read/modify any numeric parameter and execute command parameters Stroke lower limit Stroke upper limit Real time monitoring of stroke speed Motor speed Braking time Pulse ratio Motor belt-roller diameter Roller drum belt diameter Open-phase (phase loss) protection Overload protection Automatic power cut off Failure alarm In areas experiencing heavy rain or snow conditions, we recommend a small shelter be provided by the customer for the control cabinet. 9

14 Specifications Model Type TSCYJ20 TSCYJ14 TSCYJ12 TSCYJ10 TSCYJ8 Max Load Capacity (MT) Motor Capacity (kw) Stroke Length (m) Stroke Per Minute >0<4 >0<4 >0<4 >0<4 >0<4 Belt Length Gear Box Torque (kn.m) Counterweight (MT) Total Weight (MT) Dimensions (L x W x H)(m) Shipping Dimensions Operating Temperature Model Selection x 3.3 x 2.2 x 2.8 x x 2.8 x x 2.6 x x 2.6 x Same as Same as Above Same as Above Same as Above Same as Above Above Breaking System Auto / Manual Auto / Manual Auto / Manual Auto / Manual Auto / Manual Lightening Protection Standard Standard Standard Standard Standard Base Dimensions (m) 6 x 2.4 x x 2.4 x x 2.4 x x 2.1 x x 2.1 x 0.25 Base Weight (MT) Many factors contribute to the decision on which model of SRP should be used, including well type, casing size, oil viscosity, water content, oil to gas ratio, etc., however a reliable rule of thumb that can be applied is the depth at which the liquid level occurs which corresponds to the depth of the down hole pump assembly. Liquid Level Below 1250m Below 1500m Below 2000m Above 2000m Possible Model Selection TSCYJ10 TSCYJ12 TSCYJ14 TSCYJ20 However, as mentioned above this reference should only be used as a preliminary criteria and the actual size of the model should be selected after a thorough review of the available well data. Shipping Requirements Model Type TSCYJ20 TSCYJ14 TSCYJ12 TSCYJ10 TSCYJ8 Pumping Unit Structure Open Top 40 Container Control Box Packaged in Wooden Crate Inside of the Pumping Unit Structure & Secured with Tethering Base Open 20 container (2 to 4 units together depending on model) Counterweights Bundled with Steel Straps on a Pallet with Open 40 Container for Pumping Unit Structure Spare Parts Kit Tool Box Kit Motor Packaged in Wooden Crate Inside of the Pumping Unit Structure & Secured with Tethering Packaged in Wooden Crate Inside of the Pumping Unit Structure & Secured with Tethering To Avoid Damage through Vibrations Packaged in Wooden Crate Inside Pump Unit Structure 10

15 INSTALLATION General Unless otherwise specified by the Owner, the unit will be shipped to the site in four kits: HUSITE SUCKER ROD PUMP TOWER Control Box Base and Counterweight Spare Parts Package A tool kit will also be shipped that includes the basic tools and fixings for the machine that will accompany the unit. The installation site should include: Power source 35 ton or larger crane Four six meter steel ropes and four fixture rings with a load bearing of 20 tons Three workers One electrician with a frequency transformer Lube oil for the chain box (200L) and gear box (180 L) (middle-load industrial gear oil: #220 (ISO Vg220) for temperatures above -15 degrees Celsius and #150 (ISO Vg150) for temperatures below -15 degrees Celsius) The site should be prepared and the area should be checked to insure the foundation gravel for the base has been prepared and meets the necessary requirements. All workers should have work gloves, safety helmet, and heavy duty steel tipped boots. If the area for the base has been prepared, then with three workers it should take four hours to install the unit. Soil Requirements and Ground Preparations If the load bearing of the area where the base will be placed is greater than 150MPa, 300 mm of earth should be removed in an area that should be a minimum of one meter and a maximum of two meters more than the length and width of the base depending on the site conditions. Then gravel should be laid in an area that corresponds to the size of the base. If the load bearing of the area where the base will be placed is less than 150MPa, no less than 1000mm and no more than1500 mm of earth should be removed in an area that should be one to two meters more than the length and width of the base. Then gravel should be laid in an area that corresponds to the size of the base. Installation of Base The concrete base should be oriented with a marker to point towards the wellhead. The height should be measured by a leveling instrument. The base should be checked by a 100mm leveling rod. Since the pump structure is placed on the base, location and alignment is very important. The well surface must tolerate over 70 tons including the HUSITE SUCKER ROD PUMP TOWER, counter weights, base and weight of the liquid to be lifted. The center point of the wellhead and the base should be aligned. 11

16 Installation and Positioning of Pump Unit Attach six meter steel ropes to the fixtures provided on structure of the pump, and attach to crane fixture Lift pump as shown below. After lifting, move the Pump Structure to the right of a support hole of a concrete base, insert a short steel pipe (provided in Tool Kit) into the support hole to fix it Release the steel rope and move to fix location. Lift the pumping to make it stand up as showed in the picture. Pump Structure can be moved in the stand-up position with the use of four movable rollers at the bottom of the Pump Structure; the rollers can be installed and removed with a hoist jack After removing the rollers, you can use a hoist jack to lift the bottom of Pump Structure and at the same time use a bob plumb-line to align the Belt with the wellhead center and make sure the off center point is less than10mm After finishing the adjustment of the Pump Structure, fasten the bolts at the base of the structure Install belt pulley, belt and hood shield Adjust handbrake Link rope hanger and install polished rod fastener Slowly release brake to let the load on the polish rod be on the loading belt, then uninstall polish rod fastener Lower the counterweight box, open the front door and install counterbalance weights Add lubrication oil for roller chain fuel tank 12

17 Pumping Unit Operation Check and fasten all the bolts on the pumping unit Ensure pumping the pumping unit has been attached to the power supply source Check the oil level in the gearbox and roller chain lubrication box Clean the odds and ends around pumping unit. Take off brake latch on the manual brake and release handbrake. After ensuring all safety procedures have been followed Number of pules times times/min Number of pules times Setting parameters Pules ratio: 1.36 Less sped time: 3s Braking time: 1s Motor speed: 980r/m DISPLAY ALARMS OPERATOR MENU DIAGNOSTIC MENU Number of pules times Setting parameters Upper limit of pules times:3.60 times/min Lower limit of pules times:2.60times/min Oil extractor best wheel diameter: 514mm Motor belt wheel diameter: 300mm Number of pules times times/min 1 Turn on the generator Open external power switch of the engine Open the electric box power switch Turn the power control box button left from OFF to RESET, which automatically resets the electric brake Turn the power control box button right from RESET to ON Start operation: set the switch to RESET, then turn the button to the right to the ON position Shut down operation: set the button to OFF, then use handbrake. Emergency shut-down operation: press the red button EMERG STOP, the system will shut down automatically and the electrical controller will brake simultaneously. Open control cabinet, connect PLC with the system power supply Set PLC system and VBD parameters. 2 PLC system parameters: the PLC yellow button hit the RUN switch press the ESC on the display Press the arrow keys to select the Diagnostics menu and press Enter select TD400 settings, press Enter Press the arrows to select the parameter block address, the parameter block address is set to 0 and press Enter, after finishing the set up, switch PLC from RUN to STOP to RUN, restart the PLC (this step should be set up before produced by the supplier, so that no longer setting is needed). 3 SRP parameters: Press ESC press the arrow to select parameters Press Enter into the parameters set by the first screen, press the left or right arrows to select the bit, up and down arrows to select the value to set the both ends of jig frequency limits, then press Enter; press the arrow to display the next screen, set the pulse rate (see Table pulse ratio), less speed delay; the third screen is used to set the braking time, the motor synchronous speed; the fourth screen, set the motor pulley diameter, SRP pulley diameter; after finishing all these, the PLC will switch from RUN to STOP and then switch to RUN again, then press three times ESC to return to the screen display. 4 display panel operation: SHIFT + F1 (Start), SHIFT + F2 (Stop), SHIFT + F3 (emergent stop), SHIFT + F4 (reset). 5 Alarm display: Press the ESC key twice choose to display the alarm, press F8 to confirm it. PLC PICTURE when setting SRP parameter Number of pules times times/min At the PLC control box, set the parameter on the lowest stokes per minute 1 Start the first five operations using this setting If all movements are smooth, then go on to the next highest strokes per minute 2 Continue this operation for fifteen minutes and then adjust to the strokes per minute required by the Owner PLC display of unit running normally 13

18 Procedure to Relocate the Unit: Insure the polished rod is lowered to the lowest possible point Apply the brake to stabilize the counterweight and insure it has no load Secure the polished rod by the polished rod binder Separate the polished rod from the rope hanger Tie a rope on the rope hanger Insure the load belt in the center of the roller drum Create tension on the rope slowly and gradually release the handbrake Slowly drop down the counterweight assembly and then fix the rope onto the pumping unit Release the fixed bolts on the baseboard of the pump unit and base concrete, dismantle fixed bolts and install roller wheels by using hoist jack Use chain blocks to remove pumping unit, then fasten fixed bolts When the wellhead work is done, remove it back to wellhead, fix it and fasten the bolts Lift up the counterweight assembly simultaneously pulling the rope tightly downwards to lower the load belt When the rope hanger reaches the lowest point, shut down the power source and use the handbrake Connect rope hanger and install the polished rod clip Slowly release the brake allowing the polished rod to rest on the load belt, then remove polished rod clip MAINTENANCE Summary of Routine Maintenance INSPECTIONS Back Pressure Gauge Reading Polished Rod Sealer Condition Gearbox Oil Level Chain Box Oil Level Pumping Unit Operating Conditions Tension of Variable Transmission Belt SAFETY STANDARDS 400 Psi No oil drops, oil spills, or residue should be visible il should be visible above the halfway mark in the observation window il should be visible above the halfway mark in the observation window Motor, gearbox, rollers, counterweight assembly, chain and belt should have smooth movement with no abnormal noise Is belt tight or slipping MAINTENANCE METHODS If back pressure gauge displays >400Psi, turn off the pumping unit, the production valve, and flow process valve Identify if polished rod is positioned correctly or not; or if seal requires replacing Stop the pumping unit and fill oil to the top Stop the pumping unit and fill oil to the top If jerky movement or abnormal noise, stop pumping unit and insure all parts are fastened and positioned correctly If slipping, pumping unit should be stopped and belt should be adjusted OBSERVATION FREQUENCY Hourly Hourly Weekly Weekly Daily Monthly 14

19 OILFIELD SERVICES & EQUIPMENT SUPPLY Well Analysis Provided with the appropriate data from the Customer, Husite engineers can analyze the conditions of the well and propose an artificial lift solution that best suits the Customer needs. Once we have received the completed data sheet, our engineers will select the optimum artificial lift solution for the client and provide a Technical Proposal based on the necessary requirements to insure the client can achieve maximum productivity for their well. The technical proposal will include: Executive Summary Basic Data Oil Well Production Data Analysis & Recommendations Operation Objectives and Requirements Mitigation Measures Major Equipment and Apparatus Well Control Operation Process Precautions QHSE Management Requirements Emergency Response Measures Lift System Design Site Layout Plan Once the client has reviewed and commented on the Technical Proposal, Husite will adjust the proposal according to the requirements of the client and then issue a Commercial Proposal for which will be the basis for further discussions with the client. Well Renovation After an analysis of the well data with proprietary software, the Husite engineers will propose a solution for the wells that have been offered for renovation. While conditions for each client may differ, the Husite team can provide: Design of lift system All equipment necessary for installation Operation of work-over rigs Well acidization Installation of tubing Installation of sucker rods Installation of sucker rod pump tower Operation of sucker rod pump tower 15

20 EQUIPMENT SUPPLY AND SELECTION Alternate Solution for Base The metal frame pictured below was used as a base for the SRP tower as a support for the standard steel and concrete base because the well had a concrete cellar of over two meters deep. The steel structure was bolted to the cellar with special concrete bolts for greater stability. The below image illustrates how the pumping unit, base, and steel structure are fixed on the cellar of the well. 16

21 Generator and Electrical Distribution System The distribution system that supplies power to oil field electrical systems is comprised of 3 main components: the primary and secondary electrical systems, and the grounding system. The primary system supplies electricity to the field at voltages ranging from 400 to V. High-voltage primary systems are preferred when electrical power travels a long distance. To protect these systems, it is necessary to install lightning arrestors and static lines that dissipate high static charges associated with electrical storms. High voltages from the primary system are transformed to lower voltages (generally less than 400 V) through a secondary system. The secondary system includes the distribution transformers that convert the primary system voltage to the motor operating voltage and all cables, switches, controls, and other devices that operate at the motor voltage. Electrical equipment at the well site must be properly grounded for personnel safety and to ensure that the electrical devices perform satisfactorily. If utility-furnished power is not available, field-based generators can provide electrical power to operate pumping unit motors. Distribution equipment for the generator system would be the same as for utility power. The voltage requirements will depend on the size of the producing field. In a field with fewer than five wells located close to the generator, the generator voltage may be the same as the motor rated voltage. In a field with 5 to 50 wells, the generated voltage should be higher than the motor rated voltage. At each motor, a transformer would be used. This system would be considered a moderately sized system, with a generator having distribution of V. In a very large field with more than 50 wells, generated voltage of 400 or V would be stepped up to V for distribution. The higher voltage allows the use of smaller conductors and reduces line voltage drop. At each well site, a transformer will drop the distribution voltage to motor rated voltage. 17

22 An example of a generator that we have used with individual wells is as follows: Set parameter: Set type: H100 Rated power factor: COS=0.8(Lag) Rated power: 100KW Stable state voltage regulation: 1% Rated voltage (V): 400V Momentary state voltage regulation: -15%~ +20% Rated current (A): 180A Stable state frequency regulation: 3% Rated frequency: 50Hz Voltage stabilization time: 1.5sec Frequency flutter rate: 1% Voltage fluctuation rate: 1.0% Full load fuel consumption: 198g/KWh Momentary state frequency regulation: 10% Set noise(db): 95 Frequency stable time: 3sec Set size(mm): 2000*830*1400 Set dry weight(kg): 1300 Diesel Engine Parameter: Engine type: 6BTA5.9-G2 RPM 1500r/min Engine power: 110KW Varying speed method: motor Cylinder mode of arrangement: 6 cylinder upstanding type Machine oil type/volume L: CD/18 Fuel type: 0# light diesel fuel type of cooling: Enclosed water circulation airblast Four stroke,exhaust Type : turbocharger, direct injection compression ignition Way to start: 24V direct current type Motor parameter Activation: Brushless all-bronze excitation Voltage control type: AVR automatic pressure Number of phases: Three phases quad wire Insulation class: H Guarding class: IP22 Type of Cooling: Self-cooling Frequency Adjustment(%) ±0.5(stable) +10~-7(momentary) Voltage regulation(%) : ±0.5(stable) +20~-15(momentary) Control box Electric control panel displays voltage, current, frequency, water temperature and oil pressure. 18

23 Wellhead The typical wellhead installation consists of the following components: Manual or Automatic blowout preventer (BOP) Manual or Automatic gate valves (three sets: two production valves, and one wax cleaning valve); Polished rod sealer Pressure gauge flange (one set) Blind flange (one set) Basic functions A BOP includes the housing, side door assembly, gate assembly and other components and can be used alone or in combination with other supporting parts, by automatically or manually closing and opening the gate valve. A ram BOP accomplishes the following operations: Where the well has a drill stem (or other tubes), the ram BOP can close the circular gap between the casing and drill stem by closing the polished rod sealer. Where there is no drill stem in the well, it can close completely the gate, thus closing the well-hole. Structural Characteristics Pressure parts shall be designed, manufactured and tested in strict compliance with the standards of API Spec 16A Drilling Access Equipment Specifications, API Spec 6A Wellhead Equipment and Oil Tree Specifications, and SY/T Code for Wellhead Equipment and Oil Tree. If the wells have a high sulfur content, the main pressure parts of ram BOP should be manufactured using high anti-sulfur materials for effective prevention; in medium sulfur conditions, manufacturing should use electrochemical corrosion with weight loss, hydrogen embrittlement corrosion, and sulfide stress corrosion, as the corrosions may lead to the device embrittlement and fracture (crack), so the overall reliability is increased. Through the use of special heat treatment technology, the main pressure parts gain good mechanical properties, and the BOP s resistance to hydrogen sulfide stress corrosion is able to meet the standard requirements of NACE MR

24 BOP connection features flange and sealing ring. User-friendly, safe and reliable to operate, and compact in construction, and highly adaptability to application, and quick installation and easy management; Can rapidly control well blowout, overflow, and well kick; Prior to the ex-works delivery, the equipment shall be subjected to extreme pressure test, path (full bore) test, simulated site seal well-pressure test, and seal test, in accordance with GB/T Drilling and oil extraction equipment drillingthrough equipment as well as the relevant provisions of API. Sample Of Main Technical Specifications Nominal diameter: Φ65mm Rated working pressure: 35Mpa(5000Psi) Strength test pressure: 52.5MPa(7500Psi) Operating temperature: -29 ~121 Working medium: sulfur contained natural gas, oil, mud, and water Material grade: EE Drilling tools (stem) to be closed: 0-40mm Gate switch operation: Manual Connection type: upper and lower flange connection Upper flange connection: 6B 2 9/16-35 R27 Upper flange connection bolt-hole circle diameter: Ф190mm Number and size of the upper flange connection bolts: 8-1 8UN Upper flange sealing ring: R27 Lower flange connection: 6B 3 1/8-35 R35 Lower flange connection bolt-hole circle diameter: Ф203mm Number and size of the lower flange connection bolts: 8-1 1/8 8 Lower flange sealing ring: R35 20

25 Precautions There is a pressure gauge installed at the outlet of the oil extraction valve, and the display value of the gauge is the back pressure of the wellhead, so the back pressure value needs to be watched all the time in the process of oil extraction. For safety reasons, the back pressure value cannot exceed 400PSi; if it s higher than this value, the production maintenance personnel should immediately stop the SRP Tower, close the production valves and the flow process valves, and address the problem after the back pressure causes are identified, before restarting the SRP Tower to continue production. The maintenance personnel shall conduct the walk-around inspection of the back pressure gauge at a designated time every day, and document the inspection results, once an hour. POLISHED ROD Polished rod The polished rod is an important spare to hang the pimp and deliver power. Polished rod have two classes: Class I -- both ends have external threads Class II -- polish rod with one end being sucker rod external thread. 21

26 Normal size of API polish rod General dimension of API Sucker Rods Basic Functions The function of polished rod sealer is to achieve the sealing of polished rod while the polished rod is in up-and-down movement; this kind of seal is a dynamic seal. Major Structural Characteristics: The polished rod sealer features a double set of upper and lower seal, and each sealer functions with compression nuts tightening 3-4 layers of rubber sealing ring to achieve the sealing effect. 22

27 Main Technical Specifications Precautions Nominal Diameter: Regular Working Pressure: Φ32mm 400Psi Sealing rings are vulnerable to wear and should be changed regularly, and special attention should be paid if the any sign of oil drip or residue occurs. Tubing Different types of tubing are applicable for pumping systems depending on the design of whole sucker rod system. 23

28 Sucker Rods The subsurface pump is connected to the pumping unit on the surface by a string of solid sucker rods. Pony rods are shorter-length rods used to bring the rod string to the exact length needed in a well. Sucker rods are joined together by threaded connectors or couplings, which are usually about 4 inches long. Some rods are manufactured with pin-and-box couplings, while others are made with pin couplings at both ends and then joined together using rod couplings. Steel sucker rods One-piece steel sucker rods are manufactured from hot-rolled steel. The pin ends of the rod are forged, the rod is heat-treated, the pins are machined, and a finish designed to reduce corrosion is applied to the rod surface. Three-piece rods are manufactured by attaching threaded metal pin and box connectors to the threaded ends of a machined rod. These sucker rods are sometimes used in shallow wells. The choice of what size and grade of steel sucker rods to use in a well is determined by rod stress and well conditions. Rod stress is determined by the production rate, tubing and pump sizes and the characteristics of the pumping unit. The presence of H2S, CO2, salt water or other corrosive agents effectively reduce the maximum allowable stress on a rod string, and require adjustments to rod stress calculations. Fiberglass sucker rods Fiberglass sucker rods are actually made of fiberglass embedded in a plastic matrix. Steel end fittings with standard pins are attached using an adhesive. These rods are joined with standard couplings to form rod strings. The primary reasons for using fiberglass rods are because they are lighter and more corrosion-resistant than steel rods. This makes them an attractive option in deeper wells and corrosive environments. There are, however, several disadvantages to using fiberglass rods in place of steel rods. They are more susceptible to fatigue failures resulting from the repeated loading and unloading during the pumping cycle, and are more likely to fail under compressive forces. And they may lose their strength through exposure to high well temperatures or hot-oiling treatments. The resins used during manufacture of the rods are the elements that determine the rod s resistance to chemicals and temperature; different resins have different physical properties and resistance to chemicals. Continuous sucker rods Unlike conventional sucker rod strings, continuous sucker rods require couplings only at the top and bottom of the rod string - regardless of well depth. This continuous length of steel reduces the weight of the rod string and provides a more uniform contact with the production tubing a particular advantage in deviated wells. 24

29 Pump Assembly and Gas Anchor The below figure is a cross-section representation of a subsurface pump at two different stages of the pump cycle. Note the location of the standing valve at the bottom of the tubing, and the traveling valve at the bottom of the sucker rods. Note also the changing position of the plunger. On the left-hand side of the figure, the plunger is approaching the bottom of its down-stroke. The traveling valve is open, and so the standing valve is closed because it is carrying the weight of the fluid above it. At this point in the cycle, the fluid above the standing valve is moving upward through the open traveling valve. On the right-hand side of the figure, the plunger has reached the bottom of the stroke and is just beginning to move upward. The plunger starts to lift the weight of the fluid above it, and the traveling valve closes. As the plunger continues to move upward, the volume in the working barrel between the standing valve and traveling valve increases, while the pressure in the working barrel decreases. As soon as this pressure becomes less than the flowing bottom-hole pressure, the standing valve opens and formation fluids flow upward. During each upward movement of the plunger, wellbore fluids are lifted a distance equal to one full stroke length. When the plunger reaches the top of its stroke, its movement is reversed the traveling valve opens, the standing valve closes and the cycle repeats its reciprocating movement of the rods and the opening and closing of the two valves. With each stroke, fluid is moved up the tubing toward the surface. If the produced fluid contains free gas, there are two points to note regarding the pump cycle: The valves will not necessarily open and close at the exact top and bottom of the stroke. The point in the upstroke at which the standing valve opens will depend on the spacing (the volume that exists at the bottom of the stroke, between the traveling and standing valves), and on the amount of free gas present in this volume. On the down-stroke, the traveling valve remains closed until the pressure below the plunger is greater than the pressure above it. The traveling valve then opens and allows fluid to pass through it into the tubing. The exact point in the down-stroke at which the traveling valve opens depends on the free gas volume in the fluid below the valve. 25

30 The greater the volume of free gas, the greater the proportion of the stroke that is taken up in gas expansion and compression, without any true pumping action taking place. For wells producing a reasonable volume of gas, a gas anchor is normally installed on the tubing below the pump. This device allows the separated gas to be produced up the annulus before it would otherwise enter the pump. The gas anchor's primary role is to separate the liquid s gas from the tubing, and the separated gas shall be taken out of the gas vent at the top of the gas anchor, and led into the casing, so as to improving the pump efficiency. Gas anchor is consisted of two parts Upper part of air discharge including air collection hood and non-return valve Rotating separation part After gas-oil mixture enters the extractor, as the liquid is heavier than the gas in density, the gas flows upwards into the rotary gas separator, then into the conical space of the gas collection hood and is forced out of the pump forming a gas cap inside the gas collection hood. Finally, it the non-return valve to open and exits into the annulus. 26

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