Waste Injection (CRI) Pump Units Model: CRI 450 & CRI 1680 450kW to 1680kW (250HP to 2500HP) 94/9/EC ATEX - 97/23/EC - PED 2006/42/EC Machinery Directive CE Marked Applications: Waste Injection/Cuttings Injection General Well Service & Well Completion Acidising, Pressure Testing and Well Kill Cementing Coil Tubing Mud Pumps Introduction Calder Ltd has established a reputation over a period of 30 years as a designer and supplier of robust, functional and reliable High Pressure Pumping equipment for waste injection applications around the world. Every Calder Waste Injection unit incorporates the proven inherent attributes of quality and reliability whilst matching individual installation requirements. A range of plunger sizes is available for the Calder Waste Injection pumps; the optimum size is selected for each particular application. This ensures that a wide range of flows and pressures can be achieved without the need for subsequent changes of plunger. The control system requirements are uncomplicated and easily accommodated by a range of solutions from relay logic to remote, networked PLCs. The Calder Waste Injection pump packages can also be utilised for general well service, well completion and cementing duties, provided that these duties are defined and included in the selection criteria. The primary pump components; plungers, packings, valves and lubrication systems are selected on the basis of comprehensive oil-field experience. The pump satisfies API 674 rules (with some minor exceptions). Through experience, Calder Ltd has identified the key elements required to package reliable, operable and maintainable equipment. www.calderltd.com
Waste Injection (CRI) Pump Applications Waste Injection (CRI) Pump Units The pump unit is designed to continuously inject slurry over a wide range of flows and pressures, for the injection of seawater and slurries consisting of drill cuttings, drilling muds and sand into subsea strata as demanded by the oil drilling industry worldwide. Derivatives of this Calder-designed package are being used in Canada, Siberia, Caspian Sea, UK North Sea and Norwegian North Sea. Experience Calder Ltd has identified the key elements required to package reliable and easily maintainable equipment in the most arduous conditions. These key elements are included in the standard Calder package or are offered as options where applicable. The range of options ensures that the scope can be adjusted to meet each project s specific needs. Calder Ltd will work alongside clients to assist in specifying associated equipment, such as drives and controls, should the client choose to source these separately. Calder has the experience and capability to offer a wide range of services, including original design, testing and on site service support over a wide range of oilfield applications. In addition to waste injection/ well service pumps we offer a range of packages up to 2.5 MW power capacity and pressures up to 4000 bar. Hydraulic Motor Drive Full range flow adjustment. Small footprint. Smooth operation. Description The Calder Waste Injection pump package consists of a high-pressure reciprocating plunger pump and driver (electric motor with variable frequency drive (VSD) or hydraulic pump/motor; alternatively diesel engine driver with six speed transmission or hydraulic pump/motor) which are mounted on a substantial base frame. The package includes packing lubrication and power end lubrication sub-systems and associated instrumentation. The variable speed drive capability provides variable flow over a range from 10% to 100%. The pump unit can be controlled from the skid or from a remote operator station. Flow control allows the operator to select the required flow rate at the pressure that is within the wellhead, providing the pressure does not exceed the design rating of the pump and motor. The HP pump delivers a flow that is proportional to the motor speed and at the pressure necessary to inject the slurry. Calder Ltd offers a range of options such as a noise hood, oil heaters and oil coolers to suit the process and installation requirements of the specific project. A full range of Functional Tests at full flow and pressure are completed before despatch from Calder s works to ensure that commissioning can progress without delays. The package can be readily transported and installed on the platform, supported with comprehensive certification and technical literature. 2
Calder (CRI) Pump Packages Calder CRI-1680 Direct drive 1000kW CRI Design Criteria: The self-contained Waste Injection high pressure units are designed and built in the UK to conform to most international oil and gas field requirements compliant with ATEX, Norsok or Gost regulations and standards for use in a Safe Area, Zone I or II hazardous area. The high-pressure pump is selected for continuous duty service ensuring long-term reliability and low maintenance in the field. Variable speed drive options ensure that the optimum speed torque envelope is maintained with minimum current demand. Where VSD is selected the frequency converter minimises harmonic distortion and EMC radiation providing a high frequency switching and recalculation against the motor model, thus providing rapid and direct control of the drive motor. The control system provides programmable analogue and digital inputs and outputs, keypad entry, text read-out for the various parameters including frequency, current, torque and power. A range of additional management and communication facilities are available for connection to the system. The Unit Comprises: High pressure pump, gearbox and driver. Pressurised lubrication system with oil cooler. HP pressurised packing lube system. Integral suction & discharge dampers. Discharge pressure safety valve (suction PRV option). Temperature & pressure transmitters. Stroke counter or flow meter. Non-sparking coupling guard. Instrumentation, E stops and associated wiring to local JB. Anti-vibration mounts (AVM). Fully flexible control of the injection system to meet wellhead requirements. Injection rates and discharge pressures will determine the pump selection and ultimately the power required. The standard pump package supplied by Calder is a ready-to-go machine complete with all termination points at skid edge, complete instrumentation, pulsation dampers, safety relief valves, junction boxes and control systems. Finite element analysis (FEA) is supplied to primary structures and can be extended to include Blast Case analysis. 3
Diesel Engine Drive HP Pumps High Pressure Pumps The Calder CRI triplex reciprocating plunger pumps conform generally to API 674. The pump fluid ends are manufactured from forged steel designed with easy maintenance as a priority, giving fast access to valves, packings and plungers. (Duplex and Super Duplex Stainless Steel are available as options.) The internal suction & discharge valves are designed specifically for aggressive slurry injection processes. These valves have clear flow-ways and specially formulated polyurethane replacement inserts for resistance to acids and abrasives. The plunger packing system is the SSF design combined with ASF Flat Back Seal Ring and Header Rings, which are specially designed for use on slurry applications. Plungers are 4330 Alloy 6, coated with Boron Alloy that provides maximum hardness for erosion and wear resistance. A packing lubricator is fitted to enhance the life of high pressure packings. Trailer-mounted Waste Injection Pump Unit with Transmission Zone 2 Hazardous Area Suction and discharge flanges to the Calder CRI pumps are provided to suit the customer s specific requirements. As standard, the pump s discharge fittings are Weco fig.1502 with ANSI 150 lb RF. 6, 8 or 10 suction terminations to suit flow conditions. The power end of the high-pressure pump is a heavy-duty steel fabrication with a one-piece forged steel crankshaft. The four main bearings are large straight roller bearings with shell type replacement journal bearings. A speed reducer gearbox with 4.68:1 to 7.5:1 ratios is fitted directly to the power end of the pump. The reduction is achieved through a double heavy-duty helical gear machined from alloy steel, heat-treated and crown shaved. A drip tray is installed under the entire HP pump, including the pump head. Drive Options Available: Electric motor, AC variable speed. Electric motor with hydraulic pump and hydraulic motor. Diesel engine drive through semi-automatic transmission. Diesel engine drive through hydraulic pump and hydraulic motor. 4 Diesel Engine/Hydraulic Drive Waste Injection Pump Zone 2 Hazardous Area
CRI 450 Electric Units The power selected for the motor is based on the duties specified plus allowances for PSV set pressure and PSV overpressure. This selection provides a particular performance envelope to suit specific well conditions. Electric motor driven units can be Safe Area to Zone 1, II 2 G EEx de IIC T4 in accordance with guiding rules 94/9/EG ATEX. Diesel engine driven units are normally Safe Area or Zone 2 compliant. Options Calder Ltd offers a range of options. Some options are mutually exclusive of others. Options VSD for Safe-Area Application Operator Control Panel Skid Local Panel Noise/Environment Protection Enclosure Maintenance Crane Anti-vibration Mounts Lifting Equipment Pump Skid CRI 450 Electric Motor Driven CRI 450 with Acoustic Enclosure Packing Lubrication System The packing lubrication system mounts directly to the HP Pump. Packing lubrication oil is stored in a small reservoir, a series of 3 lubricator pumps are mounted into the reservoir each feeding fluid directly into the lantern ring within the packing sets. The pumps are driven from a common shaft, taking power from the HP pump crankshaft via a V belt drive. This system provides precise measures of lubricant under pressure into the packing based on pump speed. An optional large capacity packing oil header tank is available. Power End Lubrication System A 4.6 kw, 3-phase electric motor will independently drive the lubrication gear pump. This ensures a constant feed to all critical components within the power end at all HP pump speeds. This is particularly important at low speed high pressure duties. The oil is stored in an integral steel tank and is lifted from the tank by the pump, filtered to 20 microns and injected onto the bearing and gear surfaces within the power end of the HP pump; from there the oil drains from the HP pump back into the lube oil storage tank. Additional instrumentation, oil heaters and oil cooler are available, as required to suit the environmental conditions. Pulsation Dampers Suction Strainer Simplex or Duplex Suction Relief High Pressure Discharge Relief Valve Medium or High Pressure Suction Pressure Discharge Pressure Fire Detection & Gas Detection Header Tank for Packing Lubrication Space Heater Oil Sump Heaters Cooler for Power End & Diesel Engine Lubrication Witnessing of Load Test Factory Acceptance Test Noise & Vibration Tests Long Term Preservation Site Support & Commissioning Services 5
CRI 1680 Pump Units Waste Injection Pumps Client... BP Flow... 95m3/hr (10 bpm) Pressure... 345 bar (5000 psi) Hazard Area. Zone 1 ATEX Drive... 1400kW variable speed Noise... 83 db(a) Well Service Pumps Client... Aker Flow... 105m3/hr (11 bpm) Pressure... 517 bar (7500 psi) Hazard Area. Safe Area Drive... 1800kW variable speed 6
Calder Cuttings Injection Pump Model CRI-450 Pressure flow chart for all plunger sizes Flow 13 26 50 66 77 92 102 110 128 143 150 164 196 225 248 256 306 USGPM Pressure 50 100 188 250 290 350 385 416 485 540 568 620 742 850 939 970 1158 LPM 0.3 0.6 1.2 1.6 1.8 2.2 2.4 2.6 3.0 3.4 3.6 3.9 4.7 5.3 5.9 6.1 7.3 BPM bar psi 3.0 6.0 11.3 15.0 17.4 21.0 23.1 25.0 29.1 32.4 34.1 37.2 44.5 51.0 56.3 58.2 69.5 M3/HR 25 363 3 5 10 13 15 18 20 21 25 28 29 32 38 44 48 50 60 50 725 5 10 19 26 30 36 40 43 50 56 59 64 76 88 97 100 119 75 1088 8 15 29 39 45 54 60 64 75 84 88 96 115 131 145 150 179 100 1450 10 21 39 52 60 72 79 86 100 111 117 128 153 175 194 200 239 125 1813 13 26 48 64 75 90 99 107 125 139 146 160 191 219 242 250 298 150 2175 15 31 58 77 90 108 119 129 150 167 176 192 229 263 290 300 358 175 2538 18 36 68 90 105 126 139 150 175 195 205 224 268 307 339 350 418 200 2900 21 41 78 103 120 144 159 172 200 223 234 256 306 351 387 400 225 3263 23 46 87 116 135 162 179 193 225 251 264 288 344 394 436 450 250 3625 26 52 97 129 149 180 198 214 250 278 293 320 382 438 275 3988 28 57 107 142 164 198 218 236 275 306 322 352 421 300 4350 31 62 116 155 179 216 238 257 300 334 351 384 459 325 4713 34 67 126 168 194 235 258 279 325 362 381 415 351 5090 36 72 136 181 210 253 279 301 351 391 411 449 375 5438 39 77 145 193 224 271 298 322 375 418 439 5.0" Plunger 400 5800 41 82 155 206 239 289 318 343 400 445 Pressure limit 351 bar 433 6279 45 89 168 223 259 312 344 371 433 450 6525 46 93 174 232 269 325 357 386 450 4.5" plunger 500 7250 52 103 194 258 299 361 397 429 Pressure limit 433 bar 548 7946 56 113 212 282 328 395 435 624 9048 64 129 242 322 373 450 4.0" Plunger 650 9425 67 134 252 335 389 Pressure limit 548 bar 716 10382 74 148 278 369 428 752 10904 78 155 291 388 450 3.5" Plunger 873 12659 90 180 338 450 Pressure limit 716 bar 976 14152 101 201 378 1100 15950 113 227 426 3.0" plunger POWER TABLE Calder CRI 450 Pump 1120 16240 115 231 434 Pressure limit 976 bar 1161 19894 120 239 450 Power Table: Calder CRI 450 Pump 2.75" Plunger Pressure limit 1161 bar Crankshaft speed is limited to 450 RPM maximum. Max recommended speed for Slurry Service should not exceed 200 rpm. 450 kw (600 HP) maximum Intermittent Power 300 kw (400 HP) Maximum Continuous Duty. Calder Cuttings Injection Pump Model CRI-1680 Pressure flow chart for all plunger sizes Pressure 26 132 264 370 431 462 545 581 634 673 793 969 1057 1138 1255 1319 1515 USGPM 100 500 1000 1400 1631 1750 2062 2200 2400 2547 3000 3667 4000 4307 4750 4992 5734 LPM 0.6 3.1 6.3 8.8 10.3 11.0 13.0 13.8 15.1 16.0 18.9 23.0 25.1 27.1 29.9 31.4 36.0 BPM bar psi 6.0 30.0 60.0 84.0 97.9 105.0 123.7 132.0 144.0 152.8 180.0 220.0 240.0 258.4 285.0 299.5 344.0 M3/HR 25 363 5 26 52 72 84 90 106 113 124 131 155 189 206 222 245 257 296 50 725 10 52 103 144 168 180 213 227 247 263 309 378 412 444 490 515 591 75 1088 15 77 155 216 252 271 319 340 371 394 464 567 619 666 735 772 887 100 1450 21 103 206 289 336 361 425 454 495 525 619 756 825 888 979 1029 1182 150 2175 31 155 309 433 504 541 638 680 742 788 928 1134 1237 1332 1469 1544 200 2900 41 206 412 577 673 722 850 907 990 1050 1237 1512 250 3625 52 258 515 722 841 902 1063 1134 1237 1313 1546 300 4350 62 309 619 866 1009 1082 1275 1361 1485 1575 325 4713 67 335 670 938 1093 1173 1382 1474 1608 350 5075 72 361 722 1010 1177 1263 1488 1588 375 5438 77 387 773 1082 1261 1353 1594 400 5800 82 412 825 1155 1345 1443 7.5" plunger 425 6163 88 438 876 1227 1429 1534 Pressure limit 375 bar 450 6525 93 464 928 1299 1513 1624 475 6888 98 490 979 1371 1597 7" Plunger 500 7250 103 515 1031 1443 1681 Pressure limit 450 bar 525 7613 108 541 1082 1515 550 7975 113 567 1134 1588 6.5" plunger 575 8338 119 593 1186 1660 Pressure limit 525 bar 600 8700 124 619 1237 625 9063 129 644 1289 6" Plunger 650 9425 134 670 1340 Pressure limit 600 bar 700 10150 144 722 1443 800 11600 165 825 1649 5" Plunger 900 13050 186 928 Pressure limit 700 bar 1000 14500 206 1031 1100 15950 227 1134 4.5" plunger POWER TABLE 1200 17400 247 1237 Pressure limit 1000 bar 1300 19894 268 1340 4" Plunger Pressure limit 1300 bar Crankshaft speed is limited to 330 RPM maximum. Max recommended speed for slurry service should not exceed 200 rpm. 1687 kw (2250 HP) maximum Intermittent power 850 kw (1100 HP) maximum continuous duty. Power tables show approximate (kw) power absorbed at various flows and pressures. Power and flow for each plunger size. All data is based on 95% volumetric efficiency and 85% mechanical efficiency pressure and flow limits for each plunger size. Flow Power Table: Calder CRI 1680 Pump 7
Waste Injection (CRI) Pump Packages Performance Calder pump packages are designed for intermittent & continuous pumping of Oil & Gas field waste products & well service chemicals such as, Brine, Drill Cuttings & Muds within a specified duty range. Pressure Range... 80 to 1400 bar (1,200 to 20,000 psi) CRI 450... 156 M³/hr (16 BPM) CRI 1680... 344 M³/hr (36 BPM) Flow range... 10% to 100% Power range... 450 kw to 1680 kw, Safe or Hazardous area... ExN or EExd, Zones 1 & 2 Noise Level... 75 dba, 83 dba, 85 dba @1M Drive Options Electric Motor, Fixed or Variable speed using VFD or Hydraulic Drive Diesel Engine with Transmission or Hydraulic drive. Unit Configuration Options Open Skid, Trailer or Truck Mounted Noise & Environment Enclosure. Container, Offshore DNV compliant Pump type for Waste Injection (CRI) process: Reciprocating Pump Type... Calder Model CRI 450 & CRI 1680 Triplex Reciprocating Plunger. Plunger Range (diameter)... 57 mm to 180 mm (2.25 to 7.0 ) Plunger (stroke 150 & 200mm) Plunger Material Type... SS/Tungsten Carbide Valve Housing... High Strength Alloy Steel or Duplex stainless steel (option) HP Seals... SSF Design with back seal ring, Lantern & Oil Lube LP Sealing... Double Lip Seal Lubrication... Pressurised - filtered Suction Flange... 6 or 8 150lb ANSI Raised Face Discharge Flange To suit client requirements. Design Temperature.... 10 C to 85 C (-40 C + 120 C options) API 674...Compliant with exceptions Operation & Control Systems: Simple Controls to fully integrated unmanned control systems. Pump flowrate controls allow fixed or variable flow rates using variable frequency drive or hydraulic drives. Pump unit control system configurations featuring the following options: Single or multiple pump unit control systems which can be operated from a remote location. Local control systems available which can be skid mounted. Full integration and interface with client to control systems. Use of the latest communication protocols. Comprehensive instrumentation with health/status monitoring functions. Full data acquisition and logging capabilities. Optional touch-screen HMI with manual or automatic modes. During operation the system is protected by instruments monitoring the suction pressure, the discharge pressure, the lube oil pressure and the lube oil temperature. The control system also monitors its own internal communications. If any of these are lost, the whole system is shut down immediately. An external communication port is available for remote operation and monitoring. Standards & Specifications: Calder pump packages can comply with most international standards and specifications including: ATEX IEC GOST EN DNV API ANSI PED AS/NZ NORSOK NACE CE PED ISO 9001 Quality standard has been practised by Calder since 1987 with award of certification in 1999. Our rigorous application of this highly respected International Quality Standard has ensured that we consistently meet and exceed our customers most demanding expectations for both quality and reliability. ISO 14001 Environmental Standard has been held by Calder since 1999. Careful and judicious management of our working environment with the application of sound and well informed design applications utilising the latest and most efficient technologies helps us to produce equipment which minimises the environmental footprint of our production facility and the operating equipment in the field. OHSAS 18001 We at Calder pride ourselves on our safety record. As members of the British Safety Council we practise the strictest safety procedures within our factory and working environments, applying rigorous risk assessments to all activities and equipment which we design and build. Calder Ltd reserve the right to alter specifications and data to incorporate improvements in design. Calder Ltd Prescott Drive Warndon Worcester WR4 9NE United Kingdom web : www.calderltd.com email : sales@calder.co.uk tel : +44 (0) 1905 759090 fax : +44 (0) 1905 759091