CONFIND - Petroleum Clubpetroleumclub.ro/downloads/ROupstream/Gheorghe_Miloiu_Dorin_Racota.pdf · Salt water salinity: 16 – 17% The water has to be filtred before passing trough

Romanian Upstream Conference 13-14 March 2012

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CONFIND MANUFACTURER OF PROGRESSIVE

CAVITIES PUMPS (PCP) WITH HIGH FLOW AND PRESSURE FOR SALT WATER INJECTION IN GAS AND OIL DEPOSITS

CONFIND Campina

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Salt water extracted with crude oil from operating wells is further injected into reservoirs for two purposes:

To maintain reservoir pressure as that early

operation, which prolongs the operating time by natural lift (the cheapest method of extraction);

If the oilfield water would remain on the surface, it should be treated (which is an expensive operation) to avoid contamination of soil.


CONFIND Campina

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SALT WATER Salt water salinity: 16 – 17% The water has to be filtred before passing trough the pump Solid particles up to 0,05% (max sizes 0.1 mm dimensions)

Temperature: 5 ... 80 ⁰ C

For extremely corrosive fluid

PARAMETERS REQUIRED FOR THE INJECTION

High pressures: 60 – 110 and ever higher; High flows: 150 – 1000 cm/day (6 – 42 cm/h)

The pump operates continuously


CONFIND Campina

Definition of the injection process:

Piston pumps (duplex, triplex) High energy consumption, low durability Frequent interruptions + high operating costs

Conventional centrifugal pumps Provides high flow rates required, but pumping pressure is

limited to 40 – 50 bar; Frequent interruptions for replacement of wear parts.

Centrifugal pump with Pitot tube Very sensitive to the presence of abrasive particles in

suspension High costs of spare parts


4 CONFIND Campina

EVOLUTION OF SALT WATER INJECTION TECHNIQUE IN THE OILFIELD

In 2002 – 2004 CONFIND performs the first surface progressive cavities pumps, for high pressures and high flows, intended for salt water injection in the gas and oil deposits.

GP 15.100 & GP 25.80

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PUMP MAX. PRESSURE BAR

FLOW CM / H

FLOW CM / D

POWER kW

GP 15.100

100

5 – 20

120 – 480

55 / 75

GP 25.80

80

15 – 40

350 – 950

75 / 90 / 110


CONFIND Campina

Fluid sensors with Mobrey vibrating fork on the suction chamber connector Pressure gauge on the discharge chamber

(flange) connector (discharge valve between the two chambers) Heat tracing kit for 50 C or 150 C Power control panel with frequency converter

and specific PCP pumps software


6 CONFIND Campina

SAFE OPERATION OF GP PUMPS


7 CONFIND Campina

GP 15.100 Injection pump

Pressures Number of sizes

Types Flow cm / h

Low 6 … 24 bar

9 GP 10.06 5 … 60 GP 10.12/24 GP 20.12/24 GP 40.12/24 GP 60.12/24

Ave-rage

36 … 48 bar

6 GP 10.48 5 … 60

GP 20.48 GP 30.50 GP 40.48 GP 60.36 GP 60.48

High 60 … 100 bar

2 (4) GP 15.100

5 …40 GP 25.80


8 CONFIND Campina


9 CONFIND Campina

CGA – CONFIND’s walking beam driven gas compressor March 2012

HISTORY

Gas back pressure in the oil wells annulus generates a restriction to the oil and gas flow from the formation into the well bore, frequently causing gas locking of the down hole pump too. By relieving that pressure, the well production increases and the pump gas locking are eliminated or diminished. Different “well head compression” solutions were used for more than one hundred years. The waking beam driven compressor is now the most used one, especially in the US and Canada. Many companies are producing, under different names, such compressors. Among them: Permian Production Equipment – the Beam Gas Compressor Basil International – the Basil Beam Compressor Iron Horse Compression – the JACGAS Annugas Compression Consulting – the Annugas Production Enhancer Since 2010 Confind Campina – Romania is producing CGA – the Associated Gas Compressor


HISTORY The main benefits of the waking beam driven compressor: Both oil and gas production of the well is increasing; Gas locking of the pump are relieved; Capturing and compressing the vented gas; Relieving the flow in the oil & gas delivery line; Simple, rugged, driven by the jack pump, relatively low-cost equipment, are materialized in one month to one year equipment pay-back – duration highly pending on the formation structure. CGA 8x36 Compressor

in function since May 2011

Based on the very good results obtained in operation, recently Confind earned a contract for seven off CGA compressor, 10” bore, different strokes.

Basically, the CGA compressor is done by a gas compressor cylinder, special clamps to attach it to the pump jack and the hoses & piping system up to the pumping jack skid limit. The compressor piston is driven by the walking beam of the pump jack. An electronic temperature monitoring and automatic overheating protection system is included.

March 2010 The CGA prototype system, in-house tests on a 7 tons pump jack produced by CONFIND


GENERAL PRESENTATION

Confind’s standing policy of predictive adjustment of it’s production to the necessities of the oil and gas industry operators; The technical capability to develop new products; The large experience and technological capacity in manufacturing equipment for the oil and gas industry; The outstanding availability to provide at-hand technical assistance, spare parts and also maintenance for it’s products,

The system and it’s components, except for very specific ones as the relief valve or automation equipment, are SC Confind designed and produced.

The main reasons why SC Confind decided to develop

the CGA product


GENERAL PRESENTATION

CGA 6xXX Version (6” bore x XX” stroke) is targeting mainly the up to and including 5 tons pump jacks The CGA prototype, a CGA 6x36 model is functioning since 23rd of July 2010

The version of a CGA System is determined by the compressor cylinder bore. A version includes different models, characterized by the piston stroke. Three of the foreseen versions (6”, 8” and 10” bore) are already in production.

First prototype check (2 hours, during an scheduled oil well stop).


VERSIONS and MODELS

CGA 8xXX Version (8” bore x XX” stroke) is targeting mainly pump jacks in the 7 to 12 tons range Two modes were manufactured: CGA 8x36 Model (8” bore x 36” stroke) - in function since 2nd of May 2011 - the casings of other two oil wells in the

close vicinity are connected to the same CGA compressor

CGA 8x56 Model (8” bore x 56” stroke) - in function since 4th of February 2011

CGA 8x56 compressor installation works on a pump jack


VERSIONS and MODELS

CGA 10xXX Version (10” bore x XX” stroke) is targeting mainly pump jacks in the 12 to 15 tons range Under current manufacturing there are the following models CGA 10x36 Model (10” bore x 36” stroke) CGA 10x48 Model (10” bore x 48” stroke) CGA 10x64 Model (10” bore x 64” stroke)

CGA 10x36 compressor working with a pump jack since December 2011


VERSIONS and MODELS

In order to test the market and also to provide a rough guide for the potential customers to make a selection, Confind launched the following production range availability:

Preferably the version – model selection is made by consulting the producer too, and it is specific to each case (well): gas flow, well casing pressure, oil delivery line pressure, pump jack model, sucker rod stroke, double strokes per minute, working schedule of the pump jack, etc.

BORE STROKE GAS FLOW [Nm3/day] / POWER [kW] 6’’ 36’’, 48’’ up to 400 / 0.6÷0.9kW

For: 0.5 bar in the well casing, 4 bar in the discharge line, 6 double strokes per minute of the pump jack.

8’’ 36’’, 48’’, 56’’ 500 to 1000 / 1.1÷1.8kW 10’’ 36’’, 48’’, 56’’, 64’’ 600 to 1800 / 1.7÷3.2kW 12’’ 48’’, 56’’, 64’’, 72’’ 1800 to 2700 / 3.3÷5.1kW 14’’ 48’’, 56’’, 64’’, 72’’ 2400 to 4000 / 4.5÷6.9kW

In bold the preferable versions and models, able to answer to the usual necessities.


VERSIONS and MODELS

Compressor cylinder, factory assembled and equipped with: - upper and lower clevises with spherical plain bearings - suction and discharge valves - pressure safety valve - single point automatic lubricator - connection hoses


LIMIT of SUPPLY and OPTIONS

Compressor cylinder

Stuffing box

Piston rod

Inlet and Outlet gas connections

Cylinder

Lower attachment

flange

Discharge valve (2off) Suction valve

(2off)

Clevis with plain spherical bearing for the attachment with a special clamp on the walking beam

Safety valve

Discharge hose

DISCGHARGE VENT SUCTION

Clevis with plain spherical bearing for

the attachment with the special clam to the

pumping jack

Suction hose

Grounding cable

Equipped compressor cylinder

Special clamps, for easy attachment and un-attachment of the compressor cylinder to the pump jack. Non-restricted movement during operation is provided by the spherical bearings on the compressor cylinder.

Piping system up to the pump jack skid limit, with the necessary equipment: coarse suction filter, isolating and bypass valves, discharge check valve, pressure and temperature gauges.



Coarse suction filter

Electronic temperature monitoring and automatic overheating protection system for three characteristic temperatures (RTD sensors). The control panel is to be installed close and connected to the power supply panel of the pump jack.



Optional equipment: Liquids separator (scrubber) for the gas entering the CGA System -

recommended to be installed on the customer provided gas line from the well casing to the pump jack skid limit

Pressure regulator to provide a minimum required by the customer pressure in the well casing

Gas flow meter (counter) for the flow pumped from the well casing

Technical assistance for the CGA System installing, commissioning, maintenance and in-function monitoring at request.



The compressor is pumping gas according to it’s capacity, relieving the gas back pressure in the well casing up to an equilibrium value determined by the gas flow entering the casing annulus.

The gas flow is pending on the formation and on the pressure in the casing. The key to obtain the desired pressure is the estimation of that gas flow.

The compressor capacity is pending on: • Cylinder dimensions, i.e. bore and stroke • The number of double strokes per minute of the pump jack • The function-pause schedule of the well pump jack • The gas pressure at the compressor cylinder suction connection • The pressure ratio to be realized by the compressor cylinder The pump jack stroke and the pressure in the discharge line are enforcing

the limits. The best results may be obtained by selecting a CGA Compressor from the

preferential versions-models, taking into consideration the specific conditions of each application.


SELECTION of the CGA COMPRESSOR

As a guide, bellow are the flows [Nm3/day] handled by three CGA models – double action cylinders, for different gas pressures in the casing and different double strokes per minute of the pump jack, 4 bar discharge pressure.

dbl. strk. per min.

CGA 8x36 CGA 10x48 CGA 14x64 Steady pressure in the well casing [bar]

0.00 0.25 0.50 0.75 1.00 0.00 0.25 0.50 0.75 1.00 0.00 0.25 0.50 0.75 1.00

1 54 73 92 111 131 122 162 202 242 283 339 443 548 654 760 2 108 146 184 222 261 244 323 403 484 565 678 887 1 096 1 308 1 520

3 162 218 276 334 392 367 485 605 726 848 1 018 1 330 1 645 1 961 2 280

4 216 291 368 445 523 489 647 807 968 1 130 1 357 1 773 2 193 2 615 3 039

5 270 364 460 556 653 611 809 1 009 1 210 1 413 1 696 2 216 2 741 3 269 3 799

6 324 437 552 667 784 733 970 1 210 1 452 1 695 2 035 2 660 3 289 3 923 4 559

7 378 510 643 779 915 855 1 132 1 412 1 694 1 978 2 374 3 103 3 838 4 577 5 319

8 432 582 735 890 1 045 977 1 294 1 614 1 936 2 260 2 714 3 546 4 386 5 230 6 079

9 486 655 827 1 001 1 176 1 100 1 456 1 815 2 178 2 543 3 053 3 990 4 934 5 884 6 839

10 539 728 919 1 112 1 307 1 222 1 617 2 017 2 420 2 825 3 392 4 433 5 482 6 538 7 599

11 593 801 1 011 1 223 1 437 1 344 1 779 2 219 2 662 3 108 3 731 4 876 6 031 7 192 8 358

12 647 874 1 103 1 335 1 568 1 466 1 941 2 421 2 904 3 390 4 070 5 319 6 579 7 846 9 118

13 701 946 1 195 1 446 1 698 1 588 2 103 2 622 3 146 3 673 4 410 5 763 7 127 8 499 9 878

14 755 1 019 1 287 1 557 1 829 1 710 2 264 2 824 3 388 3 955 4 749 6 206 7 675 9 153 10 638

15 809 1 092 1 379 1 668 1 833 1 833 2 426 3 026 3 630 4 238 5 088 6 649 8 223 9 807 11 398



Highlighted flow for the usual ranges of pump jacks dbl. strokes per minute number and desired well casing pressure.

For a certain pressure in the well casing, the required pressure ratio is enforced by the CGA System discharge back-pressure which is mainly imposed by the pressure in the customer discharge line. The maximum safe pressure ratio is 5,0-5,5 to prevent the components overheating. That may enforce a limit in selecting the desired pressure in the well casing.

A limited number of versions and models is preferable instead to design, operate and do the maintenance for a different compressor in each case. Three bore versions, each with different stroke models are already developed. According to future requests, Confind is ready to diversify the range.

Once the most suitable model for a specific case is selected, taking into consideration the future evolution of the formation too, there are available some adjustment solutions:

• rough ones – to transform the compressor from a double acting to a simple acting one or vice-versa, for parameters big changes in time

• tuning ones – to adjust the end clearances of the compressor by changing the position of the attachments to the pump jack



Computed Capacity versus Suction pressure diagram for a CGA model. Similar ones are available for all the models.



CGA 10" x 64"

0

500

1 000

1 500

2 000

2 500

3 000

3 500

4 000

0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00

Suction pressure [bar]

Flow

t [N

mc/

day]

7 dbl.strokes/min.

6 dbl.strokes/min.

5 dbl.strokes/min.

SG=0.69natural gas

Sucking rod strokeminim 2700mm(1,67x piston stroke)

8 dbl.strokes/min.

9 dbl.strokes/min.

10 dbl.strokes/min

4 dbl.strokes/min.

3 dbl.strokes/min.

Easy to install on any pump jack type with no adjustment of it. A couple of days should be enough to install a CGA Compressor;

The compressor acts as a shock absorber. Usually no re-balancing on the pump jack is needed after a CGA installation;

Safe, noiseless, no residue. CGA is equipped with a pressure safety valve and an automatic overheating protection system;

Current operating means just a daily few minutes visual inspection, when such work is scheduled for the pump jack;

No oil lubrication system. Low maintenance, no adjustment required. No restriction to the special treatments in the well casing. If needed, the

compressor may be turned on bay-pass mode for the treatment duration; No need for a separate gas line to recover the gas in the casing; Enhances the flow in the oil delivery line by lowering the oil viscosity. The

heat in the compressed gas also reduces the freezing and deposits development;

As a local producer, SC Confind is rapidly available for the Customer, from the optimum solution development up to the whole range of after-sale services.


ADVANTAGES of UTILIZING a CGA COMPRESSOR

Documents

CONFIND - Petroleum Clubpetroleumclub.ro/downloads/ROupstream/Gheorghe_Miloiu_Dorin_Racota.pdf · Salt water salinity: 16 – 17% The water has to be filtred before passing trough