Wood Group ESP, Inc.

Surface Pumping Systems

Neil Ferrier Manager, Surface Pumping Systems John Hedges Canadian Regional Sales & Service Manager

Jim Bedford Waterflood Authorized Distributor Alberta/Saskatchewan

Surface Pumping Systems (SPS)

Agenda
Wood Group ESP heritage & core business Surface Pumping System history Alternative technology context Performance envelope Applications SPS design features Sample installations

Heritage
Wood Group is a leading international energy services company employing more than 13,000 people, and operating from bases in over 34 countries. We provide knowledge and know-how services to add value to the oil and gas, and power industries.

Heritage
Includes: Mustang Engineering Alliance Engineering JP Kenny WG Production Services

WGESP Heritage
International Locations

U.K.

Russia
Moscow Kogalym

North America
Canada U.S.A.

Europe
Germany

India

Far East
Japan China

Africa Central America

Guatemala

Pacific Rim
Nigeria Egypt Algeria

Middle East
Saudi Arabia Oman UAE Kuwait

Singapore Indonesia Vietnam

South America
Venezuela Ecuador Colombia Argentina Brazil

Typical ESP onshore

ESP Components
Pump Intake Seal Section Motor Cable Motor Controller Transformers Accessories

TRANSFORMERS

WELL HEAD MOTOR CONTROLLER

JUNCTION BOX

Power Cable Splice

Tubing Drain Valve Check Valve Casing

Pump Intake

Seal

Motor

Surface Pumping Systems (SPS)

SPS History
First SPS installation 1989 Customer driven product development Originally installations were Upstream Oilfield applications, produced water injection. (disposal, waterflood, etc) Separate SPS group established 2001 to expand core business and diversify installation base to downstream & outside of Oilfield.

Alternative Technology Summary

Centrifugal - Axially Split-Case Centrifugal - Ultra high speed Centrifugal - Canned Vertical Turbine PD positive displacement Plunger Pumps
Triplex

/ Quintiplex

Alternative technology summary

Centrifugal Axially Split Case Pump

Alternative technology summary

Centrifugal Axially Split Case Pump Limitations

Lead-times typically 6 to 12 months Initial cost Custom engineered for a specific duty point Two high price Mechanical seals required, and these can operate above suction pressure High degree of expertise required for maintenance

Alternative technology summary

Centrifugal Ultra High Speed Pump

Alternative technology summary

Centrifugal Ultra High Speed Pump Limitations
Initial

cost High noise level Can be maintenance intensive & Expensive Parts High degree of expertise required for maintenance Custom engineered for a specific duty point

Alternative technology summary

Centrifugal Canned Vertical Turbine

Alternative technology summary

Centrifugal Canned Vertical Turbine Limitations
Complex

foundation work required Mechanical seal operates at discharge psi Motor bearings must handle pump thrust Initial cost Engineered for a specific duty point Crane required to carry-out repairs

Alternative technology summary

Positive Displacement Plunger pumps

Alternative technology summary

Positive Displacement Plunger pumps

Sump required just to collect and return leakage

Alternative technology summary

Positive Displacement Plunger pumps

Leakage sump potential for contamination

Crank case oil contamination

Alternative technology summary

Positive Displacement Plunger pumps Limitations

Initial & Whole Life Cost Environmental

Leakage, Leakage collection & Disposal , Noise, Pulsation, Vibration

Maintenance required daily - even at remote sites Maintenance of additional equipment required belts, pulsation dampers, oilers & etc. Down time vs. up time & time to carry-out repairs

Alternative technology summary

Advantages of SPS design

Low initial & whole life cost Short lead-times Adaptable for changing duty conditions Minimal routine maintenance
One low pressure mechanical seal No gear reducers/increasers, v-belts, dampeners & etc

Low noise levels Environmentally friendly Ease of repair & replacement of components

Performance Envelope

Performance Envelope
Performance limits
Suction Pressure:

up to 3,000 psi
250-300 F (standard configuration) Electric Motors 100 to 1,000 hp (50/60 Hz.) Fixed or Variable Speed Engine Drive (Gas or Diesel)

Temperature:

Drive options:

Applications
Injection; Waterflood, disposal & pressure maintenance Jet pump power fluid & hydraulics fluid Transfer/pipeline booster Gas services: NGL, LPG, Ethane, Amine booster pumps Liquid CO2 Booster Condensate transfer

SPS design features

System components
Suction & Discharge Pressure Gaugeswitches Vibration Switch Thrust Chamber Motor

Pumping element (ESP style)

Flexible Coupling Suction Chamber Skid Discharge Head

Pump Supports

SPS design features

Pumping element
Adj. Nut & Shims

Impeller

ORing

Lower Diffuser
Base

Diffuser

Housing Fluid Dir.

2 pc. Ring Head Shaft

Critical Dimension Tungsten Carbide Bearing Lower Bearing Hsg.

Spacer

Comp. Tube Tungsten Carbide Bearing Comp. Bearing Hsg.

Comp. Nut, Slv. & Set Screw

SPS design features

Pumping element
Replaceable

on site with minimal down-time Industry leading designs are highly efficient Corrosion resistant materials Compression style for abrasion resistance Mixed flow stages for high efficiency and wear resistance Tungsten carbide bearings/sleeves available Various coatings & diffusion processes available to meet application requirements

SPS design features

Suction Chamber
Housing Viton ORing Pump Adapter Plate

Viton ORing

Mechanical Seal Monel Coupling

Seal Plate Monel stub Shaft

SPS design features

Suction Chamber

SPS design features

Suction Chamber Front Pull-out Cartridge

SPS design features

Mechanical Seal - Front Pull-out - Remove pipe spool piece - Move pump to access seal from front of suction chamber - Bearing housing remains in-situ - No need to re-align motor coupling etc.
2 rolling jacks standard SPS tool kit

SPS design features

Mechanical Seal options

- Leak Containment - Leak detection - Alarm &/or Shut-down

SPS design features

Suction Chamber

Open free flowing area, for optimum suction capability and seal life Silicone carbide mechanical seal faces Mech seal operates at suction pressure Stub shaft design for easy seal & shaft changeout (thrust chamber exchange not required) Cartridge seal options API682 and most API610 flush & quench plans are available Front pull out design allows seals to be replaced without affecting alignment US Patent

SPS design features

Bearing Housing/Thrust Chamber
Inspection Port Viton ORing Oil Ring Retaining Bolt Plugs Axial Thrust Ball Bearing Up Thrust

Labyrinth Seal Lock Nut

Shaft Pre-Load Wave Spring Viton ORing Housing Dual Axial Thrust Ball Bearings Down Thrust

Oil Drain

Oil Rings

SPS design features

Suction Chamber Bearing Housing & Adapter

SPS design features

Bearing Housing/Thrust Chamber
replaceable

module - with minimal down-time Simple design with low number of moving parts Minimal routine maintenance (2000hr oil change) 0.5 gal reservoir & Oil rings for low temp rise Labyrinth seals used to eliminate shaft wear Predictable bearings life. TCs endurance tested, minimum life for given pump/stage combination known

30.5 Fixed Pipework, Pump & Thrust Chamber Height

SPS Design Features Easily Modified Skid Design

Adapter Plate & Skid pre-drilled for all motor options

Integral Lifting lugs throughout Provision for future Skid Extension(s) Rigid Frame for low vibration

Bolt-on Motor Jacking Blocks & Screws

Machined Motor Adapter Plate

WG ESP US Patent

SPS design features

Why Easily Modified Skid??

Q % oil Q % Water

Time - Years Time - Years Oil Decline Curve Water Incline Curve

SPS design features

Easily Modified Skid
Finite Element Analysis F.E.A. Comparison Old Skid vs. New

EMS Design

Traditional Skid

SPS design features

Easily Modified Skid

100hp 700hp

SPS design features

Easily Modified Skid

Rigid design for smooth operation, ease of installation & start-up Ability to change motor size without cutting metal or changing pipework height Simple to add or subtract stages/pumps Skid re-usable for future applications US Patent

SPS design features Systems are laser aligned at site

SPS design features Systems are vibration tested at site

SPS design features SP75 20-75 Hp Applications

Sample SPS Installations

U.K.

North America
Canada U.S.A. Texas Oklahoma Rockies

Europe
Turkey Romania

Kazakhstan
Far East
Japan

Africa Pacific Rim

Cote DIvoire Indonesia

Central America
Pemex WTSV GoM Sealion: TOISA Pisces Aker Langsten: Bourbon Opale

Middle East
Oman Egypt UAE Kuwait

South America
Venezuela Ecuador Argentina Brazil

BP - Louisiana
(Amine Gas Treatment)

Lean Amine 7700 bpd (225gpm) 1,000 psi discharge 200 hp TJ7500 32 stages

Sample Installations Warrior Gas - Hearne , Texas

Lean Amine 7700 bpd (225gpm) 1,000 psi discharge 200 hp TJ7500 32 stages

Sample Installations Apache, Snyder Texas

6,000 bpd (175gpm) 1,500 psi 250hp TE5500 71 Tefon coated stages

PDO (Shell) - Oman

(Water Injection)

8,000 bpd (234gpm)- 4,600 psi (1,000 psi suction) 600hp TJ9000 92 stage

BP Alaska
(Jet Pump Power fluid)

12,000 bpd (350gpm)- 3,000 psi 700hp TJ12000 80 stage

Ameriven - Venezuela
(Pipeline Booster)

Crude Oil 15000 bpd (440gpm) 500 psi discharge 200 hp TM520A 12 stages

Sample Installations BP, Louisiana

5,000 bpd (150gpm) 1,000 psi 60hp TE5500 Amine

Sample Installations Denbury, Jackson Dome MS

C02 5500 bpd (160gpm) 1,600 psi (1,200psi suction) 100hp TE7000 29 stages API682 Double seal Plan 53 & Graphalloy Bearings

Sample Installations Duke, Texas

1000 bpd (15gpm) 800 psi 20hp TD850 Amine

Sample Installations Wyoming Resources

Pumpkin Butte, Wyoming

1,000 bpd (29gpm) - 4,300 psi 150hp TD1200 - 359 stage (floater)

Sample Installations Wafra, Oman (PDO)

8,000 bpd (234gpm)- 4,600 psi (1,000 psi suction) 600hp TJ9000 92 stage

Sample Installations Apache Crane Texas

16,500bpd (482gpm)- 1,400psi 600hp TJ20000 41 Teflon coated stages

Sample Installations Chevron/Simonette, Alberta

900 bpd (26gpm) - 4200 psi 200 hp TD980 401 stage (Ryton Stages)

Sample Installations PDVSA - Venezuela

Jet pump Power Fluid 1700 bpd (50gpm) - 3300 psi 200 hp TE1500 136 stage

Pemex - GoM TIOSA Pisces

(Sea Water Injection & Oil Transfer)

Injection Pumps 5000bpd @ 3000 psi 500hp Export Pumps 30,000bpd @ 500psi 350hp

Pemex - GoM TIOSA Pisces

Injection Pumps 5000bpd @ 3000 psi 500hp Export Pumps 30,000bpd @ 500psi 350hp

Modec FPSO - Cote DIvoire

(Sea Water Injection)

Modec, for CNR - FPSO Baobab

Modec FPSO - Cote DIvoire

(Sea Water Injection)

100,000 Bpd 3000gpm @ 2500psi 6 x TM675 44st

Modec - FPSO

Surface Pumping Systems (SPS)