New technologies at Lukoil: The “Geyser” Hydraulic Rod Pump

Lukoil-Perm recently completed field testing, and put into action, the “Geyser” hydraulic rod well pump. The hydraulic drive consists of two basic parts: the frame with hydraulic power cylinder, which is installed directly at the wellhead, and the pumping station, which is mounted next to the well in a control room. The power cylinder and the station are connected with
hydraulic lines.

The first pilot unit of the Geyser Hydraulic rod pump was installed on November 13, 2009 at well #1291 at the TSDNG-10, Kokuy oil field. Following the launch of the equipment on November 26, 2009, the energy consumption was carefully monitored and the follow data was retrieved:

»    low energy consumption using this recovery system helps reduce costs, leading to decrease in overall operational  expenditure;

»    light weight at 2.7 tonnes, and quick assembly without engaging expensive special machinery;

»    no foundation meaning it is possible to install in swampy, undeveloped areas;

»    electronic control system, with continuously variable adjustment (oscillation frequency, beam stroke) offering a wide range of adjustments for downhole pumping equipment at OWI;

»    possibility of creating an “intellegent” well cluster – using a single control unit to operate a number of hydraulic drives at the cluster site, with full automation of the production process, including remote control of the equipment and video surveillance of the operation, which allows a reduction in personnel. This also reduces the “human error” factor.

»    Mobile phones can used for remote control and it does not require engaging any service personnel. Video surveillance and communications require a reliable 3G cellular connection.

»    possible to use for dual pumping operation;

Hydraulic drives test results
»    Total hydraulic drive operating time at well #1291, Kokuy oil field, since November 26, 2009 – 2664 hours.

»    Total hydraulic drive operating time at well #2049, Kokuy oil field, since January 12, 2009 – 1259 hours.

»    All time of these operations, the equipment operated without failure at an ambient temperature from 0˚С to – 45˚С.

»    The equipment enabled the well to be stabilized and avoided any down time due to feed failures

Controlled testing of these pumps was started in November 2009 and finished in March 2010. The current total operating time for well #1291 of TSDNG-10 at the Kokuy oil field is 8712 hours, and for well #2049 – 4512 hours (this hydraulic drive was upgraded twice to increase its reliability, efficiency and durability, with a dome-shaped support, not connected to the fittings, being made and one of the  cylinders was upgraded).

The implementation of the Geyser pump allowed us to increase the delivery rate from 0.4 to 0.6 and 0.7, and energy consumption decreased by 5.6% (“Geyser” – 7.1 kWh; SK8 – 7.5 kWh). The temperature range for operational testing was from +29˚С to – 45˚С. At – 45˚С however, the substation shut down. The pump then initiated its launch preparation sequence however (heating the oil and checking its level), and then launched automatically, without an operator.

The main benefits of Geyser pump can be seen on the image:
»    low specific metal content – 4.5 t;

»    absence of large units such as a gearbox, balance beam or crank arm;

»    does not require special foundation;

»    easy to assemble;

»    assembly and startup adjustments require 6 hours (a conventional pumping unit usually takes at least 3 working shifts);

»    variable control of stroke length and oscillation frequency.

Currently, Lukoil Perm is in the process of a new intelligent well cluster for oil and gas production. The main purpose of the project is to create a principally new oil production process, which would enable us to monitor and remotely control the production process, in real time, with minimum human staffing required.  The monitoring and production control may be arranged either from a stationary control point or from a mobile phone (smartphone).

At the 1st stage of this project, the following works are being carried out:
»    design work and preparation for well cluster 923 at the Kokuy oil deposit (total 5 wells);

»    manufacturing of two hydraulic drives with a single  control station;

»    Implementation of an automation control system, with the data being streamed to the operator’s console. The drive can also then be controlled from the same console;

»    equipment operation video surveillance is also planned.

Proposals for the 2nd stage include:
»    An automation control system for the Geyser pump, allowing parameters such as strike length, oscillation frequency etc to be  changed remotely.

»    Further training of personnel for these operations

In 2010, Lukoil-Perm installed 5 more hydraulic rod pumps (making a total of 7).

Our specialists have developed a program to replace all conventional pumping units with hydraulic drives between 2011-2013. It includes 172 “Geysers”, of them 56 – for reconstruction and drilling new wells and 116 – to replace existing conventional pumping units that have been in operation for over 30 years.

In 2011, we plan to purchase and assemble 42 “Geysers” in total, of these 32 will be under ONSS (equipment not included in the construction estimate) program and 10 – for reconstruction sites and new wells.

By 2020, about 3000 conventional pumping units of Lukoil-Perm will have worked two normative lifetimes (30 years), and thus modernization in this sector is key.