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As we gained experience with the EP01 and received customer feedback, Triol determined that the target flow rate for the EP01 is wells with flow rates up to 300 bpd and pressures up to 6,560 ft and 8,200 ft. The EP01 single-action unit does not provide this kind of flow rate. The solution is obvious at first sight – to increase the unit’s power and thereby expand the range of products. But Triol specialists have set themselves the task that the modernization of EP01 provides a number of advantages such as:
- doubling the flow rate as compared to single-pass units;
- reduced energy consumption per barrel of oil produced;
- unification of motors with the expansion of the feed range;
- ensuring a service life of at least 9 million cycles;
- improved maintainability; and
- customization for different operating conditions.
Therefore, after a conceptual study of this issue, we came up with a non-standard and novel solution to the double-action pump scheme, which allows us to increase the flow rate by half while maintaining the power of the motor.
Figure 1 - Submersible part of the EP01 double-acting unit
The main advantages of this offer will be discussed below.
Thanks to the patented valve system and the dual-plunger system, the EP01 double-action pump can double the flow rate of a single-action unit with the same plunger diameter. For example, a pump with a 1.25” plunger diameter and a stroke length of 47.2 inches has a flow rate of 125 bpd, while a double action pump EP01 of the same plunger diameter has a flow rate of 240 bpd.
Figure 2 - Dependence of single- and double-action pump performance on the number of cycles
When using the double-action operation scheme, we get a 25% reduction in specific energy costs due to the lack of empty strokes since the stroke of the rod up and down leads to the raising of the fluid, which cannot be said about the single-action scheme, which has an empty stroke when the rod moves down.
Figure 3 - Dependence of specific energy consumption of a single- and double-action pump on the head pressure
Since the double-action scheme doubles the flow rate with a smaller plunger diameter (which is a major factor in selecting motor power), this allows the LPMM-15-P3-114 motor to cover head ranges from 1640 ft to 8200 ft with flow rates from 5 bpd to 240 bpd.
This only allows you to minimize the number of nomenclatures in the warehouse but also to reduce the storage space.
Table 1 - Motor and pump configuration
Since the double-action pump operates with a load on the up and down strokes, this may shorten the operating life compared to a single-action pump. To maintain the overhaul period and ensure trouble-free operation of the unit during the warranty period, materials were selected based on calculations, modeling and tests.
The selected materials and design solutions allow for at least 9 million cycles of the unit’s service life.
Figure 4 - Example of strength calculation of NPG housing parts under the influence of maximum pump pressure
After receiving feedback from the first operating experience, the pump design was modified to reduce repair time. The modular design of the double-action pump allows individual pump components to be replaced and the pump to be tested in a single work shift. Then, after the pump has already been sent to the field, the previously replaced assemblies can be analyzed and repaired in order to reuse them.
Figure 5 - Main pump components
The design of the double-action pump is a set of modules with a flanged connection for each module. This solution allows the customer’s stock pumps to be upgraded for the process task at hand by the flanged connection of an additional module or replacement of one module with another.
Examples of customization operations:
- replacement of the intake filter with a filter with a reduced slit gap due to operation in the well with a smaller fraction of solids;
- installation of gas separator for wells with high gas factor; and
- replacement of the valve pair design due to operation in more aggressive conditions.
To perform the above operations, simply unscrew the nuts (6 pcs.) install or replace the module and tighten the nuts.
Figure 6 - Pump intake filter
Triol - Elegant and fundamental solutions!
