Jet Pump Systems Operations, Maintenance and Start-Up

Contents
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Down-hole Assembly ....................................................................................................................................................2 Wellhead & Tree..............................................................................................................................................................2 Power Fluid & Return Lines ......................................................................................................................................2 Power Fluid Manifold ...................................................................................................................................................2 Multiplex Pump & Booster Pump ...........................................................................................................................2 Tankage/Storage ............................................................................................................................................................3 Separator ............................................................................................................................................................................3 Inlet Manifold ...................................................................................................................................................................3 Flow Lines ..........................................................................................................................................................................3 Fluid Transfer Pump ................................................................................................................................................4 Procedure for Pump Start-Up .............................................................................................................................4

Prestart .....................................................................................................................................................................................4 Start Up of Pump ..................................................................................................................................................................4 12. 13. Operations.....................................................................................................................................................................5 Maintenance .................................................................................................................................................................5 Daily Maintenance..........................................................................................................................................................5 Weekly Maintenance ....................................................................................................................................................5 Monthly Maintenance...................................................................................................................................................6 90 Day Maintenance......................................................................................................................................................6 14. 15. Normal Equipment Parameters .........................................................................................................................6 Specifications & Capabilities ...............................................................................................................................6 Pumps ...................................................................................................................................................................................6 Engines and Drive ..........................................................................................................................................................7 16. Jet Pump System Troubleshooting ...................................................................................................................8

1. Down-hole Assembly
The down-hole assembly is made up of the BHA and standing valve which is run in on the tubing string and anchored with a packer to seal the wellbore from the tubing. This BHA has the seating profile for the jet which is made up of a body or housing, the nozzle and the throat. The body holds the seating assembly that seals the jet into the profile of the BHA. The nozzle and throat size combinations are mated according to software simulations or calculations to provide volume and pressure in order to best lift the fluid to surface. The jet is circulated into the well through the top of the wellhead tree referred to as the catcher. Power Fluid is pumped into the tubing and through the jet nozzle to provide a low pressure area or venturi. The power fluid comingles with the reservoir fluid and is re-pressured through the throat and lifted to surface up the casing using this pressure.

2. Wellhead & Tree

The wellhead and tree is made up the tubing hanger, casing bowl and wing valves. There is a wing valve for controlling the casing or back side, and for the tubing or front side. The tree is made up of the pipe connecting the catcher and connecting the two sides of the fluid delivery system, the power side (tubing) and the discharge side (casing) or inlet and outlet respectively. The two sides are controlled using high pressure valves and are connected to the power fluid and return lines.

3. Power Fluid & Return Lines

Power fluid lines are high pressure pipelines that connect the wellhead tree to the power fluid manifold to deliver the pressurized fluid to the jet.

4. Power Fluid Manifold

The power fluid manifold houses the chokes, gauges, meters and valves that measure and control the pressure and volume of fluid from the multiplex pump to the wellhead. Bypass lines are placed in line to provide a provision for changing out the chokes or other fittings that require adjustment, replacement or repair. The manifold can also be used to control or isolate individual wells in multiple well setups. Chokes are to be set according to rate requirements or pressure equalization for the power fluid using the simulations for the optimized pressure and rate for each jet pump as a starting point.

5. Multiplex Pump & Booster Pump

Multiplex pumps use multiple connected plungers with seals, valves and lubricators to create pressure and volume to supply the wells with power fluid. The pressure and volume created are based on plunger size (outside diameter) stroke length and RPM. Essentially there are two sections to the pump, the fluid end and the power end. The power end case contains the crank shaft and connectors for the plungers and the fluid end contains the valves and chambers

compressed by the plungers to increase the pressure of the fluid. There is an inlet pipe to allow fluid to enter from the tank or booster pump which moves into the chambers in the fluid end and is compressed by the plungers overcoming the back pressure of the valves. This fluid is moved into the discharge pipe to become the power fluid which is then supplied to the jet in the well. Because of the pulsing nature of the plunger system there is a dampener to smooth the flow of this fluid. Suction pipe size = 6 NSD 600 RJ Discharge pipe size = 3 NSD 5000 RJ The booster pump is between the tank (fluid supply) and the Multiplex pump or power fluid pump in order to provide enough feed of fluid to the system to have proper volumes.

6. Tankage/Storage
Tanks are split into three categories in the facility: Separated fluid storage Produced fluid with the power fluid component separated out ready for delivery to the treatment facility. Testing & Measurement To be used for testing and measure of water cut or to calculate production levels based on windows of time vs volume. Power fluid Fluid for supply to the power fluid pump to produce the well Tank accessories include automatic level controllers, pressure relief valves and flare systems for handling the gas.

7. Separator
The separator works to segregate the comingled fluid from the wellbore and the power fluid allowing for the reuse of the power fluid to energize and produce the well. This is accomplished by utilizing baffles, gravity and pressure to separate the fluids. Fluids= oil, water, gas The separator is connected to the return manifold or inlet manifold.

8. Inlet Manifold
Return lines from wells tie into the inlet manifold or return manifold to combine the fluids from individual wells into a common line that connects to the separator for segregation or for well isolation such as in a test configuration.

9. Flow Lines
Flow lines are high pressure pipelines connecting the return side of the wellhead tree to the inlet manifold to deliver the comingled fluid from the wells.

10.Fluid Transfer Pump

The fluid transfer pump works in the same way as the power fluid pumps with the exception that it is typically much lower pressure but has the capability for much higher volumes. These pumps provide the energy to move the fluid from the tank containing the separated production fluid into the production line and onto the treatment facility.

11. Procedure for Pump Start-Up

Prestart
Ensure pump is mounted properly to base and is in alignment with prime mover (Diesel or Electric) Guards are in place and fastened properly Belts are tensioned properly/clutch has proper pressure Stuffing boxes are tightened to proper specification Piping is attached properly Fluids are to proper levels and with proper type of fluid Check rotation of prime mover to ensure connecting rods come over the top of the cranks and are driving towards the fluid end Breather caps and covers are in place All lines, manifolds and connections have been pressure tested

Start Up of Pump
Ensure tank volumes and system open Open wellhead valves Ensure plunger packing is greased Fill reservoirs with lubricant Rotate the pump by hand to ensure smooth operation Open the bypass valve Open the valve at the supply tank an start booster pump if utilized Apply power slowly through manually ramping or utilizing a VFD Fully open the discharge piping while the power increases close the bypass line Check supply of lubricant is adequate Check stuffing box/plunger lubrication Check suction pressure and temperature Check the discharge pressure and temperature Check the pressure of the dampener is stable Check for any leaks and remedy Sign over to operations after 30 minutes of run time

12. Operations
Pump speed should be ramped up slowly to maximum rpm of 380rpm~motor speed of 1438rpm (Pump speed can be run as low as 200RPM)

Suction pressure can be between 15psi and 40psi but 20-30psi is optimal. Listen closely to the pump to ensure that it is filling properly to avoid valve damage. The pump should not be pounding which would indicate improper filling. Ensure the pulsation dampeners are nitrogen pressurized to adequate levels. Pressure setting = 700Kpa Suction and 13,500Kpa Discharge (starting point for ~13500Kpa pump discharge pressure). Monitor injection rates and pressures to wells adjusting chokes appropriately to normalize and balance the power fluid rate and pressure. Monitor equipment temperatures are within suggested specification (pump, motor, booster pump, clutch, engine) Monitor wellhead pressures to ensure proper flow Compare production levels with simulation, IPR and historical values Perform maintenance according to Daily, Weekly, Monthly and Bi Yearly schedules Monitor for abnormal wear to plungers, packing and valves. Ensure proper lubricants are used and look clean Monitor packing for excessive leakage

13.Maintenance
Daily Maintenance Check oil levels in power end, lubricator, and chain case Check for contaminants and remove carefully Check oil temperature is in range (up to 80C - AGMA-EP460 type) Check booster pump and lubricate Check the packing visually and adjust to lightly tight Drain plunger leakage Check suction pressure = 15-40psi Check stabilizer pressure and fluid level Check discharge pressure Check pressure on the discharge pulse dampener Check and clean general pump area (water, rust, oil spill, dirt) Weekly Maintenance Flush the fluid in the cradle drain lines Check the valves and seat for wear and replace any cut or worn inserts Check the valve stem guide bushing and replace if required Check the piston crosshead coupling for tightness and damage, replace if required

Check hoses for reliability Check guards and connections visually for good working order Check prime mover belts, clutch, drive train Check coolant levels and ensure proper mixture for temperature and corrosion control

Monthly Maintenance Check tightness on all major connections in the system Check the pressure relief valve is operational and set to the appropriate level Check plungers for wear and damage, replace if required Check extension rods for wear and damage, replace if required Clean out crank case breather Check valves, seats, springs, replace as required 90 Day Maintenance Oil change, filter and crankcase breather Check crossheads and pins are in good condition and have proper clearance Check main bearing has proper clearance Check crank pin bearing has proper clearance Check foundation and hold down bolts for tightness. Ensure the pump is secure to the foundation Check suction and discharge bolts are tight and no leaks Check pump sheave or coupling is secure Flush pump case out removing any water or contaminants

14. Normal Equipment Parameters

** Packing should leak slightly** Over-tightening the packing increases wear to the plungers and destroys packing which creates down-time. Normal Oil temperature up to 80deg C (AGMA-EP460) First oil change is needed at 400hours or 16days Subsequent oil changes at every 90 days Normal running temperature range for pump = Normal running temperature for engine =

15. Specifications & Capabilities

Pumps

W200M

PUMPING RATE: 2595bbl/day PLUNGER DIAMETER: 2 " PUMP SPEED: 391 rpm @ 0.95 Volumetric Efficiency SUCTION PRESSURE: 29 psig DISCHARGE PRESSURE: 3771 psig POWER CONSUMPTION: 193 HP @ 0.9 Mechanical Efficiency PUMPING RATE: 4665bbl/day PLUNGER DIAMETER: 2 " PUMP SPEED: 392 rpm @ 0.95 Volumetric Efficiency SUCTION PRESSURE: 29 psig DISCHARGE PRESSURE: 3406 psig POWER CONSUMPTION: 256 HP @ 0.9 Mechanical Efficiency PUMPING RATE: 4697bbl/day PLUNGER DIAMETER: 2-1/8 " PUMP SPEED: 359 rpm @ 0.95 Volumetric Efficiency SUCTION PRESSURE: 29 psig DISCHARGE PRESSURE: 3947 psig POWER CONSUMPTION: 350 HP @ 0.9 Mechanical Efficiency

300Q-5M

QX-300(UNION)

300Q-5H

PUMPING RATE: 4663bbl/day PLUNGER DIAMETER: 2 " PUMP SPEED: 392 rpm @ 0.95 Volumetric Efficiency SUCTION PRESSURE: 29 psig DISCHARGE PRESSURE: 3406 psig POWER CONSUMPTION: 285 HP @ 0.9 Mechanical Efficiency PUMPING RATE: 3017bbl/day PLUNGER DIAMETER: 2-1/4 " PUMP SPEED: 425 rpm @ 0.95 Volumetric Efficiency SUCTION PRESSURE: 29 psig DISCHARGE PRESSURE: 1800 psig POWER CONSUMPTION: 102 HP @ 0.9 Mechanical Efficiency

GD TDD100

Engines and Drive

Driver Cat3406 Diesel Cumm N14 Diesel TECO Electric Gearbox 4.33:1 5.77:1 3.58:1

Teco Electric Motor Operation

When motors are installed in good manner, ensure the wiring is according to the diagram. Also, the following points should be noted: Make sure all wiring is correct. Ensure the sizes of cable wires are appropriate and all connections are well made for the currents they will carry. Ensure all connections are properly insulated for the voltage and temperature they will experience. Ensure the capacity of fuses, switches, magnetic switches and thermo relays etc. are appropriate and the contactors are in good condition.

 Make sure the frame and terminal box are grounded. Make sure that the starting method is correct. Make sure switches and starters are set at their right positions. Motor heaters must be switched off when the motor is running.

Cummins N14
Please refer to the manufacturers manual

CAT 3406C
Depending on its specifications, the 3406 engine can produce anywhere between 250 horsepower at 1,600 rpm and 550 horsepower at 2,100 rpm. It can produce between 1,000 pound-feet of torque at 1,200 rpm and 1,850 pound-feet of torque at 1,200 rpm. In this context, torque refers to the total amount of work that the 3406 engine can do, while horsepower is a rate-based measurement of how quickly the engine can perform that work.

Torque Specifications
The Cat 3406's peak torque rating is 1,378 pound-feet when the engine is operating at 1,400 rpm. When this engine achieves its maximum horsepower of 419 when operating at 1,800 rpm, it can achieve 1,225 pound-feet of torque. This engine will redline at 1,800 rpm. At its lowest measured speed of 1,100 rpm, it can produce a maximum of 1,337 pound-feet of torque.

Fuel Rate
When operating at 1,400 rpm and achieved peak torque, this engine will consume 17.8 gallons of diesel fuel an hour. At the lowest measured speed of 1,100 rpm, the engine will consume 15 gallons of diesel fuel an hour. At the maximum speed of 1,800 rpm, the engine will consume 20 gallons of diesel fuel an hour

Maintenance
Refer to the manufactures manual

16. Jet Pump System Troubleshooting

See document for Jet Pump Troubleshooting