Electro-hydraulic Downhole Pump DriveEfficient and future orientated crude oil production

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Efficient Energy Management Starts with the Production Process

Crude oil and natural gas are the most important energy sources in our present world. Without them, our modern life in prosperity would hardly be conceivable. The demand for energy in our industries as well as for maintaining our infrastructure is still increas-ing. Therefore, oil companies are looking for more efficient ways to tap energy resources. Instead of mechanical oil extraction methods they are increasingly focusing on electro-hydraulic technologies. Bosch Rexroth offers tailor-made system solutions to enhance the efficiency and availability of your oil well.

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Sustainably Increased Output Quantities – by Means of Efficient State-of-the-Art Technologies

The still increasing demand for energy makes it necessary to tap deposits which are difficult to access – sometimes under raw climatic conditions. Our components and sys-tems are ready to reliably meet all requirements – no mat-ter if you have to deal with Siberian permafrost or hot and wet tropical climates.

As a well-established partner of outfitters and operators, Bosch Rexroth develops future orientated automation solutions for the extraction of crude oil and natural gas, exactly tailored to your requirements. For many years, our components have been in service in almost all climatic zones of our world – to the great satis-faction of our customers. Today, our industry experts offer complete systems and modules which can deal with the most difficult extraction conditions.

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Modern Crude Oil Production – Maximum Productivity, Easy Installation

Our demand for energy is constantly increasing, yet we are confronted with the dwindling of our natural resources. The environmental conditions for the extraction of crude oil are often difficult in secluded areas. Companies striving to maintain their leading market position in the future have to focus on maximum profitability and efficiency of their oil production facilities.

Many oil fields in the world still use downhole pumps with mechanical pump jacks. The drawbacks of these solutions are obvious: They require an enormous amount of energy and expose the production wells components to maximum mechanical stress. Sucker rod strings often have to be up to 4,000 meters long in order to reach the oil resources and be able to lift weights up to 20 tons. The mechanical drive has to provide the necessary power, which requires an enormous construction height and a stable concrete foun-dation.

Therefore, Bosch Rexroth focuses on solutions with hydrau-lic drives for downhole pumps. They facilitate lower con-struction heights and allow for the individual adaptation of downhole pump cycle times and stroke lengths to the oil inflow. This makes oil extraction quicker, more energy-and cost-efficient than with traditional mechanical systems.

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Quickly Installed andAlways Perfectly Under Control Year-long experience with raw material production systems has sharpened our awareness for those aspects, which are specifically important to our customers in day-to-day opera-tion.

Our modular system R7 is quickly installed and put into operation. All components impress with their reliability and long life cycles. During operation, all operating data is logged. Easy maintenance ensures maximal availability for many years. With Bosch Rexroth’s system R7, you can easily and accu-rately adjust pump strokes and cycle times to the individual requirements at your facility – either directly via the control console of the machine or remotely from a central control room.

Your Benefits

f The compact module design facilitates easy instal-lation and quick commissioning on site

f Individual adjustment of cycle times for increased productivity

f Pump strokes and speed can be freely and easily adjusted to the oil level and consistency

f Long life cycles and increased reliability

f Direct output and monitoring of operation data (dynamogram)

f The production well site can be directly controlled via the machine control console or via remote data transmission

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The Downhole Pump Drive R7 –Electro-hydraulics for Increased Production Effi ciency

Upward StrokeThe axial piston unit (A) swivels into the pump mode and transports the hydraulic oil to the cylinder. It generates the required tractive force to lift the cylinder rod, the attached sucker rod system and the pump piston. The necessary power for the lifting process is provided by the electric motor (E) and the fl ywheel mass (F).Downward StrokeThe axial piston unit swivels into the motor mode. This is driven by the potential energy of the sucker rod system and the downhole pump piston, which in turn accelerates the electric motor and the fl ywheel until they reach the syncro-nous electrical supply line frequency. The electrical motor works with a maximum slip of 10 %. Safe and ReliableThe R7 drive system is CE-marked and meets the safety requirements of the machinery directive 2006/42/EG. The cylinder and the mounting console meet the requirements of the Atex directive 94/9/EG.

The downhole pump drive R7 consists of a hydraulic cylin-der, which is directly mounted onto the sucker rod, a hydraulic hydraulic power unit equipped with an axial piston unit (A), an electric motor with integrated fl ywheel mass (F), and the system control unit (C). With the upward and downward stroke of the pump piston, the crude oil is transported from the deposit to the surface. The energy consumption is evenly distributed over the entire movement cycle. This helps to signifi cantly reduce the power consumption of the electric motor.

A · Axial piston unit

E · E-motor

F · Flywheel mass

C · Control unit

Vmax

1

0,5

0-0,25 t-0,5

Vmax

1

0,5

0-0,25 t-0,5

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Signifi cantly Increased Effi ciency Compared to Mechanical Solutions

Compared to mechanical deep pump drives, the clear benefi ts of electro-hydraulic systems have a direct impact on the effi ciency during operation and the productivity of the oil production:

f The maximum stroke speed is not limited by the maxi-mum lowering speed and vice versa

f Eff ective overload protection by means of automatic monitoring and limitation of the tractive force. Break-age of the sucker rods is virtually eliminated.

f The entire oil production process is constantly moni-tored. The acquired data can be used at the control center for direct and quick optimization

f Easy maintenance and quick commissioning

Electro-hydraulic drive

Mechanical drive

Technical Data

f Max. operating pressure: 350 bar

f Electric drive power: up to 90 kW

f Stroke lengths: up to 6 m (standard)

f Lifting force: up to 20 t

f Sucker rod length : up to 4,000 m

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Electro-hydraulic Downhole Pump Drive R7 –the Standard Configurations

Rexroth Type Combination 1 stroke (in)/spm

Combination 2 stroke (in)/spm

Combination 3 stroke (in)/spm

Power (kW) @60Hz

Force (lbs) max. dyn.

Output BFPD*

R7-365- 144/7.5 168/6.5 192/6.0 90.0 36,500 29,200 530

R7-305- 120/8.0 144/6.5 168/6.0 66.0 30,500 24,400 460

R7-305- 120/6.5 144/5.5 168/4.5 54.0 30,500 24,400 360

R7-256- 120/6.5 144/5.5 168/4.5 44.4 25,600 20,480 360

R7-256- 100/6.0 120/5.0 144/4.5 36.0 25,600 20,480 290

R7-213- 100/5.5 120/4.5 144/4.0 26.4 21,300 17,040 260

* Theoretical output of a downhole pump (nominal size 2“, η = 1)

Ready for all production conditions: The hydraulic power units of the R7 standard range offer exactly the perfor-mance that optimally fits the conditions on your oil field. You can combine power units with different hydraulic cylin-ders to cover a broad range of tasks. Further nominal sizes can be realized upon request.

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Also with crude oil and natural gas production, the following applies: The productivity of your production facilities relies on the availability of your machines. As your long-term partner, Rexroth offers a broad range of services covering the entire life cycle of your system.

Our service offers comprehensive support in all parts of the world in order to guarantee maximum availability of your production well site, over the entire life cycle of your system.

Bosch Rexroth is always in the vicinity of your production facilites. As we are present in more than 80 countries. This ensures short response times and the quick supply of spare parts.

Our service specialists will also assist you to modernize and retrofit your facilities. In close cooperation with you, we analyze the current state of your system and offer you comprehensive solutions from a single source, including planning, design, assembly and commissioning. Bosch Rexroth is your partner, if you would like to sustainably increase your output.

For detailed information, please visitwww.boschrexroth.com/service

Bosch Rexroth Services, not only in the case of a failure – Your Partner for the Entire Life Cycle

Spare parts Repairs Field service

Retrofit and ModernizationHotline

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References

Production facilities with Bosch Rexroth’s electro-hydraulic downhole pump drive R7 can be found on oil fields all over the world today. Our systems work efficiently and reliably under the most difficult climatic and geographical condi-tions. We constantly improve our well-established compo-nents and systems and adapt them to the individual require-ments of our customers.

f Argentina

f Type: R7-365-280-4 f Stroke length: 7.0 m f Dry steppe climate

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f Indonesia

f Type: R7-132-120-10 f Stroke length: 3.0 m f Serial delivery f Tropical rainforest

e China

f Type: R7-213-120-4 f Stroke length: 3.0 m f Moderate continental climate

f (temperatures from f -20 °C to +35 °C)

c Turkmenistan

f Type: R7-180-100-6 f Stroke length: 2.5 m f Desert (temperatures from

f -10 °C to +45 °C)

c Columbia

f Type: R7-220-240-2 f Stroke length: 5.0 m f Tropical climate

The data specified only serve to describe the product.As our products are constantly being further developed, no statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.

R999000451 (2014-12) © Bosch Rexroth AG 2014 Subject to changes!

Find your local contact person here: www.boschrexroth.com/contact

Bosch Rexroth AGZum Eisengießer 1Tel.: +49(0)9352-181158www.boschrexroth.com