presentation of oilfield equipment produced by irz
TRANSCRIPT
www.irz.ru
Oilfield Equipment
Izhevskiy Radiozavod (IRZ)
2
AO “Izhevskiy Radiozavod” (IRZ)
Date of foundation
Total number of employees
Engineering department
Parts testing center
Customer representative offices
Company is certified to
• Russian company producing radio-electronic equipment
• March 6, 1958
• 5 200
• 600
• procurement, tests, supply of electronic components
• Ministry of Defense, Russian Railways
• AS/EN 9100 standard of International Aerospace Quality Group (IAQG) for aerospace and military products
3
TECHNOLOGIES
Products testingAssembly and integration
Design and development
Procurement, test and supply of electronic components
Hybrids production PCB production
SMT Mechanical processing
4
PRODUCT LINES
Space-related electronics for on-board and ground segments
User navigationequipment
Railway automatics andsafety systems
Telecommunication systems
Oilfield electronic equipment Control and measuring equipmentVideo systems Mobile robotic systems
OIL MARKET – FACTS & FIGURES
95% of oil wells utilize artificial lift
44% of artificial lift oil wells utilize ESP
Over 130 000 ESP units are used worldwide
IRZ’s Russian market share for ESP Telemetry
Systems has been growing since 2009 from 8% to
40% in 2014
IRZ’s Russian market share for control stations is 20%
Main Customers
IRZ40%
Electon20%
Borets14%
Novomet10%
Triol7%
Others9%
ESP Telemetry SystemsRussian Market, 2014
2. ESP Telemetry Systems
1. ESP Control Stations
Smooth Starter
EQUIPMENT FOR ESP
3. Equipment for testing and maintenance
Frequency control (VSD)
Downhole sensors
Surface acquisition units
TM-data (telemetry) includes: Pump suction pressure Stratum fluid temperature Motor oil pressure Motor oil temperature Motor stator winding temperature Motor vibration level Motor power cable insulation resistance
Downhole sensor
ESP TELEMETRY SYSTEM - CONFIGURATION
TM-d
ata
Surface Acquisition Unit
TM-data
ESP Control Station
Downhole sensors are designed for: parametric monitoring of motors
parametric monitoring of formation fluid at pump intake
transmission of TM-data to ground unit via motor power cable
Features: high accuracy
tolerant to interferences
high endurance
easy maintenance
3 years lifetime
low cost
Serial production of downhole telemetry systems since 1998
More than 20 000 downhole sensors
already in operation
ESP TELEMETRY SYSTEMS – DOWNHOLE SENSORS
IRZ TMS
ESP TELEMETRY SYSTEM - SPECIFICATION
Parameter Downhole SensorBP-103М3
Downhole SensorBP-103DM
Intake pressure: Range, atmResolution, atmAccuracy, %
0 – 250/320/6000,010,5
0 – 250/320/6000,010,5
Intake temperature: Range, °СResolution, °СAccuracy, %
0 – 15012
0 – 15012
Motor stator winding and oil temperature:
Range, °СResolution, °СAccuracy, %
0 – 25012
0 – 25012
Motor vibration (X, Y): Range, gResolution, gAccuracy, %
0 – 50,12
0 – 50,12
Motor vibration (Z): Range, gResolution, gAccuracy, %
---
---
Insulation resistance: Range, кОhmResolution, кОhmAccuracy, %
0 – 9999 1
2 – 5
0 – 9999 1
2 – 5
Parameters scanning time, sec., no more than 20 20
Discharge pressure: Range, atmResolution, atmAccuracy, %
---
0 – 250/320/6000,010,5
Discharge temperature: Range, °СResolution, °СAccuracy, %
---
0 – 15012
Pressure build-up curve (PBUC) in vertical oil well (example)
Example: the research done by IRZ TMS system allowed to evaluate the parameters of the reservoir (in-place permeability, conductivity), condition of bottomhole formation zone (skin)
In Russia downhole sensors are always used in the oil wells with the output of 5 tons/day
Telemetry system is used to: protect ESP from
overheating, vibration, etc.
hydrodynamic research
Research by method of indicative diagrams at 6 stable operation modes
Example: this kind of researches include measurement of pressure and output at several stable operation modes in oil wells with different output. The sensor is placed at the fixed depth close to the reservoir to be tested. Customer can define the pressure of reservoir, flow rate factor.
TMS IRZ can be used to study the oil wells parameters.
Benefit: No need to pay for
hydrodynamic researches
No need to stop the oil well for research
ESP CONTROL STATIONS
IRZ-700ESP Control Stationwith smooth starter
Main functions: Motor control and protection in
manual or automatic mode Motor parametric monitoring Motor smooth start and braking
Advantages: 8 starting and braking modes operation log-file can be saved to USB
flash-drive software update during Motor operation bus design of power system
Parameter Value
Supply voltage, V 270 -490
Motor power range, kW 14 - 220
Motor start/brake time range, sec 0 - 90
In-rush current limit, % of rated current
100 - 500
Motor Operating current control, A 0 - 200
Insulation resistance control range (downhole telemetry - power cable - Motor), kOhm
0 - 10000
Turbine rotation frequency control, Hz 1 - 48
Current, voltage, rotation frequency and time setting control error, %
2
Insulation resistance control error, % 5
Cabinet protection class IP43
Operating temperature, °С minus 60 ... +60
Technical specification
IRZ-500ESP Control Stationwith frequency control – Variable Speed Drive
Main functions: Motor manual or automatic control
(power range from 14 to 320 kW) Motor parametric monitoring Motor soft start, smooth braking Motor rotation frequency control
Advantages: adaptive control algorithms service operation modes: inching,
wedging, gas bleeding, shaking, proportional-integral control
operation log-file can be saved to USB flash-drive
integrated output sinus filter software update during Motor operation bus design of power system
Parameter Value
Supply voltage, V 270 -520
Motor power range, kW 14 - 320
Motor rotation frequency control range, Hz
0.5 – 100(increment 0.1)
Motor operating current control range, A
0 - 200
Insulation resistance control range (downhole telemetry - power cable - Motor), kOhm
0 - 10000
Turbine rotation frequency control, Hz
1 - 48
Current, voltage, rotation frequency and time setting control error, %
2
Insulation resistance control error, % 5
Cabinet protection class IP43
Operating temperature, °С minus 60 ... +50
Technical specification
ESP CONTROL STATIONS
ROD PUMPS CONTROL STATIONS
IRZ-400Rod Pump Control Station with frequency control
Main functions: rod pump electric motor manual or
automatic control (power range from 5 to 55 kW)
parametric monitoring and diagnostics of oil well
soft start, smooth braking rotor frequency control
Advantages: oscillation frequency control without
stoppage or changing pulleys compatible with different types of
pressure and temperature sensors smart control algorithms (option) optional dynamograph operation log-file saved to USB flash-
drive software update during rod pump
operation
Technical specificationParameter Value
Supply voltage, V 270 -520
Electric motor power range, kW 5- 55
Rotor frequency control range, Hz 0.5 - 100 (increment 0.1)
Current, voltage, rotation frequency and time setting control error, %
2
Cabinet protection class IP54
Operating temperature, °С minus 60 ... +50
Connection options: oil-field telematics (contacts normally
open/closed) SCADA-system (via RS232/RS485
interfaces) GPRS-modem (on-line access)
CONTROL STATIONS - OIL PRODUCTION OPTIMIZATION
Energy saving mode:
Due to the selection of optimal voltage, the active current is
reduced
CONTROL STATIONS - OIL PRODUCTION OPTIMIZATION
IRZ control stations along with the IRZ telemetry system (downhole sensors) allows to:
Provide efficient control of the reservoir – oil well – pump
Provide efficient protection of ESP
Optimize oil production
Reduce power consumption
DUAL COMPLETION SYSTEMS
ESPDownholesensor
Electric Valve
Casing separatorPackerBack valve
Sludge trap
System features: switch between lower and upper zones
for direct measurement through a group metering station
pressure measurement for each segregated zone
use of one ESP VSD is used to control the valve
without stopping the ESP
Downhole sensor Electric valve Control station (VSD)
Functions: control of main geological
parameters in each segregated zone
control of bottom hole pressure in each segregated zone
dual production
In collaboration with:
DOWNHOLE FLOW METERING SYSTEM
The system consists of: Downhole sensor BP-103DR Flow meter RM20 Surface acquisition unit TMS-E5-01 Bearing support Logging cable for connection between downhole sensor and flow
meter
System features:RM20 flow meter is installed at the discharge of electric submersible pump (ESP) and is designed to measure actual and day volume of fluid production, pressure and temperature at the discharge of a pump, tubing annulus pressure at the point of installation of the flow meter, 3-axis vibrations.
The data is transmitted through the logging cable between the downhole unit and flow meter. The data from the downhole units is transmitted to the ground units through the link between downhole sensor zero-cable to ESP power cable and ESP Y-connection.
RM20 is a vortex-type flow meter with no moving parts and that is an advantage comparing to a paddle flow meter using a turbine - the weakest part of it. The flow meter is resistant to corrosion in reservoir operating conditions.
Downhole sensor Electric valve
Functions:Downhole monitoring system with the flow meter registers and transmits measurement data including flow rate, fluid temperature and pressure at the discharge of a submersible pump.
Surface acquisitionunit
ANTI-SCALING SYSTEM - RESONANT UNDULAR COMPLEX
PILOT-1Resonant Undular Complex (RUC)Pilot-1 is a patented device for treating oil wells in order to reduce scaling on the outer and inner surfaces of downhole equipment and to achieve the highest efficiency of the oil well.
Pilot-1 is connected directly to the base of motor and powered from the stator coil of electric motor.
Change of crystal structure
Before After Before After
Anti-scaling
ANTI-SCALING SYSTEM - RESONANT UNDULAR COMPLEX
Crystal structure is modified:
Effect:• downhole pumping equipment is not clogged with
restructured crystals• system acts over the whole well - from the bottom hole
area to the top hole area• fluid viscosity is reduced due to the impact of
asphaltenes (oil-water emulsion stabilizers)
PILOT-1
ANTI-SCALING SYSTEM - RESULTS OF IMPLEMENTATION
RUC Pilot-1 has been industrially implemented on complicated well stocks in 2014:
A number of field tests were launched in the following oil companies in 2014:
Proven results in production
optimization:
Before After
ANTI-SCALING SYSTEM - CHANGE OF OIL-WATER PHYSICAL PROPERTIES AND REDUCTION OF FLUID VISCOSITY
Effect of electromagnetic field on fluid viscosity
Increase of production rate depending on fluid viscosity
• Increase of water cut up to 70-75% leads to increase of oil-water emulsion viscosity. Viscosity may increase by 10 times and more.
• Water cut of 50-75% is close to the critical value at which viscosity reaches its maximum value.
• Lab tests showed that viscosity decreases under the action of electromagnetic field.
• RUC Pilot-1 influences on the well fluid and reduces the oil-water viscosity thus providing a smoother lifting of the fluid.
• The simulation showed that the drop of viscosity by 22% resulted in 14% increase of the production rate.
Fluid shear rate, 1/sec
Effe
ctiv
e vi
scos
ity ,
Pa*
sec Hz
kHz
idle
Fluid rate, m3/day
Bot
tom
-hol
e pr
essu
re, a
tm.
ANTI-SCALING SYSTEM - PERFORMANCE
Qж (куб.м./сут.) Qн (тн./сут.) Наработка (сут.)0
10
20
30
40
50
60
42
21.9101
53
26
295
ДоПосле
+26% +19%
1. Totally more than 40 units were implemented;2. Failures due to scaling – none;3. Chemical treatment – none;4. Oil-water viscosity and wall packing reduction allow to
increase production by an average 26%;5. Before the implementation of RUC Pilot-1 all controlled wells
were inclined to scaling and were treated with scaling inhibitors and acids solutions.
RUC “Pilot-1”
+192%
Before
After
Q, m3/day Q, ton/day mean time to failure, days
ANTI-SCALING SYSTEM - ADVANTAGES OVERCHEMICALS
•Mean time between failures increased by a factor of more than 2•Flow rate increase by an average 20%•Protection of electrical centrifugal pump unit over the whole lifetime
Efficient
•Payback in 5 monthsCost effective
•Scaling reduction from the bottom hole area to the top hole area•Fluid viscosity reduction•Operation parameters are monitored by downhole gaugeHigh Performance
•Remote control optionSmart
•No R&D work and efficiency estimation of inhibitors/dissolvers required;•Easy transportation and storing
Easy in operation
•Electrical centrifugal pump + packer/enclosing shield; ・BHA sticking;•High fluid salinity; ・water
cut <5%
Application
ANTI-SCALING SYSTEM - CONNECTION
Downhole sensorBP-103 DM
PILOT-1
Connection scheme:• downhole sensor (BP-103 DM) is connected to the
bottom of the SEM (submersible electric motor)• sensor is powered from zero point and PILOT-1 is
powered from the SEM primary winding• PILOT-1 is monitored by downhole telemetry system Advantages:• data can be transferred via telemetry system when SEM
is off• reliability and serial production• telemetry systems (downhole sensors) are fully
compliant with technical requirements of national oil companies
Tested and approved by:
ANTI-SCALING SYSTEM - ASSEMBLY
ADVANTAGES OF IRZ PRODUCTS
Low price(competitive with analogues)
Service and maintenance cost reduction
Increase of oil production output
Cost Effective
Quality Management System
Reliability in operation
Recognized Russian Supplier
High Quality
Full Cycle Production
Advanced Technologies
In-House Design
Production Facilities
IRZ offers:
Integrated solutions for optimization of oil production process
Integrated supplies of oilfield equipment according to customer needs
Training & service
CUSTOMER BENEFITS
You are welcome to cooperate!
Your points of contact:
Anton STARKOV | Sales ManagerTel: + 7 3412 722 971Fax: +7 3412 726 954 E-mail: [email protected]
Sergey FEOFILAKTOV | Chief DesignerE-mail: [email protected]
Izhevskiy Radiozavod (IRZ) 19 Bazisnaya street, city of Izhevsk, Russia, 426034 Tel: + 7 3412 501 501Fax: +7 3412 686 555 E-mail: [email protected] Web: www.irz.ru