Ssi tech introduction
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The document summarizes SSi Artificial Lift Systems, which manufactures surface-mounted artificial lift systems to optimize oil and gas well production. It discusses the management team's extensive industry experience, the manufacturing facility, robust supply chain, and features of the pumping and power units. The pumping units provide lift capacities from 15,000 to 80,000 lbs and strokes from 168” to 372”, while the power units range from 15 to 200 hp. Key features that increase well efficiency and production include long strokes, high load capacities, variable up/down speeds, and integrated pump-off control.
Ssi tech introduction
- 1. Introduction SSi Artificial Lift SystemsTM (SSi) manufactures, sells, and services surface-mounted artificial lift systems used to optimize production in oil and gas wells in onshore applications. SSi Lift System design maximizes well production while reducing operating and maintenance cost and providing its customers with low acquisition and installation costs. Management The members of the management team bring over 100 years of industry experience. These years of experience include specific experience in the following areas, among many others: • Artificial Lift • Well Optimization • Quality Management • Manufacturing Engineering • Electrical Engineering • Hydraulic Engineering With this vast base of experience, the management team is focused, cohesive and collaborative, resulting in a powerful driver of value to its customers. Manufacturing & Technology Center The Company utilizes a 50,000 square foot facility located in Calgary, Alberta, Canada. From this facility, SSi Artificial Lift System performs its engineering, manufacturing, assembly, full load testing operations. The facility is optimized to meet the unique needs of the SSi Artificial Lift System including sophisticated hydraulic fluid handling, unique cranes, a customized cylinder assembly room, and one-of-a-kind full load tester. The current assembly capability of the Calgary facility is approximately 100 to 150 units per month depending on the size of the unit manufactured, utilizing a two-shift operation. With appropriate outsourcing and optimizing make/buy decisions, the company’s existing manufacturing facilities are sufficient to accommodate up to 1,200-1,800 units per year with a two-shift operation. Robust Supply Chain SSi Artificial Lift System purchases material from major suppliers who maintain proper inventories and capacities which support SSi Artificial Lift System’s production scalability. Specifically, a worldwide search was conducted to identify the best suppliers and only top-tier suppliers were
- 2. selected. The partnership between SSi and its suppliers enables the superior quality of all the components, Just-in-Time delivery (JIT), and continuous improvement to exceed customers’ expectations. SSi System Overview The SSi Artificial Lift System is a surface-mounted artificial lift system that is used to extract fluids from both shallow and deep wells to produce crude oil or dewatering for natural gas production. The SSi Artificial Lift System works in conjunction with a bottomhole pump and rod string. The SSi Artificial Lift System is comprised of two main components: the pumping unit and power unit. Pumping Unit SSi Artificial Lift System offers seven Pumping Unit models ranging from a Model 150, with 15,000 lbs. lift capacity and a 168” stroke to a Model 800, with 80,000 lbs. lift capacity and a 360” stroke. The Pumping Unit is comprised of a triple chamber hydraulic cylinder, a heavy duty structural base, a counterbalance vessel containing nitrogen gas under pressure, and a pulley/wire rope lift mechanism which doubles sucker rod stroke relative to cylinder travel. The counterbalance can be adjusted at the well simply by adjusting the pressure of the gas in the storage vessel. The direction and speed of the pump is then controlled by sending hydraulic fluid under pressure to either the up or the down chambers of the cylinder. Since the pump is computer controlled, the speed and stroke limits can be independently established, thereby allowing for independent speeds for the up and down stroke. Pumping Unit ● Provides lift capacity – 15,000lbs to 80,000lbs ● Determines stroke length based on model – Max stroke lengths from 168” to 372” ● 7 models Power Unit ● Provides driving force and control for the pumping unit ● Determines max speed which with the pumping unit it can run ● 9 models – 15hp to 200hp
- 3. Power unit SSi Artificial Lift System offers multiple horsepower options per Pumping Unit model ranging from 15 Hp. to 200 Hp. The Power Unit provides the driving force and control for the Pumping Unit. It is comprised of a hydraulic system, variable speed drive (VSD) control and a computer control system (PLC). The system utilizes many sensor mechanisms to provide optimum stroke control and full monitoring of well and pump conditions. The self-monitoring system provides warnings of impending failure conditions, both at the surface and down-hole, and stops the pump prior to a catastrophic failure. The system includes a sealed hydraulic reservoir and various valves for precise control of the cylinder throughout the pumping cycle. The Power Unit is connected to the Pumping Unit by means of high-pressure hoses and electronic control circuitry. The electronics include computer controls that allow for the pump to be controlled by closed loop feedback for precise operation of stroke speed and position. SSi Artificial Lift Systems Features and Characteristics The SSi Artificial Lift System Pumping System has been designed to increase the overall productive efficiency of a well by incorporating several beneficial features: • Long Stroke – Having a long stroke reduces rod stretch as a percent of stroke length. The rod stretch can be a significant percentage of the overall stroke of a rod pump system, which has the undesirable effect of reducing the effective stroke length of the down-hole pump. In general, the longer the stroke of the down-hole pump, the larger the fluid flow from the well. For a given pump size and fluid production rate, the slower number of strokes per minute means fewer rod direction reversals which reduces the rate of fatigue in the rod string, thus increasing rod life, reducing the frequency of well workovers, and increasing uptime, and increasing production. Pumping Unit Model 150 250 350 400 400LS 600 800 Stroke Length 168” 240” 372” 288” 336” 336” 360”
- 4. • High Polish Rod Load Capability - The well depth and bottom hole pump size determine the rod string design and ultimately the rod load. Larger bottom hole pumps increase the efficiency of a well by reducing the pressure drop of fluid as it enters the pump. As a result, the driving pressure stays high and more fluid moves into the pump, increasing the rod load. The SSi Artificial Lift System, by having larger lift capacities and lower accelerations, can take advantage of using larger bottom hole pumps, thereby optimizing production. Pumping Unit Model 150 250 350 400 400LS 600 800 Lift Capacity 15,000lbs 25,000lbs 35,000lbs 40,000lbs 40,000lbs 60,000lbs 80,000lbs • Variable Speed Up/Down – The SSi Artificial Lift System incorporates eight independent speeds for up and down stroking. Acceleration and deceleration transitions are also independently controlled during rod reversal, which substantially reduces rod stresses. Slower down stroking reduces the compressive load which can cause buckling of the rods, leading to fewer rod and tubing failures. Controlled acceleration at the start of the up stoke reduces the peak rod load. Controlled acceleration and slower cycling on the down stroke minimizes the loss of rod load, which can lead to rod buckling and carrier bar separation. As a result, the loading and unloading of the rod string is minimized, reducing fatigue, therefore increasing the life of the rod string. Lighter API rod tappers can also be used resulting in reduced installation cost and a reduction in electrical consumption. Bottom hole pump leakage is reduced by cycling faster on the up stroke than on the down stroke. By operating faster up than down, fluid leakage due to slippage past the plunger and traveling valve is reduced as a percentage of the total cycle time, resulting in increased production per stroke. Example: 8 seconds up 12 seconds down = 3 SPM, 20% less time for the down-hole pump to leak compared to operation at equal time in both directions. Cycling at a slower speed on the down stroke assures that the bottom hole pump fillage is maximized. • Integrated Pumpoff Control – Maximum formation flow is achieved when the fluid pumped from the casing is equal to the fluid coming into the casing from the reservoir. The pumpoff controller measures for a pumped off condition on every pumping cycle. Instead of shutting off, the speed down is reduced when a pumped off condition is detected. The decrease in speed on the down stroke reduces the strokes per minute which reduces the theoretical flow while maintaining the fluid level above the pump. Compared to systems that shut off when “pumpoff” is detected,
- 5. the fluid is maintained close to the pump, maximizing the pressure differential between the formation and the well bore. Typically maintaining the fluid level low over the down-hole pump improves the water cut and reduces sand interference, thus optimizing fluid production. Automatically changing the cycling to match the well bore inflow eliminates the inefficiencies and harmful effects of continuing to pump in a “pumpoff” condition. For extreme pumpoff conditions, the controller has a second level of pumpoff control that shuts the system down for a set period of time which is adjustable and set in the controller. • High Efficiency – The factors described above, combined with a counterweight design that incorporates virtually no inertia, permits the SSi Artificial Lift System to use significantly less installed horsepower drive units for the same or greater lifting load capability. The design is also based on a constant torque drive system, which results in a power factor close to one and makes the unit able to operate with smaller transformers and wiring. These factors are extremely important since the SSi Artificial Lift System consumes less energy than other artificial lift alternatives and reduces the need for additional field electrical capacity when they are installed. Additionally, the variable speed drive that is integrated into the SSi Artificial Lift System allows for a “soft start,” which requires a lower installed power. • Diagnostic Feedback – The SSi Artificial Lift System takes full advantage of diagnostic feedback to provide a fully self-monitored system, including detection of surface equipment malfunctions and down-hole related problems such as stuck pumps and parted rods. The self-monitoring provides warnings of impending failure conditions and also stops the pump prior to a catastrophic failure. Because of this, major expensive repairs and unscheduled down time can be avoided. • Well Work Over Service – The Pumping Unit has a small footprint V-Base mounted on rails. The well can easily be prepared for well service by releasing the load from the carrier bar and tracking the system back using a standard pickup truck or hand-operated winch. No hoses or other connections need to be disconnected. When well work over is completed, simply track the pumping unit forward into the stops, which assures proper alignment and reconnect the carrier bar to the rod string. The entire track-back operation takes one technician, no heavy equipment, and approximately seven minutes to complete. This results in substantial cost savings when the well must be worked over. • Reliability – The SSi pumping units are designed to give maximum up time while in service. A report is available for every unit that is on the SCADA system. At present the SSi units are averaging 98.2% uptime with 1.8% downtime due to internal faults.
- 6. Power Efficiency The SSiArtificial Lift System will yield the highest power efficiency the well will support! The SSi Artificial Lift System is engineered and optimized to provide the most compact and the most efficient sucker rod pump power solution. When a sucker rod pump is stroking up, it is lifting the useful payload of the pumped fluid. While lifting the fluid, it is also lifting the weights of the string, the down-hole pump and the carrier bar. The work spent to lift these parts is non-productive and wasted energy. In wells that are over 1,000 meters deep, the non-useful payloads of the rod string usually make up a high percentage of the column weight. In addition, the power supply must be sized to be able to lift the fluid column, and, in addition, the rod string (non-useful payload) components. Distinct from its competition, the SSi Artificial Lift System is designed to spend energy only on lifting the useful payload - the fluid column. No energy is spent on lifting the payloads of the rod string. In addition, the prime mover is sized to lift only half of the fluid column weight. This results in the prime mover (electric motor, combustion engine, etc.) being the most efficient and the most compact power package possible. These significant savings of power and size are accomplished by the use of a counterbalance air spring in conjunction with a triple-chamber, dual-acting hydraulic cylinder. The SSi Artificial Lift System offers additional substantial power savings by using high efficiency electric motors (greater than 95%) and high efficiency hydraulic pumps (greater than 94%). Additional power savings are achieved by using a direct hydraulic transmission without using flow regulating valves, thereby minimizing hydraulic fluid flow losses. In summary, the SSi Artificial Lift System design offers an artificial lift oil pump with an unsurpassed power efficiency exceeding 85%. Optimized Production The SSi Artificial Lift System incorporates functional capabilities enabling optimization of fluid production by taking advantage of the following SSiTM Artificial Lift System features: • A wide range of pumping unit and power unit combinations • Computerized control of independent UP and DOWN speeds, accelerations, decelerations, and direction at any point. • Long stroke
- 7. • Computerized sensing and monitoring devices • Low inertia of the SSiTM Artificial Lift System moving parts • Safety alarms and controls These features enable production optimization by: • Tailoring pumping equipment for each well’s desired production requirements and depth • Enabling fast speed UP, thereby minimizing fluid leakage losses • Enabling slow speed DOWN, allowing complete fillage of the down-hole pump • Reducing rod stretch, and increasing bottomhole efficiency • Enabling accurate and efficient turnaround accelerations and decelerations, thereby maximizing stroke speed while minimizing dynamic loads, minimizing stresses and wear, and maximizing up time • Sensing of pump-off conditions and enabling continuous slow-speed operation instead of stop- and-go, thereby reducing sand build up, dynamic loads, excessive stresses and wear, and maintenance downtime and cost • Enabling instantaneous stroke change, speed change, acceleration and deceleration changes, to meet varying well conditions while avoiding downtime • Protecting the SSi Artificial Lift System from damage in the event of a catastrophic bottomhole equipment failure, including a rod part failure • Protecting the bottomhole equipment from damage in the case of a binding bottomhole pump or rod string • Preventing a well blowout in the event of pressure buildup in the flow lines • Providing real time production data, including surface dynomometer cards, enabling immediate control adjustments to adapt to well conditions
- 8. Installation Options There are two basic installation methods for the SSI Artificial Lift unit. The installation method depends on the soil conditions of the site. If the ground conditions allow the SSi unit can be installed on concrete piers. This is common in areas where the ground is very stable. For areas where frost or ground heaving can occur the SSi unit is normally mounted on piles that are either driven or screwed into the ground. Concrete Pier Installation Pile Installation SSi Artificial Lift also has the capability to custom design and manufacture bases for all applications. Supervisory Control and Data Acquisition (SCADA) The SSi Artificial Lift System incorporates a dedicated serial port for remote monitoring and control using standard Modbus protocol. Communication can be achieved via radio modem or via satellite for remote areas. SSi Artificial Lift System can also furnish a memory map for configuration to other SCADA systems. Wireless modems and related hardware is not included and would need to be installed by SCADA technicians.
- 9. Product Support SSi Artificial Lift System is focused on providing professional service in a timely manner. Internationally, our distributors are factory-trained and factory-supported through SSi Artificial Lift System Technical Services organization. SSi Artificial Lift System will provide ongoing product support and customer service throughout the life of the product. SSi Artificial Lift support is based on a strong engineering and production infrastructure and includes training, documentation and spare parts availability.