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Home > Applications by Industry Overview > Oil & Gas Production > Upstream and Midstream Processing Applications
RELIABLE PUMPS THAT LOWER COSTS IN UPSTREAM & MIDSTREAM APPLICATIONS
Keep your processes producing for a more sustainable future – safely, reliably and efficiently for a lower total cost of ownership.
Protecting operators and the environment – 100% leak-free
No ground contamination, no spillage of hazardous chemistry such as Benzene, Toluene, Ethylbenzene and Xylenes, hydrogen peroxide and crude oil; zero emissions of aromatic hydra-carbons. Hydra-Cell Pro’s range of EX-certified pumps offer complete peace of mind for ATEX/hazardous areas.
Reduced maintenance costs – eliminate seal and packing maintenance
High reliability in pumping liquids laden with metal particles from corroded pipelines, at high pressure and high temperature; handling non-lubricating and low viscosity liquids including NGLs, and handling shear sensitive polymers with no degradation of the process liquid.
Reduced energy consumption
The true positive displacement pumping action and minimal internal losses of Hydra-Cell Pro API674 & API675 pumps achieve high efficiencies, as measured from pump shaft to hydraulic output power, lowering energy usage.
OIL PROCESSING
Keep your processes producing for a more sustainable future - safely, reliably and efficiently with lower energy usage, 100% leak-free, reduced maintenance for a lower total cost of ownership.
Reliability in LACT Unit Transfers
A LACT (Lease Automatic Custody Transfer) unit not only transfers the crude oil from the extraction company to the collection and processing company, but also measures the volume transferred. The seal-less, packing-free design of a Hydra-Cell Pro Q155 ensures accurate, reliable transfer with 100% containment of the pumped oil, zero leakage, run dry capability and minimal service requirements.
Pumping Sand-Laden Liquid & Reducing Maintenance Costs
A major Hungarian oil & gas company had high maintenance with their multistage centrifugal pumps used in transferring an oil/water mix to their separator. The presence of sand added to the problem. Plunger pumps were also tried to improve the cost of ownership but no improvements were seen. Installing Hydra-Cell Pro pump technology solved the issues dramatically reducing maintenance costs.
Proven Reliability in High-Speed Diesel Sampling
Crude/Oil sampling is a critical quality control process in Upstream and Midstream operations. A reliable sample feed and return pump is very important. With thousands of Hydra-Cell Pro pumps installed in major Oil & Gas companies around the world, reliability is proven.
Reliable Processing in Remote Desert Location
The initial process of driving gases and light hydrocarbons from extracted crude is important to aid further processing. The Heater Treater fulfills this purpose. Different fuels can be used to feed the nozzles of the heater treater, commonly used is diesel sometimes NGL. The flexibility of the Hydra-Cell Pro P200 pump ensures this customer in Oman a reliable process in the middle of the desert.
Hot Water for Portable Offshore Steam Generation Systems
This customer operates an extensive hire fleet of steam generators, producing high volumes of continuous steam. The steam heats chemicals used in descaling pipes and deluge systems, offshore and in refineries. On the portable units (1.4 Mbtu capacity), Hydra-Cell Pro pumps were successfully deployed in place of piston/plunger pumps.
Gas Processing
Keep your processes producing for a more sustainable future - safely, reliably and efficiently with lower energy usage, 100% leak-free, reduced maintenance for a lower total cost of ownership.
Gas Sweetening with Monoethanolamine
Replacing piston plunger pumps prone to dynamic seals leaks and unacceptable pulsation within system pipework, Hydra-Cell Pro seal-less pumps handle non-lubricating, low viscosity Monoethanolamine and corrosion inhibitors on natural gas extraction systems, eliminating leaks while saving on maintenance and energy costs.
Spraying hot Tri-Ethylene Glycol (TEG)
For the removal of water from the gas stream, the processes operators found themselves subject to frequent and unplanned maintenance due to the leaking of the existing plunger process pumps. Reliable handling of low viscosity, non-lubricating Tri-Ethylene Glycol (TEG) at 172° F (78°C) was achieved with Wanner Hydra-Cell Pro seal-less pumps.
Safe removal of BTEX aromatic components
The removal of BTEX (Benzene, Toluene, Ethylbenzene and Xylenes ) aromatic components by the Aromatic Fractionation Unit from natural gas prior to liquification is critical for efficient LNG production. If not removed, BTEX aromatics can cause precipitation of solids (freezing) and fouling of main liquefaction heat exchangers. The unique features of Hydra-Cell Pro pump technology make it an ideal solution for safely pumping applications in BTEX processing.
Reliably Pumping Corrosive and Non-Lubricating Demineralized Water
A major gas producer in the UAE needed to replace their API 674 plunger pumps due to high maintenance and service costs created by the corrosive and non-lubricating nature of the demineralized water used in the absorber water wash process. They found the solution in seal-less, packing-free Hydra-Cell Pro pumps. From installation in 2018 to 2022, the only service has been an annual oil change.
Ethyl Mercaptan - Putting the Smell in Gas
Pumped into odorless natural gas, ethyl mercaptan gives it a distinctive smell that can be the first indication of a gas leak. Mag drive gear pumps were originally used but they were working near the limit of their maximum pressure capability and unable to pump accurately at the very low flow rates specified. Hydra-Cell Pro G20 pumps provides accurate dosing at high flow rates.
Formation Water Dosing
At the site of a gas processing facility in Hungary, the customer was experiencing high levels of sulfur in the gas. Sulfur build-up on the inner walls of the pipework was causing inefficiencies which were not acceptable and gave rise to other issues as well. Hydra-Cell Pro was chosen above other pump technologies and after several years of non-stop operation, there has been no breakdowns and maintenance requirements have been minimal.
Water Management
Keep your processes producing for a more sustainable future - safely, reliably and efficiently with lower energy usage, 100% leak-free, reduced maintenance for a lower total cost of ownership.
Solving Seal and Valve Failures
A major Oil & Gas customer in Austria experienced reliability issues with seals and the valves of the previously installed plunger pump due to corrosive, abrasive characteristics of salt water. Replacing the plunger pumps with Hydra-Cell Pro seal-less, packing-free pumps isolate the pumped liquid from the pump mechanics, dramatically reducing maintenance costs and downtime.
Reliable Salt Water Disposal
A well-known Texas-based oil company involved in well operation, engineering and equipment supply, installed their first Hydra-Cell Pro pump for disposal of salt water originating below ground and surfacing during production operations. The seal-less, packing-free pump solution dramatically reduced maintenance costs, reliably handling the corrosive and abrasive salt water.
Alkali-Surfactant-Polymer (ASP) Injection for EOR
For an Enhanced Oil Recovery operation, injection of Alkali-Surfactant-Polymer (ASP) solution is carried out by 14 injection wells through two injection manifolds. Each injection manifold has 7 injection lines, and each line is provided with individual reciprocating pumps for injection. In three years of operation since switching to Hydra-Cell Pro pumps, the only maintenance has been the recommended oil changes, saving 21,000 tons of polymer and $1/4 million in maintenance.
Virtually Pulse-less Linear Flow, Exceeding API675
Dosing water treatment chemicals is an important part of this Omani Oil & Gas company’s produced water management. With multiple diaphragms in a single pump head, Hydra-Cell Pro delivers a virtually pulse-less linear flow, exceeding API 675 performance criteria of linearity, repeatability, and steady state accuracy far superior to traditional single-diaphragm metering pumps.
Reducing Downtime and Minimizing Costs for Unmanned Site
A US Oil & Gas company needed a more reliable and cost-effective way to decant and transfer produced water from gun barrel collection tanks. The site is unmanned, creating unacceptable downtime due to existing pumps running dry and leaking. By introducing Hydra-Cell Pro G35 pumps driven diesel engines, the customer achieved a very reliable solution, minimizing the cost of operation.
High Pressure RO Feed Pump for Offshore OEM Systems
Maintaining a supply of drinking water for manned offshore platforms in the Gulf of Mexico is critical. An OEM specializing in RO units for these requirements needed a very reliable, high-pressure feed pump for their OEM systems. Reliability and energy usage were vital for these lease systems, as costs are incurred by the OEM. They selected Hydra-Cell Pro D/G35 pumps that operate reliably in the corrosive environment, and accommodate the large variation in inlet pressure to the RO system.
Well Fluid Processing
Keep your processes producing for a more sustainable future - safely, reliably and efficiently with lower energy usage, 100% leak-free, reduced maintenance for a lower total cost of ownership.
Replacing ESP & RRL Pumps Increases Production and Reduces Opex
Electric Submersible Pumps (ESP) were replaced 5 times in 7 years costing the customer $300m.
Reciprocating Rod Lift (RRL) pump was unstable, due to gas slugging and required disproportionate amount of operator time to monitor and adjust pumping unit. Wanner Jet Pump Artificial Lift, driven by Hydra-Cell Pro technology, enabled a much more reliable, low-maintenance solution.
Dosing Corrosion Inhibitors at High Pressure for Mobile Truck
A Russian Oil & Gas company needed a very compact dosing pump for their mobile truck units to inject corrosion inhibitors at high pressure into pipelines and producing wells. The Hydra-Cell Pro dosing pumps provided an ideal solution, with a more compact footprint that also allowed a lower-power pump drive to achieve the required pressures and flow.
Smallest, Lightest & Most Energy Efficient Solution
A Russian Oil & Gas company needed a semi-mobile solution for injection of Methanol for well de-icing. The container unit needed to be designed for easy transportation for processing at different wells. Injecting Methanol at 150 l/ph and at 124 bar, a Hydra-Cell Pro pump solution was the smallest and the lightest solution the customer found, offering high efficiencies, a lighter weight motor, and lower energy consumption than alternative pump solutions.
Safely and Reliably Injecting Amine for Gas Sweetening
Following frequent breakdowns and costly maintenance with a single-diaphragm metering pump, a leading oil and gas development company in India chose Hydra-Cell Pro to pump lean amine solution at high pressure in this gas sweetening application. The injection pumps have been so reliable operating within the severe application conditions, the company has specified additional Wanner Hydra-Cell pumps.
Safety and Efficiency Pumping Hazardous Chemicals
A well acid treatment process involves pumping hazardous chemicals at high pressure. To enable ease of mobile, the rig had to be mobile in size and weight. With their multiple diaphragm pump head design, Hydra-Cell Pro T100 pumps were able to meet the customer's criteria.
Cleaning Drilling Fluid Mud Filters on Oil Rigs
In drilling an oil well borehole, drilling fluid (‘mud’) is injected as lubricant, coolant and carrier of a harsh mix of broken rock shales and other constituents as it rises back to the surface. Before reinjection, the mud is cleaned and separated from solids, initially by shaker screens. Cleaning these screens thoroughly without damaging them is a vital operation. A specialist Norwegian OEM serving the offshore industry has developed a new, efficient cleaning system, relying on the seal-less Hydra-Cell Pro high-pressure pumps for sustainable performance under difficult conditions.
Condensate Processing
Keep your processes producing for a more sustainable future - safely, reliably and efficiently with lower energy usage, 100% leak-free, reduced maintenance for a lower total cost of ownership.
Reliably Pumping Natural Gas Liquids
A major oil and gas company in the Midwestern United States was using conventional plunger pumps with packing to pump Natural Gas Liquids (NGL). These pumps required frequent adjustment and replacement of the packing, and further attention to plunger and stuffing box wear. Following replacement with Hydra-Cell Pro pumps and after one year of operation, the company reports outstanding performance and reduced costs.
Safe and Reliable KOD Condensate Transfer
For a KOD pump application, a customer employing a Progressive Cavity Pump (PCP) experienced leakage through its mechanical seal, resulting in costly maintenance and unplanned downtime. Replacement with seal-less Hydra-Cell Pro pumps eliminates these leaks, reducing maintenance requirements and operational losses.
