COSCO Pump Company
Canadian Oilwell Systems Company
Quality Electric Submersible Pump Equipment
Control Solutions for
Electric Submersible Pumps
www.coscoesp.com
The System
Electric Submersible Pump Systems are designed by COSCO applications
engineers to meet the customer’s requirements and well conditions.
Specialized
Wellhead with
Electrical
Feed-Through
COSCO’s wide and varied product line, including some of the most
advanced controls in the industry, allows COSCO engineers the
flexibility to design an ESP system to meet virtually any requirement.
Switchboard or
Variable Speed
Drive and
Controls
Cable
Vent
Box
Power
Transformer(s)
Surface Components
Sub Surface Components
Gas Separator
or Intake
Power Cable
Motor
Motor Guide
Pump Section(s)
Protector
Motor Lead
Cable
The Company
Down Hole
Sensor
Building on a strong foundation of being one of the ESP industry’s leading control suppliers since 1986,
COSCO made the transition to being a complete ESP system provider in 1996 with the addition of down hole
pumps and motors to its product line. The result is a well-proven product line with COSCO products operating in
many oilfields world wide.
At COSCO we are expanding our service bases to allow more customers to be able to take advantage of our
high quality products and unique services. Market focus has traditionally been on North African, Middle
East, and Russian markets, particularly those countries that require products manufactured outside the USA.
COSCO will maintain and expand its customer service capabilities in these countries as well as expand into
new geographic locations.
Qualified servicemen and applications engineers are available and ready to travel from our centers in several
countries to ensure equipment is installed and operated properly and to provide design services and training of
customer personnel.
COSCO is reducing artificial lift costs, and extending run lives on equipment for many customers in many
countries. If you are installing ESP equipment, we believe COSCO can provide the products and services you
need at a fair price and with a level of service unmatched in the industry.
COSCO - A Different Kind of Pump Company
Pumps
COSCO offers a wide range of submersible pumps to fit most production applications. Pumps are available in
production ranges between 100 and 10,000 barrels per day with new sizes regularly added to the product line.
COSCO submersible pumps are multi-stage centrifugal type. Each stage consists of a rotating impeller and a
stationary diffuser designed for a flow rate range. The number of stages added in the pump housing determines
the amount of lift the pump can deliver.
Stage materials are Ni-Resist (A nickel–aluminum-bronze-corrosion resistant alloy)
K-Monel shafts are standard on all COSCO pumps. Optional high strength shafts are also available in Inconel
or Hastalloy.
Corrosion resistant coatings and ferritic steel housings are available for corrosive applications.
Abrasion resistant pumps are available for sandy wells and for use where maximum pump
life is desired. Additional hardened alloy bearings are added at regular intervals between
stages in abrasive resistant (AR) designs.
338 Series Pumps
Minimum Casing Size 4 1/2”
Horsepower
Flow Capacity Recommended Range
Shaft Limit
50 Hz
60 Hz
50 Hz
60 Hz.
BPD
M3/D
BPD
M3/D
Pump
Model
Shaft
Diameter
(in)
TA 550
0.625
78
94
333 - 583
53-93
400-700
63-111
TA 900
0.625
78
94
583-883
93-140
700-1060
111-169
TA 1200
0.625
78
94
666-1375
106-219
800-1650
127-262
TA 1500
0.688
104
125
833-1666
140-265
1000-2000
159-318
Pump
Model
387 or 400 Series Pumps
Shaft
Horsepower
Diameter
Shaft Limit
(in)
50 HZ
60 HZ
37
78
78
78
104
104
104
104
213
213
44
94
94
94
125
125
125
125
256
256
Minimum Casing Size 5 1/2”
Flow Capacity Recommended Range
50 HZ
60 HZ
BPD
M3PD
BPD
M3PD
TD 280
TD 450
TD 610
TD 700
TD 1000
TD 1300
TD 1750
TD 2000
TD 3000
TD 4000
0.500
0.625
0.625
0.625
0.688
0.688
0.688
0.688
0.875
0.875
83-375
208-500
290-635
410-756
583-1042
667-1333
1000-1708
1170-2080
1667-3083
2833-4333
13-60
33-80
46-101
65-120
93-166
106-212
159-272
186-330
265-490
450-689
100-450
250-600
350-760
492-907
700-1250
800-1600
1200-2050
1400-2500
2000-3700
3400-5200
16-72
40-95
56-121
78-144
110-200
125-255
190-325
220-400
320-590
540-825
Pump
Model
Shaft
Diameter
(in)
TG 1600
0.875
213
256
833-1790
132-284
1000-2150
158-341
TG 2000
0.875
213
256
1330-2250
210-360
1600-2700
254-430
TG 2500
0.875
213
256
1500-2585
240-410
1800-3100
285-495
TG 3100
0.875
213
256
1830-3000
290-475
2200-3600
350-570
TG 4000
1.000
313
375
2080-4170
330-660
2500-5000
400-795
TG 5200
1.000
313
375
3250-5500
515-575
3900-6600
620-1050
TG 5600
1.000
313
375
3330-6250
530-995
4000-7500
635-1190
TG 7000
1.000
313
375
4170-7500
660-1190
5000-9000
795-1430
TG 10000
1.188
531
637
5830-10000
925-1600
7000-12000 1110-1900
500 Series Pumps
Horsepower
Shaft Limit
50 HZ
Minimum Casing Size 6 5/8”
Flow Capacity Recommended Range
50 HZ
60 HZ
60 HZ
BPD
M3PD
BPD
M3PD
Motors
COSCO motors are two pole, three phase, squirrel cage induction type and are
hand wound. At installation, motors are filled with a highly refined mineral oil to
provide dielectric strength, bearing lubrication, and thermal conductivity to transmit
heat generating in the windings to the housing. Fluid flow past the motor housing
carries away generated heat.
High temperature, high load thrust bearings and high strength shafts are available.
Compare COSCO horsepower per rotor and motor length to competitive designs.
COSCO motors are designed to run cooler, the most significant factor affecting
motor life.
A special slim line cable called Flat Cable Extension or Motor Lead Cable is used
to terminate the cable into the motor pothead. The slim line cable is required to
run along side the pump due to limited room in the pump / casing annular space.
Motor Series
Casing OD
60 Hertz HP
50 Hertz HP
375
4 1/2”
(114.3 mm)
7.5 to 120
6.3 to 106.3
456
5 1/2”
(139.7 mm)
10 to 240
8.5 to 200
540
7”
(177.8 mm)
20 to 600
16.5 to 500
562
7”
(177.8 mm)
30 to 1200
25 to 1000
Protectors (Seal Sections)
COSCO protectors (seal sections) provide protection against well
bore fluids entering the motor. They also serve as an oil reservoir
for the motor and balance the internal pressure of the motor with
the well annular pressure, a means of minimizing the possibility
of well fluid entering the motor due to high pressure differentials.
The thrust bearing carries the load of the pump.
Protectors combine the proven technologies of the labyrinth protector
with the positive seal protector and can be supplied in Tandem or
Modular form depending on the type of application.
The use of tandem protectors combines labyrinth and positive seal
protectors providing greater flexibility of selection in the field,
whereas the Modular construction allows the operator to customize
a protector design to a particular application.
Gas Separators and Intakes
COSCO gas separators are used in high GOR applications to remove
a high percentage of free gas from the produced fluid. Gas is vented
to the annulus prior to entering the pump, thereby preventing gas
lock, cycling and pump cavitation and providing a stable motor load,
increased production and extended run life.
The rotary gas separator uses centrifugal force to separate the free gas
from liquids. The gas/fluid mixture enters the intake ports and moves
to the screw type inducer. Here the pressure of the fluid is increased
and moved to the centrifuge where the separation occurs. The liquids
are forced to the outside of the separator and on to the first pump
stage. The lighter gas rises through the flow divider and is vented to
the annulus.
For lower GOR applications, a reverse flow separator or standard
ported intake section are available.
Separation efficiencies realized vary greatly from application to
application due to many variables that affect efficient separation such
as: annular intake volume, bubble size, flow rate and gas/liquid ratios
etc. However, stable pumping of fluids with gas/liquid ratios of 60%
can be achieved in the right conditions.
Switchgear
Switchboards (motor starter panels) are used to start and control the ESP motor in fixed speed
applications.
I I 05
COSCO switchboard are some of the most advanced and high quality equipment available in
the industry. Approvals from several certification authorities such as Canadian
Standards Association (CSA), NEMA, and Goststandart of Russia are available.
Russian and
CSA
Certifications
Enclosures are available in NEMA 1, 3R, 4 and 4X styles, with NEMA 3R being the
most popular for standard outdoor applications.
Since most customers have differing requirements, numerous options, security
features, voltage and current ratings and features are available in both standard and
custom models.
Available Switchboard Sizes
Voltage
Rating
Current
Rating
480 V
HP
Rating
@ 60 Hz
Size 3
Size 4
Size 5
Size 6
380 V
100 A
180 A
300 A
400 A
75
150
250
350
@ 50 Hz
Size 3
Size 4
Size 5
Size 6
1500 V
100 A
180 A
300 A
400 A
180 A
55
90
160
220
400
3300 V
180 A
400 A
180 A
400 A
180 A
800
1500
800
1500
1500
3600 V
5000 V
Custom built NEMA 4X, Stainless Steel Enclosure
Standard 3300 Volt Model
1500 Volt Model
With security door
Variable Speed Drives
Variable Speed Drives (VSD) vary the frequency of the power delivered to the ESP motor, thereby changing motor
and pump RPM, allowing production volume flexibility. COSCO can provide a number of VSD packages including:
•
Low Voltage VSD’s
•
Medium Voltage VSD’s
•
NEMA 1, 3R, 4, or 4X enclosures
•
Skid mounted or building enclosed packages
•
Air conditioning or liquid cooling available for high
ambient temperature applications
•
Allen Bradley Power Flex series are standard equipment
•
Other brands also available
VSD’s can damage system insulation, shortening ultimate run life
of the ESP installation. Therefore, the technology utilized is of
significant importance if variable speed capability is required.
Example of near-perfect sine-wave form
produced by Allen Bradley Series 7000
Medium Voltage VSD
Allen Bradley VSD’s offer near sine-wave outputs with low harmonic
content resulting in better motor performance and extended motor
and cable run life.
In some cases, input filters and sine-wave filters are also employed.
Power
Flex
7000
Power
Flex
700
Allen Bradley Power Flex 7000 Series Medium Voltage VSD’s utilize advanced power conversion technology
with Current Source topology using an active front–end called a Pulse Width Modulated Rectifier (PWMR).
This eliminates the need for a multi-winding transformer to mitigate unwanted harmonics.
Allen Bradley Power Flex 700
Series VSD’s are available for
low voltage (480 V) applications.
Step up transformers to provide motor voltage are eliminated in most cases, since the MV drive can output
motor voltage. Besides being motor friendly and cost effective, reduced space requirements are an
added benefit, particularly important in offshore applications.
A step up transformer is
utilized to deliver motor
voltage.
Motor Controls
A recognized leader in ESP controls technology, COSCO has a number of motor control products and
solutions for fixed and variable speed ESP motor control.
The motor controller monitors motor load, power supply, down hole sensor data, external switch devices,
analog instruments, and remote SCADA station commands. The controller protects the system by shutting it down or preventing starts if it is unsafe to operate or start the motor.
Alarm set points are field adjustable and time delays, time delay curves and alarm actions are fully adjustable to accommodate virtually any pump control application or problem.
Software is available for all models to allow local connection to a portable computer or remote connection
via radio, telephone or other communications means. Set points, run history, alarms and historical
logged data can all be accessed utilizing the software package.
Standard Motor Controller Features
•
•
•
•
•
•
•
•
Protection from power supply problems
Protection from motor load problems
Protection from surface, down hole, and system faults.
Includes Stall, Short Circuit protection.
Compatible with standard ESP control wiring circuits
allowing easy retrofitting into existing switchgear.
Remote displays
Alarm tracking
Optional Motor Controller Features
•
•
•
•
•
•
•
Backspin protection
Data logging
Down hole sensor interface (multiple brands)
Additional inputs / outputs
PID loop for variable speed applications
Telemetry / SCADA interfaces
Graphical Displays
COSCO Manufactured
Vortex Motor Controller
COSCO’s latest ESP control system, the most advanced in the industry, is in the final stages of development
and will be released in late 2005.
Down Hole Sensors
Recent advances in down hole sensor technology have resulted in reliable and lower cost sensors for use with ESP’s. The
use of a sensor provides additional protection for ESP systems, particularly against motor overheating, a common source
of failure and reduced run life as well as reservoir data.
COSCO is a leader in this technology and can provide several sensor options to meet any production requirement.
COSCO sensors utilize the ESP main power cable to transmit sensor signals to surface. A surface choke or filter is
required at surface to obtain the sensor signals.
Standard Parameters
• Pump Intake Pressure
• Pump Intake Temperature
• Motor Oil (or Winding) Temperature.
Optional Parameters
• Pump Discharge Pressure
• 2 Plane Vibration
• Insulation Resistance.
Down Hole Sensor Interface
2 3/8” EUE connection for motor
guide
COSCO DHT Down Hole Sensor Tool
For Electric Submersible Pumps
Well Bore
(Intake)
Temperature
Transducer
Well Bore
(Intake)
Pressure
Transducer
Four Parameter Version Shown
1.
2.
3.
4.
Pump Intake Pressure
Pump Intake Temperature
Motor Oil (or Winding) Temperature
Optional Discharge Pressure
Hydraulic Line to
Discharge
Pressure
Sub
Sealed Electronics
Section
Two Circuit Boards
Data is transmitted from
the tool through the motor
windings and up the high
voltage power cable
Instrument Wires Pack
Off
Bulkhead
HV Teflon Insulated Wire
Connection to Motor
Winding Star Point
Choke Section
(Contains Motor Oil)
3 1/2 “ EUE Connection to
Motor Base Adapter.
Motor Oil Temperature Probe
(Can be replaced by RTD
welded to motor winding)
Alternately Top Tool
Connection can be furnished
with Motor Flange
Refer to Data
Section to see how data
from the sensor tools is
recorded, displayed and
used
Data and Automation
COSCO multi-channel data loggers
provide valuable ESP system and
reservoir data, particularly when used
with down hole sensors. Data stored
can be downloaded at the well site to a
portable computer or transmitted to a
remote central control station.
Data is recorded in standard formats
such as Microsoft Excel, allowing the
user to easily view, utilize or graph
data in a variety of ways.
Better Data
Equals
Better Decisions
Example of Power Supply, Motor Load, and Sensor Data Logged Into Excel Spreadsheet
Exam ple Well , Minute Data
PIP Increasing, Motor and Wellbore
Temp Increasing >Obvious
Restricted Flow .
Increasing Current > Greater Work
Required, Probable Sand in Pump
System
250
Erratic PIP, Current & Motor
Temp. Values indicate
intermittent fluid
restrictions…other
causes?
200
30
28
26
24
150
22
20
100
18
16
50
14
Increasing Load
12
Example of Data Graphing Capabilities Showing Graph of Above Data.
1/24/2000 9:00
1/24/2000 0:12
1/23/2000 6:36
1/23/2000 15:24
1/22/2000 21:48
1/22/2000 13:00
1/22/2000 4:12
1/21/2000 19:24
1/21/2000 10:36
1/21/2000 1:48
1/20/2000 17:00
1/20/2000 8:12
1/19/2000 23:24
1/19/2000 14:36
1/19/2000 5:48
1/18/2000 21:00
1/18/2000 12:12
1/18/2000 3:24
1/17/2000 18:36
1/17/2000 9:48
1/17/2000 1:00
1/16/2000 7:24
1/16/2000 16:12
1/15/2000 22:36
1/15/2000 13:48
1/15/2000 5:00
0
BHP
BHT
MTRT
InpAmpsA
InpAmpsB
InpAmpsC
Transformers
ESP systems require specialized three
phase transformers to transform power
supply voltage to the voltage required by
the pump motor. COSCO transformers
feature a wide range of taps to allow the
flexibility to accommodate motor changes,
since voltage requirements differ for each
size of ESP motor.
COSCO transformers feature sealed tank
designs suitable for use in any ambient
temperature from desert to arctic
conditions.
Pad mount models with enclosed bushings
or pole mount models with exposed
bushings are available.
Typical Multi-Tap ESP Pole Mount Transformer
Transformer Features
•
•
•
•
•
•
•
•
•
•
•
•
Type ONAN
Five legged, shell type magnetic core available
Desert service models rated for 50 degrees C. temperature rise above 50 degrees C.
ambient temperature
Sealed tank design
Drain valve
Thermometer and oil level gauge (optional contacts)
Enclosed HV and LV bushings (pad mount style construction)
Painted white as standard color, other colors available
For fixed and variable speed applications
Designed to match the type of VSD technology used in variable speed applications
Wide tap ranges.
Standard tap ranges: 1000 to 3000, or 700 to 2500 volts over 25 tap settings
Power Cable
COSCO utilizes power cable from a number of vendors
to provide its customers with the most reliable and economical
system.
A wide range of cable sizes and construction types are
available. Selection of the cable is based on an analysis
of a number of factors including well conditions, available
space and motor size as follows:
•
Conductor size based on motor current load
•
Insulation voltage rating based on motor voltage
•
Choice of flat or round cable based on available
annular space
•
Well bore temperature
•
Amount of gas present
•
Corrosiveness of well fluids.
Examples of Round and Flat Cable
As a general rule, round cable is preferable to flat due to current unbalances that are inherent characteristic of
flat cable. However annular space restrictions, high gas, or temperature conditions requiring lead sheath
insulation protection often dictate that flat cables must be used.
Cable
Type
KV Rating
Conductor
Sizes
(AWG)
Maximum
Operating
Temperature
Insulation
Material
Jacket
Material
Configurations
Available
PPNP
3 KV
5 KV
1, 2, 4, 6
205 deg. F
96 deg. C
Polypropylene
Nitrile
Rubber
Round
Flat
EPNP
4 KV
1, 2, 4, 6
270 deg. F
130 deg. C
EPDM
Nitrile
Rubber
Round
Flat
EPEP
5 KV
1, 2, 4, 6
400 deg. F
204 deg. C
EPDM
EPDM
Round
Flat
EPOP
4 KV
5 KV
1, 2, 4, 6
16 mm2
450 deg. F
232 deg. C
EPDM
Braid over Lead
Flat
Wellhead Equipment
COSCO carries a complete line of specialized API wellhead equipment for use with ESP’s including its own proprietary
electrical feed-through system.
The COSCO Connector system comes in three main configurations:
•
Top entry two piece electrical system. A low cost completion for wellheads not requiring a bonnet or tubing
head adapter flange.
•
Top entry three piece electrical system. Used where a bonnet is required.
•
Side entry electrical system. Used in cellar or offshore installations where vertical space is a consideration.
COSCO connector systems are tough, rugged, dependable and affordable.
A number of wellhead adapter spools are available to convert existing wellhead equipment for use with ESP’s.
Specialized wellhead designs are available for any ESP completion requirements.
Other wellhead components such as valves, chokes, pressure switches, and pressure transducers are also available.
Tubing Head Spool with
COSCO 2 Piece Electrical Connector System
Tubing Head Spool with
COSCO 3 Piece Electrical Connector System
Miscellaneous ESP Equipment
ESP Production Packers
By-Pass Systems
COSCO offers a variety of
packers and packer electrical
feed-through penetrators for
completions where packers are
called for.
Cable Feed-Through Penetrator
ESP by-pass systems, also commonly
called “Y-Tools”, are used to permit
such operations as production logging
or stimulation / injection below the
ESP assembly.
Blanking plugs, isolation plugs,
logging plugs and standing valves
are available accessories that may
be required.
Bypass tools are available in standard
and corrosive service materials.
Check Valves and Bleeders
Check valve and bleeder (drain valve) combinations,
or retrievable standing valves with seating nipples are
available for all common tubing sizes
Check
Valve
Bleeder or
Drain
Sales and Service
COSCO LOCATIONS
AGENTS
Canada
Kingdom of Saudi Arabia
Canadian Oilwell Systems Company Ltd.
Arabian Establishment for Trade and Shipping Ltd.
Petroleum Services Division
Middle East Commercial Centre
First Floor, Suite 8
Dhahran Street, Dammam 31411
Telephone:
(966 3) 896-0035
Telefax:
(966 3) 896-0709
Email:
saudiarabia@coscoltd.com
9760 - 60 Avenue
Edmonton, Alberta, Canada
T6E 0C5
Telephone:
Telefax:
E-mail:
(780) 430-0840
(780) 430-0367
info@coscoltd.com
Malta
Iran
COSCO Pump Company Limited
Hirgan Energy Co.
F. Ghasemi
#7, Fourth Floor
NO. 1.1, 53 Street, Assadabadi Avenue
Tehran, Iran
Telephone:
(011) 98 21 804 6730
Telefax:
(011) 98 21 860 6537
Email:
info@hirganenergy.com
240 Apartment 5, Tower Road
Sliema, Malta, SLM 09
Telephone:
Telefax:
E-mail:
(356 21) 430817
(356 21) 311835
malta@coscoltd.com
Libya
COSCO Pump Company Limited
Sudan
Tripoli, Libya, GSPLAJ
NAPESCO Ltd.
St. 25, Al-Amarat, New Exit
Khartoum, Sudan
Telephone:
(249) 11 484964 / 5
Telefax:
(249) 11 484966
Telephone:
Telefax:
E-mail:
(218 21) 483-2589
(218 21) 483-2589
libya@coscoltd.com
Russia
Egypt
Canadian Oilwell Systems Company
NAPESCO Ltd.
Mr. Saleh Ghoniem
Mobile:
+20 12 3989890
Email:
saleh.ghoniem@napescoegypt.com
Telephone:
E-mail:
(8553) 356849
diana@coscoltd.com
Ecuador
AZUL
N41 Ave. de los Granados E11-124 y Colimes
Quito – Ecuador
Telephone:
+5932-297-7600/227-7722
Telefax:
+5932-225-4083
Email:
Sebastián.tobar@azul.com.ec
Oman
www.coscoltd.com
RAS AL HAMRAH L.L.C GROUP OF COMPANIES
Zubair Building, Block 5, First Floor
Adhaibah, Oman
Po Box 2087, Postal Code 111 Central Post Office
Muscat, Oman
Telephone:
+968 24491103 / 24495273
Telefax:
+968 24493772
E-Mail:
saidrah5@omantel.net.om