On December 22, 2020, new production facilities to repair electric centrifugal pump units (ECPU) were opened on the territory of the production base (Pryluki) (Oilfield Service Department, Ukrnafta PJSC). The modern base is the only one in Ukraine where the entrance control of new ECPUs and the repair of ECPUs is carried out with the registration of the computer verification protocol.
The base is equipped with the latest equipment (manufacturers from USA, Germany, UK) placed in the production areas so to be under the audit of potential foreign customers preliminary talks on cooperation are held with and, if necessary, be certified by the American Petroleum Institute (API).
The capacity of the new shop allows one to carry out the input control of new ECPUs and a full cycle of ECPUs repairs: to repair engines, hydraulic protection, pumps, cables and other components of ECPUs. And all this is carried out in compliance with the manufacturer's indicators – after having been repaired, the unit must fully comply with the factory parameters.
Depending on the work, the capacitiesare divided into:
• maintenance area to repair pump sections and hydraulic protection;
• maintenance area to repair submersible motors;
• maintenance area to repair cables and extension cables.
Work arrangement in the maintenance area to repair pump sections and hydraulic protection includes 3 stages:
• first: the equipment undergoes external and internal washing, disassembly and defecation of parts and elements of the equipment;
• second: the equipment is assembled from verified parts;
• third: the inspection of the repair using computerized stands with the registration of the protocol.
The quality of the repair is certified by the protocol generated automatically. There are stands for checking hydraulic protection and pump sections. In particular, the ECPU test bench allows one to record pressure and flow characteristics and other parameters in real time. The hydraulic protection test bench allows one to run tests with the record of all parameters, including those under load.
Maintenance area to repair submersible motors (SM) also has a fully closed cycle. First, the motor is disassembled, the winding is removed. Further, the box for the internal washing of the SM stators and the shafts. Next to the box there are two ovens for drying SM stators. The capacity of each is designed for simultaneous drying of 6 stators up to 9 meters long.
The paint box is designed for the possibility of simultaneous treatment of two SM stators. The base is also equipped with two stator winding lines. One of the stator winding lines is fixed at a length of 6 meters, the second-with the possibility of increasing to a maximum of 9 m of the repaired stator.
After having been repaired, the submersible motors are subject to tests. The PC-based stand allows one to check the operation of the SMs both at idle run and under load. All parameters are entered on record.
At the maintenance area to repair cables and extension cables, 4 line start-up work was installed and commissioned. The lines make it possible to repair drums with cables for a total weight of up to 10 tons.
As for repairs, the organization of work in the shop has been completely changed due to the clear delineation of processes. This means that employees who disassemble/defect/assemble/check the components of the ECPU are engaged only in their part of work and do not proceed to the next stage. Such division of responsibilities encourages the quality control of finished products - each next worker checks the work of the previous one and promptly fixes all inaccuracies (if any).
Modern technologies will increase the inter-repair period of wells and reduce the cost per ton of oil produced. This is one of the main figures for the company to determine the efficiency of work and the cost price of production.
