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March 2014
Mega Prizma
Hot Oil & Pumping Services
Edgar Menge
Hot Oil & Pumping Services Supervisor
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Functions of the Mega Prizma Hot Oil Units
There are 2 main functions of the Mega Prizma Hot Oil Unit.
First is the heating function
and second is the pumping function.
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Functions of the Mega Prizma Hot Oil Units
The 2 functions to the Hot Oil Unit, Heating& Pumpingcombine to
provide clients with a well rounded, multi purpose, multi tasking,
heating & pumping unit.
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Uses for Mega Prizma Hot Oil Units
The main use of a Hot Oil Unit is to heat & pump fluidsinto the well to remove wax built up on the productiontubing.
Pumping hot fluids through coil tubing to clean outhydrates or waxed off production tubing, or by pumping
through the coil tubing for well stimulation.
Hot fluid is often pumped through tubulars to clean themprior to a work-over.
Clean out wax and other material in pipelines. Pumping of flow line pigs & pipeline testing equipment
(smart pigs), also for pressure testing of pipelines.
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Uses for Mega Prizma Hot Oil Units
Hot fluids are circulated to thaw ice or coagulatedmaterial in cold climates.
Hot fluids are used to pump through manifolding to cleanout obstructions & restrictive materials in piping or toclean out facilities prior to a turn around inspection.
Refineries often use Hot Oil Units to clean out lines,circulate tanks and re-boilers, and to treat de-ethylene &distillation towers.
Hot Oil Units are used around rigs to preheat tanks,transfer, and pump out fluids.
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Uses for Mega Prizma Hot Oil Units
Hydro-blasting and jetting for cleaning facility tanks & rig
tanks.
Pre-heating treatment fluids for well stimulation services
such as fracturing & cementing operations.
With the utilization of mixing equipment, the pumps on a
Hot Oil unit can be used to mix a variety of chemicals to
premix or mix on the fly during well stimulation or
treatment.
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Equipment Description - Heater
The Heaters on the Mega Prizma Hot Oil Units are 1,465 kW (5,000,000 BTU)
output, with a heating efficiency rating of 85%.
The flow through the 3 heater coils
can be changed from series to
parallel to change maximum flow
rates from 350 L/min in series to
450 L/min in parallel.
This allows the heater output to be geared tospecific flow & temperature requirements. In
series, the output temperature is increased as
the flow decreases. The opposite is true for
the parallel flow.
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Equipment Description - Heater Safety
Control & Safety Equipment on the heater has been designed to prevent
overheating of the fluid. The Mega Prizma Hot Oil Units are equippedwith a Kimray Thermostatic Controller which cuts off the fuel supply to
the heater in the event of overheating of the fluid.
This Kimray thermostat is calibrated
before each heating job and set at the
clients requested maximum workingtemperature. If the heater output
temperature increases above the set
point, the thermostat signals the fuel
system master valve to cut fuel supply
to the heater and extinguish the burner.
Adjusted 5 to 7 degrees above average
requested working temperature or at 80% of
fluid flash point. It can also be used as
thermostat when heating non-flammable fluids
Safety First
and
Foremost
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Equipment Description - Fire Safety
With the safe operation of any equipment, the worst case scenario
must be predicted and an action plan to resolve every possiblesituation. For this reason all of Mega Prizmas Equipment are
equipped with a Fire Suppression systems. In case of a fire, the Mega
Prizma Hot Oil Unit, has specific two fire extinguisher systems.
First there is a 150 Lb., ABC, wheeled fire extinguisher
that is unloaded by a winch and moved 10 meters fromthe unit before each job. This extinguisher is designed
to control a fire outside the heater.
Safety First
and
Foremost
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Equipment Description - Fire Safety
The second fire extinguisher is a 15 Liter
CO2 extinguisher. This extinguisher isdesigned to control a fire inside the
heater. In the unlikely even that a heater
coil leaks flammable fluid into burner,
this extinguisher will help to contain &
quench the fire before it can spread.
Safety First
andForemost
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Equipment Description - Pumps
There are three pumps on the Mega
Prizma Hot Oil Units. Each pump can
be operated separately or in
conjunction with the other 2 pumps
simultaneously.
The Roper Load / Unload Pump
The Mission Circulation Pump
And the SPM TriplexPressure Pump
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Equipment Description - Pumps
The Roper Pump is a hydraulically driven, variable speedpump, with a maximum output of 625 L/min. Mostly, thispump is used to load & un-load the unit tanks or to transferfluids.
The pump is self priming
and able to draw fluids froma source below the level ofthe pump. This is helpfulwhen transferring fluid frommud pits or fresh water from
ground sources.
Another function of the Roper pump is to act as a back uppump should the Centrifugal pump fail during heatingoperations.
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Equipment Description - Pumps
The Mission pump is a 3X 4X 13centrifugalpump. This
pump is driven with a variable speed hydraulic system andits main purpose is to supply fluid circulation for the heater& supercharge the suction of the triplex.
The second use of this
pump is to transfer fluid tothe unit tanks or betweenclient tanks when needed.
At 2 m/min, the Missionmakes short work of large
volumes of fluid to betransferred.
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Equipment Description - Pumps
The SPM Model TWS600S triplex pump is 450 kW (600HHP) intermittent duty, and 260 kW (350 HHP) continuousduty.
The maximum pressure
rating of this pump is 15,000psi. With our standardplunger size of 3-1/2 thepressure rating is 10,000psi. The Mega Prizma Hot
Oil Units can changeplunger sizes from 2-1/2 to4-1/2 for different flow &pressure ratings.
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Equipment Description - Relief Valve
As with any pump, there needs to a Safety First system.
The Mega Prizma Hot Oil units are equipped with a pressurerelief valve located directly after the pump. This valvedumps safely to the unit tanks.
This SPM Safety Relief valveis adjustable from 100 psi to
15,000 psi. This valve isadjusted appropriately beforeeach pumping job & tested toprotect the unit, the clientsequipment, and the personnel
working on location.
Safety First
and
Foremost
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Equipment Description - Tanks
The Hot Oil Units are equipped with 4 separate tanks. Eachtank is gauged for fluid level by a mechanical float & pointer.The tops of tanks can allow for top loading of fluids.
The first 2 tanks are the main fluidtanks. Each tank has a capacity of
4 m .
The 3rd, Methanol or Chemical Tank,on the unit is used to store flushingfluids to keep the unit from freezing in
the winter. The capacity of this tank is1.4 m.
The rear most tank is the heater fuel tank & has a capacityof 2.2 m of diesel. This enables the unit to heat aroundthe clock, at maximum output, for 24 hours.
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Equipment Description - Instrumentation
The unit is equipped with simple reliable gauges & meteringdevices to ensure readings are always correct and dependable.
The Marten Decker main treating pressuregauge is mounted in the operatorspanel in
clear view of the operator & the client.
An electronic NuFlo MC II Flow Analyzeris also mounted on the operatorspanelin clear view of the operator & client.
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Equipment Description - Instrumentation
Mechanical Temperature & Pressure gauges are installed atvarious points on the unit to clearly show condition of fluidsat various stages.
Heater inlet &intermediate coiltemperature.
Heater fuel mainpressure & throttledfuel pressuregauges.
Heater outputtemperature &pressure gauges.
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Equipment Description - Instrumentation
Each Hot Oil unit has a chart recorder on standby if
needed. These Barton (circle chart) recorders arecertified, calibrated, & tested as per manufacturersspecification and Mega Prizma standards.
The chart can be timed tovarious intervals of 1 hour to12 hours as needed, andprovide positive proof of
pressure testing or processpressure to a maximum of700 Atm (10,000 psi).
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Work Done in Kazakhstan - Heating
We have heated fluids for many different clients. We have
expanded the parameters of heating beyond themanufacturers expectations and have created newmilestones for Hot Oil Units.
Heating of Well Treatment Mix Fluids
In October of 2005 the unit was called for our first job forthe Hot Oil Unit as an independent department. The unitspent the next six months heating more than 100,000 mof water & diesel fuel for fracturing campaigns in the
Aktobe region and at KPO in Aksai.
Since that time the unit has heated fluids that werepumped ourselves for Lancaster Petroleum, AralPetroleum Capital, Sun Drilling, Oil Techno-Group, andMaersk Oil.
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Work Done in Kazakhstan - Heating
Heating of rig Tanks
In the Fall of 2006 the unit was called upon by Lancaster
Petroleum to heat drilling fluid tanks. The unit first heated
water in the rig tanks before the drilling fluid was
prepared. We then were asked to heat through thesteam lines with hot water to keep the drilling fluids from
freezing.
On numerous occasions since that time, the units has
been asked to heat mix waters for drilling rigs & to keepthe tanks warm in cold winter months, when the rigs
steam system was not working.
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Work Done in Kazakhstan - Heating
Hot Oil Well Treatments
From the 19th of August to the 15th of November in
2006 the unit completed 78 hot oil treatments for
KKMOC (Lancaster Petroleum) in their Kumsai and
Kokzhide fields. Most of the treatments were directly toremove wax from the production tubing, but many of
the treatments were the first steps in the CHOPS
system to increase the oil production of heavy oils in
high water and high sand producing wells.
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Work Done in Kazakhstan - Pumping
Since the fall of 2005, our unit has been called to pump
many different types of fluids. Though these units are
basically designed to pump water and hydrocarbons, we
have proven that the units have pumping abilities far
beyond the normal Hot Oil Unit.
The fact that we have used an oilfield pump with a much higher
Hydraulic Horse Power (HHp)rating than a normal Hot Oil Unit,has truly been an asset.
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Work Done in Kazakhstan - Pumping
Pumping of Hydrocarbons
We have pumped such hydrocarbons as crude oil, diesel fuel,xylene, gasoline, condensate, and produced sales oil. In mostcases this has been for well stimulation, but in some cases tocirculate the wells. We are often asked to pump these fluidsbecause of ability to coupe with the pressures and precise volume
measurements needed & because we have our own tanks.
Pumping Drilling Fluids
We have often been asked to pump drilling fluids into a well tocirculate out heavy fluids out. Due to the high differential pressuresin wells of 4,000 to 7,000 meters, most rig pumps and Soviet pumptrucks, can not deal with the prolonged high pressure pumpingrequired to circulate drilling fluids to water.
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Work Done in Kazakhstan - Pumping
Pumping Services for Coil Tubing
In December of 2006, Aral Petroleum Capital asked that Hot Oil
Unit to supply heating and pumping services to BJ ServicesCoil
Tubing unit. The unit was able to heat on the fly while pumping at
various rates to clean powdered Asphaltines. Our unit provided 4
months of pumping services without any down time to the
operation.
Leak-off Testing
Due to our cost effect services, our unit has preformed many
pressure tests and leak off tests after our competitors have
finished cementing operations.
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Work Done in Kazakhstan - Pumping
Injectivity Testing
Our unit has performed injectivity tests on many wells.The Mega Prizma Hot Oil unit is well adapted for thiswork with our wide range of pumping rates and preciseflow metering.
Pumping Acid & Chemicals
Our Hot Oil Unit has been tasked with providingeconomical acid & chemical pumping services on manyoccasions. The unit has mixed & pumped hydrochloricacid in volumes in excess of 100 m up to 20%solutions. We have also pumped a variety of chemicalsonce each chemical's compatibility has beenestablished.
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Work Done in Kazakhstan - Pumping
Cement Plug Placement for Plug & Abandonment
In October of 2008 our unit had the opportunity to diversify our
services into a new area. Lancaster Petroleum made plans to plug
and abandon 3 wells in Kokzhide.
The unit was asked to supply pumping services to mix, accurately
pump, and displace 3 cement plugs in this 4600 meter well. The clientsupplied batch mix tanks for the cement and our Hot Oil unit batch
mixed and then pumped the slurry into the well precisely where
required.
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Work Done in Kazakhstan - Pumping
For a continuous pumping of injection or water flood, the our Hot OilUnit supplied economical pumping services over the short term. The
unit can individually provided 285 available hydraulic horse power
(212 kW) for this type of long term pumping.
At Maersk Oil, one unit pumped 8 months, continuously, up to 700m/day at a pressure of 3,500 psi. We pumped more than 150,000 mduring this time.
Water Injection & Water Flood
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Work Done in Kazakhstan - Pressure Testing
Pressure Testing
We have been called to complete many pressure testing.
Well Heads
BOP (Blow Out Preventers)
Drilling Surface Equipment Production Tubing
Casing & Cement Integrity
Packers
Pipelines Facility Vessels & Piping
Well Testing Equipment & Third Party Equipment
Wireline Equipment (on well site & for Certification)
W k D i K kh t L P
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Work Done in Kazakhstan - Low PressurePumping
Fluid Mixing
The Mega Prizma Hot Oil Unit can supply fluid flow to rig mixingsystems. We have also used our large unit tank hatches to allowsalts and other non-corrosive dry & liquid chemicals to be mixed inour tanks.
Fluid Transferring
In many cases, Mega Prizma has been asked to transfer fluidsfrom rig tanks or drilling rig mud pits. Because we are able to selfprime our suction manifolds with our Roper Pump, we are able tothrow a hose in the top of a tank and transfer fluids around the rigwhenever needed.
Fluid DisposalWe have been called many times to pump out flare pits, drillingfluid, and mud pits. Again, our Roper pump has come into play aswe are able to catch prime with the Roper pump, then switch to thecentrifugal pump on the fly to quickly pump fluids from pits totransport tank trucks.
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In Closing
The Mega Prizma Hot Oil & Pumping Services would like
to offer your Company our uniquely effective services that
can not be matched by other local companies.
We would also like to offer your Company our pricing
which is un-paralleled by other international servicecompanies.
Please feel free to contact us at Mega Prizma for further
information and a demonstration of our services.