ROD PUMPING OPTIMIZATION TRAINING

ROD PUMPING OPTIMIZATION

Training Outline :

1. INTRODUCTION:

·         Sources of Profitability Reduction.

·         System Low Efficiency.

·         Equipment failures.

·         Modern Tools to optimize mechanical pumping.

·         Modern Technology.

·         Pump Mechanic. Advantages and Disadvantages.

2. Safety in Operations:

·         Fundamental Concepts

·         Good judgment and common sense

·         Making Safety Labour Party

·         Security Procedure When driving to the Well

·         Common Causes of Accidents

·         The consequences of accidents

·         Defensive Driving

·         Security Procedure to be in the Location

·         Basic precautions

·         Inspection of Potential Hazards

·         Operating Safety Standards pumping units

·         Safety Recommendations

·         Safety procedures usually used to secure the handles.

3. Review of Fundamentals:

·         Stress and pressure

·         Labour

·         Power

·         Energy

·         Torque and Momentum.

4. Pumping System Mechanic:

·         Team Size

·         Head of Production

·         Pumping Unit

·         Downhole Equipment

·         String of Cabillas

·         tubing.

·         Shoes

·         Production Casing

·         Lining or Liner

·         Subsurface Pumps

·         Designation API for pumps

·         Balls and Seats.

·         Pistons

·         Special pumps

·         Anchor Gas.

5. Operation and Service Pumping unit:

·         Mechanical lift with electric motors

·         Mechanical lift with gas engine

·         Programming pumping

·         Maintenance of the pumping unit:

·         Daily Inspection

·         Weekly inspection

·         Monthly Inspection

·         Quarterly or Semiannual Inspection

·         Problems in Pumping Unit

·         Problems with the gearbox or Pitman arms

·         Direction of rotation of the drive

·         Problems caused by poor maintenance

·         Making Adjustments to the Pump Unit

·         Changing the position of the counterweights

·         Balancing the pumping unit

·         Changing the length of the stroke

·         Raising or lowering the string of Cabillas (Spacing).

·         Focusing the elevator on the head.

·         Failure Prevention

·         polished rod.

·         Startup Procedure, Operation and Pit Stop by rod pump.

6. Engines:

·         Electric Engines

·         Gas Engines

·         Diesel Engines

·         Natural Gas Systems

·         Electrical Safety

·         Safety Grounding Unit.

7. Field Measurements:

·         Measurement Equipment:

·         Gauge

·         Thermometer

·         Test Separator : Getting the measure of output

·         Tank Capacity : Getting the measure of output

·         Analog measurements

·         Dynamometer LEUTERT (Dynamometer Chart).

·         Test pressure (PP).

·         Sonic Record (Sonolog).

·         Digital Measurements:

·         Dinamometer Chart  Digital (Electronic dynamometer T1 – Echometer

·         Test Valves

·         Measuring the effect of counterbalancing.

·         Amperage Chart.

·         Dynamic Level (Echometer).

·         Additional Data

·         Pumping System Diagnosis

·         Diagnostic Procedure mechanical pumping method

·         Diagnosis of the condition of the mechanical pumping system

·         Diagnosis and troubleshooting.

·         Diagnosis and troubleshooting. letter Dynamometer chart

·         Additional Data

·         Pumping System Diagnosis:

·         Diagnostic Procedure mechanical pumping method

·         Diagnosis of the condition of the mechanical pumping

·         system.

·         Diagnosis and troubleshooting.

·         Diagnosis and troubleshooting. Dynamometer chart 

·         Typical Dynamometer Chart (Downhole).

8. Monitoring Wells And Diagnostic System:

·         Annexes

·         Steps to Making Dynamometer Chart (Echometer - T1).

·         Test Valves (Echometer).

·         Counterbalance Effect Test.

·         Measuring of Amperage (Echometer).

·         Risk Management. CO2.

·         Decision-Level

·         Risk Analysis at Work

API 653 – TANK INSPECTION CODE - Inspection, Repair, Alteration, & Reconstruction of Steel Aboveground Storage Tanks

API 653 – TANK INSPECTION CODE

Inspection, Repair, Alteration, & Reconstruction of Steel Aboveground Storage Tanks

Diskripsi :

                Kegagalan tangki penyimpanan minyak jenis atap kerucut (Cone roof tank) dapat berakibat defleksi permanen karena terabaikannya kondisi operasi dan persyaratan konstruksi. Prediksi tegangan kritis pada tangki penyimpanan minyak sangat diperlukan. egangan kritis yang berupa kombinasi antara membrane stress dan bending stress sangat penting untuk diketahui agar senantiasa dapat dimonitor.

                Salah satu fungsi utama dari inspeksi adalah untuk memastikan kehandalan (reliability), keberadaan (availability) dan profitability (benefit) dari peralatan operasional industrial plant sehingga dapat menghindari tidak berfungsinya peralatan dan dapat mengakibatkan: Bencana, Profitabilitas menurun, Hilangnya waktu, Menurunnya produksi, Dan lain-lain

                Kajian  terhadap perencanaan aktifitas inspeksi pada tangki penyimpanan crude oil  dengan menggunakan metode RBI (Risk Based Inspection) dimana jika diterapkan dapat berfungsi untuk memprediksi terjadinya kegagalan. RBI adalah suatu metode dengan menggunakan analisis resiko peralatan sebagai dasar untuk memprioritaskan perencanaan manajemen program inspeksi. Metode ini memberikan kemampuan untuk mengalokasikan sumber daya inspeksi dan perawatan yang lebih untuk peralatan yang berisiko tinggi dan penghematan pemakaian sumber daya tersebut untuk peralatan dengan resiko rendah.

Outline :

1.       Section 1 – Scope: Introduction, Compliance With This Standard, Jurisdiction, Safe Working Practices Section 2 – Referenced Publications

2.       Section 3 – Definitions

3.       Section 4 – Suitability For Service: General, Tank Roof Evaluation, Tank Shell Evaluation, Tank Bottom Evaluation, Tank Foundation Evaluation

4.       Section 5 – Brittle Fracture Considerations:General, Basic Considerations, Assessment Procedure

5.       Section 6 – Inspection General, Inspection Frequency Considerations, Inspections from the Outside of the Tank, Internal Inspection, Alternative to Internal Inspection to Determine Bottom Thickness, Preparatory Work for Internal Inspection, Inspection Checklists, Records, Reports, Non-Destructive Testing

6.       Section 7 – Materials: General, New Materials, Original Materials for Reconstructed Tanks, Welding Consumables

7.       Section 8 – Design Considerations for Reconstructed Tanks: General, New Weld Joints, Existing Weld Joints, Shell Design, Shell Penetrations, Wind Girders and Shell Stability, Roofs, Seismic Design

8.       Section 9 – Tank Repair And Alteration: General, Removal and Replacement of Shell Plate Material, Shell Repairs Using Lap-Welded Patch Plates, Repair of Defects in Shell Plate Material, Alteration of Tank Shells to Change Shell Height, Repair of Defective Welds, Repair of Shell Penetrations, Addition or Replacement of Shell Penetrations, Alteration of Existing Shell Penetrations, Repair of Tank Bottoms, Repair of Fixed Roofs, Floating Roofs, Repair or Replacement of Floating Room Perimeter Seals, Hot Taps

9.       Section 10 – Dismantling And Reconstruction: General, Cleaning and Gas Freeing, Dismantling Methods, Reconstructions, Dimensional Tolerances

10.   Section 11 – Welding: Welding Qualifications, Identification and Records

11.   Section 12 – Examination And Testing: Nondestructive Examination, Radiographs, Hydrostatic Testing, Leak Tests, Measured Settlement During Hydrostatic Testing

12.   Section 13 – Marking And Recordkeeping: Nameplates, Recordkeeping, Certification

Peserta :

Plant engineers, Inspection Engineers, Corrosion & Materials Engineers yang pekerjaannya sangat berkaitan dengan implementasi sistem RBI (Risk Based Inspection).

API Standard: Pengelompokan Berdasarkan Penggunaan

API Standard: Pengelompokan Berdasarkan Penggunaan

Pressure Equipment:

1. API 510: Pressure Vessel Inspection Code: Maintenance, Inspection, Rating, Repair and Alteration
2. API 530: Fired Heater Tubes
3. API 570: Piping Inspection Code: Inspection, Repair, Alteration, Rerating of In-Service Piping Systems.
4. API 571: Conditions Casuing Failure
5. API 572: Inspection of Pressure Vessel.
6. API 573: Inspection of Fired Boilers and Heaters.
7. API 574: Inspection of Piping, Tubing, Valves and Fittings.
8. API 575: Inspection of Atmospheric and Low Pressure Storage Tanks.
9. API 576: Inspection of Pressure Relieving Devices.
10. API 577: Welding Inspections.
11. API 578: Material Verification Program for New and Existing Alloy Piping Systems.
12. API 579: Fitness-for-Services.
13. API 581: Base Resource Document-Risk Based Inspection.
14. API 582: Recommended Practice and Supplementary Welding Guidelines for The Chemical, Oil, and Gas Industries.
15. API 598: Valve Inspection and Test.
16. API 610: Centrifugal Pumps for Petroleum, Heavy Duty Chemical and Gas Industry Services.
17. API 611: General Purpose Steam Turbines for Petroleum, Chemical, and Gas Industry Services.
18. API 612: Special Purpose Steam Turbines for Petroleum, Chemical, and Gas Industry services.
19. API 613: Special Purpose Gear Unit for Petroleum, Chemical, and Gas Industry services.
20. API 617: Centrifugal Compressors for Petroleum and Gas Industry.
21. API 618: Reciprocating Compressors for Petroleum, Chemical, and Gas Industry Services.
22. API 619: Rotary-Type Positive Displacement Compressors for Petroleum, Chemical, and Gas Industry.
23. API 620: Design and Construction of Large, welded, Low Pressure Storage Tank.
24. API 650: Welded Steel Tank for Oil Storage.
25. API 651: Cathodic Protection of Above Ground Storage Tanks.
26. API 652: Lining of Above Ground Petroleum Storage Tanks.
27. API 653: Tank Inspection, Repair, Alteration, and Reconstruction Code.
28. API 674: Positive Displacement Pump – Reciprocating.
29. API 675: Positive Displacement Pump – Controllod Volume.
30. API 676: Positive Displacement Pump – Rotary.
31. API 686: Machinery Installation and Installation Design.
32. API 751: HF Acid
33. API 850: API Standards 620, 650 and 653 Interpretations.
34. API 920: Preventions of Brittle Fracture of Pressure Vessels.
35. API 937: Evaluating Design Criteria for Storage Tanks with Frangible Roof Joints.
36. API 941: Steels for Hydrogen Service at Elevated Temperatures and Pressures in Petroleum Refineries and Petrocehmical Plants.
37.  
38. API 945: Avoiding Environtmental Cracking in Amine Units.
39. API 1107: Pipe Line Maintenance Welding.
40. API 2510: Design and Instruction of LPG Installation.

API Valve Publication:

1. API 589: Fire Test for Evaluation of Valve Stem Packing.
2. API 591: User Acceptance of Refinery Valves.
3. API 594: Wafer Check Valves
4. API 595: Cast Iron Gate Valves
5. API 598: Valve Inspection and Testing
6. API 599: Metal Plug Valves-Flanges and Welding Ends
7. API 600: Steel Gate Valves, Flanges and Butt Welding Ends
8. API 602: Compact Steel Gate Valves
9. API 603: Class 150 Cast Corrosion Resistant Flanged End Gate Valves
10. API 604: Ductile Iron Gate Valves, Flanged Ends
11. API 606: Compact Steel Gate Valve, Extended Body
12. API 607: Fire Test for Soft Seat Quarter Turn Valves
13. API 608: Metal Valves, Flanged and Butt Welding Ends
14. API 609: Butterfly Valves Lug Type and Wafer Type

API Pipeline Transportation Publications::

1. API 5L: Specification for Line Pipe
2. API 5L1: Railroad Transportation of Line Pipe
3. API 6D: Specification of Pipeline Valves
4. API 10E: Application of Cement Lining to Steel Tubular Goods, handling, Installation, and Joining.
5. API 15HR: Specification for High Pressure Fiberglass Line Pipe.
6. API 15LE: Specification for Polyethylene Line Pipe.
7. API 15LP: Specification for Thermoplastic Line Pipe.
8. API 15LR: Specification for Low Pressure Fiberglass Line Pipe.
9. API 15L4: Recommended Practice Care and Use of Reinforced Thermosetting Resin Line Pipe.
10. API 1102: Steel Pipelines Crossing Railroads and Highways.
11. API 1104: Welding of Pipelines and Related Facilities.
12. API 1109: Marking Liquid Petroleum Pipeline Facilities.
13. API 1110: Pressure Testing of Liquid Petroleum Pipelines.
14. API 1111: Design, Construction, Operation, and Maintenance of Offshore Hydrocarbon Pipeline and Riser.
15. API 1113: Developing of Pipeline Supervisory Control Center.
16. API 1114: Design of Soluditon-Minded Undergound Storage Facilities.
17. API 1115: Operation of Solution-Minded Underground Facilities.
18. API 1117: Movement of In-Servie Pipelines.
19. API 1123: development of Public Awareness Program by Hazardoud Liquid Pipeline Operators.
20. API 1130: Computational Pipeline Monitoring.
21. API 1132: Effects of Oxygenated Fuels and Reformulated Diesel Fuels on Elastomer and Polymers in Pipeline/Terminal Component.
22. API 1149: Pipeline Variable Uncertainties and Their Effect on Leak Detectability.
23. API 1155: Evaluation Methodology of Software Based Leak Detection Systems.
24. API 1156: Effects of Smooth and Rock Dents on Liquid Petroleum Pipelines.
25. API 1157: Hydrostatic Test Water Treatment and Disposal Operations for Liquid Pipelines Systems.
26. API 1158: Analysis of DOT Reprotable Incidents for hazardous Liquid Pipelines, 1986 Through 1996.
27. API 1160: Managing System Integrity for Hazardous Liquid Pipelines.
28. API 1161: Guidance Documents for The Qualification of Liquid Pipeline Personnel.
29. API 2200: Repairing Crude Oil, Liquefied Petroleum Gas and Product Pipelines,

API Overpressure Protection Publications:

1. API 11V7: Repair, testing, and Setting Gas Lift Vlaves.
2. API 520: Sizing, selection, and Installation of Pressure Relieving Devices in Refineries.
3. API 521: Guide for Pressure Relieving and Depressurizing System.
4. API 526: Flanged Steel Safety Relief Valves.
5. API 527: Seat Tightness of Pressure Relief Valves with Metal-to-Metal Seats.
6. API 2000: Venting Atmospheric and Low Pressure Storage Tanks. Non-Refrigerated and Refrigerated.