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Waste Injection CRI Pump Units

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					Waste Injection (CRI) Pump Units


                                                                                   ■    Model: CRI 450 & CRI 1680
                                                                                        450kW to 1680kW (250HP to 2500HP)

                                                                                   ■    94/9/EC ATEX - 97/23/EC - PED
                                                                                        2006/42/EC Machinery Directive
                                                                                        CE Marked


                                                                                   Applications:

                                                                                     	 •		Waste	Injection/Cuttings	Injection

                                                                                     	 •		General	Well	Service	&	Well	Completion

                                                                                     		•		Acidising,	Pressure	Testing	and	Well	Kill

                                                                                          C
                                                                                     	 •			 ementing

                                                                                          C
                                                                                     	 •			 oil	Tubing

                                                                                          M
                                                                                     	 •			 ud	Pumps




Introduction
   Calder Ltd has established a reputation     without the need for subsequent changes         The primary pump components;
over a period of 29 years as a designer and    of plunger.                                   plungers, packings, valves and lubrication
supplier of robust, functional and reliable                                                  systems are selected on the basis of
High Pressure Pumping equipment for              The control system requirements are         comprehensive oil-field experience. The
waste injection applications around the        uncomplicated and easily accommodated         pump satisfies API 674 rules (with some
world. Every Calder Waste Injection unit       by a range of solutions from relay logic to   minor exceptions).
incorporates the proven inherent attributes    remote, networked PLCs.
of quality and reliability whilst matching                                                     Through experience, Calder Ltd has
individual installation requirements.            The Calder Waste Injection pump             identified the key elements required
                                               packages can also be utilised for general     to package reliable, operable and
  A range of plunger sizes is available for    well service, well completion and             maintainable equipment.
the Calder Waste Injection pumps; the          cementing duties, provided that these
optimum size is selected for each particular   duties are defined and included in the
application. This ensures that a wide range    selection criteria.
of flows and pressures can be achieved
                                                                                             ■     www.calderltd.com
                                       Waste Injection (CRI) Pump Applications


Waste Injection (CRI)
Pump Units
   The pump unit is designed
to continuously inject slurry
over a wide range of flows and
pressures, for the injection of
seawater and slurries consisting
of drill cuttings, drilling muds
and sand into subsea strata as
demanded by the oil drilling
industry worldwide. Derivatives
of this Calder-designed package
are being used in Canada, Siberia,
Caspian Sea, UK North Sea and
Norwegian North Sea.

Experience
   Calder Ltd has identified the
key elements required to package
reliable and easily maintainable
equipment in the most arduous
conditions. These key elements
are included in the standard
Calder package or are offered as
options where applicable.

   The range of options ensures        	Hydraulic	Motor	Drive
that the scope can be adjusted to
                                         •		Full	range	flow	adjustment.
meet each project’s specific needs.
Calder Ltd will work alongside           •		Small	footprint.
clients to assist in specifying          •		Smooth	operation.
associated equipment, such as
drives and controls, should the        Description
client choose to source these             The Calder Waste Injection pump package        pump and motor. The HP pump delivers a flow
separately.                            consists of a high-pressure reciprocating         that is proportional to the motor speed and
                                       plunger pump and driver (electric motor with      at the pressure necessary to inject the slurry.
   Calder has the experience and       variable frequency drive (VSD) or hydraulic
capability to offer a wide range of    pump/motor; alternatively diesel engine              Calder Ltd offers a range of options such
services, including original design,   driver with six speed transmission or hydraulic   as a noise hood, oil heaters and oil coolers to
testing and on site service support    pump/motor) which are mounted on a                suit the process and installation requirements
over a wide range of oilfield          substantial base frame. The package includes      of the specific project.
applications.                          packing lubrication and power end lubrication
                                       sub-systems and associated instrumentation.          A full range of Functional Tests at full
   In addition to waste injection/                                                       flow and pressure are completed before
well service pumps we offer a             The variable speed drive capability provides   despatch from Calder’s works to ensure that
range of packages up to 2.5 MW         variable flow over a range from 10% to 100%.      commissioning can progress without delays.
power capacity and pressures up        The pump unit can be controlled from the skid     The package can be readily transported and
to 4000 bar.                           or from a remote operator station.                installed on the platform, supported with
                                                                                         comprehensive certification and technical
                                         Flow control allows the operator to select      literature.
                                       the required flow rate at the pressure that is
                                       within the wellhead, providing the pressure
                                       does not exceed the design rating of the




   2
                                           Calder (CRI) Pump Packages

                                                                                               Calder CRI-1680
                                                                                               Direct drive 1000kW




CRI Design Criteria:
                                                         	The	Unit	Comprises:
   The self-contained Waste Injection high pressure
units are designed and built in the UK to conform         •	   High	pressure	pump,	gearbox	and	driver.
to most international oil and gas field requirements
compliant with ATEX, Norsok or Gost regulations           •	   Pressurised	lubrication	system	with	oil	cooler.
and standards for use in a Safe Area, Zone I or II
hazardous area. The high-pressure pump is selected        •	   HP	pressurised	packing	lube	system.
for continuous duty service ensuring long-term
reliability and low maintenance in the field.             •	   Integral	suction	&	discharge	dampers.

   Variable speed drive options ensure that the           •	   Discharge	pressure	safety	valve	(suction	PRV	option).
optimum speed torque envelope is maintained with
minimum current demand. Where VSD is selected the         •	   Temperature	&	pressure	transmitters.
frequency converter minimises harmonic distortion
and EMC radiation providing a high frequency              •	   Stroke	counter	or	flow	meter.
switching and recalculation against the motor model,
thus providing rapid and direct control of the drive      •	   Non-sparking	coupling	guard.
motor.
                                                          •	   Instrumentation,	E	stops	and	associated	wiring	to	local	JB.	
   The control system provides programmable
analogue and digital inputs and outputs, keypad           •	   Anti-vibration	mounts	(AVM).
entry, text read-out for the various parameters
including frequency, current, torque and power. A         •	   Fully	flexible	control	of	the	injection	system	to	meet	well-
range of additional management and communication               head	requirements.
facilities are available for connection to the system.

   Injection rates and discharge pressures will
determine the pump selection and ultimately
the power required. The standard pump package
supplied by Calder is a ready-to-go machine
complete with all termination points at skid edge,
complete instrumentation, pulsation dampers, safety
relief valves, junction boxes and control systems.
Finite element analysis (FEA) is supplied to primary
structures and can be extended to include ‘Blast Case’
analysis.


                                                                                                                        3
                                    Diesel Engine Drive HP Pumps




                                                                       Trailer-mounted Waste Injection Pump Unit with
                                                                       Transmission
                                                                       Zone 2 Hazardous Area
High Pressure Pumps
  The Calder CRI triplex reciprocating plunger pumps conform             Suction and discharge flanges to the Calder CRI pumps are
generally to API 674.                                                  provided to suit the customer’s specific requirements. As standard,
                                                                       the pump’s discharge fittings are Weco fig.1502 with ANSI 150 lb
  The pump fluid ends are manufactured from forged steel               RF. 6”, 8” or 10” suction terminations to suit flow conditions.
designed with easy maintenance as a priority, giving fast access
to valves, packings and plungers. (Duplex and Super Duplex                The power end of the high-pressure pump is a heavy-duty
Stainless Steel are available as options.)                             steel fabrication with a one-piece forged steel crankshaft. The
                                                                       four main bearings are large straight roller bearings with shell
   The internal suction & discharge valves are designed specifically   type replacement journal bearings.
for aggressive slurry injection processes. These valves have clear
flow-ways and specially formulated polyurethane replacement               A speed reducer gearbox with 4.68:1 to 7.5:1 ratios is fitted
inserts for resistance to acids and abrasives.                         directly to the power end of the pump. The reduction is achieved
                                                                       through a double heavy-duty helical gear machined from alloy
   The plunger packing system is the SSF design combined with          steel, heat-treated and crown shaved.
ASF Flat Back Seal Ring and Header Rings, which are specially
designed for use on slurry applications. Plungers are 4330 Alloy         A drip tray is installed under the entire HP pump, including
6, coated with Boron Alloy that provides maximum hardness              the pump head.
for erosion and wear resistance. A packing lubricator is fitted to
enhance the life of high pressure packings.



 Drive Options Available:

 ■       Electric motor, AC variable
         speed.

 ■       Electric motor with hydraulic
         pump and hydraulic motor.

 ■       Diesel engine drive through
         semi-automatic transmission.

 ■       Diesel engine drive through
         hydraulic pump and hydraulic
         motor.
                                                                                                            Diesel Engine/Hydraulic Drive
                                                                                                            Waste Injection Pump
     4                                                                                                       Zone 2 Hazardous Area
                                               CRI 450 Electric Units

The power selected for the motor is based on the duties specified plus allowances
for PSV set pressure and PSV overpressure. This selection provides a particular
performance envelope to suit specific well conditions.

 Electric motor driven units can be Safe Area to Zone 1, II 2 G EEx de IIC T4 in
accordance with guiding rules 94/9/EG ATEX .
Diesel engine driven units are normally Safe Area or Zone 2 compliant.

                                                                                       ■        Options
                                                                                       Calder Ltd offers a range of options. Some options
                                                                                       are mutually exclusive of others.



                                                                                           Options

                                                                                           •	    VSD	for	Safe-Area	Application

                                                                                           •	    Operator	Control	Panel

                                                                                           •	    Skid	Local	Panel

                                                                                           •	    Noise/Environment	Protection	
                                                                                                 Enclosure	

                                                                                           •	    Maintenance	Crane

                                                                                           •	    Anti-vibration	Mounts

                                                                                           •	    Lifting	Equipment	–	Pump	Skid

                                                                                           •	    Pulsation	Dampers
CRI 450
Electric Motor Driven CRI 450 with Acoustic Enclosure                                      •	    Suction	Strainer	–	Simplex	or	Duplex

                                                                                           •	    Suction	Relief	
■    Packing Lubrication System                                                            •	    High	Pressure	Discharge	Relief	Valve	
The packing lubrication system mounts directly to the HP Pump. Packing                           –		Medium	or	High	Pressure
lubrication oil is stored in a small reservoir, a series of 3 lubricator pumps are
mounted into the reservoir each feeding fluid directly into the lantern ring               •	    Suction	Pressure	
within the packing sets. The pumps are driven from a common shaft, taking                  •	    Discharge	Pressure	
power from the HP pump crankshaft via a “V” belt drive.
                                                                                           •	    Fire	Detection	&	Gas	Detection
This system provides precise measures of lubricant under pressure into the
packing based on pump speed. An optional large capacity packing oil header                 •	    Header	Tank	for	Packing	Lubrication	
tank is available.                                                                         •	    Space	Heater

                                                                                           •	    Oil	Sump	Heaters
■    Power End Lubrication System
A 4.6 kW, 3-phase electric motor will independently drive the lubrication gear             •	    Cooler	for	Power	End	&	Diesel	Engine	
                                                                                                 Lubrication	
pump. This ensures a constant feed to all critical components within the power
end at all HP pump speeds. This is particularly important at low speed high                •	    Witnessing	of	Load	Test
pressure duties.
                                                                                           •	    Factory	Acceptance	Test	
The oil is stored in an integral steel tank and is lifted from the tank by the pump,
                                                                                           •	    Noise	&	Vibration	Tests
filtered to 20 microns and injected onto the bearing and gear surfaces within
the power end of the HP pump; from there the oil drains from the HP pump                   •	    Long	Term	Preservation
back into the lube oil storage tank.
                                                                                           •	    Site	Support	&	Commissioning	
Additional instrumentation, oil heaters and oil cooler are available, as required                Services
to suit the environmental conditions.


                                                                                                                                     5
                                                       CRI 1680 Pump Units




                                                                         Waste Injection Pumps
                                                                         Client  .  .  .  .  .  .  .  .  . BP
                                                                         Flow  .  .  .  .  .  .  .  .  .  . 95m3/hr (10 bpm)
                                                                         Pressure  .  .  .  .  .  . 345 bar (5000 psi)
                                                                         Hazard Area  .  . Zone 1 ATEX
                                                                         Drive .  .  .  .  .  .  .  .  .  . 1400kW variable speed
                                                                         Noise  .  .  .  .  .  .  .  .  . 83 db(A)




    Well Service Pumps
    Client  .  .  .  .  .  .  .  .  . Aker
    Flow  .  .  .  .  .  .  .  .  .  . 105m3/hr (11 bpm)
    Pressure .  .  .  .  .  .  . 517 bar (7500 psi)
    Hazard Area  .  . Safe Area
    Drive .  .  .  .  .  .  .  .  .  . 1800kW variable speed




6
 ■      Calder Cuttings Injection Pump Model CRI-450
        Pressure flow chart for all plunger sizes
                                                                                                        Flow
                 13     26      50      66         77          92           102       110        128        143           150           164         196          225       248         256         306     USGPM
    Pressure      50    100    188     250        290         350           385       416        485        540           568           620         742          850       939         970        1158      LPM
                 0.3    0.6    1.2      1.6        1.8         2.2           2.4       2.6        3.0        3.4           3.6           3.9         4.7          5.3       5.9         6.1        7.3      BPM
  bar      psi   3.0    6.0    11.3    15.0       17.4        21.0          23.1      25.0       29.1       32.4          34.1          37.2        44.5         51.0      56.3        58.2       69.5     M3/HR
   25     363      3      5     10      13         15          18            20        21         25         28            29            32          38           44        48          50          60
   50     725      5     10     19      26         30          36            40        43         50         56            59            64          76           88        97         100         119
   75     1088     8     15     29      39         45          54            60        64         75         84            88            96         115          131       145         150         179
  100     1450    10     21     39      52         60          72            79        86        100        111           117           128         153          175       194         200         239
  125     1813    13     26     48      64         75          90            99       107        125        139           146           160         191          219       242         250         298
  150     2175    15     31     58      77         90         108           119       129        150        167           176           192         229          263       290         300         358
  175     2538    18     36     68      90        105         126           139       150        175        195           205           224       268            307       339         350         418
  200     2900    21     41     78     103        120         144           159       172        200        223           234           256         306          351       387         400
  225     3263    23     46     87     116        135         162           179       193        225        251           264           288         344          394       436         450
  250     3625    26     52     97     129        149         180           198       214        250        278           293           320         382          438
  275     3988    28     57    107     142        164         198           218       236        275        306           322           352         421
  300     4350    31     62    116     155        179         216           238       257        300        334           351           384         459
  325     4713    34     67    126     168        194         235           258       279        325        362           381           415
  351     5090    36     72    136     181        210         253           279       301        351        391           411           449
  375     5438    39     77    145     193        224         271           298       322        375        418           439                                                         5.0" Plunger
  400     5800    41     82    155     206        239         289           318       343        400        445                                                                       Pressure limit 351 bar
  433     6279    45     89    168     223        259         312           344       371        433
  450     6525    46     93    174     232        269         325           357       386        450                                                                      4.5" plunger
  500     7250    52    103    194     258        299         361           397       429                                                                                 Pressure limit 433 bar
  548     7946    56    113    212     282        328         395           435
  624     9048    64    129    242     322        373         450                                                                                4.0" Plunger
  650     9425    67    134    252     335        389                                                                                            Pressure limit 548 bar
  716    10382   74     148    278     369        428
  752    10904   78     155    291     388        450                                                                3.5" Plunger
  873    12659   90     180    338     450                                                                           Pressure limit 716 bar
  976    14152   101    201    378
 1100    15950   113    227    426                                                  3.0" plunger                                    POWER TABLE Calder CRI 450 Pump
                                                                                                                                        Power Table: Calder CRI 450 Pump
 1120    16240   115    231    434                                                  Pressure limit 976 bar
 1161    19894   120    239    450
                                                           2.75" Plunger
                                                           Pressure limit 1161 bar

Crankshaft speed is limited to 200 RPM maximum . Max recommended speed for Slurry Service is 200 rpm . 450 kW (600 HP) maximum
Intermittent Power 300 kW (400 HP) Maximum Continuous Duty .



■       Calder Cuttings Injection Pump Model CRI-1680
        Pressure flow chart for all plunger sizes
                                                                                                     Flow
                 26    132    264     370       431        462         545         581       634        673        793           969       1057        1138         1255      1319        1515     USGPM
    Pressure     100   500    1000    1400     1631        1750       2062         2200      2400       2547       3000          3667      4000        4307         4750      4992        5734      LPM
                 0.6   3.1    6.3     8.8      10.3        11.0       13.0         13.8      15.1       16.0       18.9          23.0          25.1     27.1        29.9       31.4       36.0      BPM
  bar     psi    6.0   30.0   60.0    84.0      97.9       105.0      123.7        132.0     144.0      152.8      180.0     220.0         240.0       258.4       285.0      299.5       344.0    M3/HR
  25      363     5    26     52      72        84          90         106         113       124        131        155           189           206         222      245        257         296
  50      725    10    52     103     144       168        180         213         227       247        263        309           378           412         444      490        515         591
  75      1088   15    77     155     216       252        271         319         340       371        394        464           567           619         666      735        772         887
  100     1450   21    103    206     289       336        361         425         454       495        525        619           756           825         888      979       1029        1182
  150     2175   31    155    309     433       504        541         638         680       742        788        928           1134      1237        1332         1469      1544
  200     2900   41    206    412     577       673        722         850         907       990        1050       1237          1512
  250     3625   52    258    515     722       841        902        1063         1134      1237       1313       1546
  300     4350   62    309    619     866      1009        1082       1275         1361      1485       1575
  325     4713   67    335    670     938      1093        1173       1382         1474      1608
  350     5075   72    361    722     1010     1177        1263       1488         1588
  375     5438   77    387    773     1082     1261        1353      1594
  400     5800   82    412    825     1155     1345        1443                                                                                                                                   7.5" plunger
  425     6163   88    438    876     1227     1429        1534                                                                                                                                   Pressure limit 375 bar
  450     6525   93    464    928     1299     1513        1624
  475     6888   98    490    979     1371     1597                                                                                                                          7" Plunger
  500     7250   103   515    1031    1443     1681                                                                                                                          Pressure limit 450 bar
  525     7613   108   541    1082    1515
  550     7975   113   567    1134    1588                                                                                                            6.5" plunger
  575     8338   119   593    1186    1660                                                                                                            Pressure limit 525 bar
  600     8700   124   619    1237
  625     9063   129   644    1289                                                                                          6" Plunger
  650     9425   134   670    1340                                                                                          Pressure limit 600 bar
  700    10150   144   722    1443
  800    11600   165   825    1649                                                                    5" Plunger
  900    13050   186   928                                                                            Pressure limit 700 bar
 1000    14500   206   1031
 1100    15950   227   1134                                          4.5" plunger                                      POWER TABLE
 1200    17400   247   1237                                          Pressure limit 1000 bar                                        Power Table: Calder CRI 1680 Pump
 1300    19894   268   1340
                                              4" Plunger
                                              Pressure limit 1300 bar

Crankshaft speed is limited to 330 RPM maximum . Max recommended speed for slurry service is 200 rpm .
1687 kW (2250 HP) maximum Intermittent power 850 kW (1100 HP) maximum continuous duty .
Power tables show approximate (kW) power absorbed at various flows and pressures . Power and flow for each plunger size . All data is
based on 95% volumetric efficiency and 85% mechanical efficiency pressure and flow limits for each plunger size .

                                                                                                                                                                                                           7
  Waste	Injection	(CRI)	Pump	Packages


   ■         Performance                                                                ■      Discharge Flange
  Calder pump packages are designed for intermittent & continuous                       To suit client requirements.
  pumping of Oil & Gas field waste products & well service chemicals                    • Design Temperature . . . . . . . 10°C to 85°C
  such as, Brine, Drill Cuttings & Muds within a specified duty range.                                                                 (-40°C + 120°C options)
  • Pressure Range ..................... 80 to 1400 bar (1,200 to 20,000 psi)           • API 674 . . . . . . . . . . . . . . . . . . .Compliant with exceptions
  • CRI 450 .................................... 156 M³/hr (16 BPM)
  • CRI 1680................................... 344 M³/hr (36 BPM)
  • Flow range ............................. 10% to 100%                                ■      Operation & Control Systems:
  • Power range ........................... 450 kW to 1680 kW,                          Simple Controls to fully integrated unmanned control systems.
  • Safe or Hazardous area ..... ExN or EExd, Zones 1 & 2                               Pump flowrate controls allow fixed or variable flow rates using
  • Noise Level ............................. 75 dbA, 83 dbA, 85 dbA @1M                variable frequency drive or hydraulic drives.

                                                                                        ■      Pump unit control system configurations
   ■         Drive Options                                                                     featuring the following options:
  • Electric Motor, Fixed or Variable speed using VFD or Hydraulic                         • Single or multiple pump unit control systems which can be
    Drive                                                                                    operated from a remote location.
   • Diesel Engine with Transmission or Hydraulic drive.                                   • Local control systems available which can be skid mounted.
                                                                                           • Full integration and interface with client to control systems.
                                                                                           • Use of the latest communication protocols.
   ■         Unit Configuration Options                                                    • Comprehensive instrumentation with health/status
  • Open Skid, Trailer or Truck Mounted                                                      monitoring functions.
  • Noise & Environment Enclosure.                                                         • Full data acquisition and logging capabilities.
  • Container, Offshore DNV compliant                                                      • Optional touch-screen HMI with manual or automatic
                                                                                             modes.

   ■         Pump type for Waste Injection (CRI) process:                                  During	operation	the	system	is	protected	by	instruments	monitoring	
                                                                                           the	suction	pressure,	the	discharge	pressure,	the	lube	oil	pressure	
  • Reciprocating Pump Type ...... Calder Model CRI 450 & CRI 1680                         and	the	lube	oil	temperature.	The	control	system	also	monitors	its	
                                                      Triplex Reciprocating Plunger.       own	internal	communications.	If	any	of	these	are	lost,	the	whole	
  • Plunger Range (diameter)...... 57 mm to 180 mm (2.25” to 7.0”)                         system	is	shut	down	immediately.	An	external	communication	port	
                                                      Plunger (stroke 150 & 200mm)         is	available	for	remote	operation	and	monitoring.
  • Plunger Material Type.............. SS/Tungsten Carbide
  • Valve Housing ............................. High Strength Alloy Steel or Duplex
                                                      stainless steel (option)
  • HP Seals ........................................ SSF Design with back seal ring,
                                                      Lantern & Oil Lube
  • LP Sealing .................................... Double Lip Seal
  • Lubrication .................................. Pressurised - filtered
  • Suction Flange ........................... 6” or 8” 150lb ANSI Raised Face

   ■	        Standards	&	Specifications:
  Calder pump packages can comply with most international standards and specifications including:

       ATEX | IEC | Gost | EN | DNV | API | ANSI | API 610 | API 674 | AS/NZ | Norsok | NACE.

  | Safety HSE We at Calder pride ourselves on our 29 year safety record. As members of the British Safety Council we practise the strictest safety
                procedures within our factory and working environments, applying rigorous risk assessments to all activities and equipment
                which we design and build.
  | ISO 9001    Quality standard has been practised by Calder since 1986 with award of certification in 1999. Our rigorous application of this
                quality standard has ensured that we consistently meet and exceed our customers’ most demanding expectations for both quality
                and reliability.
  | ISO 14001 Environmental Standard has been held by Calder since 1999. Careful and judicious management of our working environment
               with the application of sound and well informed design applications utilising the latest and most efficient technologies helps us to
               produce equipment which minimises the environmental footprint of our production facility and the operating equipment in the
               field.

                                                                                                                      Calder	Ltd            	 web	:	    www.calderltd.com
                                                                                                                      Gregory’s Bank        email :     sales@calder.co.uk
                                                                                                                      Worcester                 tel :   +44 (0) 1905 723 255
                                                                                                                      WR3 8AB                  fax :    +44 (0) 1905 723 904
Calder Ltd reserve the right to alter specifications
and data to incorporate improvements in design.                                                                       United Kingdom

				
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