Overcoming Extreme Oil & Gas Operating Conditions
CUSTOMER CHALLENGE
In the Permian Basin, oil and gas companies need to move large volumes of produced water through pipeline networks to keep their businesses operational and profitable. A pump’s reliability, corrosion resistance and installation integrity are critical requirements rather than design preferences. A West Texas operator was struggling to meet these challenges. Its pumps used carbon steel components that corroded prematurely when exposed to chlorides and hydrocarbon contamination common in produced water. Unplanned maintenance and downtime were often needed, including removing equipment from a containment pad, a costly and time consuming effort. Even getting the equipment operational was a struggle, as alignment issues during installation and startup were common. Operational constraints and environmental requirements dictated a containment pad installation, limiting pumping options. Additionally, the system required large, high-performance pumps that could stand up to the corrosion and abrasion of produced water, which often means long-lead stainless steel pumps.
THE SOLUTION
To address these challenges, the operator worked with Pioneer Pump® to configure an ElectricPAK™ Pump Package, Pioneer Pump’s patented electric motor-driven pump product line, with a stainless steel 86C21 clear water pump specifically for high head produced water service. This customization included stainless steel wetted components that could withstand corrosive chloride- and hydrocarbon-laden fluids. The system was outfitted so it could deliver high flow at high head in duplex stainless construction – a combination that is hard to find without significant engineering and lead times. All ElectricPAK Pump Packages are built with an integrated motor stool designed to mechanically couple the pump and motor, keeping them permanently aligned them during installation and over continuous operation, ensuring that installation alignment issues would not repeat themselves. For the operator, this not only meant increased reliability but also a more streamlined installation that eliminated the need for post startup alignment adjustments. The team quickly installed the ElectricPAK skid on the containment pad, pulling from a large, open produced water tank. Instrumentation and electrical support assisted with variable frequency drive (VFD) programming and startup, including setup of Bluetooth-based monitoring and control features.
THE RESULTS
The combination of high-flow, high-head stainless hydraulics, a permanently aligned motor stool design, and a rugged VFD package rated for extreme temperatures delivered reliable continuous operation in a corrosive environment. The system has since operated continuously, delivering approximately 75,000 barrels per day at 440 feet of head. The system has been operating continuously under corrosive produced water conditions without early seal or wear failures. The VFD control provided stable operation and reliable flow adjustment, supporting integration with the shared filtration system.
Compared to previous carbon-steel installations, corrosion resistance was significantly improved. When maintenance is needed, the unit can be serviced in the field, saving time and minimizing disruptions. Overall uptime increased, directly protecting the operator’s throughput-driven revenue model while reducing labor and maintenance costs.
