Extract’s Dedicated Monitoring and Optimization Team Helps Maximize Productivity and Run Life for ESPs and H-Pumps

How do you balance your pump performance—electric submersible pumps (ESPs) or horizontal pumps (HPSs) between maximum flow rates vs. extended pump life? Faster speeds mean more profits from production but could mean greater repair expenses and lost production from unexpected down time. How do you know where to draw that line? With today’s staffing limitations, you probably don’t have the internal resources for the research required to answer those questions.

Here’s the solution. Extract’s Monitoring and Optimization team uses 24/7 SCADA monitoring and evaluation of ESPs to identify trends that indicate a need for service and to alert technicians proactively. Or, in extreme cases, they can remotely shut off a pump, either ESP or HPS. The team’s lift system expertise gives them deep insight into running those systems at peak efficiency.

For optimization, this extensive database and analysis combined with an understanding of client production goals give Extract’s experienced team the information they need to maximize productivity and lift system life.

And in system design, Extract uses their proprietary XSIZE™, the industry's most powerful production engineering software, to incorporate and analyze well conditions, customer production goals, and lift types to arrive at the best mix of production and lift system life. In SWD injection, the HOSS team also combines customer input with well and pump data to recommend the optimal system for all parameters.

This is where spreadsheets for both production and profit peak in sync. Keep reading to learn more about both monitoring and system design.

What 24/7 Monitoring and Control Means to You

For ESPs: Well conditions and pump operations change constantly—at times so slowly that differences can be invisible if the only observation is by a pumper driving to the site every other day. But those trends can lead to pump failures or worse if not detected and dealt with. A SCADA system makes 24/7 monitoring cost-effective. The Extract team monitors a long list of downhole and surface equipment parameters, including flow rates, incoming power status of the programmable logic computer (PLC), pump temperatures, and much more.

With all that detail, they can take immediate action when something happens. And in many cases, trend analysis empowers them to be proactive, preventing a problem from ever happening.

Remote control helps the Extract team make many adjustments remotely, eliminating costly and time-consuming site trips. If on-site repairs do become necessary, technicians will know right away, with a clear picture of the parts and supplies needed onsite.

You can set up alerts however you would like. Whether Extract should alert your field service team or send one of our technicians—or both—that’s your call. Either way, your team will have full access to our team’s extensive knowledge and experience.

For HOSS Horizontal Pumps: Similar to ESPs, HPS monitoring is real-time. Tracking all related surface equipment, including the PLC, tank levels (high or low), pump vibrations, induction and discharge pressures, and measuring that information against pre-set alarms and callouts allows immediate responses.

For example, increased pump vibrations could signal bearing wear that needs attention. The Extract team will evaluate the overall situation to recommend replacing the bearings or, if pump repairs are adding up, to replace the entire system.

Since the HPS is a central link in a chain of possession of produced water, any change in its status has ramifications above and below it. Timely alarms allow for quick response to keep the whole system running smoothly or adjust the other components if extreme measures are unavoidable.

As with the ESPs, Extract can make remote changes as needed, or they can notify and advise you first.

Safety in (ESG) Numbers

The safety numbers for remote monitoring and control are significant. As stated, pumpers or technicians cut their site-trip miles by the thousands every month because the data they previously wrote on a notepad now flows seamlessly and instantly to the monitoring system. Fewer road miles—and hours—means less exposure to accidents, tire issues, and windshield time. Field people are also avoiding onsite dangers from equipment and flammable materials.

Real-time data and control allow operators to proactively adjust or shut off lift systems to prevent an otherwise dangerous situation. No more will a pumper drive up to find a spill of crude oil or produced water. This increased safety for all—employees, nearby landowners/communities, and the environment—can boost ESG numbers.

Why Extract

By relying on dedicated lift system experts, your team can concentrate on their main goals of boosting profitability and strengthening your ESG score. The Extract team knows how to maximize lift systems to help you meet both of those goals and we are proud to be your wingman for success.