Santos BlOck Oil Storage Pump

Application: Oil and Gas     Download Power Profile

Market Segment: Oil and Gas


POWER NEEDED

March 2009 represented a milestone for Energy Power Systems Australia (EPSA) with the handover of the first locally designed, engineered and manufactured Block Oil Storage Pump for local petroleum giant Santos.

Destined for operation at Santos’ Moomba production and processing facility in central Australia, the multi-stage pump package is testament to EPSA’s design and engineering prowess - with the completed package attaining compliance with the stringent Australian Gas Standards that govern the local Oil and Gas Industries.


BACKGROUND

With Caterpillar a preferred engine supplier, EPSA was approached by several leading pump OEMs who were bidding for the tender and asked for various scopes of supply ranging from engine supply only through to a
total packaged solution designed, engineered and manufactured at EPSA’s facilities in Hallam, Victoria.

Quoting on the project commenced in August 2007, with EPSA receiving acceptance for an engine package and cooling system on a base frame in late December. 


SOLUTION

At the heart of the package was a field proven 27 litre, 600 hp, CAT G3412 gas engine that’s coupled to a multi-stage pump via a Cotta S13E speed increasing transmission that enables the pump to operate at twice the engine’s speed.

As the job progressed the scope of works was expanded to include the control and condition monitoring systems and the gas-skid that incorporated valving and processing equipment for the regulated supply of gas to the engine. These additional components significantly increased the complexity of the project and provided a myriad of challenges to be conquered by EPSA’s engineering team.

In the end EPSA designed, engineered, manufactured and assembled the entire package, which according to EPSA’s Dave Heard is a real feather in the cap for EPSA as traditionally complicated multi-stage pump packages like these are imported from specialist overseas packagers.

“The Moomba processing facility is a massive operation, accepting production from 115 gas fields and 28 oil fields that contain 536 producing gas wells and 177 producing oil wells through approximately 5,600 kilometres of pipelines and flow lines via 24 oil and gas satellite facilities, many of which incorporate field boost compression.


RESULT

“Being awarded the contract for the entire pump package was a first for EPSA, as instead of just supplying an engine our engineers were able to supply an entire engineered solution for Santos, who currently use over fifty
Caterpillar engines for power generation, gas compression and pumping applications at their Cooper and Eromanga basin fields, in South Australia.

“The decision to manufacture in Australia was driven by a number of issues, cost being one, delivery being another, plus it gave Santos the opportunity to test the water with local suppliers.

“It was a highly disciplined design, engineering and manufacturing exercise that ensured the completed unit was intrinsically safe to enable operation in explosive environments with complete safety. The CAT G3412 gas engine was built to ensure its surface temperature doesn’t exceed 300°, while all the control wiring – which is encased in stainless steel conduit and featured special field connectors, had to be installed by an accredited technician in order to ensure non-spark performance.

“By having done so, ESPA’s engineers have gained further valuable and extensive insights into the intricacies of the stringent Australian Gas Standards which will provide a useful time and cost saving template for future projects.

“In all over 1,000 man-hours were involved in order to gain compliance, with every item stamped, tagged and
recorded in finite detail in a process that was continually monitored by consultants, assessors and expediters
who reviewed every aspect of the project with a fine toothcomb. 

“At the conclusion of the project the mass of the paperwork generated appeared to equal the mass of the engine, but with all the research and development done EPSA’s engineering team now have a strong foundation on which to effectively manufacture more Oil Field Pump packages and hopefully retain this business within Australia,” Dave said.


About Energy Power Systems Australia

Energy Power Systems Australia is Australia’s specialised Caterpillar engine dealer, supplying Australia and Papua New Guinea with the world’s finest power systems.

We provide Caterpillar engines and systems for virtually any application, from road and marine to power generators and compressors, if it’s Caterpillar, then Energy Power Systems Australia is right behind it.

Through our network of offices across Australia and Papua New Guinea, our people give comprehensive engineering support and technical advice to the Caterpillar Engine community.

When it comes to powering your business, only Energy Power Systems Australia can deliver this combination of technically superior Caterpillar engines and unmatched technical and after-sales support. 

For more information on Caterpillar’s diesel generator sets, from 11 to 16,200 kW, or gas-powered generator sets from 100 to 6,000 kW:

Contact Energy Power Systems Australia on

1800 800 441, or visit: www.energypower.com.au

CALL 1800 765 660

Follow us on LinkedIn Follow us on Twitter Follow us on YouTube Follow us on Facebook


Innovation place

Block Oil Storage Pump under construction at
EPSA’s engineering facility at Hallam, Victoria

“It was a highly disciplined design, engineering and manufacturing exercise that ensured the completed unit was intrinsically safe to enable operation in explosive environments with complete safety.....”

CUSTOMER

Santos Limited

LOCATION

Moomba production facility, central Australia

CUSTOMER ISSUE

Traditionally, multi-stage storage pump packages are imported from specialist overseas manufacturers. In this instance, the decision to manufacture in Australia was driven by a number of issues, cost being one, delivery being another, plus it gave Santos the opportunity to test the water with local suppliers.

SOLUTION

Energy Power Systems Australia designed, engineered, manufactured and assembled the entire pump package that included the engine, frame, multi-stage pump, speed
increasing transmission, control and monitoring systems, gas skid and gas processing equipment.

PRODUCT

Caterpillar G3412 - 600 hp, 27 litre gas engine

FURTHER INFORMATION

CALL: 1800 800 441

http://www.energypower.com.au/


Block Oil Storage Pump for
Santos’ Moomba production
and processing facility

Lake Mountain Resort - Olympian generator

“In all over 1,000 man-hours were involved in order to gain compliance, with every item stamped, tagged and recorded in finite detail.....”