Energy Power Systems Australia (EPSA) designed, engineered and manufactured a block oil storage pump for local petroleum giant Santos for operation at their Moomba production and processing facility in central Australia.
The multi-stage pump package designed and engineered by EPSA met the compliance requirements of the stringent Australian Gas Standards that govern the local Oil and Gas industries.
With Caterpillar a preferred engine supplier, EPSA was approached by several leading pump OEMs who were bidding for the tender 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.
Having received acceptance for the project, EPSA designed the engine package and cooling system on a base frame with a field-proven 27-litre, 600 hp, CAT G3412 gas engine at its core.
The Caterpillar engine was coupled to a multi-stage pump via a Cotta S13E speed increasing transmission that enabled the pump to operate at twice the engine’s speed.
The scope of works was expanded to include control and condition monitoring systems as well as a gas-skid that incorporated valving and processing equipment for regulated supply of gas to the engine.
EPSA designed, engineered, manufactured and assembled the entire package in-house, which was a significant achievement since complicated multi-stage pump packages are usually 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.
Typically engaged to supply only engines, the project was a first for EPSA in terms of being contracted to deliver an entire engineered solution for Santos. The petroleum company currently uses over 50 Caterpillar engines for power generation, gas compression and pumping applications at their Cooper and Eromanga basin fields in South Australia.
Cost and delivery time were the two key drivers for Santos to choose a local manufacturer for the multi-stage pump package. The decision also enabled them to test the water with local suppliers.
EPSA designed and engineered the complete unit carefully to ensure safe operation in explosive environments. The CAT G3412 gas engine was built to ensure its surface temperature never exceeded 300ºC while all the control wiring encased in stainless steel conduit and featuring special field connectors had to be installed by an accredited technician in order to ensure non-spark performance.
Having delivered the multi-stage pump package to Santos, EPSA’s engineering team now have the expertise to effectively manufacture more oil field pump packages in Australia.