On July 2, 1993, an enterprise called JSC BEPUS (base for electric submersible units) was founded on the basis of the Variogan Central Industrial Maintenance Base for ESPs in the city of Raduzhny, Khanty-Mansiysk Autonomous District, which was engaged only in the repair of submersible equipment of various manufacturers and well maintenance. Mr. Rashid Abdulin was appointed part-time director. From this period to 2012, Mr. Rashid Abdulin created an enterprise for the manufacture of ESPs and oil submersible cables starting from the base for the repair of ESPs, localizing the production of components inside the enterprise at the level of 95%
In 1994, a joint company Tandem LLC was organized from the cable section. It repaired cable products of various manufacturers. The enterprise received further development thanks to the overhaul of the cables.
Work of the enterprise
In 1999, Almaz LLP underwent restructuring and
was renamed Almaz LLC.
The company's specialists manufactured the first submersible electric motor of our own production. The company started manufacturing serial induction and parametric electric motors.
Since 2001, the company started serial production of electric submersible pumps.
The work was carried out with suppliers of stages made from gray cast iron. Until 2004, carbon fiber working bodies were also installed. Due to the increase in the depth of the ESP running over 1,300 meters, as a result of prolonged exposure to the high temperature of the reservoir fluid and overheating of the ESPs, the weaknesses of the carbon fiber working bodies were revealed – they melted, clogged the through-openings and led to premature failure.
Working bodies made of cast iron worked well when the particles content was no more than 0.2 g/liter, but downhole conditions became more and more difficult in the serviced fields.
Release of the first gas separator
The company began to work closely with the manufacturers of pump stages and a joint venture Almaz-Kineshma was created. The stages were made of pseudo-alloy powder. The monthly scope of stages supply exceeded 50 thousand pieces.
In December 2005, all three directions: repairs – BEPUS, cables – Tandem, production – Almaz merged. The company serially supplied its own products: ESP motors, ESPs, protectors, pump modules (gas separators, handlers), inlet modules, valves, spare parts, cable products. With the increase in the requirements for the mean time between failures, it became obvious that the installation of more wear-resistant alternative materials is required. Improving the design of products, providing process equipment, increasing the volume of tests and research allowed the company to supply products in various directions, participate in pilot field tests.
The professionals of the plant developed a new design of the submersible cable KIFBP-230 (ESP cable, flat, PTFE, heat resistance: 230 °C), which has heat resistance like a leaded cable, but has half the weight, smaller dimensions by up to 30%, greater simplicity during installation operations.
Quality management system
In 2006, the company was audited and implemented a quality management system according to ISO 9001-2001.
From the point of view of technological development, for the first time in the world, ESP working bodies made of stainless steel were introduced.
In 2009, pump modules of unsupported design, ESPs of unsupported design, equipment with stainless steel housings, shafts and couplings with involute connections were developed.
Safety and environment
In 2010, the company was audited and implemented the environmental management system according to GOST R ISO 14001-2007 (ISO 14001:2004) and the occupational safety and health management system according to GOST 12.0.230-2007 (OHSAS 18001:2007).
In 2010, protectors of modular design with reinforced thrust runner assembly, in-house temperature and pressure measurement system with self-diagnosis system and, for the first time in world practice, ESP induction motors with increased voltage were developed.
By this year, Almaz LLC covers up to 40% of the needs of TNK-BP Management LLC, and the number of new ESP motor sections manufactured by Almaz LLC per month reaches 515 units.
The period from January 2013 to April 2014 was the most difficult in the history of the company's development, since in July 2013 Rosneft acquired TNK-BP Management LLC.
Previously, more than 90% of the production plan consised of equipment for TNK-BP, and deliveries to Rosneft were insignificant. Establishing connections was extremely difficult. This prompted the search for new sales markets, including to other oil companies Lukoil-Western Siberia, Surgutneftegaz, Tatneft, Bashneft, Gazprom Neft. During this period, Almaz was visited by professionals from oil companies with audits, the equipment successfully passed pilot tests. In April 2014, for the first time in the history of the company, Almaz LLC started servicing and leasing submersible equipment at PJSC Samotlorneftegaz on a total stock of 4,500 wells.
During this period, additional modules (displacement modules) were introduced to reduce the transverse dimension.
In October 2016, Almaz LLC, for the first time in the history of the enterprise, started servicing wells of RN-Yuganskneftegaz LLC. The number of serviced wells at the time of the 10-month contract completion was 2,750. Production sites were deployed in the village of Singapay and directly at the Priobskoye field. Manufacture, transportation and commissioning of process and testing equipment 550 km from the place of permanent deployment in a short time allowed the company to declare the possibility of rapid strategic mobilization. As of April 1, 2017, the total stock of serviced wells and lease amounted to about 9,000 units.
t that time, a gas separator in size 6.1, and permanent magnet submersible electric motors in size 81 mm were released, a temperature and pressure measurement system with TRANSFER data exchange protocol was introduced, ESPs in size 8 and ESPs in size 2A were developed
As of September 1, 2017, the total stock of serviced and lease wells decreased by 2,750 wells, and amounted to 6,250 wells.
The decrease in the scope of work in the village of Singapay contributed to increased attention to the scope of services provided in the Nizhnevartovsk district.
At that time, finned submersible electric motors of low power in a size of 140 mm were developed.
Since January 1, 2018, Almaz LLC increased well servicing of JSC Samotlorneftegaz from 3 workshops (over 3,000 wells since April 2015) to 6 workshops (about 6,000 wells). For this purpose, in accordance with the road map, a repair and maintenance production base was deployed in a short time at the 43th kilometer of the Nizhnevartovsk-Raduzhny highway in the immediate vicinity of the Samotlorskoye field. The total stock of serviced and lease wells amounted to about 9,500, and the number of personnel of the Almaz Group of Companies exceeded 2,500 people.
From the point of view of technological development, assemblies of 3 sizes were introduced in ESPs.
Pilot field tests and the introduction of finned submersible electric motors of low power in a size of 140 mm, as well as the introduction of downhole reactive power compensation devices were completed.
Change of management
"In 2021, a new legal entity, ALMAZ Oilfield Service LLC, was registered. The control of the company was transferred to a new management in partnership with the largest metallurgical and industrial Holding having a leading position in terms of procurement and processing of ferrous and non-ferrous scrap on the territory of the Russian Federation and CIS countries."
In 2022, the plant began to carry out complex maintenance, repair of electric submersible equipment for oil production, manufacture of cable lines and extension cords for 2,225 wells of the Pravdinskoe field of RN-Yuganskneftegaz LLC, the largest subsidiary of PJSC NK Rosneft.
As part of the contract, a new service base was mastered in the village of Poykovsky: the area of the plot is 19,700 m2, the area of production and auxiliary premises is 5,700 m2, a temporary (at the time of the main base preparation) cable workshop in Nefteyugansk with an area of 1,700 m2 was prepared. The staff of the enterprise was reinforced with 140 employees of the previous contractor, the free staff of the enterprise in the amount of 40 people was mobilized.