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20082008
Texas A&M UniversityTexas A&M University
2424thth International Pump UsersInternational Pump Users
SymposiumSymposium
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Multiphase PumpingMultiphase Pumping
By: Bob Heyl
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Presentation ContentsPresentation Contents
Definitions and Criteria: Multiphase Flow, GasDefinitions and Criteria: Multiphase Flow, GasVolume (Void) Fraction (GVF) and CriteriaVolume (Void) Fraction (GVF) and Criteria
Types of Multiphase PumpsTypes of Multiphase Pumps
General ApplicationsGeneral Applications
Advantages and Disadvantages of DifferentAdvantages and Disadvantages of DifferentTypes ofTypes of MPPsMPPs
Specific ApplicationsSpecific Applications
Sample EconomicsSample EconomicsReasons to Use OffshoreReasons to Use Offshore
Subsea DevelopmentsSubsea Developments
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Definitions and CriteriaDefinitions and Criteria
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What is Multiphase Flow?What is Multiphase Flow?
Flow consisting of at least:Flow consisting of at least:
-- LiquidLiquid
-- GasGas
(But often high volumes of gas, mixed with(But often high volumes of gas, mixed with
oil, water, and solids)oil, water, and solids)
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MutiphaseMutiphase Pump CriteriaPump Criteria
Gas Volume (Void) Fraction [GVF] at Suction ConditionsGas Volume (Void) Fraction [GVF] at Suction Conditionsmeasured in %measured in %
ParticulateParticulate -- measured in %measured in %Maximum Particle Size and DistributionMaximum Particle Size and Distribution
Liquid ViscosityLiquid Viscosity
TemperatureTemperatureGas CompositionGas Composition
Suction PressureSuction Pressure
Discharge PressureDischarge Pressure
Flow RateFlow Rate
Potential for Slug FlowPotential for Slug Flow
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GVF for GasGVF for Gas--OilOil--Water MixturesWater Mixtures
Need: Oil Rate in BPDNeed: Oil Rate in BPD
Gas Rate in SCFDGas Rate in SCFD
Water Rate in BPDWater Rate in BPD
Pump Inlet Pressure in PSIGPump Inlet Pressure in PSIGPump Discharge Pressure in PSIGPump Discharge Pressure in PSIG
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GVF for GasGVF for Gas--OilOil--Water MixturesWater Mixtures
Actual BPD of Gas =Actual BPD of Gas =
(ACFD) (7.481 gal/cu ft)(1 bbl/42 gal) =(ACFD) (7.481 gal/cu ft)(1 bbl/42 gal) =(ACFD) (0.178 bbl/cu ft.)(ACFD) (0.178 bbl/cu ft.)
wherewhere
ACFD = [(SCFD) (14.7ACFD = [(SCFD) (14.7 psiapsia) (MPP Inlet Temp) (MPP Inlet Temp
F+460) (Z)]/[(MPP Inlet PressF+460) (Z)]/[(MPP Inlet Press psiapsia) (520R)]) (520R)]
where Z is often 1.0where Z is often 1.0
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GVF for GasGVF for Gas--OilOil--Water MixturesWater Mixtures
BPD = (Actual BPD of Gas + BPD of Oil +BPD = (Actual BPD of Gas + BPD of Oil +
BPD of Water )BPD of Water )
And thereforeAnd thereforeGVF = (Actual BPD of Gas)/(BPD)GVF = (Actual BPD of Gas)/(BPD)
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Types of Multiphase PumpsTypes of Multiphase Pumps
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Types of Artificial Lift andTypes of Artificial Lift and
Multiphase Pumps (MPPs)Multiphase Pumps (MPPs)
Electric Submersible Pumps (ESPElectric Submersible Pumps (ESPs)s)
RotordynamicRotordynamic
Progressive Cavity Pumps (PCPProgressive Cavity Pumps (PCPs)s) -- PositivePositiveDisplacementDisplacement
HelicoHelico--Axial PumpsAxial PumpsRotordynamicRotordynamic
CentrifugalCentrifugal
TwinTwin--ScrewScrewPositive DisplacementPositive Displacement
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Electric Submersible Pumps (Electric Submersible Pumps (ESPsESPs))
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Progressing Cavity Pumps (PCPs)Progressing Cavity Pumps (PCPs)
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Progressing Cavity Pumps (PCPs)Progressing Cavity Pumps (PCPs)
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MPP7-stage helico-axial
125,000 bpd700 hp motor w/ VFD (3600 rpm)
HelicoHelico--AxialAxial
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HelicoHelico--Axial PumpAxial Pump
BEARINGS
MECHANICAL SEAL
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HelicoHelicoAxial Rotor AssemblyAxial Rotor Assembly
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Buffer TankBuffer Tank
BUFFERTANK INLET
BUFFERTANK
OUTLET
BUFFER TANK DRAIN
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HelicoHelico--Axial Subsea PumpAxial Subsea Pump
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Hydraulic CentrifugalHydraulic Centrifugal
Special design ofSpecial design of helicohelico--axial pump with aaxial pump with a
multistage hydraulic turbine fed by amultistage hydraulic turbine fed by aremote high pressure pumpremote high pressure pump
Turbine and pump integrated on aTurbine and pump integrated on acommon shaft in a cartridge barrel casingcommon shaft in a cartridge barrel casing
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Hydraulic CentrifugalHydraulic Centrifugal
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Hydraulic Centrifugal SubseaHydraulic Centrifugal Subsea
PumpPump
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TwinTwin--ScrewScrew
500 HP
125,000 BPD@1925 RPMVFD to 2300 RPM
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TwinTwin--Screw: ScrewsScrew: Screws
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TwinTwin--Screw: ScrewsScrew: Screws
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Twin-Screw: Screws in Pump Case
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TwinTwin--Screw: MaintenanceScrew: Maintenance
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Twin-Screw: Liner in Pump Case
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TwinTwin--Screw: Timing GearsScrew: Timing Gears
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MPP DrivesMPP Drives
Usually Motors withUsually Motors with ASDsASDs, especially for Positive, especially for Positive
Displacement Pumps (PCPs and TwinDisplacement Pumps (PCPs and Twin--Screws)Screws)
Engines (Natural Gas, Diesel)Engines (Natural Gas, Diesel)
Hydraulic TurbinesHydraulic Turbines
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General ApplicationsGeneral Applications
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Upstream ApplicationsUpstream Applications
Eliminate Flaring at Reduced CostEliminate Flaring at Reduced Cost Reduce Backpressure at WellheadReduce Backpressure at Wellhead
and Increase Production at Wellheadand Increase Production at Wellhead
Pump Gas & Liquid Mixtures up toPump Gas & Liquid Mixtures up to100% GVF (usually designed for100% GVF (usually designed forspecific time periods)specific time periods)
Reduced Installed CostReduced Installed Cost vsvs TraditionalTraditionalSystemsSystems
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Downstream ApplicationsDownstream Applications
Flare KO DrumsFlare KO Drums
Any Highly Gaseous Liquid StreamAny Highly Gaseous Liquid Stream Replace Centrifugal Pumps that HaveReplace Centrifugal Pumps that Have
Cavitation Problems Due to ExcessiveCavitation Problems Due to ExcessiveGasGas
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Advantages and DisadvantagesAdvantages and Disadvantages
of Different Types of MPPsof Different Types of MPPs
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ESPsESPs
GENERAL CHARACTERISTICS OF MULTIPHASE PUMPS
ESPs
PUMP ADVANTAGES DISADVANTAGES
Electric SubmersiblePumps (ESPs)
Rotodynamic
Traditionally down-hole andsubmersible, but can be used on the
surface If solids, potential erosion
Primarily UpstreamApplications Good for low viscosity liquids Cant handle higher viscosities
Speed 3600 rpm, Flowrates to 200,000BPD No higher than 65% GVF
Low cost High shear - potential emulsions
Can handle higher temperatures Installed Units: Normal MTBF of 3 years
Gas conditioners to 40% (65%) GVF
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PCPsPCPs
GENERAL CHARACTERISTICS OF MULTIPHASE PUMPS
PCPs
PUMP ADVANTAGES DISADVANTAGES
Progressing Cavity
(PCPs)PD Down-hole, submersible or surface Elastomer problems above 300 F
Upstream orDownstreamApplications Handles some solids Contacting rotor and stator
1450 PSI differentials Can't run dry
Speed: 1800 rpmFlowrates: up to 11,000 BPD
Can run higher viscositiesRelatively low shear
GVF 35% (100%)
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HelicoHelico--AxialsAxials
GENERAL CHARACTERISTICS OF MULTIPHASE PUMPS
Helico-Axials
PUMP ADVANTAGES DISADVANTAGES
Helico-Axial
Rotodynamic Down-hole, surface, or submersible If solids, potential for erosion?
Upstream orDownstream High speed: 4000-6800 rpm High sheer
Flowrates up to 560,000 BPD
Differential Pressures up to 1125 psi
Can achieve up to 100% GVF
TwinTwin--ScrewsScrews
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TwinTwin-ScrewsScrewsGENERAL CHARACTERISTICS OF MULTIPHASE PUMPS
Twin-Screws
PUMP ADVANTAGES DISADVANTAGES
Twin-ScrewPD
Surface, down-hole (incommercialization by one supplier), orsubmersible (in commercialization) Surface Pump with 4 mechanical seals
Upstream orDownstream
Speed: Low to high speedFlowrates: up to 440,000 BPD (surfacepumps)
Can achieve up to 100% GVF fordesigned time periods
Can run higher viscosities
Can run high temperatures
Low shear
Low NPSHr
Can run dry, non-contacting rotor andstator
1400 psig differentials
Particulates to 0.5 wt. %
S f
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Specific Applications bySpecific Applications by
ChevronChevron
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Sample List of Chevron ApplicationsSample List of Chevron Applications
Texas: HumbleTexas: HumbleSurface TwinSurface Twin--ScrewScrew
Indonesia: Minas andIndonesia: Minas and DuriDuriSurface TwinSurface Twin--ScrewScrew
30 to 100% GVF30 to 100% GVF
Chad: Various FieldsChad: Various FieldsSurface TwinSurface Twin--ScrewsScrews
38% to 56% GVF38% to 56% GVF
Great Britain: CaptainGreat Britain: CaptainHydraulic DriveHydraulic Drive HelicoHelico--AxialAxial
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Sample List of Chevron ApplicationsSample List of Chevron Applications
Venezuela:Venezuela: BoscanBoscan -- Surface TwinSurface Twin--ScrewsScrews
40% GVF40% GVF
Venezuela:Venezuela: HamacaHamaca -- DownDown--hole PCPshole PCPs
-- Surface TwinSurface Twin--ScrewsScrews
92% GVF92% GVF
California: Midway SunsetCalifornia: Midway Sunset -- Surface TwinSurface Twin--ScrewsScrews
59 to 90% GVF59 to 90% GVF
California: Midway SunsetCalifornia: Midway Sunset -- Surface TwinSurface Twin--ScrewScrew
-- Charge to heaterCharge to heater treatertreater
-- Slugs of 100% GasSlugs of 100% Gas
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HumbleHumbless TwinTwin--Screw PumpScrew Pump
Indonesia LOSF Multiphase PumpsIndonesia LOSF Multiphase Pumps
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Collect and boost 95% GVF
Stream to Eliminate Flaring
Indonesia LOSF Multiphase PumpsIndonesia LOSF Multiphase Pumps
Indonesia: Light Oil SteamIndonesia: Light Oil Steam
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60,000 BPD
250 hp motor, 4 poles
460V VFD
API plan 32 seal flush
Enlarged bearing
housing
Air-cooling for bearing
lube oil cooling; with
blower installed at
coupling hub Borided screws
6 chambers screws
Stellite 12 welded on
liner ID
Indonesia: Light Oil SteamIndonesia: Light Oil Steam
Flood (LOSF) TwinFlood (LOSF) Twin--ScrewsScrews
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Natural sand build-up oninlet section
No evidence of sand
accumulation inside liner
Stellite Liner: 65 HRC
Indonesia: Twin-Screws and Sand
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California: Midway Sunset TwinCalifornia: Midway Sunset Twin--ScrewScrew
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Chad: TwinChad: Twin--ScrewsScrews
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California: Multiphase Pump SolutionCalifornia: Multiphase Pump Solution
).
Discharge
Piping
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TwinTwin--Screw: Subsea PumpScrew: Subsea Pump
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TwinTwin--Screws and ParticulateScrews and Particulate
C B T h l
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Current Best TechnologyCurrent Best Technology
TwinTwin--Screw: ScrewsScrew: Screws nitridednitrided oror boridedborided to depthto depthof 0.003of 0.003
TwinTwin--Screw: CasingScrew: Casing designed with replaceabledesigned with replaceable
linerliner
TwinTwin--Screw: LScrew: Liner coated with tungsten carbideiner coated with tungsten carbide
oror StelliteStellite 1212
HelicoHelico--Axial impellers coated withAxial impellers coated with MetcoMetco SUMESUME
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Mechanical SealsMechanical Seals
Use correct API flush planUse correct API flush planUse correct seal facesUse correct seal faces
Hard Particulate: hard face vs. hardHard Particulate: hard face vs. hardfaceface
Softer Particulate or none: carbon vs.Softer Particulate or none: carbon vs.
tungsten or silicon carbidetungsten or silicon carbide
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Multiphase production and the installation costs ofMultiphase production and the installation costs of
the traditional system demands simpler andthe traditional system demands simpler and
smaller installation and a more cost effectivesmaller installation and a more cost effectiveproduction system.production system.
Twin Screw multiphase pumping application inTwin Screw multiphase pumping application in
heavy oil steam flood in sandy environment isheavy oil steam flood in sandy environment is
proven to be feasible.proven to be feasible.
To date, operational reliability satisfies if notTo date, operational reliability satisfies if not
exceeds acceptable industrial standard.exceeds acceptable industrial standard.
Indonesian ExperienceIndonesian Experience
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Sample EconomicsSample Economics
M l i h I ll i Ad
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Multiphase Installation AdvantagesMultiphase Installation Advantages
MPP
Wellhead
MultiphaseLineWellhead
Gas line
Oil line
MultiphaseTraditional Separation
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MULTIPHASE BOOSTINGMULTIPHASE BOOSTING
Pressure
Flowrate
Boosted WHFP
Unboosted WHFP
Flowline losses
P
Q
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Typical Production IncreasesTypical Production Increases
Production Increase Due toProduction Increase Due to
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Production Increase Due toProduction Increase Due to
Reduced Backpressure on WellsReduced Backpressure on Wells
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DuriDuri Production Increases with MPPsProduction Increases with MPPs
Multiphase Pump Field Trial - Duri Field 1998
Oil Production at Duri Area 6 SouthEast Quadran
8,000
9,000
10,000
11,000
12,000
13,000
14,000
98/07/01
98/07/07
98/07/13
98/07/19
98/07/25
98/07/31
98/08/06
98/08/12
98/08/18
98/08/24
98/08/30
98/09/05
98/09/11
98/09/17
98/09/23
98/09/29
98/10/05
98/10/11
98/10/17
98/10/23
98/10/29
98/11/04
98/11/10
98/11/16
98/11/22
98/11/28
98/12/04
98/12/10
98/12/16
98/12/22
Oil
Production
(18d
eg
API),
BOPD
Twinscrew MPP Test
Oct 5 - Nov 6Heli coaxial MPP test
Nov 23 - Dec 20
Reasons to Use MPPs Offshore (orReasons to Use MPPs Offshore (or
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Reasons to Use MPPs Offshore (orReasons to Use MPPs Offshore (or
Onshore)Onshore)No need to have separation vesselNo need to have separation vessel
One MPP vs. liquid pump and gasOne MPP vs. liquid pump and gascompressorcompressor
Smaller installed footprint (especially forSmaller installed footprint (especially foroffshore rigs)offshore rigs)
Less weight (especially for offshore rigs)Less weight (especially for offshore rigs)
One COMBINED liquid/gas line (especiallyOne COMBINED liquid/gas line (especially
for offshore rigs and Subsea installations)for offshore rigs and Subsea installations)
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Subsea DevelopmentsSubsea Developments
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Multiphase Pumps: Subsea EffortsMultiphase Pumps: Subsea Efforts
TwinTwin--Screw:Screw: One Commercial ApplicationOne Commercial Application
HelicoHelico--Axial:Axial: Approximately 25 ApplicationsApproximately 25 Applications
Hydraulic TurbineHydraulic Turbine HelicoHelico--Axial:Axial: Several in NorthSeveral in North
SeaSea
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SummarySummary
MPPs have been used to pump multiphaseMPPs have been used to pump multiphase
fluids that have:fluids that have:
-- Temperatures from ambient to 300FTemperatures from ambient to 300F
-- Suction pressures from 6 psigSuction pressures from 6 psig
-- Discharge pressures to 2000 psigDischarge pressures to 2000 psig
-- GVFGVFss to 100% (for designed time periods)to 100% (for designed time periods)
-- Particulate concentrations to 0.5 wt.%Particulate concentrations to 0.5 wt.%-- Almost any viscosityAlmost any viscosity
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SummarySummary
MPPs have been used to:MPPs have been used to:
-- Eliminate Flaring at Reduced CostEliminate Flaring at Reduced Cost-- Reduce Backpressure at WellheadReduce Backpressure at Wellhead
-- Increase ProductionIncrease Production
-- Pump with Low Shear & DecreasedPump with Low Shear & DecreasedEmulsion FormationEmulsion Formation
-- Pump with Low NPSHAPump with Low NPSHA
-- Reduce Installed Cost and MaintenanceReduce Installed Cost and MaintenanceCostsCosts vsvs Traditional SystemsTraditional Systems
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The EndThe End
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