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Calgary Pump Symposium 2013
Axel Jäschke Technical Director - ITT Bornemann USA Office: Mobile: +1 832 320 2500 +49 170 576 4115 +1 832 293 7935
Twin Screw Technology General Overview and Multiphase Boosting 11/2013
Calgary Pump Symposium 2013
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Calgary Pump Symposium 2013 Bio Axel Jäschke Axel Jäschke, currently the technical director of ITT Bornemann USA, has been involved with twin-screw pumps for various applications in the oil/gas industries during the past 15 years. His technical experience in multi-phase boosting technologies had brought him to various projects in Columbia, Venezuela, Russia, Abu Dhabi and Thailand. As head of the R&D department for Subsea Boosting he was involved in several new developments and patents regarding multiphase boosting during the last years. Based out of Houston, he is responsible for the development of new, US based multiphase boosting solutions. A Graduate Mechanical Engineer from University of Hanover, Germany, Axel was also involved in the design and management of various tank farm projects in Europe prior to starting with Bornemann in 1998.
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Calgary Pump Symposium 2013 Content
Pumping Principles: Centrifugal Pumps (CFP) and TSP Why Twins Screw Pumps TSP Performance and NPSH TSP Applications and Operating Range Multiphase Boosting – Considerations and Solution Typical Installations
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Calgary Pump Symposium 2013
A Pump is a Pump ….
but some pumps are different.
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Calgary Pump Symposium 2013 Twin Screw Pumps
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Calgary Pump Symposium 2013 TSP Multiphase Systems
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Calgary Pump Symposium 2013
Basic pumping principles ...
Centrifugal Pumps (CFP) and Twin Screw Pumps (TSP).
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Calgary Pump Symposium 2013 Pumping Principles
Hydrodynamic Pumps = Centrifugal Pumps (CFP) Adding KINETIC ENERGY to the fluid and converting it into flow (and pressure)
depending on the required system pressure. Hydrostatic Pumps = Twin Screw Pump (TSP) Moving a fixed VOLUME against the given system pressure. (Positive Displacement – PD)
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Calgary Pump Symposium 2013 CFP Power Flow Relation Hydrodynamic Pumps: Flow is depending on Pressure (or head). Power is a relation of pump speed and efficiency at operating point.
1660rpm
1455rpm
1780rpm
0
10
20
30
40
50
60
70
80
90
100
0 2000800400 1200 1600 2400 2800 3200
flow
head
PUMP PERFORMANCE CURVE
0
10
20
30
40
Pow
er1660rpm
1455rpm
1780rpm
BOP
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Calgary Pump Symposium 2013 Centrifugal Pump Consideration o Good Peak Efficiency at BOP (best operating point)
o Low Cost
o Sensitive to Gas, High Fluid Viscosities, changing Fluid Density
o Sensitive to low Inlet-Pressure and Cavitation
o Not operating at BOP can lead to reduced pump lifetime
o Limited Overall Efficiency
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Calgary Pump Symposium 2013 Why Twin Screw Pumps
Handles almost all types of fluids – conventional and unconventional Fluid density does not influence pump performance – self priming Very wide operating range at overall high efficiency Very low NPSH requirements and not sensitive to vapor and cavitation Very good flow control
Higher Cost compared to Centrifugal Pumps
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Calgary Pump Symposium 2013
Twin Screw Pump (TSP) Performance.
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Calgary Pump Symposium 2013 Twin Screw Pump – Flow Inside Pump
Inlet
Outlet
Moves Fluid in Closed Chambers
Two Rotors with Conveyer Screws
Typical Twin Screw Pump
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Calgary Pump Symposium 2013 Twin Screw Pump
Casing Liner Shafts Screws
No Contact between Screw and Screw and Screws and Liner / Casing
No Contact à small Gaps!
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Calgary Pump Symposium 2013 Flow and Backflow inside the Rotor
Liner
Shaft
“Flow” Direction
Direction of Rotation
Inlet, pin Outlet, pout
Screw “Flow” Direction
Positive Flow Backflow
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Calgary Pump Symposium 2013 TSP Performance – Flow Rate Capacity depends on:
Chamber Size + number of screw Speed Differential Pressure (Dp) Viscosity Gap Design (screws, liner/casing)
Total Flowrate = Volumtric Flow – Backflow Qtotal = Qvolumetric – Qbackflow
Qbackflow » Dp; Viscosity; Gap Design
Flow Rate Q à
Diff
eren
tial P
ress
ure
Dp à
Qbackflow
Qvolumetric
Qtotal
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Calgary Pump Symposium 2013 TSP Performance – Viscosity Capacity depends on:
Chamber Size + number of screw Speed Differential Pressure Viscosity, Gas Content Gap Design (screws, liner/casing)
Less Backflow with higher fluid Viscosity! Less Backflow with Gas.
Flow Rate Q à
Diff
eren
tial P
ress
ure
Dp à
Low Viscosity
High Viscosity and Gas
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Calgary Pump Symposium 2013 TSP Performance – Power Consumption Power Consumption depends on:
Speed Differential Pressure Viscosity
Shaft Power = Hydraulic Power + Friction Pshaft = Phydraulic + Pfriction
Pfriction » speed; viscosity
Phydraulic » speed * differential pressure
Flow Rate Q à Shaft Power P à
Diff
eren
tial P
ress
ure
Dp à
Pshaft
ConstantSpeed
Flow
Pfrict.
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Calgary Pump Symposium 2013 TSP Performance – Power Consumption
Flow Rate is directly proportional to speed.
Power Consumption depends on speed and differential pressure.
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Calgary Pump Symposium 2013 Typical Twin Screw Performance Diagram
400 HP 300 HP 200 HP 100 HP
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Calgary Pump Symposium 2013
Performance Range,
Parallel Installation and
Installation in Series
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Calgary Pump Symposium 2013 Overall Operating Range of our TSPs
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Calgary Pump Symposium 2013 Pumps in Parallel psi bar
2.180 150
2.110 145
2.030 140
1.960 135
1.890 130
1.820 125
1.740 120
1.670 115
1.600 110
1.530 105
1.450 100
1.380 95
1.310 90
1.240 85
1.160 80
1.090 75
1.015 70
945 65
870 60
800 55
725 50
655 45
580 40
510 35
435 30
365 25
290 20
220 15
145 10
75 5
0 00 100 200 300 400 500 600 700 800 900 1.000 1.100 1.200 1.300 1.400 1.500 1.600 1.700 1.800 1.900 2.000 2.100 2.200 2.300 2.400 2.500 m 3/h0 16.000 31.000 46.000 61.000 76.000 92.000 107.000 122.000 137.000 152.000 168.000 183.000 198.000 213.000 228.000 244.000 259.000 274.000 289.000 304.000 320.000 335.000 350.000 365.000 380.000 BPD0 500 1.000 1.400 1.900 2.300 2.800 3.200 3.700 4.100 4.600 5.100 5.500 6.000 6.400 6.900 7.300 7.800 8.200 8.700 9.100 9.600 10.100 10.500 11.000 11.400 GPM
Pump Flow Rate
Pum
p H
ead
/ Pum
p D
iffer
entia
l Pre
ssur
e
9-H
DP
9-50
9-60
9-75
9-100
9-HC
Why Pumps in parallel? - Optimized Efficiency - Flexibility = Efficiency - Redundancy = Availability
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Calgary Pump Symposium 2013 Pumps in parallel psi bar
2.180 150
2.110 145
2.030 140
1.960 135
1.890 130
1.820 125
1.740 120
1.670 115
1.600 110
1.530 105
1.450 100
1.380 95
1.310 90
1.240 85
1.160 80
1.090 75
1.015 70
945 65
870 60
800 55
725 50
655 45
580 40
510 35
435 30
365 25
290 20
220 15
145 10
75 5
0 00 100 200 300 400 500 600 700 800 900 1.000 1.100 1.200 1.300 1.400 1.500 1.600 1.700 1.800 1.900 2.000 2.100 2.200 2.300 2.400 2.500 m 3/h0 16.000 31.000 46.000 61.000 76.000 92.000 107.000 122.000 137.000 152.000 168.000 183.000 198.000 213.000 228.000 244.000 259.000 274.000 289.000 304.000 320.000 335.000 350.000 365.000 380.000 BPD0 500 1.000 1.400 1.900 2.300 2.800 3.200 3.700 4.100 4.600 5.100 5.500 6.000 6.400 6.900 7.300 7.800 8.200 8.700 9.100 9.600 10.100 10.500 11.000 11.400 GPM
Pump Flow Rate
Pum
p H
ead
/ Pum
p D
iffer
entia
l Pre
ssur
e
9-60 9-60 9-60 9-60
Here the frame size 9-60 has been selected. - 4 x 33% capacity
- Redundancy = 1 x 33%
- Flexibility ... less flow? Run less pumps.
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Calgary Pump Symposium 2013 Pumps in Series psi bar
2.180 150
2.110 145
2.030 140
1.960 135
1.890 130
1.820 125
1.740 120
1.670 115
1.600 110
1.530 105
1.450 100
1.380 95
1.310 90
1.240 85
1.160 80
1.090 75
1.015 70
945 65
870 60
800 55
725 50
655 45
580 40
510 35
435 30
365 25
290 20
220 15
145 10
75 5
0 00 100 200 300 400 500 600 700 800 900 1.000 1.100 1.200 1.300 1.400 1.500 1.600 1.700 1.800 1.900 2.000 2.100 2.200 2.300 2.400 2.500 m 3/h0 16.000 31.000 46.000 61.000 76.000 92.000 107.000 122.000 137.000 152.000 168.000 183.000 198.000 213.000 228.000 244.000 259.000 274.000 289.000 304.000 320.000 335.000 350.000 365.000 380.000 BPD0 500 1.000 1.400 1.900 2.300 2.800 3.200 3.700 4.100 4.600 5.100 5.500 6.000 6.400 6.900 7.300 7.800 8.200 8.700 9.100 9.600 10.100 10.500 11.000 11.400 GPM
Pump Flow Rate
Pum
p H
ead
/ Pum
p D
iffer
entia
l Pre
ssur
e
9-60 9-60
What to do if start up pressure might be (sometimes?) higher? Run the pumps in series!
TSP TSP
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Calgary Pump Symposium 2013 TSP Applications Application Special Process Requirements Asphalt and Bitumen High viscosity, high temperature, low NPSH
Vacuum Residue Oil Very low NPSH, various viscosities
Liquid Sulfur High temperature, high viscosity
Polymer Changing viscosity and wide capacity-range
Loading / Unloading Different viscosities, wide capacity-range, temporary gas content, low NPSH
Stripping High gas content, wide viscosity- and capacity-Range
Tank Farm Operation Wide viscosity- and capacity-range, good control of flow rates, temporary gas handling
Pipeline Transport Wide, high viscosity-range, adjustable reliable capacity at changing system pressures
Marine (Fluid handling on Tankers) Wide viscosity- and capacity-range, good control of flow rates, temporary gas handling
Food (sanitary) Beverage, Dairy (Yoghurt, Cheese Curds), Meat, Chocolate, Cosmetics, etc.
Wide range of viscosities, flow rates. Low NPSH and low shear required. Cleaning and sterilisation of pump and pipeline with the same pump (CIP, SIP)
Multiphase / Oil and Gas Production Very much changing operating conditions, slug-flow, gas
Wet Gas Compression / Vapour Recovery Up to 99.999% gas, changing pressures and flow rates
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Calgary Pump Symposium 2013
Multiphase Boosting
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Calgary Pump Symposium 2013 Multiphase Boosting
Control the OIL & GAS Well Production by
controlling the Wellhead Pressure and
overcoming the Pipeline Backpressure .
Improve the Oil Production!
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Calgary Pump Symposium 2013 Multiphase Production
Reservoir
Gathering Station
Oil Field
MPC
MPC Multiphase Pump / Compressor
Separator
MPCMPC
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Calgary Pump Symposium 2013 Multiphase Mixture
GAS
OIL
MULTIPHASE
Multiphase includes a wide range of hydrocarbon compositions, CO2, H2S, N2, water and other components. They all together are influencing the physical phases (gas, multiphase, liquid) and the total volume, which will be present at the pump at the required pressure and temperature.
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Calgary Pump Symposium 2013 Multiphase Oil and Gas Mixture
Gas Liquid
Gas Oil Ratio (GOR): Gas / Liquid @ standard condition
Gas Volume Fraction (GVF): Gas / (Oil+Gas) @ inlet conditions
Required Pump
Capacity
Oil produced offshore is transported through pipelines as a mixture of liquid and gas. The amount of gas is given in standard volume compared to the oil content (GOR) or in percentage of the total flow (GVF).
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Calgary Pump Symposium 2013 Multiphase Slug Flow Oil produced offshore is transported through pipelines as a complex mixture of oil, gas and water. One flow regime is known as slug flow, in which liquid flows intermittently along the pipes. It is highly complex and instable, difficult to predict. It depends on flow velocity, gas content, pipeline position, etc.. Slug flow and gas pockets have to be handled by Multiphase Pumps.
Flow regime and Slug flow slugflow probability inside pipeline
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Calgary Pump Symposium 2013 Multiphase Production
Actual Volume Flow (Oil+Gas)
Pipeline Performance
pout
pin
potential production
natural production
Pre
ssur
e
Gas + Oil Flow
MPP
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Calgary Pump Symposium 2013 Technical Solution (TSP) Liquid Separation and Liquid Hold Up. Controlled Liquid Circulation.
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Calgary Pump Symposium 2013 System Solution Plug & Pump Systems, combining Pumps and Drives with Control Equipment and Process Know How!
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Calgary Pump Symposium 2013 Multiphase Boosting Multiphase Boosting is an approved technology, based on different pump types and provided by various vendors. More than 2000 installations are
worldwide in operation – on shore, off shore and subsea.
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Calgary Pump Symposium 2013
Multiphase Boosting
some typical installations.
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Calgary Pump Symposium 2013 Single Well and Casing Gas
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Calgary Pump Symposium 2013 Arctic Conditions
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Calgary Pump Symposium 2013 Installation in Series
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Calgary Pump Symposium 2013 Wet Gas Boosting
source: Murray Milbrandt, CNRL Canada source: Murray Milbrandt, CNRL Canada
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Calgary Pump Symposium 2013 Subsea
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Calgary Pump Symposium 2013 Subsea Vacuum Cleaner
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Calgary Pump Symposium 2013
Still ....
a Pump is a Pump ….
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Calgary Pump Symposium 2013
Questions?