2008 Texas A&M University 24th International Pump Users Symposium

Multiphase Pumping

By: Bob Heyl

Presentation Contents
Definitions and Criteria: Multiphase Flow, Gas Volume (Void) Fraction (GVF) and Criteria Types of Multiphase Pumps General Applications Advantages and Disadvantages of Different Types of MPPs Specific Applications Sample Economics Reasons to Use Offshore Subsea Developments

Definitions and Criteria

What is Multiphase Flow?

Flow consisting of at least: - Liquid - Gas (But often high volumes of gas, mixed with oil, water, and solids)

Mutiphase Pump Criteria

Gas Volume (Void) Fraction [GVF] at Suction Conditions measured in % Particulate - measured in % Maximum Particle Size and Distribution Liquid Viscosity Temperature Gas Composition Suction Pressure Discharge Pressure Flow Rate Potential for Slug Flow

GVF for Gas-Oil-Water Mixtures

Need: Oil Rate in BPD Gas Rate in SCFD Water Rate in BPD Pump Inlet Pressure in PSIG Pump Discharge Pressure in PSIG

GVF for Gas-Oil-Water Mixtures

Actual BPD of Gas = (ACFD) (7.481 gal/cu ft)(1 bbl/42 gal) = (ACFD) (0.178 bbl/cu ft.) where ACFD = [(SCFD) (14.7 psia) (MPP Inlet Temp F+460) (Z)]/[(MPP Inlet Press psia) (520R)]
where Z is often 1.0

GVF for Gas-Oil-Water Mixtures

BPD = (Actual BPD of Gas + BPD of Oil + BPD of Water ) And therefore GVF = (Actual BPD of Gas)/(BPD)

Types of Multiphase Pumps

Types of Artificial Lift and Multiphase Pumps (MPPs)

Electric Submersible Pumps (ESPs) Rotordynamic Progressive Cavity Pumps (PCPs) - Positive Displacement Helico-Axial Pumps Rotordynamic Centrifugal Twin-Screw Positive Displacement

Electric Submersible Pumps (ESPs)

Progressing Cavity Pumps (PCPs)

Progressing Cavity Pumps (PCPs)

Helico-Axial

MPP 7-stage helico-axial 125,000 bpd 700 hp motor w/ VFD (3600 rpm)

Helico-Axial Pump

MECHANICAL SEAL BEARINGS

HelicoAxial Rotor Assembly

Buffer Tank

BUFFER TANK INLET BUFFER TANK OUTLET

BUFFER TANK DRAIN

Helico-Axial Subsea Pump

Hydraulic Centrifugal
Special design of helico-axial pump with a multistage hydraulic turbine fed by a remote high pressure pump Turbine and pump integrated on a common shaft in a cartridge barrel casing

Hydraulic Centrifugal

Hydraulic Centrifugal Subsea Pump

Twin-Screw

500 HP 125,000 BPD@1925 RPM VFD to 2300 RPM

Twin-Screw: Screws

Twin-Screw: Screws

Twin-Screw: Screws in Pump Case

Twin-Screw: Maintenance

Twin-Screw: Liner in Pump Case

Twin-Screw: Timing Gears

MPP Drives
Usually Motors with ASDs, especially for Positive Displacement Pumps (PCPs and Twin-Screws) Engines (Natural Gas, Diesel)

Hydraulic Turbines

General Applications

Upstream Applications
Eliminate Flaring at Reduced Cost Reduce Backpressure at Wellhead and Increase Production at Wellhead Pump Gas & Liquid Mixtures up to 100% GVF (usually designed for specific time periods) Reduced Installed Cost vs Traditional Systems

Downstream Applications
Flare KO Drums Any Highly Gaseous Liquid Stream Replace Centrifugal Pumps that Have Cavitation Problems Due to Excessive Gas

Advantages and Disadvantages of Different Types of MPPs

ESPs
GENERAL CHARACTERISTICS OF MULTIPHASE PUMPS ESPs
PUMP Electric Submersible Pumps (ESPs) Rotodynamic Primarily Upstream Applications ADVANTAGES Traditionally down-hole and submersible, but can be used on the surface Good for low viscosity liquids Speed 3600 rpm, Flowrates to 200,000 BPD Low cost Can handle higher temperatures Gas conditioners to 40% (65%) GVF DISADVANTAGES

If solids, potential erosion Cant handle higher viscosities No higher than 65% GVF High shear - potential emulsions Installed Units: Normal MTBF of 3 years

PCPs
GENERAL CHARACTERISTICS OF MULTIPHASE PUMPS PCPs
PUMP Progressing Cavity (PCPs) PD Upstream or Downstream Applications ADVANTAGES DISADVANTAGES

Down-hole, submersible or surface

Elastomer problems above 300 F

Handles some solids 1450 PSI differentials Speed: 1800 rpm Flowrates: up to 11,000 BPD Can run higher viscosities Relatively low shear GVF 35% (100%)

Contacting rotor and stator Can't run dry

Helico-Axials
GENERAL CHARACTERISTICS OF MULTIPHASE PUMPS Helico-Axials
PUMP ADVANTAGES DISADVANTAGES

Helico-Axial Rotodynamic Upstream or Downstream

Down-hole, surface, or submersible High speed: 4000-6800 rpm Flowrates up to 560,000 BPD Differential Pressures up to 1125 psi Can achieve up to 100% GVF

If solids, potential for erosion? High sheer

Twin-Screws
GENERAL CHARACTERISTICS OF MULTIPHASE PUMPS Twin-Screws
PUMP Twin-Screw PD Upstream or Downstream ADVANTAGES Surface, down-hole (in commercialization by one supplier), or submersible (in commercialization) Speed: Low to high speed Flowrates: up to 440,000 BPD (surface pumps) Can achieve up to 100% GVF for designed time periods Can run higher viscosities Can run high temperatures Low shear Low NPSHr Can run dry, non-contacting rotor and stator 1400 psig differentials Particulates to 0.5 wt. % DISADVANTAGES

Surface Pump with 4 mechanical seals

Specific Applications by Chevron

Sample List of Chevron Applications

Texas: Humble Surface Twin-Screw Indonesia: Minas and Duri Surface Twin-Screw 30 to 100% GVF Chad: Various Fields Surface Twin-Screws 38% to 56% GVF Great Britain: Captain Hydraulic Drive Helico-Axial

Sample List of Chevron Applications

Venezuela: Boscan - Surface Twin-Screws 40% GVF Venezuela: Hamaca - Down-hole PCPs - Surface Twin-Screws 92% GVF California: Midway Sunset - Surface Twin-Screws 59 to 90% GVF California: Midway Sunset - Surface Twin-Screw - Charge to heater treater - Slugs of 100% Gas

Humbles Twin-Screw Pump

Indonesia LOSF Multiphase Pumps

MPP Primary Functions: Collect and boost 95% GVF Stream to Eliminate Flaring

Indonesia: Light Oil Steam Flood (LOSF) Twin-Screws

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: Twin-Screws and Sand

Natural sand build-up on inlet section No evidence of sand accumulation inside liner Stellite Liner: 65 HRC

California: Midway Sunset Twin-Screw

Chad: Twin-Screws

California: Multiphase Pump Solution

Discharge Piping

).

Twin-Screw: Subsea Pump

Twin-Screws and Particulate

Current Best Technology

Twin-Screw: Screws nitrided or borided to depth of 0.003 Twin-Screw: Casing designed with replaceable liner Twin-Screw: Liner coated with tungsten carbide or Stellite 12 Helico-Axial impellers coated with Metco SUME

Mechanical Seals
Use correct API flush plan Use correct seal faces Hard Particulate: hard face vs. hard face Softer Particulate or none: carbon vs. tungsten or silicon carbide

Indonesian Experience
Multiphase production and the installation costs of the traditional system demands simpler and smaller installation and a more cost effective production system. Twin Screw multiphase pumping application in heavy oil steam flood in sandy environment is proven to be feasible. To date, operational reliability satisfies if not exceeds acceptable industrial standard.

Sample Economics

Multiphase Installation Advantages

Traditional Separation
Gas line
Wellhead Wellhead

Multiphase
Multiphase Line

Oil line

MPP

MULTIPHASE BOOSTING

Pressure Flowline losses

P Q

Boosted WHFP

Unboosted WHFP Flowrate

Typical Production Increases

Production Increase Due to Reduced Backpressure on Wells

O il P ro d u ctio n (18 d eg AP I), BO P D

10,000 11,000 12,000 13,000 14,000 8,000 9,000

Multiphase Pump Field Trial - Duri Field 1998 Oil Production at Duri Area 6 SouthEast Quadran

Twinscrew MPP Test O ct 5 - Nov 6 Helicoaxial MPP test Nov 23 - Dec 20

Duri Production Increases with MPPs

98 /0 7 9 8 /0 1 /0 7 9 8 /0 7 /0 7 9 8 /1 3 /0 7 9 8 /1 9 /0 7 9 8 /2 5 /0 7 9 8 /3 1 /0 8 9 8 /0 6 /0 8 9 8 /1 2 /0 8 9 8 /1 8 /0 8 9 8 /2 4 /0 8 9 8 /3 0 /0 9 9 8 /0 5 /0 9 9 8 /1 1 /0 9 9 8 /1 7 /0 9 9 8 /2 3 /0 9 9 8 /2 9 /1 0 9 8 /0 5 /1 0 9 8 /1 1 /1 0 9 8 /1 7 /1 0 9 8 /2 3 /1 0 9 8 /2 9 /1 1 9 8 /0 4 /1 1 9 8 /1 0 /1 1 9 8 /1 6 /1 1 9 8 /2 2 /1 1 9 8 /2 8 /1 2 9 8 /0 4 /1 2 9 8 /1 0 /1 2 9 8 /1 6 /1 2/2 2

Reasons to Use MPPs Offshore (or Onshore)

No need to have separation vessel One MPP vs. liquid pump and gas compressor Smaller installed footprint (especially for offshore rigs) Less weight (especially for offshore rigs) One COMBINED liquid/gas line (especially for offshore rigs and Subsea installations)

Subsea Developments

Multiphase Pumps: Subsea Efforts

Twin-Screw: One Commercial Application Helico-Axial: Approximately 25 Applications Hydraulic Turbine Helico-Axial: Several in North Sea

Summary
MPPs have been used to pump multiphase fluids that have: - Temperatures from ambient to 300F - Suction pressures from 6 psig - Discharge pressures to 2000 psig - GVFs to 100% (for designed time periods) - Particulate concentrations to 0.5 wt.% - Almost any viscosity

Summary
MPPs have been used to: - Eliminate Flaring at Reduced Cost - Reduce Backpressure at Wellhead - Increase Production - Pump with Low Shear & Decreased Emulsion Formation - Pump with Low NPSHA - Reduce Installed Cost and Maintenance Costs vs Traditional Systems

The End