MULTIPHASE PUMP APPLICATION FOR PRODUCTION

ENHANCEMENT

Emiliano Maianti, Bonatti SpA

This paper was presented at the 14th Offshore Mediterranean Conference and Exhibition in Ravenna, Italy, March 27-29, 2019. It was
selected for presentation by OMC 2019 Programme Committee following review of information contained in the abstract submitted by
the author(s). The Paper as presented at OMC 2019 has not been reviewed by the Programme Committee.

ABSTRACT

After production startup on standard Oil , Lean and Rich Gas Fields, some of the reservoirs have
shown a continuous pressure decline that was affecting real production potential in many of the
wells, as the surface wellhead flowing pressures approached the network pressure. In this regard a
“do nothing” production forecast was calculated and the results were showing that many wells
would be most likely equalized with the flow line pressure within months, expecting significant
production losses due to the wells instability operating at critical condition, followed by eventual
shut ins that will jeopardize the original production targets. Moreover, the flow regime in the
pipeline network can create instability also in the hydrocarbons treatment process.
It is a common use to apply boosting solutions, able to work with low inlet pressure , improving
production and prolonging the useful life of each single reservoir system.
Common best practice are based on “compressor+separator” systems, mainly in presence of
multiphase fluids and several balance of plant components , increasing the complexity of every
operation and maintenance activity.
According to last technology improvement and operator experiences, applied to OEM solution,
today, multiphase pump applications are allowing to summarize all the following added values:

1) Possibility to apply multiphase pumps also with GVF value , close to 100%, working like “a
compressor”
2) Eliminate separators and balance of plant equipments
3) Shortage of mobilization time (saving time during installation phase)
4) Application of “No Flare” environmental approach

INTRODUCTION

The main purpose is to demonstrate , with an high complexity example , the real benefit of the
multiphase technology improvement. The exposed case is a real case. Customer and country
cannot be disclosed.

The example will included mainly:

 A number of gas and oil Wellsite facilities
 A number of gas gathering Manifolds
 Production pipeline
 A Central Processing Facility

The gathering Field system consist of manifolds. Each manifold site gathers typically more that 3
wells. The combined well flow is then sent on to processing facility, via the main gathering trunk
line. Some of the Field Manifolds also gather flows from other manifolds as well as from wells. The

1
figure 1 below illustrate the possible network configuration , showing also the different local
boosting systems installation sites.

Fig. 1 – Example of complex application

After a complete flow assurance analysis considering the network facilities for both fields the do
nothing calculated production performance will not guarantee the original production target and
may not even guarantee the minimum production for the facility continuous operation.

In this regard local boosting system has been strategically positioned in order to affect as many
wells as possible and increase the total production in a meaningful way.

The selected boosting system consisted of Multiphase Twin Screw Pumps

This paper will describe the required boosting system highlighting all the expected issues for an
immediate field installation.

TWIN-SCREW PUMPS DESCRIPTION AND FUNCTION PRINCIPLES

Since the start of commercial applications for multiphase pumps, their installations have increased
steadily. Today a number of manufacturers offer a widespread pump range in regard to flow rate
and pressure building capability, however, the foremost working principle still is the twin-screw
technology that is commonly attributed to the Archimedes' screw, also known by the name of
Archimedean screw or screw pump, which was an ancient machine used for transferring water
from a low-lying body of water into irrigation ditches.

Today the Twin-Screw multiphase pumps are used to transfer a volume of liquid (oil and water)
and gas from inlet to discharge. This is achieved by two rotors each carrying a set of two screws.
These screws are intermeshing and thereby forming locks or chambers, which, upon counter-
rotation of the rotors, are moving axially from inlet to discharge so the fluids are pushed out against
the backpressure of the downstream system. The assembly is designed to run without metal-to-

2
metal contact between the rotating members and inside the housing. Most pumps have a split inlet,
so that from every pump end the fluid is transferred to the middle, where the discharge is located.
Figure 2 shows the flow paths of the fluid on a rotor assembly.

Discharge

Drive
Gears Shaft

Suction

Fig. 2 - Twin-Screw Pump cut and cutaway and flow paths through a rotor assembly

A liner is inserted in the casing which, among other features, may be regarded as a wear element,
the liner and screw tips may be hard coated in order to offer a better wear resistance against
sediments and solid production.

The screws have a special flank profile, which is vital to minimize the backflow through the
clearances. The lathing process offers the possibility to have a decreasing pitch toward the
discharge end of the screws, thus making internal compression for a higher efficiency in
multiphase flow. The Pitch size determine the pump operating parameters, so the smaller the pitch
the higher the differential pressure the pump can provide (at lower rate) while a bigger pitch will
allow higher rate (at lower differential pressure). The plots presented on the figure 3 below illustrate
the pitch performance for a 600Kw pump and a 2.2Mw pump respectively.

Fig. 3 - Twin-Screw pumps performance and pitch selection.

As already described there is no metal-to-metal contact between the rotors, and the rotors and the
liner, so very small gaps do exist. This “clearance” must be sealed by liquid to enable an efficient
pumping process. This required sealing is achieved by separating the pumped liquid inside the
casing or downstream the pump to then recirculate it to the inlet.

3
During the pumping process heat is generated due to friction and compression of gas, that will be
eliminated through air coolers

MULTI-PHASE FLUID FLOW CONSIDERATIONS

The operation of multiphase pumps requires observing up and downstream flow scenarios, as well
as detailed knowledge of the entire pumping process in order to find the most suitable technical
design for a given scenario. Furthermore potential solids production has to be taken into account.

The multiphase flow may starts in the well down the hole and extends until the flow enters the first
stage of separation at the central process facilities. The flow scenario is fully transient and slugging
may occurs along the way. Under this scenario a pump design has to cope with gas volume
fractions between (GVF) 0 and 100 %, i.e. liquid or gas only. The further the distance from the
wellhead or manifold, the longer are the gas phases to be considered, consequently if a multiphase
pump is to be installed, then it should certainly be as close as possible to the fluid appearance at
surface, because of gas slugs are being (sometimes) considerably shorter, and the benefit of a
lower wellhead pressure will be maximized. However in order to minimize the foot print and
recurrent installations for single wells the ideal installation should be carried out at manifold level,
managing the flow pattern issues with a proper multiphase pump system installation.

The matter of the fact is that pumps are mainly designed to produce liquid, or liquid and gas but not
dry gas or (100 % GVF), because this would result in overheating and a potential “no flow”
scenario, due to a system shut-down. To this scope a compressors should be used instead,
however they will not be able to manage an increased amount of liquid for example when wells
must be produced with a high water cut. In this situation the pumps will provide a superior
advantage.

Consequently the primary idea to continuously operate multiphase pumps, to produce lean gas, is
to artificially reduce the GVF to a level than can be properly managed by the selected pump
system. This is possible with an internal and or external recirculating system specifically designed
to keep the pump under operation regardless the fluids flow composition.

The non-contacting characteristic of the screws and the flow paths inside the pumps allow some of
the pumped fluids to escape the pressure increase, getting back to the inlet side. This
unfortunately cannot be avoided but the potential liquid holdup will help the pump to cool down.
The manufacturers also use and recommend a downstream separated liquid source to prevent the
pump from dry running, as this would result in a system shut-down due to overheating. This liquid
may be separated either in an independent downstream (or upstream) vessel, or a pump casing
chamber at the outlet side of the pump. The separated liquid can be re-circulated as a constant
fraction in the range of 3 to 5 % of the pumps total capacity. This “operational assistance” slightly
decreases the pump’s efficiency, but the process temperature increase can be limited and local
overheating be avoided while produce a constant fluid flow with 100% Gas Volume Fraction.

SOLIDS AND SEDIMENT FLOW CONTROL

Sand production from oil and gas wells is a well-known challenge in the industry. Unconsolidated
hydrocarbon layers, as well as non-appropriate well-head pressure draw-down, among others, may
deliver a considerable contribution. The presence of solids represents a challenge for all kinds of
surface equipment, furthermore their presence on the re-circulation or potential back-flow losses
may create a continuous abrasive wear effect when recycled.

With the tight clearances between the intermeshing screws and the screws and the liner, twin-
screw pumps are an especially endangered kind of pumps. The abrasive wear opens up the gaps,
which are in the range of a couple of tenth of millimeters only and will lead into increased back flow
losses, which can hardly be compensated for a longer time by increasing the pump speed.

4
Consequently all the efforts must be concentrated and undertaken to remove reservoir solids
upstream of the multiphase pumps, simple single pots filtering packages has be implemented and
installed with success to eliminate any flowing particle bigger than 70 micros.

In addition to these circumstances it seems to be advisable applying surface hardening or coating

to the screw tips and liner bore, in order to further prolong the lifetime of a pump. In case of no
precaution in this regard the exchange of pump internals may become necessary after only a few
months. This unsustainable situation has led to a variety of measures to make the internal surfaces
more wear resistant, applying tungsten carbide to the screw tips and a hard chrome layer to the
liner bore. Similar consideration must be taken for proper material selection in case of CO2 and
H2S production.

MULTIPHASE TWIN-SCREW PUMPS SYSTEM DESIGN FOR UP TO 100% GVF

The most suitable multiphase pump system required for our purpose are the twin screw pumps,
already described as positive displacement machines that can work independently of density and
inlet pressure as well as backpressure and changes in GVF assisted by inlet separators and
internal recirculating system.

The system has been proved ideal for multiphase production (rich and lean gas) because it can
handle up to 100% GVF. During the life of the field, the multiphase flow can be controlled by
controlling the speed of the pumps, so it can manage a wide range of production scenarios. The
total volume produced through the pump is a function the required differential pressure.

The pumps systems have been designed to cope with slug flow with no impact on the operations,
high GVF as well as wet gas are handled with an integrated recirculation of liquids. The
compression heat is removed with the liquid recirculation, however for lean gas flow (100% GVF)
process coolers has been included.

Twin-screw pumps depend on liquid availability to seal the internal clearances and remove
compression and friction heat generated. Different technical solutions has been analyzed and to
overcome this issue a separation, storage and recirculation system of the produced liquid has been
designed. All the separators has been provided with an internal demister before the outlet to further
separate any residual liquid on the gas stream. In case of need the liquid can be also sourced
externally.

To this end the Twin-screw pumps essential components such as the cooler and the lubrication oil,
along with all the safety devises were complimented with secondary equipment to create a
complex system that, so far has been ensuring a continuous optimum performance of the installed
pumps. Two different scenarios has been considered, as such single and multiple pumps
installations have been properly designed and successfully installed at manifold level and close by
the central process facility.

The pumps installed in parallel have require special attention to split the upstream flow and
includes a general inlet separator to manage any potential slugs arriving from wells which are far
away while provide more liquid to the recirculating system in addition to the internal separator
vessel on every pump.

The basis of design for both configuration (3 pump in parallel are shown) are concentrated to
properly address all the fluid flow constrains and include the following components that are
graphically shown in figures 4 :

5
1. Inlet Separator.
2. Flute pimping manifold.
3. 3 Multiphase Twin Screw Pumps on a portable skid, that includes:
 Base frame with an electric motor,
 Pump,
 Shaft Pump Coupling,
 Internal Separator or KO drum,
 Lube Oil system,
 Instrumentation and Local control panel.
4. Piping skid connections, safety devises and a filtering package.
5. Cooler Skids.
6. Cabin containing the control and data transition system.
7. External injection point to aid the recirculating system.

Fig. 4 – Example of PI&D diagram for three twin-screw pumps of 600Kw connected in parallel

For the single pump installation (figures 6 and 7), the configuration and components are basically
the same, the main difference is that the pump does not has the internal separator and has been
included externally, here the separator has two functionalities absorb the flow instabilities as a slug
catcher and provide the necessary liquid to keep the system within the temperature range, the
components are presented as follow:

6
1. Inlet manifold system for future pumps installation,
2. 1 Multiphase Twin Screw Pump on a portable skid, that includes:
 Base frame with an electric motor,
 2.2MW Pump,
 Shaft Pump Coupling,
 Lube Oil system,
 Instrumentation and Local control panel.
3. Piping skid connections, safety devises and a filtering package.
4. Cooler Skid.
5. Cabin containing the control and data transition system.
6. External injection point to aid the recirculating system.

Fig. 6 – PI&D for a single twin-screw pumps of 2.2Mw

7
 Fig. 7 – Single twin-screw pumps of 2.2Mw field location.

MULTIPHASE FLOW CHARACTERISTICS AND PRODUCTION RESULTS

In the example , the pump configuration has been selected considering the inlet pressures as low
as possible based on the expected treated volume (gas, condensate and water) and the discharge
pressure through the trunk line. The expected volumes coming from the wells have been
calculated considering the wells average production. The technical solution was highly customized
by the Contractor, according his experience and consequently, deeply standardized, in order to
improve reliability and short mobilization path.

The calculations showed that one single pump of 2.2MW was required to manage the expected
production wells applying a 30 bar differential pressure at surface and would also allow an
important production increase. After installation the pump was not only able to stop the dramatic
and sharp production decline but also increase the production, by more than 50% at the start up,
after optimization on the well parameters, imposing 20 bars of differential pressure the system is
successfully operating with a GVF of 99.9% sustained over the time. As observed the plots the
production increase over the time tend to be more than 100% given the facts that the wells will not
be able to produce due to the high pressure on the surface network and the wells instabilities that
will lead to a total shut down in many of them after producing with intermittent flow for few months.

The normalized production parameters are presented through figures 8 to 11

Fig. 8 Gas rate before and after installation Fig. 9 Condensate rate before and after installation

8
 Fig. 10 GVF rate before and after installation Fig. 11 Differential pressure before and after installation

MULTIPHASE TWIN-SCREW PUMPS SYSTEM PERFORMANCE

All the multiphase pumps installed so far in the field with different configurations and capacity has
shown to be very effective to manage the sharp wells head pressure decline showing an important
production increase recovery and sustained over the time. The performance of the different system
are presented in the plots below, highlighting the reliability of the designed configurations to
manage a flow stream with almost 100% Gas Volume Fraction, the performance continue to
improve over the time and it is also affected by the necessary programmed maintenance after a
number of hours of continuous service.

Fig. 12 – 2.2 MW Pump performance since the Start Up

The main issues that caused the down times are related to change of the pitch, material upgrade
for some corrosion and mechanical seals

The downtime for all the pumps installed has been minimized due to a 24hrs monitoring through a
satellite system that shows all the critical parameters in real time, allowing data storage for trends
analytics and system optimization (Figure 13). This provide the response maintenance team with
fundamental data to either foreseen problems in the system and or quickly assess the potential
problems in case of unscheduled shut downs.

9
 Fig. 13 – 2.2MW pump system real time monitoring

CONCLUSIONS

The Twin-Screw Multiphase Pumps has been proved to be very effective to produce and manage
fluid flow of 100% after properly addressing all the complexities relative to multiphase pumping with
a real understanding of the process. It becomes obvious that a successful operation of multiphase
pumps is much more than bare equipment supply, but understanding the complete scenario
starting from the reservoir.

The multiphase pump itself and the knowledge thereof combined with different disciplines, such as
reservoir, production, engineering, construction and maintenance are vital to get proper designs
and strategies to ensure the success.

The possibility to install extra pumps either in parallel or in series in the same manifold to further
reduce the suction pressure add to the installed systems more flexible to keep the wells on
production over a much more longer period of time.

ACKNOWLEDGMENTS

The authors wish to thank to his Company Customers for the financial and technical support to
make this project possible from a conceptual design to a full field implementation in a record time
frame.

10
REFERENCES
E M Alhasan, M Buali, R Alanazi, Saudi Aramco. “Extending Mature Field Production Life using a Multiphase
Twin-Screw Pump“. 15th International Conference on Multiphase Production Technology, Cannes, France,
2011

D Müller-Link, G Rohlfing. Joh. Heinr, Bornemann GmbH. “Flow Issues Up and Downstream of
Twin-Screw Multiphase Pumps”. 7th North American Conference on Multiphase Technology, Banff,
Canada, 2010

C Dorenbos, D Müller-Link, SPE. A Jäschke, Joh. Heinr, Bornemann GmbH. SPE 69846, “Sand
Handling During Multiphase Operations With Twin-Screw Pumps”. SPE International Thermal
Operations and Heavy Oil Symposium Porlamar, Venezuela, 2001

L Bortolin, Consultant. “Multiphase Pumps in Heavy Oil Production, Lessons Learned”. 2nd EMBT
Conference, Hannover, Germany, 2008

Abhay Patil and Gerald Morrison, Texas A&M University. SPE 186099, “Performance of
Multiphase Twin-Screw Pumps During the Period of Wet Gas Compression”. SPE Production and
Operations Journal Paper, 2018.

Gerald Morrison, Ryan Kroupa and Abhay Patil, Texas A&M University; Jun Xu, SPE; Stuart Scott,
Shell and Sven Olson, Leistritz. SPE 159910 “Experimental Investigation of Wellhead Twin-Screw
Pumps for Gas Well Deliquefication”. SPE Annual Technical Conference and Exhibition, San Antonio Texas,
USA, 2012.

11