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Abstract
This study explores the application of multiphase pumps as an alternative to conventional
separation using rigorous steady-state simulation models incorporating a newly developed
multiphase pumping model. The simulation results show that multiphase pumps are
advantageous in not only reducing facilities, but can also increase production rates by lowering
the backpressure on wells. Additionally, the complexities associated with multiphase flow through
a single pipeline are compared to running dual single-phase pipelines and important
considerations observed with the steady-state simulation are highlighted.
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1.0 Introduction
Following it’s emergence from research labs a decade ago, multiphase pumping has become a viable
solution to a wide number of field development plans. While the technology is seen to be particularly
beneficial in remote locations such as the deepwater Gulf of Mexico, pumps have also been deployed to a
number of onshore locations ranging from Alaskan North Slope to Columbia and from West Africa to the
Middle East.
Interest in the subsea deployment of multiphase pumps has grown as operators search for methods to
improve recoveries and economics for subsea completed wells. While subsea completed wells enable
development of deepwater resources as well as marginal fields in normal water depths, without some form
of subsea processing, these wells are expected to experience poor ultimate recoveries due to the high
backpressures. For example, conventional production operations routinely drawdown wellhead pressures to
100-200 psig. A subsea completed well, however, may have abandonment wellhead pressures of 1,000-
2,000 psig due to the backpressure added by the long multiphase flowline. In addition, operating as such a
continual high backpressure has been shown to have a direct impact on production decline behavior, acting
to reduce ultimate recovery (Martin & Scott, 2002). Maintaining a high backpressure can be viewed as a
production practice that wastes reservoir energy. Energy that could be used to move reservoir fluids to the
wellbore and out of the well is instead lost to flow through a choke or a long flowline. It is anticipated that
some form of subsea boosting and/or processing of produced fluids will be necessary to improve
efficiencies, allowing longer production from these wells and better recovery factors. Subsea processing
covers a wide spectrum of subsea separation and boosting scenarios. Subsea multiphase pumping
technology is perhaps a decade ahead of subsea separation and provides many advantages in terms of
intervention when compared with wellbore artificial lift methods.
Multiphase pumping is a relatively new technology and acceptance has been hampered by a lack of
engineering design tools. Recently, pipeline simulation codes have incorporated the ability to model
multiphase pump performance as part of the overall multiphase production system. This paper illustrates
the use of such a model to evaluate the benefits of subsea multiphase pumping.
Over the past decade, several multiphase pump technologies have emerged for gas-liquid multiphase
flow in the petroleum industry. As shown in Figure 1, these methods fall into the broad categories of the
positive displacement and rotodynamic pumps. Figure 2 shows that the number of multiphase pump
installations has increased rapidly over the past 5-7 years (Scott, 2002). This figure also shows the
breakdown between the different multiphase pump technologies. It should be noted that while the helico-
axial technology only represents a small number of the total multiphase pump installations, they are used in
the majority of offshore and subsea applications and have the capacity to pump much large volumes of
fluids than the positive displacement technologies.
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Multiphase Pumps
Helico-axial
Twin Screw (Poseidon type)
Piston
Diaphram
400
Piston
350
Helico-Axial
300 Single-Screw (PCP)
Twin-Screw
250
200
150
100
50
0
89
90
91
92
93
94
95
96
97
98
99
00
01
02
20
19
19
19
19
19
19
19
19
19
19
19
20
20
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A good summary of the development of multiphase pumping technology is given by Cooper et al (1996)
and Scott & Martin (2001). Recently, a transient model has been proposed to describe the behavior of a
rotodynamic pump (Ramberg and Bakken, 1997). Ideas on modeling the twin-screw pump have been
presented by Vetter & Wincek (1993) and Egashira et al. (1996) and these pumps have been successfully
incorporated into field use (Oxley & Shoup, 1994; Jaggernauth et al., 1996; Caetano et al., 1997; Guevara,
1999; and Giuggioli et al., 1999)). The following sections discuss the most commonly used types of
multiphase pumps.
Positive displacement pumps operate on the principal that a definite amount of fluid is transferred through
the pump based on the volume created by the pumping chamber and the speed at which this volume is
moved. The amount of differential pressure that develops in the pump is a function of the resistance to
flow downstream of the pump - that is, the pressure losses that must be overcome to deliver the fluid to a
set pressure downstream of the pump. For any positive (or near positive) displacement pump, the
interaction between the pump and the adjacent pipeline segments determines pump performance.
The twin-screw is by far the most popular multiphase pump in use and is manufactured by Bornemann,
Flowserve and Nuovo Pignone. Twin-screws are particularly adept at handling high Gas Volume Fractions
(GVF) and fluctuating inlet conditions. These pumps remain functional even at GVF’s of 95% and with re-
circulation systems can function at 100% GVF for short periods of time.
Figure 3 gives a schematic of a twin-screw pump. The multiphase mixture enters one end of the pump and
split into two flow streams that feed into inlets situated on opposite sides of the pump – a design that
equalizes stresses associated with slugging. Flow then passes through a chamber (created by the
interlocking screws) that moves along the length of the screws to the outlet. The volumetric flow rate is
dependent on the pitch and diameter of the screws and the rotational speed. As the gas is compressed, a
small amount of liquid will slip back through the small gaps between the screws and the containment
chamber wall resulting in a reduced volumetric efficiency.
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2.2.2 Progressing Cavity Pumps (Single-Screw)
Widely used in shallow wells as an artificial lift method, the Progressing Cavity Pump (or Moyno pump)
has been adapted for surface multiphase pumping. Note that the number of PCP pumps listed in Figure 2
represents only the surface installations of this technology. The PCP pump is comprised of a rubber stator
and a rotating metal rotor (Fig. 4). This pump is effective for low flow rates (less than 30,000 bbl/day total
volume of gas, oil and water) and for lower discharge pressures (maximum of 400 psig). This pump has
One of the simplest forms of multiphase pumping is the use of a large double-acting piston to compress the
multiphase oil, water and gas mixture. This approach is effective in the low and moderate flow rate ranges
with a maximum capacity of approximately 110,000 bbl/day (total volume of gas, oil and water) and
maximum discharge pressure of approximately 1,400 psig. The first type of piston pump, the “Mass
Transfer Pump”, was installed June 1998 by National Oil Well in Canada. As shown in Figure 5, this
pump makes use of the same gear box and prime mover that is utilized in conventional sucker rod pumping
units. Also, the pumping chamber functions much like a downhole sucker rod pump. It is comprised of
two check valve assemblies which operate is the same fashion as the standing valve and traveling valve in a
downhole pump. There are currently 8 installations of this pump in Canada.
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In 1999, Weatherford Artificial Lift Systems introduced their “RamPumpTM” (Fig. 6) which is comprised of
a hydraulically actuated vertical piston. This pump was first utilized in an on-shore installation, but has
recently been applied offshore in the U.S.A. Gulf of Mexico (Sommer, 2002). Large clearances allow for
moderate amounts of sand production. The vertical configuration of the piston provides an advantage for
offshore installations where deck space is at a premium.
Figure 6: RAMPump ™
The diaphragm pump is a reciprocating pump consisting of two pumping chambers. The piston and motor
are immersed in hydraulic oil supplied by a conventional axial-piston hydraulic pump. An elastomeric
diaphragm separates the hydraulic oil from the pumped fluids. While these pumps have been primarily
associated with the liquid-solids flow associated with deepwater drilling operations, they can be modified
to accommodate 100% GVF fluids with high efficiency. Rates of up to 30,000 BPD and differential
pressures of 550 psi have been achieved with prototype pumps (Beran, 1995).
Dynamic pumps operate on the principal that kinetic energy is transferred to fluid which is then converted
into pressure. In rotodynamic pumps, this occurs when angular momentum is created as the fluid is
subjected to centrifugal forces arising from radial flow though an impeller. This momentum is then
converted into pressure when the fluid is slowed down and redirected through a stationary diffuser.
The Helico-axial pump is a type of rotodynamic pump developed by the Poseidon Group (IFP, Total and
Statoil) and manufactured by Framo and Sulzer.
The fluid flows horizontally through a series of pump stages, each consisting of a rotating helical shaped
impeller and a stationary diffuser (Fig 7). This configuration is akin to a hybrid between a centrifugal
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pump and an axial compressor. Each impeller delivers a pressure boost with the interstage diffuser acting
to homogenize and redirect flow into the next set of impellers. This interstage mixing prevents the
separation of the gas-oil mixture, enabling stable pressure-flow characteristics and increased overall
efficiency. As the gas is compressed though successive stages, the geometry of the impeller/diffuser
changes to accommodate the decreased volumetric rate.
The impeller clearances are sufficient to allow production of small amounts of sand particles. While
helico-axial pumps are more prone to stresses associated with slugging, installation of a buffer tank
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3.0 Multiphase Pump Performance Analysis
Unlike single-phase pumps and compressors, no generalized model exists that is able to accurately
characterize the performance of multiphase pumps. This is due in part to complex and highly proprietary
internal pump geometries. Additionally, the variety of fluid properties and in-situ phase distributions make
it extremely difficult to rigorously describe the thermo-hydraulics occurring within the pump. For these
reasons it is common practice to characterize multiphase pumps with performance curves of the type
Increasing power
requirement
Commercial simulators often base designs on boundary conditions established upstream of the pump inlet.
For example, if a pressure is set at the reservoir or at a manifold located some distance upstream of the
pump, the pressure at pump suction becomes flowrate dependant. Thus, it is not possible to move about the
performance curve to explore different flowrates without affecting a change in the suction pressure, thereby
invalidating the curve. In such cases, it becomes impractical to use series of individual curves to size
pumps and explore the operational envelope for changing conditions. The need arises for a model that
responds to these changes - not only during iterative calculations performed for one set of conditions, but
for sensitivities performed on system parameters and analysis of overall system properties that change over
time.
The steady-state multiphase flow simulator used in this study (PIPESIM) addresses this issue with three
types of pump performance models – a generic model, a twin-screw model, and a helico-axial model. The
simplest approach is to use the generic model that treats the multiphase pump as a single-phase liquid pump
and gas compressor operating in parallel. Conventional pump and compressor theory is used to calculate
the shaft horsepower required. Efficiencies of the pump and compressor can be adjusted based on typical
values taken from field conditions. Due to the limiting assumptions in this approach, use of the generic
multiphase pump model is recommended only as a preliminary analysis.
The twin-screw pump performance model is derived from empirical data covering wide range of gas
volume fractions, suction pressures and pump speeds. Pump performance at specific inlet conditions is
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calculated by a rigorous interpolation routine that determines differential pressure, flow rate, pump speed
and power requirement. The test data is based on a liquid viscosity of 6 cSt. with corrections applied for
different actual viscosities. Seven pump sizes are available and are characterized in terms of nominal
capacity – that is, the theoretical rate at 100% speed, 0% GVF, zero differential pressure and with no
internal leakage. Available nominal rates range from of 37,500 to 300,000 BPD (250-2000 m3/hr) of total
suction flowrate. Additional pumps can be modeled with data supplied by the vendor or acquired in
precomissioning tests.
4.0 Example
The following example illustrates the benefits of a subsea twin-screw multiphase pump installation in
comparison to a satellite platform with conventional separation facilities. Steady-state multiphase flow
simulation models are used to evaluate the two alternatives.
An oil well is planned to be drilled in a water depth of 3600’ and 8 miles from a host platform. In a
traditional development, a satellite platform would be fixed directly above the wellhead with fluids
producing up a riser to a separator operating at 200 psia (Fig. 10). Gas is compressed and liquid is pumped
through separate lines to the host platform. Alternatively, a twin-screw multiphase pump can be installed
subsea to facilitate full wellstream production through a single subsea tieback to the host platform at an
arrival pressure of 200 psia. (Fig. 11).
Satellite platform
pump
3600’
8” riser
38ºF 2 ft/s
8 mile gas line
9
Host platform
Multiphase
pump 3600’ 8” riser
Pressure specified boundary conditions are set at the reservoir (which changes over time) and the separator
(assumed constant at 200 psia for both cases). A simple productivity index is applied to determine pressure
losses across occurring in the reservoir and the Hagedorn-Brown and Beggs-Brill flow correlations are used
to calculate the two-phase pressure loss for vertical and horizontal flow respectively. The ambient
temperature along the flowline is 38º F and the water current is 2ft per second, typical values for deepwater
environments.
Initial producing conditions are represented with a nodal analysis plot (Fig. 12). The intersection of the
well curve with the flowline curve shows that the well is capable of naturally flowing at 23,500 STBD with
a wellhead pressure of 1100 psia. To achieve higher rates, a pressure boost is provided to reduce the
wellhead pressure. The amount of differential pressure required for a specific rate is equivalent to the
difference of these two curves and is represented as a single curve in Fig 13. The key difference between
this figure and typical curves (Fig. 9) is that the different rates correspond with different suction conditions
specific to the system being modeled. This allows one to determine the pump speed required for various
rates and corresponding differential pressure required to meet the delivery pressure. As shown, at
maximum speed, the pump is able to produce 33,100 STBD with a differential pressure of 937 psia. A
marginally higher rate can be achieved using a larger pump, though at the expense of higher upfront capital
costs and lower operating efficiencies later in life.
The pressure profile for this case (shown in Figure 14) indicates that pressure losses in the 8 mile flowline
are roughly equivalent to that in the 3600’ vertical riser. The pressure losses occurring in the flowline are
100% frictional, while the pressure losses occurring in the riser are 90% elevational. As rates decline over
time, the elevational losses in the riser will become the dominant factor in the total pressure loss.
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Pr = 6000 psi, GOR = 400, wcut = 10%
3,200
3,000
2,800
2,600
2,400
2,000
1,800
1,600
1,400
1,200
1,000
Pump ∆P
800
600
Flowline & riser resistance curve
400
200 Increased rate
0 5,000 10,000 15,000 20,000 25,000 30,000 35,000
Stock-tank Liquid (STB/d)
Figure 12: Nodal Analysis at Initial Producing Conditions
Pump Performance
1,000
950
Pump ∆P = 937 psi
900
90%
850
80%
800
750
700 70% 100%
650
speed
Pump DP (psi)
600
550
500
60%
450
400
350
300
250 System curve
200
150
100
50
0
25,000 30,000 35,000
Stock-tank Liquid (STB/d) 33,100
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Pressure Profile
1,300
1,200
∆P flowline
1,100
1,000
900 ∆P Pump
800
700
600
500
300
Arrival pressure
200
0 10,000 20,000 30,000 40,000
Total Distance (ft)
To account for system performance over time, a reservoir performance table is used which correlates
pressure decline to cumulative production (Fig 13). The reservoir is initially undersaturated with a bubble
point pressure of 3700 psia. As the reservoir depletes, the watercut and gas-oil ratio increase. Production
continues until an economic watercut is 85% is reached.
8 % WC X 10
7
Bubble point
6
Pres X 1000 (psia)
5
1 GOR X1000
(scf/STB)
0
0 5 10 15 20 25
Cumulative Liquid (MMSTB)
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The performance of several twin screw pump models was considered on the basis of operational flexibility
throughout the life of the well. The pump is designed to initially operate at maximum capacity while not
exceeding a maximum pressure differential of 1000 psi. As rates decline and watercut and gas-oil ratio
increase, the pump speed is reduced to maintain the wellhead pressure at 200 psia while still operating at an
acceptable efficiency. In this example, a Nuovo Pignone PSP 210 having a nominal rate of 151,000 BPD
(1000 m3/hr) was selected to best meet changing conditions.
Table 1 shows pump performance over time. For the first year of production the pump operates at a speed
A forecast of both development scenarios (Fig. 16) was made based on the reservoir performance table.
The higher rates achieved with the multiphase pump allow for a shorter production cycle (4 years vs. 6
years for conventional separation). Additionally, in the satellite platform scenario, the well is not able to
naturally produce at reservoir pressures less than 3000 psia (wellhead pressure of about 520 psia) and must
be abandoned. By lowering the backpressure on the wellhead, the multiphase pump is able to produce to
the economic watercut (85%) which corresponds to a reservoir pressure of 2600 psia. The result is an
overall recovery of 15.1 MMSTB vs. 13 MMSTB, or an increased recovery of 16%.
30000
25000
Oil Rate (STB/ D)
20000
Boosted
15000 Cum Oil = 15.1 M M STB
10000
5000
Unboosted
Cum Oil = 13 M M STB
0
0 1 2 3 4 5 6
Time (yrs)
Figure 16: Oil Rate Vs. Time
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4.4 Pump Operational Considerations
To operate in a subsea environment, the pump must be marinized and designed to withstand external
pressures of approximately 1600 psia. The most frequent operational issue is seal failure which requires
intervention using service vessels equipped with Remotely Operated Vehicles (ROV’s) to conduct repairs.
An umbilical must be installed to deliver power to the pump and significant voltage losses will occur in the
line. The actual operating efficiency of the pump will be significantly less than calculated in the simulation
because of the voltage losses in the umbilical and in the pump motor.
While the multiphase pump improves recovery and eliminates the need for a satellite platform, a number of
operational issues involving multiphase flow are introduced. The Taitel-Dukler (1976) flow regime map
indicates that slug flow is the predominant flow regime throughout the producing life. A slug catcher
located on the host platform must be sized to receive large slugs associated with long flowlines. Statistical
analysis applied to the Scott (1986) slug length correlation indicates that the 1/1000 slug length, that is the
longest slug of 1000 occurrences, is 3557 feet (221 bbl) and occurs at the highest (initial) flow rate.
Should severe slugging occur, a larger slug catcher will be required. The Pots (1985) method suggests
severe slugging at the riser base is likely for all cases in this example. This occurs when the length of the
liquid slug exceeds the length of the riser causing liquid to accumulate at the riser base trapping gas
upstream until the flowline pressure is high enough to drive the slug out of the riser. This results in
unstable production rates and pressure control problems at the separator. Severe slugging can be mitigated
by means of riser base gas lift injection with gas supplied from the topsides or through a mechanism that
transfers in-situ pipeline gas to a point above the riser base (Sarica and Tengesdal, 2000).
The formation of emulsions at watercuts in the range up to about 60% is also an issue. The viscosity of
emulsions are significantly greater than oil or water alone and is calculated using the (Woelflin, 1942)
correlation. The higher viscosity increases the frictional pressure losses in the flowline and reduces pump
efficiency as shown in the pump performance table for the 50% watercut case.
Finally, a detailed flow assurance study must be performed to ensure that that the temperature in the
flowline does not fall below the cloud point for wax deposition or below the hydrate formation temperature.
The low ambient temperature along the flowline (38º F) and a swift water current (2ft/s) leads to significant
forced convection and heat loss especially at low rates when the fluid velocity is the lowest. It is therefore
necessary to insulate the line and in this case 1” thick insulation having a conductivity of 0.1 BTU/hr/ft/ºF
is sufficient to avoid hydrate formation. Still, it may be necessary to run a separate line to the pump outlet
to perform pigging operations in order to remove hydrate or paraffin buildup that may occur during shut-in
and start-up operations.
5.0 Conclusions
Multiphase pumps have emerged as a viable alternative to conventional separation, pumping and
compression. Significant cost savings can be realized through the reduction of conventional equipment.
Additionally, the use of multiphase pumps can increase recoverable reserves, especially in remote operating
environments. A variety of multiphase pumps technologies have been developed and the two most
promising types, twin-screw and helico-axial, have been incorporated into multiphase flow simulation.
Special considerations surrounding multiphase pumping operations include the need to handle produced
slugs, flow assurance issues and pump operability.
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6.0 References
Beran, W.T.: “On the Threshold – Subsea Multiphase Pumping,” Journal Of Petroleum Technology, pg
326 (April, 1995).
Caetano, E.F, R.M. Silva , R.G. da Silva, R.M.T Camargo and G. Rohlfing: “Cooperation on Multiphase
Flow Pumping,” paper presented at the Offshore Technology Conference (May 1997).
Cooper, P., et al.: “Tutorial on Multiphase Gas-Liquid Pumping,” presented at the 13th International Pump
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About the Authors
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