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OTC 24428

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Subsea High Boost Multiphase Pump System Development and
Applications
C. E. Souza, C. Kuchpil, L. C.Carbone, L.C. Silva, M. B. Cerqueira, Petrobras; R. V. Huguenin, OneSubsea

Copyright 2013, Offshore Technology Conference

This paper was prepared for presentation at the Offshore Technology Conference Brasil held in Rio de Janeiro, Brazil, 29–31 October 2013.

This paper was selected for presentation by an OTC program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The material does not necessarily reflect any position of the Offshore Technology Conference, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Offshore Technology Conference is prohibited. Permission to
reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of OTC copyright.

Abstract
The paper discusses the development of the Subsea High Boost Multiphase Pump System, which led to the first
installation of this technology in the Barracuda field, Campos Basin, offshore Brazil. The Helico-axial High Boost
Multiphase pump qualification program was started in 2007 (ref. 6), and went through extensive testing and
qualification activities, with the latest endurance test being performed in 2011. The Barracuda subsea multiphase
boosting system is installed at a water depth of 1040 m with a tie-back distance of 10.5 km to the P-48 platform
and was started up in July 2012. The Barracuda multiphase pump is capable of providing high differential
pressure in a wide range of gas volume fractions. The high boost multiphase pump is currently being considered
to several other applications worldwide as we move towards deeper waters and longer tie-backs. Some more
work is being done so this technology could reach the next step, being qualified to a broader range of applications
in order to meet the industry needs. The paper will also discuss current and future applications of this technology,
and present the latest status of the Barracuda project.

Introduction
Subsea multiphase boosting is an important technology to the oil and gas industry. Many companies have
invested a lot of effort, recourses and time in research and developments over the years seeking to develop
reliable and robust solutions for the subsea environment. With more than 18 years since the first field application
at the Draugen (Shell) field the helico-axial impellers are currently one of the most important and robust
technologies for subsea multiphase pumping.

The initial idea for subsea boosting was to extend satellite production from 10 to 50 km away from existing
infrastructure. This would make some field developments feasible as it would allow the same production unit to be
used for remote well tie-backs. Another clear benefit of this technology is the possibility to increase the oil
recovery and accelerate the production without interfering with the wells or the fluid characteristics.

With the growing subsea activities over the past years the operators faced challenges that required equipment
which could be able to add higher differential pressure to the multiphase flow. Without modifying the field proven
helicon-axial design the multiphase pump was further developed to be able to handle the required differential
pressures.

In 2007 the High Boost pump prototype was designed and built in Norway being first tested in February 2008.
After conducting tests over more than 2 years the High Boost technology was qualified. In 2012 the first High
Boost pump was started up in the Barracuda field (PETROBRAS – Campos Basin) which has been in continuous
operation for more than one year so far.

Helico-Axial Multiphase Pump


The helico-axial impellers development started in 1986 with the Poseidon project, although the pump design has
been improved over the past 25 years, the hydrodynamic principle has been kept as it was proven to be efficient,
reliable and flexible. These pumps use the dynamic principle to add energy to the multiphase fluid by converting
2 OTC 24428

speed into pressure as it flows through the pump stages across the impellers and diffusers series (Figure 1). This
concept was selected as ideal for subsea application mainly due to:

• Adequate pressure boosting capabilities;


• Safe operation from 0-100% GVF (gas volume fraction);
• Simple and robust design (sand tolerant);

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• Compact and low weight;
• Easy marinization.

Figure 1 - Helico-axial impellers and diffuser

The first project deployed with the helico-axial technology was the Shell Draugen field in 1994. The Draugen
pump was designed for 35 bar differential pressure at a capacity of 210 m3/h at a GVF of 30%. The pump was
driven by a water turbine. The first project that used the electric induction motor to drive a subsea pump was the
Lufeng project for Statoil in 1997 (Figure 2).

Figure 2 - Lufeng Pump

Between 2001 and 2003 some improvements were made to the standard multiphase pump design that increased
the reliability of the pumps. One of these upgrades was that the barrel design was changed to ROV clamp
connector design for the pump process connections. These changes have been proven in over 20 projects
delivered/being delivered and the Ceiba (Hess) project was where these modifications were introduced for the
OTC 24428 3

first time. Three dual pump stations with 6 multiphase pumps and two single pump stations were delivered for this
project. Ceiba has completed 10 years of operation in November 2012.

The main components of a subsea helico-axial multiphase pump are:

• Motor rotor
• Motor stator

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• Motor pressure casing
• Flexible coupling
• Pump casing
• Double acting bearings handling the thrust forces
• Radial bearings
• Pump shaft with multiphase impellers (Helico-axial)
• Pump housing with diffusers
• Mechanical seals

Motor Section

Pump Section

Figure 3 - Typical subsea multiphase pump cross section (OneSubsea)

High Boost pump concept


The standard multiphase pump can handle maximum differential pressures from 40 to 60bar depending on the
impeller diameter and process conditions (GVF, suction pressure and fluids properties). To meet the industry
needs it was necessary to develop a solution that could provide higher differential pressures. Therefore a Joint
Industry Project (ref. 6) was created to build and test a machine that would be able to handle these requirements.
The goal for that JIP was to design a pump that could generate 150 bar differential pressure with 30% gas volume
fraction (at the pump inlet).

In order to face the higher differential pressure across the equipment a new element was introduced in the
standard multiphase pump: the balance piston. This element has been used for several years in regular
centrifugal pumping applications; the challenge was to apply this technology to the multiphase flow. The balance
piston should work at the same way as it does for the traditional centrifugal pumps, it should be placed after the
last impeller and a small line should connect the outer part of the balance piston to the pump suction, balancing
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the pressures. Therefore the resulting balanced axial thrust force would be reduced (Figure 4) and the same core
elements could be used to design the new equipment reducing significantly the required modifications and the
risks associated to it.

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Figure 4 - Balance Piston Principle

The high boost pump is identical to the standard OneSubsea multiphase pump except for the balance piston and
a higher number of impeller/diffuser stages. These pumps have accumulated more than 1.8 million operating
hours (up to July 2013) and approximately 90 pumps have been manufactured to date.

The pump was designed according to API 610 - Centrifugal Pumps with some exceptions since the multiphase
pumps are of helico-axial hydraulic design instead. For the High Boost prototype it was used a 1.8 MW induction
rotor motor operated at 6.6 kV. The pump and motor have individual shafts connected through a flexible coupling.
The motor is submerged in barrier fluid (dielectric oil) for cooling, to prevent water ingress and to lubricate
bearings and mechanical seals.

The design point defined for the High Boost pump is 150 bar differential pressure at 30% GVF and with a flow of
220 m3/h (Actual conditions). To verify the performance and rotor-dynamic of the pump a prototype was built and
tested in different conditions with water/gas, and oil/gas mixtures.

Test Set Up
To test the pump performance through the conditions specified for the qualification program a test loop was
configured as shown in Figure 5. Liquid and gas are separated and flow through individual lines from the
separator. The flow rates coming to the pump are controlled remotely by individual valves placed on the gas and
liquid line.

A multiphase flow meter (MPFM) was used for the liquid flow measurements and also to provide the gas fraction
through a dual gamma densitometer, one of the main constituents of the flow meter. For gas flow measurements
a Coriolis meter was installed at the gas line coming from the separator.

Downstream the metering sections, gas and liquid are combined to create the multiphase mixture required. Gas
and liquid can also be mixed upstream the MPFM which enables measurement of the total flow through that line.
Another MPFM is used to measure the total flowrate and gas fraction through the balance piston.

A cooler circuit is included in the loop in order to maintain a constant temperature in the separator. The loop is
built for operation with highly viscous fluids which requires a shell and tube heat exchanger (also governed by
OTC 24428 5

pressure level). All the process fluid is routed through the tube side in the heat-exchanger and is cooled by sea
water on the shell side.

The separator is a two-phase separator and is pressure and temperature monitored. A pressure relief valve is
installed in the gas phase on top of the separator vessel. Having a MPFM installed at the liquid line makes it
possible to have an optimum control of the GVF (Gas Volume Fraction) actual faced at the pump inlet, since it is
possible to know the amount of gas carried over through the liquid line. Then the total gas flow rate desired can

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be adjusted through the combination of the gas flowing from the gas line with the gas remaining in the liquid line
after the separation process.

Figure 5 - Test Set Up

Pump Performance
The basic performance test was carried out under a water and gas mixture since the main purpose was to test the
performance predicted against the observed given a certain amount of gas at the pump inlet. The performance
test proved the hydraulic design as the observed points matched very well the predicted curves (Figure 6). The
blue curves shown at the chart were predicted through the OneSubsea pump design simulation tool according the
pump speed and the red marks are the real points measured. The vertical axis represents the differential pressure
3
in bar and the horizontal axis the total flow rate in Am /h, this means the gas and liquid sum at the pump inlet
pressure and temperature conditions.
6 OTC 24428

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Figure 6 - Pump Performance

The hydraulic performance estimates have been improved by adjusting the software with input from test rig
results and CFD simulations.

The black curves at the right and left side limiting the envelope are the minimum and maximum flow lines
respectively. They are based at the allowable operating range for the impeller type being corrected for the internal
leakage through the balance piston line. This is a standard procedure for pumps and compressors with balance
pistons or other types of process seals.

The performance test was carried out in 2008 and then repeated in 2009. The tests results proved that the
concept would perform as expected and demonstrated that the simulation tool used to design the High Boost
multiphase pump is very accurate and could predict within reasonable margins the performance observed during
the tests.

Performance on Viscous flow


The high boost pump was also tested with higher liquid viscosities. For this performance test it was used oil and
gas in order to achieve the right viscosity to be tested. Cooling capacity played a key role in this test since it was
very important to keep the fluid temperature low to simulate the desired viscosity. As expected the efficiency and
head generation capacity are affected by the viscosity. As a result from the viscous flow test the viscosity model
has been updated and the helico-axial performance can be better predicted when higher viscosities are expected.

This test was done in 2009 and the objective was to map the pump performance for fluids with viscosities
between 60 – 240 cP. Other projects have demanded even higher viscosity requirements and during a separated
testing program the helico-axial stages have been tested in start-up conditions with viscosities up to 4000 cP.

The performance envelope below (Figure 7) demonstrates one of the observed curves, specifically for 30 cP and
30% GVF. Once again, the predicted curve was very well within the observed results.
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Figure 7 - Performance Envelope corrected for 30 cP viscosity

Balance Piston Characteristics


The balance piston is used in the High Boost pump to limit the axial loads on the thrust bearing. From the
hydraulic design point of view it is important to control the leakage rate through the balance piston minimizing the
volumetric flow losses and also to avoid high temperatures in the balance piston clearance. Since this pump was
specifically designed to operate with multiphase flow it is also important to control the gas fraction through the
balance piston.

The graphic below (Figure 8) represents the results found by the multiphase meter that measured the gas fraction
through the balance piston during the performance tests mentioned previously. As demonstrated by the referred
chart the gas volume fraction at the pump inlet (red symbols) was very similar as the one measured at the
balance piston outlet (blue symbols). This proved the balance piston design and the stable operation under
different liquid and gas mixtures.

Figure 8 - Comparison: pump inlet GVF x Balance Piston outlet


8 OTC 24428

Qualification Process Conclusions


After testing the pump with several combinations of GVFs and with different viscosities for more than 3 years
since the program start the pump was qualified matching the design point without any issues. Since the
performance excided the expectations the pump was tested beyond the original requirements being tested up to
160 bar differential pressure with 60% GVF (Figure 9).

The full qualification program was finished in February 2011 with a final endurance test. This test was done with

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water and gas and the equipment run for 180 hours with different conditions to represent some typical scenarios
for the field operation such as: cold/hot start and trips. The pump presented stable hydraulic and mechanic
performance confirmed by the data recorded before and after the final test. After the test the pump was
disassembled for inspection and no wear was noted at the balance piston, seal or bearings. The data obtained
provided a high level of confidence in the mechanical integrity of the equipment.

Figure 9 - High Boost pump being tested

With all this work done and the success of the High Boost program, lead to the first field application of this
technology in the Barracuda field for PETROBRAS. The Barracuda High Boost multiphase pump is currently in
continuous operation in the field and has been running for more than one year.

With the growing confidence in the High Boost design several other major oil companies are also looking for
possibilities to apply this technology. This would make it possible to overcome the challenges with regards to
longer tie-backs and deeper waters, with possible significantly increase of the recovery factor for the field.

The next project to deploy the High Boost technology will be the GiRi field for Total in West Africa. This project is
ongoing and will utilize even more of the application envelope for this pump. The GiRi project will be installed in
2015 and has the following design parameters:

• Water Depth: 1400 m


• Tie-Back distance: 2 – 17 km
• Number of Pumps: 4 (+ 2 spare units)
• Total Flow (per pump): 600 m3/h
• Differential Pressure: up to 130 bar
• Design GVF: 20 – 50%
OTC 24428 9

Barracuda MPP (HighBoost Technology)


A project to produce a complementary area of the Barracuda field has been implemented, this project included
production and injection wells with offset between 10 and 15 kms. Due to the higher pressure drop at the long
horizontal flowlines the gas-lift method has lower efficiency, flow simulations indicated benefits with a 60 bar
differential pressure MPP.

Other similar analyses in other PETROBRAS fields indicated that the MPPs could be more efficient than the gas-

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lift method just with differential higher than 45 bar. Thus the helico-axial pumps installed in the past with
differential pressures lower than 40 bar, using the former technology, do not demonstrate advantage to these
PETROBRAS scenarios.

In spite of the possibility to extend the former technology up to 60 bar, due to the good prototype test results and
the possibility to use these MPPS at even higher differential pressures in the future, it was decided to use at
Barracuda field a MPP of 60 bar the new HighBoost technology. A Technological Co-operation Agreement has
been established to install a 60 bar HighBoost system at the Barracuda Field and evaluate its field performance,
complementary qualification and evaluation tests have been carried out during the FAT and SIT.

Barracuda SHMPPS - Field Operation Experience


The Subsea Helico-axial Multiphase Pump System (SHMPPS) shall deal with many operational conditions
expected in the life of the well, not only steady state production. Detailed operation procedures and protection
systems were prepared to all of the foreseen conditions. Some of these operational conditions are:

• Steady State Well Production with Pump;


• Pump Start-up without gas-lift;
• Start-up with gas-lift or with MPS assistance;
• Shutdown (normal pump shutdown, platform emergency shutdown, electrical power shutdown, X-tree
shutoff or platform separator shutoff, etc.);
• Pigging through pump by-pass;
• Chemical Injection (ethanol);
• Flowline depressurization to hydrate dissociation;
• Flushing to withdraw the Pump Module or flowlines;

Taking into account the multiphase flow parameters and operational conditions, a 13 stage pump was defined
having a design operational point with a 177m³/h flowrate at pump intake considering a fluid viscosity of 14cP.
Other design data is given in Tabela 1.

Table 1 - Pump Design Data


Design Operational Point Operational Limits
Differential pressure 60 bar Maximum differential pressure 70 bar
Pump speed 3480 rpm Pump Speed 1500 rpm to 4600 rpm
Power at the motor shaft 820 kW Maximum power at the motor shaft 1530 kW
Torque 2250 Nm Maximum motor torque 3149 Nm
Suction pressure 88 bara Suction pressure limits 64 bara to 126 bara
Gas at pump intake 35% Maximum GVF 70%
Fluid temperature 65 °C Temperature range 4 °C to 85 °C

The subsea equipment installation and the connection to the X-Tree and the FPSO P-48 have been completed by
Jun/2012. The Barracuda subsea multiphase boosting system is installed at a water depth of 1040 m with a tie-
back distance of 10.5 km to the P-48 platform. The system commissioning has been carried out based in a
procedure prepared by FRAMO and following guidelines of a PETROBRAS standard to commissioning of subsea
boosting and processing system. This phase includes conditioning, pre-operation and assisted operation. The
conditioning phases involved the following systems: Low Voltage and control system; subsea valves; High
Voltage system; control fluid system; barrier fluid system; ethanol injection system; and topside facilities systems.
The execution of these procedures was completed successfully, some difficulties have been faced but all of them
were overcome. Some relevant points of this commissioning were:
10 OTC 24428

• The VSD cells connectors have not been properly qualified to offshore operations;

• The barrier fluid pressure time response has been evaluated during a shut-down test. During this test it
was verified that would be necessary to increase the barrier fluid differential pressure across the seals in
order to avoid process fluid ingress at the seals during this transients. The barrier fluid pressure at the
seal is controlled by the topside HPU. This result indicates that the umbilical length is close to the limit of
the approach used in this project to control the barrier fluid pressure at the pump seals;

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• Some problems in the assembly of the Integrated Umbilical junction box have been faced. The integrated
umbilical is complex, also some difficulties to its subsea installation and connection has been faced.
Efforts to simplify this umbilical shall be carried out in future projects.

After the conditioning of all these systems, the commissioning and start-up of the SHMPP have been performed.
The procedures of pre-operating, direction of rotation test and assisted operation were performed without any
nonconformity.

The Subsea Helico-axial Multiphase Pump (SHMPP) of Barracuda started the operation on 14 July 2012, since
then, the hydraulic performance of HMPP is performing as expected, operating with a differential pressure of 60
bar. This SHMPP condition lead to an average liquid production gain of approximately 40% of the well potential
point without the pump. All the flow parameters (flow rates, GVF, BSW, viscosity, slugs, etc.) are inside the
SHMPP operation envelope.

Some important operational parameters along this period are presented in figures Figure 10 e Figure 11.

Average Monthly Values of Electrical Current, GVF, Power, Rotation and


Differential Pressure in the SHMPPS
70.0 4000.0

63.0 3600.0

56.0 3200.0
Diffrential Pressure [kgf/cm²]
Elect. Current [A], GVF [%] &

Speed [RPM] & Power [kW]


49.0 2800.0

42.0 2400.0

35.0 2000.0

28.0 1600.0

21.0 1200.0

14.0 800.0

7.0 400.0

0.0 0.0
12

3
2

3
2

3
2

13
2

13

01
1

01

01
1

01
01
01

01
20

20

20

20
20

/2
2

/2
/2

/2
l/2

t/2
/

v/

n/
/

n/
go

br
ov
ut

ai
ez

ar
Ju

Se

Fe

Ju
Ja

M
O

A
D
N
A

Months

Elect. Current [A] GVF [%] DP_SHMPP [kgf/cm²] Power [kW] Speed [RPM]

Figure 10 - Average monthly values for pump operational parameters


OTC 24428 11

History Well Production vs. SHMPP Operational Variables

100 200

90 180
DP_SHMPP, BSW & Relative Total

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80 160

70 140
Liquid Production

Pump_Pdisc
60 120

50 100

40 80

30 60

20 40

10 20

0 0
2

3
12

12

12
2

12

3
01

01

01

01
01

01

01

01

01

01
20

20

20
20
2

2
/2

/2

/2

/2

/2

/2
0/

1/

2/
8/

9/

1/

7/
/7

/8

/8

/9

10

/4

/6
9/

7/

3/

9/
/1

/1

/1
31

20

28

25

18

25
4/

18

23

26
Well Production Events

BSW [%] Relative Total Liquid Production [%] DP_SHMPP [kgf/cm²] Pump_Pdisc [kgf/cm²]

Figure 11 - History well production vs. SHMPP operational variables

During the assisted operation a hands-on offshore training plan has been implemented to of all operators’ shifts.
This offshore training complemented an onshore training, performed before the SHMPPS commissioning. This
training program has provided conditions to the P-48 team to conduct the SHMPPS operation. The system is
working with operational stability and little disruption to platform routine activities, the barrier fluid quality control at
HPU is one of main attention points.

In addition to the hydraulic performance, the SHMPPS depends on various components and subsystems. The
functionality, availability and reliability of these are essential to this new SHMPPS technology. Various operating
parameters such as oil barrier fluid consumption, barrier fluid temperature at bearings and electrical motor
insulation indicate that the critical components and subsystems are operating properly. In future systems, the
installation of subsea proximity probes vibration transducers could give better information about the SHMPP
rotodynamic performance.

The Barracuda SHMPPS uptime has been 100% up to the time of writing this paper (late June 2013). It has been
submitted to 11 shutdowns during the pump commissioning, pre-operation and training phases, just one
shutdown has been generated by a spurious P-48 emergency shutdown signal and other during the manual GVF
adjustment. Others 12 events were due to emergency shutdowns from Platform and operational actions. The
production downtimes of all of these events were very short. Operators immediately initiated the pump start-up
procedure. Just one of these events required to perform the hydrate prevention procedure.
12 OTC 24428

SHMPP Events: Stopped and Started - Jul/2012 to Jun/2013

10

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8

7
Stopped and Started

0 0 0 0
0
Jul/2012 Aug/2012 Sep/2012 Oct/2012 Nov/2012 Dec/2012 Jan/2013 Feb/2013 Mar/2013 Apr/2013 May/2013 Jun/2013
Events in the Month

Started Stopped

Figure 12 - SHMPP events of stopped and Started

Conclusions
The number of subsea multiphase pumping applications is considerable, but the maximum differential pressures
have been lower than 45 bar. A new technology of subsea helico-axial multiphase pump has been introduced to
enable differential pressures higher than 60 bar. The first system has been installed in the Barracuda field and it is
the first system of this technology operating with real fluids at real operational conditions. The system
performance up to now is remarkable, the uptime is 100%, and the impact in the oil production is substantial.

The expansion of the operational envelope of subsea helico-axial multiphase pumps will enable its use in
important scenarios, accelerating the number of applications and increasing the benefits of this important subsea
boosting method.

Acknowledgments
The authors wish to thank all PETROBRAS colleagues that collaborated with valuable additions to this paper and
particularly to OneSubsea engineering personal involved in this project.

References
1. C. Kuchpil, C.E.M. Souza, E.J.J. Coelho, L.C.T. Silva, M.B. Cerqueira, L. Carbone, PETROBRAS, 2012.
Barracuda Subsea Helico-Axial Multiphase Pump Project. Paper OTC 1349.

2. G. Hua, Schlumberger; G. Falcone, Texas A&M University; C. Teodoriu, Clausthal University of


Technology; Gerald L. Morrison, Texas A&M University, 2012. Comparison of Multiphase Pumping
Technologies for Subsea and Downhole Applications. Paper SPE 146784-PA.

3. M.P. Arnaudeau, Inst. Français du Pétrole, 1988. Development Of A Two-Phase Oil Pumping System For
Evacuating Subsea Production Without Processing Over A Long Distance: Poseidon Project. Paper OTC
5648-MS presented at the 1988 Offshore Technology Conference, 2-5 May 1988, Houston, Texas.
OTC 24428 13

4. A.B. Olsen, P.J. Bibet, 2012. Subsea Multiphase Boosting, Framo and JIP Partners open the path to
High Pressures. MCE Deepwater Development, Paris.

5. M.A.N. Herdeiro, C.H.G. da Cunha, B.R.F. Motta, PETROBRAS, 2005. Development Of The Barracuda
And Caratinga Subsea Production System - An Overview. Paper OTC 17054-MS presented at the 2005
Offshore Technology Conference, 2 May-5 May 2005, Houston, Texas.

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6. JIP Partners have been: Total/ Statoil/ Shell/ BP/ ExxonMobil /+

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