Artificial Lift Presentation

Multiphase Pumps

Gabriel CastanedaMBA, MEng, PEng

(403) 397-1296Gabriel.castaneda@mail.mcgill.ca

A technology review

Optimizing the oilpatch

Table of Contents• Introduction to multiphase flow• Artificial lift advantage• Types of artificial lift systems

Conventional Multiphase Pumps (MPP)- Rod Pump- Water Injection- Gas Lifting

• Benchmark of artificial lift systems• Pump control & interlocks• Life-enhancers for MPP – Ceramic coatings• MPP applications

– Production increase– SAGD– Surface streamlining

• Multiphase Flow Meters (MPFM)• Summary

- Electric Submergible Pump (ESP)- Helico-Axial- Progressive Cavity Pump (PCP)- Twin Screw Pump

Multiphase Flow Regimes

Image by Cholet

Liquid vs Gas Velocity

Image by Cholet

Artificial Lift Advantage

Image by Fleshman

Rod Pump

Image by Fleshman

Jet Pump

Image byFleshman

Well Flow Composition

Images by C-Fer Bornemann

Gas Injection

P = gh

Decreases hydrostatic head by decreasing density

Image by Fleshman

Multiphase Pump Technology

M u l t i p h a s e p u m p s

Rotordynamic Positive Displacement

Multistage centrifugal “ESP type”

Helico-Axial

PCP “single screw”

Twin screw

ESPsPUMP ADVANTAGES DISADVANTAGES

Electric Submersible

Pumps (ESPs)

Traditionally down-hole and

submersible, but can be used on the

surface

If solids, potential erosion

Rotordynamic

Good for low viscosity liquids

Can't handle higher viscosities

Primary Upstream

Applications

Speed 3600 RPM, Flowrates to 50,000

BPD

No higher than 65% GVF

  Low CostHigh shear -

potential emulsions

 Can handle higher

temperatures

Installed units: normal MTBF of 3

years

 Gas conditioners to

40% (65%) GVF 

Table by Bob Heyl

difuser

impeller

ESPs

ESPs

Image by Schlumberger

ESP with Caisson

Image by Baker Hughes Centrilift

ESPs - Gas Locking

Images by Schlumberger

ESPs - Gas Locking

Image by Fleshman

Helico-Axial Pump

PUMP ADVANTAGES DISADVANTAGES

Helico-AxialDown-hole, surface or

submersibleIf solids, potential for

erosion

RotodynamicHigh speed: 4000-

68000 RPM High shear

Upstream or Downstream

Flowrates up to 600,000 BPD

 Differential pressures up

to 2175 PSI  

 Can achieve up to100%

GVF  

Table by Bob Heyl

Gas Separators

MVP stageCentrilift

Gas Separators

Helico-Axial Impeller

Images by Schlumberger Framo

PC PumpPUMP ADVANTAGES DISADVANTAGES

Progressive Cavity (PCPs) PD

Down-hole, submersible or

surfaceElastomer problems above 300oF

Upstead or Downstream Applications

Handles some solids Contacting rotor and stator

  2100 psi differentials Can't run dry

  Speed: 1800 RPM  

 Flowrates up to

7000 BPD 

 Can run higher

viscosities 

  Relatively low shear  

  GVF 35%  

Table by Bob Heyl

PCP

PCP issues

Images by Hirschfeldt

PCP - metal stator

Twin-ScrewPUMP ADVANTAGES DISADVANTAGES

PD surface, down-hole or submersibleSurface pump with 4 mechanical

seals

Upstream or Downstream speed: low to high speed  

Flowrates: up to 400,000 BPD (surface pumps)

56,000 BPD (downhole 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  

3500 PSI differentials with water (downhole)

5000 psi static, surface  

  particulates to 1 % wt  Table by Bob Heyl

Twin-Screw

Images by Polymerprocessing.com

Artificial Lift

  Poor performance   Good

  Meets requirements   Excellent

  Rod Pump Hydraulic Jet

Pump Gas Lift ESP

Helico - Axial

PCP Twin

Screw

Offshore Application

good if space for power system

Good Excellent Good Excellent Good Good

Solid Handling Capabilities

prod less than 200 ppm

Prod up to 3% No problem Prod Less than 200

ppm yes

No problem up to 5%

up to 1%

Maximum Temperature, oC

260 260 175288

(550F) 175

350 (metal) 120

(elastomer)350

Volume Capabilities, BPD

< 650 5,000 50,000 50,000 600,000 7,000

400,000 surface 56,000

downhole

Fluids              

Viscous               Corrosive               Abrasive              

Depositing               Emulsifiable               High GLR              

Table inspired by Cholet

GVF

GVF %

100

15

45

75

98

98

100

0 10 20 30 40 50 60 70 80 90 100

Twin-Screw operating

Twin-Screw maximum

ESP (Centrifugal)

ESP (Centrifugal) with inlineseparator

ESP (Centrifugal) with Helico-Axial stages

Helico-Axial Operating

Helico-Axial Maximum

Gas Volume Fraction

Data by Intec Engineering

Pump Comparison

Image by Cholet

Pump Control

Image by Hirschfeldt

Pump Interlocks

Image by Hirschfeldt

Life Enhancers -Ceramic Coatings

CoatingHardness

Hv Vickers

Coating Adherence,

PSI

Coating Process

Maximum Service

Temperature

Sand 1000

uncoated coated

60 hr test in slurry loop

Applications

Production Increase

Production Increase

Production Increase

Production Increase

SAGD

Image by Schlumberger

ESP in SAGD

Suncor Firebag: 2,500 m3/well day, 15,725 bpd 250 hp, 550oF (required is 500oF)

PCP installation

Images by:

Cold LakeImperial Oil

JoslynTOTAL/ ConocoPhillips

Twin Screw in SAGD

Twin Screw in SAGD & Offshore

• Very low emulsions• NPSHR very low• Very High GVF• Used by Conoco-Phillips in Bohay Bay and Surmont Project• Potential contract with Conoco-Phillips of 100 pumps at the end of trial

Downhole Twin Screw

Production Streamlining

Production Streamlining

Image by Framo

Production Streamlining

Production Streamlining

Image by Schlumberger

Multiphase Flow Meters MPFM• Production testing and

trending• Exploration and Appraisal

testing• Well cleanup optimization• Gas lift optimization

Images by Framo / Haimo

density watercutSlip

correlationsDifferential pressure

Gas Fraction

Gammametry Capacitance microwaves

Venturi

Oil FractionWater

Fraction

Total Flowrate

Gas Flowrate

Oil Flowrate

WaterFlowrate

Multiphase Flow Meters MPFM

Image by Falcimagne

Multiphase Flow Meters MPFM

Images by Agar / Framo

Online MPFM

Image by Framo

Online MPFM

Image by Framo

Online MPFM

Image by Framo

Artificial Lift Expenditures

Production Per Artificial Lift System

NPV per artificial lift type

IPR and tubing curves

Composite IPR curve

Takacs

ESP with different tubings

Pumping performance curves for viscous service

Takacs

Pressure profile inside pumps

Centrifugal Screw pump

Reservoir Completion Methods

Summary• MPP can increase production flows in

conventional and heavy oil processes• High-viscosity MPP could decrease SOR in

SAGD, therefore would reduce operational costs• Pump Monitoring and Ceramic coatings can

decrease operational expenditures and shutdown times

• MPP can decrease new project expenditures by having a central processing facility

• MPFM is a mature technology that can reduce operational costs

ThanksFor more information:

Gabriel Castaneda, MBA, MEng, PEng

(403) 397-1296