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Multiphase Pumps
Gabriel CastanedaMBA, MEng, PEng
(403) [email protected]
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
