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[email protected] / [email protected] Thursday, November 07, 2013 1

Calgary Pump Symposium 2013

Axel Jäschke Technical Director - ITT Bornemann USA Office: Mobile: +1 832 320 2500 +49 170 576 4115 +1 832 293 7935

Twin Screw Technology General Overview and Multiphase Boosting 11/2013



Calgary Pump Symposium 2013 Bio Axel Jäschke Axel Jäschke, currently the technical director of ITT Bornemann USA, has been involved with twin-screw pumps for various applications in the oil/gas industries during the past 15 years. His technical experience in multi-phase boosting technologies had brought him to various projects in Columbia, Venezuela, Russia, Abu Dhabi and Thailand. As head of the R&D department for Subsea Boosting he was involved in several new developments and patents regarding multiphase boosting during the last years. Based out of Houston, he is responsible for the development of new, US based multiphase boosting solutions. A Graduate Mechanical Engineer from University of Hanover, Germany, Axel was also involved in the design and management of various tank farm projects in Europe prior to starting with Bornemann in 1998.


Calgary Pump Symposium 2013 Content

Pumping Principles: Centrifugal Pumps (CFP) and TSP Why Twins Screw Pumps TSP Performance and NPSH TSP Applications and Operating Range Multiphase Boosting – Considerations and Solution Typical Installations



A Pump is a Pump ….

but some pumps are different.


Calgary Pump Symposium 2013 Twin Screw Pumps


Calgary Pump Symposium 2013 TSP Multiphase Systems



Basic pumping principles ...

Centrifugal Pumps (CFP) and Twin Screw Pumps (TSP).


Calgary Pump Symposium 2013 Pumping Principles

Hydrodynamic Pumps = Centrifugal Pumps (CFP) Adding KINETIC ENERGY to the fluid and converting it into flow (and pressure)

depending on the required system pressure. Hydrostatic Pumps = Twin Screw Pump (TSP) Moving a fixed VOLUME against the given system pressure. (Positive Displacement – PD)


Calgary Pump Symposium 2013 CFP Power Flow Relation Hydrodynamic Pumps: Flow is depending on Pressure (or head). Power is a relation of pump speed and efficiency at operating point.

1660rpm

1455rpm

1780rpm

0

10

20

30

40

50

60

70

80

90

100

0 2000800400 1200 1600 2400 2800 3200

flow

head

PUMP PERFORMANCE CURVE

0

10

20

30

40

Pow

er1660rpm

1455rpm

1780rpm

BOP


Calgary Pump Symposium 2013 Centrifugal Pump Consideration o Good Peak Efficiency at BOP (best operating point)

o Low Cost

o Sensitive to Gas, High Fluid Viscosities, changing Fluid Density

o Sensitive to low Inlet-Pressure and Cavitation

o Not operating at BOP can lead to reduced pump lifetime

o Limited Overall Efficiency


Calgary Pump Symposium 2013 Why Twin Screw Pumps

Handles almost all types of fluids – conventional and unconventional Fluid density does not influence pump performance – self priming Very wide operating range at overall high efficiency Very low NPSH requirements and not sensitive to vapor and cavitation Very good flow control

Higher Cost compared to Centrifugal Pumps



Twin Screw Pump (TSP) Performance.


Calgary Pump Symposium 2013 Twin Screw Pump – Flow Inside Pump

Inlet

Outlet

Moves Fluid in Closed Chambers

Two Rotors with Conveyer Screws

Typical Twin Screw Pump


Calgary Pump Symposium 2013 Twin Screw Pump

Casing Liner Shafts Screws

No Contact between Screw and Screw and Screws and Liner / Casing

No Contact à small Gaps!


Calgary Pump Symposium 2013 Flow and Backflow inside the Rotor

Liner

Shaft

“Flow” Direction

Direction of Rotation

Inlet, pin Outlet, pout

Screw “Flow” Direction

Positive Flow Backflow


Calgary Pump Symposium 2013 TSP Performance – Flow Rate Capacity depends on:

Chamber Size + number of screw Speed Differential Pressure (Dp) Viscosity Gap Design (screws, liner/casing)

Total Flowrate = Volumtric Flow – Backflow Qtotal = Qvolumetric – Qbackflow

Qbackflow » Dp; Viscosity; Gap Design

Flow Rate Q à

Diff

eren

tial P

ress

ure

Dp à

Qbackflow

Qvolumetric

Qtotal


Calgary Pump Symposium 2013 TSP Performance – Viscosity Capacity depends on:

Chamber Size + number of screw Speed Differential Pressure Viscosity, Gas Content Gap Design (screws, liner/casing)

Less Backflow with higher fluid Viscosity! Less Backflow with Gas.

Flow Rate Q à

Diff

eren

tial P

ress

ure

Dp à

Low Viscosity

High Viscosity and Gas


Calgary Pump Symposium 2013 TSP Performance – Power Consumption Power Consumption depends on:

Speed Differential Pressure Viscosity

Shaft Power = Hydraulic Power + Friction Pshaft = Phydraulic + Pfriction

Pfriction » speed; viscosity

Phydraulic » speed * differential pressure

Flow Rate Q à Shaft Power P à

Diff

eren

tial P

ress

ure

Dp à

Pshaft

ConstantSpeed

Flow

Pfrict.


Calgary Pump Symposium 2013 TSP Performance – Power Consumption

Flow Rate is directly proportional to speed.

Power Consumption depends on speed and differential pressure.


Calgary Pump Symposium 2013 Typical Twin Screw Performance Diagram

400 HP 300 HP 200 HP 100 HP



Performance Range,

Parallel Installation and

Installation in Series


Calgary Pump Symposium 2013 Overall Operating Range of our TSPs


Calgary Pump Symposium 2013 Pumps in Parallel psi bar

2.180 150

2.110 145

2.030 140

1.960 135

1.890 130

1.820 125

1.740 120

1.670 115

1.600 110

1.530 105

1.450 100

1.380 95

1.310 90

1.240 85

1.160 80

1.090 75

1.015 70

945 65

870 60

800 55

725 50

655 45

580 40

510 35

435 30

365 25

290 20

220 15

145 10

75 5

0 00 100 200 300 400 500 600 700 800 900 1.000 1.100 1.200 1.300 1.400 1.500 1.600 1.700 1.800 1.900 2.000 2.100 2.200 2.300 2.400 2.500 m 3/h0 16.000 31.000 46.000 61.000 76.000 92.000 107.000 122.000 137.000 152.000 168.000 183.000 198.000 213.000 228.000 244.000 259.000 274.000 289.000 304.000 320.000 335.000 350.000 365.000 380.000 BPD0 500 1.000 1.400 1.900 2.300 2.800 3.200 3.700 4.100 4.600 5.100 5.500 6.000 6.400 6.900 7.300 7.800 8.200 8.700 9.100 9.600 10.100 10.500 11.000 11.400 GPM

Pump Flow Rate

Pum

p H

ead

/ Pum

p D

iffer

entia

l Pre

ssur

e

9-H

DP

9-50

9-60

9-75

9-100

9-HC

Why Pumps in parallel? - Optimized Efficiency - Flexibility = Efficiency - Redundancy = Availability


Calgary Pump Symposium 2013 Pumps in parallel psi bar

2.180 150

2.110 145

2.030 140

1.960 135

1.890 130

1.820 125

1.740 120

1.670 115

1.600 110

1.530 105

1.450 100

1.380 95

1.310 90

1.240 85

1.160 80

1.090 75

1.015 70

945 65

870 60

800 55

725 50

655 45

580 40

510 35

435 30

365 25

290 20

220 15

145 10

75 5

0 00 100 200 300 400 500 600 700 800 900 1.000 1.100 1.200 1.300 1.400 1.500 1.600 1.700 1.800 1.900 2.000 2.100 2.200 2.300 2.400 2.500 m 3/h0 16.000 31.000 46.000 61.000 76.000 92.000 107.000 122.000 137.000 152.000 168.000 183.000 198.000 213.000 228.000 244.000 259.000 274.000 289.000 304.000 320.000 335.000 350.000 365.000 380.000 BPD0 500 1.000 1.400 1.900 2.300 2.800 3.200 3.700 4.100 4.600 5.100 5.500 6.000 6.400 6.900 7.300 7.800 8.200 8.700 9.100 9.600 10.100 10.500 11.000 11.400 GPM

Pump Flow Rate

Pum

p H

ead

/ Pum

p D

iffer

entia

l Pre

ssur

e

9-60 9-60 9-60 9-60

Here the frame size 9-60 has been selected. - 4 x 33% capacity

- Redundancy = 1 x 33%

- Flexibility ... less flow? Run less pumps.


Calgary Pump Symposium 2013 Pumps in Series psi bar

2.180 150

2.110 145

2.030 140

1.960 135

1.890 130

1.820 125

1.740 120

1.670 115

1.600 110

1.530 105

1.450 100

1.380 95

1.310 90

1.240 85

1.160 80

1.090 75

1.015 70

945 65

870 60

800 55

725 50

655 45

580 40

510 35

435 30

365 25

290 20

220 15

145 10

75 5

0 00 100 200 300 400 500 600 700 800 900 1.000 1.100 1.200 1.300 1.400 1.500 1.600 1.700 1.800 1.900 2.000 2.100 2.200 2.300 2.400 2.500 m 3/h0 16.000 31.000 46.000 61.000 76.000 92.000 107.000 122.000 137.000 152.000 168.000 183.000 198.000 213.000 228.000 244.000 259.000 274.000 289.000 304.000 320.000 335.000 350.000 365.000 380.000 BPD0 500 1.000 1.400 1.900 2.300 2.800 3.200 3.700 4.100 4.600 5.100 5.500 6.000 6.400 6.900 7.300 7.800 8.200 8.700 9.100 9.600 10.100 10.500 11.000 11.400 GPM

Pump Flow Rate

Pum

p H

ead

/ Pum

p D

iffer

entia

l Pre

ssur

e

9-60 9-60

What to do if start up pressure might be (sometimes?) higher? Run the pumps in series!

TSP TSP


Calgary Pump Symposium 2013 TSP Applications Application Special Process Requirements Asphalt and Bitumen High viscosity, high temperature, low NPSH

Vacuum Residue Oil Very low NPSH, various viscosities

Liquid Sulfur High temperature, high viscosity

Polymer Changing viscosity and wide capacity-range

Loading / Unloading Different viscosities, wide capacity-range, temporary gas content, low NPSH

Stripping High gas content, wide viscosity- and capacity-Range

Tank Farm Operation Wide viscosity- and capacity-range, good control of flow rates, temporary gas handling

Pipeline Transport Wide, high viscosity-range, adjustable reliable capacity at changing system pressures

Marine (Fluid handling on Tankers) Wide viscosity- and capacity-range, good control of flow rates, temporary gas handling

Food (sanitary) Beverage, Dairy (Yoghurt, Cheese Curds), Meat, Chocolate, Cosmetics, etc.

Wide range of viscosities, flow rates. Low NPSH and low shear required. Cleaning and sterilisation of pump and pipeline with the same pump (CIP, SIP)

Multiphase / Oil and Gas Production Very much changing operating conditions, slug-flow, gas

Wet Gas Compression / Vapour Recovery Up to 99.999% gas, changing pressures and flow rates



Multiphase Boosting


Calgary Pump Symposium 2013 Multiphase Boosting

Control the OIL & GAS Well Production by

controlling the Wellhead Pressure and

overcoming the Pipeline Backpressure .

Improve the Oil Production!


Calgary Pump Symposium 2013 Multiphase Production

Reservoir

Gathering Station

Oil Field

MPC

MPC Multiphase Pump / Compressor

Separator

MPCMPC


Calgary Pump Symposium 2013 Multiphase Mixture

GAS

OIL

MULTIPHASE

Multiphase includes a wide range of hydrocarbon compositions, CO2, H2S, N2, water and other components. They all together are influencing the physical phases (gas, multiphase, liquid) and the total volume, which will be present at the pump at the required pressure and temperature.


Calgary Pump Symposium 2013 Multiphase Oil and Gas Mixture

Gas Liquid

Gas Oil Ratio (GOR): Gas / Liquid @ standard condition

Gas Volume Fraction (GVF): Gas / (Oil+Gas) @ inlet conditions

Required Pump

Capacity

Oil produced offshore is transported through pipelines as a mixture of liquid and gas. The amount of gas is given in standard volume compared to the oil content (GOR) or in percentage of the total flow (GVF).


Calgary Pump Symposium 2013 Multiphase Slug Flow Oil produced offshore is transported through pipelines as a complex mixture of oil, gas and water. One flow regime is known as slug flow, in which liquid flows intermittently along the pipes. It is highly complex and instable, difficult to predict. It depends on flow velocity, gas content, pipeline position, etc.. Slug flow and gas pockets have to be handled by Multiphase Pumps.

Flow regime and Slug flow slugflow probability inside pipeline


Calgary Pump Symposium 2013 Multiphase Production

Actual Volume Flow (Oil+Gas)

Pipeline Performance

pout

pin

potential production

natural production

Pre

ssur

e

Gas + Oil Flow

MPP


Calgary Pump Symposium 2013 Technical Solution (TSP) Liquid Separation and Liquid Hold Up. Controlled Liquid Circulation.


Calgary Pump Symposium 2013 System Solution Plug & Pump Systems, combining Pumps and Drives with Control Equipment and Process Know How!


Calgary Pump Symposium 2013 Multiphase Boosting Multiphase Boosting is an approved technology, based on different pump types and provided by various vendors. More than 2000 installations are

worldwide in operation – on shore, off shore and subsea.



Multiphase Boosting

some typical installations.


Calgary Pump Symposium 2013 Single Well and Casing Gas


Calgary Pump Symposium 2013 Arctic Conditions


Calgary Pump Symposium 2013 Installation in Series


Calgary Pump Symposium 2013 Wet Gas Boosting

source: Murray Milbrandt, CNRL Canada source: Murray Milbrandt, CNRL Canada


Calgary Pump Symposium 2013 Subsea


Calgary Pump Symposium 2013 Subsea Vacuum Cleaner



Still ....

a Pump is a Pump ….



Questions?

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