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Introduction / Overview
Multiphase Pumps (MPP) are at the heart of thisExtra-Heavy Crude Oil (EHCO) Projects operation
Both, the operating environment and the relativeyouth of this technology have presented challengesto establishing reliable, cost effective operations.
Multiphase Pumps
in Heavy Oil ProductionLessons learned
Luigi Bortolin, Consultant
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2ND INTERNATIONAL EMBT CONFERENCE // MULTIPHASE PUMPS IN HEAVY OIL PRODUCTION LESSONS LEARNED
Reservoir Characteristics
Introduction
Porosity 32 %Avg. Permeability 11.600 md
Oil Viscosity 2.000 cpOil Mobility 6 md/cp
Oil Gravity 9 APIPressure 775 psiTemperature 120 F
Heavy Foamy Oil
We normally dont worry about 3-10%
shrinkage, but this crude may have 50%,not by mass but by fluff
1.5 Bill. bls (35 years)
Reservoir OIP 1.4 Tril. bls EHCO
Oil Mobility 6 md/cp
Outline
Introduction to Project
Solids Impact / Separation
Gas Separation
Performance Monitoring & Diagnosis
Wrap-Up / Lessons Summary
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MPP Decision Drivers
Eliminate high capital cost of remote flow-stations
Reduce operations manpower and hopefully OPEX
Reduce back pressure on production wells
(increases ultimate recovery late in field life)
Eliminate annular gas gathering along with associated
condensate problems
Facilitate 2-stage separation at the CS to reduce gas
compression requirements
Make the field development plan more flexible
Fuel Coke
The Process
UPGRADERExtra Heavy Crude
Production Facilities
Heavy Syncrude
Light Syncrude
Diluted Oil Pipeline
Diluent Pipeline
Syncrude
LPG
Sulfur
To a foreign
Refinery Gas Oil
To a local
RefineryTo local
Customer
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MPFM
Test System
Gathering
System
Multiphase Pump
Central Station
Diluent
Distribution
System
Diluent
Injection
Skid
Typical Cluster with MPP
Clusters layout and MPPs
CS
2ND INTERNATIONAL EMBT CONFERENCE // MULTIPHASE PUMPS IN HEAVY OIL PRODUCTION LESSONS LEARNED
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What wasFound
High Percentage of Oil in Place
in Thinner Sands
How good are
the Junctions?
Multilateral
Solids Impact/Separation
The Source What wasExpected
High Percentage of Oil in Placein Thick Sands
Single Lateral
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Living w/solids
- Solids are an area of concern, have impacted operatingcosts and the potential to cause significant flow restrictions
- MPPs are an early indicator of solids production
- Limited success in preventing solids at the surface
- Hardening is part of the answer, but not 100%
- Pilot test to remove specific grain-size, high wear solids
(long-term bulk solids removal is needed)
Issue: Wear Rate / Long Term Operating Costs
Pass, Push or Crush
Issue: Wear Rate / Long Term Operating Costs
Three ways for Solids to pass an MPP:
Pass fine solids (now its a processing problem)
Push larger solids (now its a pipeline problem)
Gap sized solids Roll & Crush at leading edge of Screw(now its an MPP problem)
2ND INTERNATIONAL EMBT CONFERENCE // MULTIPHASE PUMPS IN HEAVY OIL PRODUCTION LESSONS LEARNED
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Tested several sand cyclone systems for construction of a
pilot solids removal facility ( to eliminate solids impairing
MPP performance - not bulk solids removal )
Inlet
Overflow
Underflow
Solids removal test
50 micron and below solids appear to adhere to the crude
and pass through the MPP with nominal impact Particles between 100 and 350 microns create abrasive and
erosive effects
Particles above 350 microns are rolled and crushed at the
leading edge of the screw causing rapid loss of performance
Solids removal was targeted at particles > 100 microns
Sand Removal Test6" Cyclone
0.005.00
10.0015.00
20.0025.00
30.0035.00
3360
2000
800
594
420
300
177
150
44 -
Microns
%byweightoftotal
sample
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Years
Gas separation
Oil & Gas production history
GOR 130
cf/bbl
GOR 465
cf/bbl
Solids Removal Pilot
Pilot test successfully removed high wear grain-size solids
2ND INTERNATIONAL EMBT CONFERENCE // MULTIPHASE PUMPS IN HEAVY OIL PRODUCTION LESSONS LEARNED
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160160
MBOEPDMBOEPD
3939
MBOEPDMBOEPD
EHCOEHCO
25% of25% of
CapacityCapacity
5454
MBOEPDMBOEPD
3939
MMBOEPDBOEPD
106MBOE Liquid capacity yields 4.7MMSCFD Gas capacity106MBOE Liquid capacity yields 4.7MMSCFD Gas capacity
Effect of Gas Volume Factor
Pass or Bypass
Issue: Wear Rate / Lost Capacity / CAPEX / OPEX
Impact:
Pumps are positive displacement and Gas steals a large
fraction of capacity
Slugging / Blowby effects
Impact on bearing and case temperatures
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Performance & Diagnostics
Issue: Managing Wear Rates and Field Performance
Early detection of abnormal operating conditions are critical
to managing MPP operting costs
Linking MPP performance to other process information has
synergistic benefits.
Pre-separation at MPP suction
MPFM
Test System
Gathering
System
MultiphasePump
Central
Station
Diluent
Distribution
System
Diluent
Injection
Skid
Gas
Extraction
Increase in EHCO Production
2ND INTERNATIONAL EMBT CONFERENCE // MULTIPHASE PUMPS IN HEAVY OIL PRODUCTION LESSONS LEARNED
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Other Diagnostics/Observations
Multiphase Pump performance variables can act as a check meter to
multiphase meters for well testing. The systems complement one
another
Actual vs. Calculated Power (Kw)
Kw
0
100
200
300
400
500
600
700
800
900
1000
Location
Tied to RPM and Gas, a good indicator
of lost capacity.
Condition and process monitoring should be an essential part of
the design
Actual vs. Calculated rpm
0
200
400
600
800
1000
1200
1400
1600
1800
2000
Location
rpm
Good indication of wear and increased
gap between the screw and linerThe difference between the bearing and the discharge
temperature is normally in a range from 40 to 90F.
A deviation will mean a low rate of diluent flushing
In&Out-Bearings, Casing and Discharge Temperatures
0.00
25.00
50.00
75.00
100.00
125.00
150.00
175.00
200.00
225.00
250.00
time
F
Discharge Temp. (F)Casing Temp. (F)
Inbearing Temp. (F)
OutBearing Temp. (F)Difference
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Wrap-Up / Lessons summary
Top Ten Failures by Class by Cost (One year)
52%
73%
78%
82%
100%98%
95%93%
89%
86%
1 2 3 4 5 6 7 8 9 10
MPPs Solids & Gas
Heat
ExchangersSolids
Submergible
Well pumps
Costs
Due to exposed pipelines, large fluctuations in temperature and
pressures are seen between night/day. This complicates long term
trending (variations up to 40 F)
2ND INTERNATIONAL EMBT CONFERENCE // MULTIPHASE PUMPS IN HEAVY OIL PRODUCTION LESSONS LEARNED
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Reduce gas lock effects by improving piping design for
gathering system( routing to reduced undulations in flowline )
Maintenance is going to be high, but likely still lower than
a stand-alone flow station
( quick turn-around key to Uptime )
Structural design critical for vibration control
( foundation and inlet/outlet piping )
MPP Lessons learned
Design modifications
Hard-Hard faces on Bearings and relocated throttle bushings to
make more resistant to solids
Modification to Bearing types & extended Shaft landing area
Diluent injection at the suction of the MPP to counteract gas
slugging
Change in maintenance philosophy. Rapid change-outs of
screws and liners
Future Ultra-hardened screws/liners
Integration of solids removal with Gas removal systems
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Eliminate high capital cost of remote flow-stations
Reduce operations manpower and hopefully OPEX
Reduce back pressure on production wells
(increases ultimate recovery late in field life)
Eliminate annular gas gathering along with associated
condensate problems
Facilitate 2-stage separation at the CS to reduce gas
compression requirements
Make the field development plan more flexible
MPP Decision Drivers
Reduce
(not w/o Gas handling)
Deffer
(higher GOR & sooner)
?
X
X
2ND INTERNATIONAL EMBT CONFERENCE // MULTIPHASE PUMPS IN HEAVY OIL PRODUCTION LESSONS LEARNED