wet gas compression - calgary pump symposium · wet gas compression 1 calgary pump symposium 2005...
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1Wet Gas CompressionCalgary Pump Symposium 2005
Britta Schöneberg
Joh. Heinr. Bornemann GmbH, Germany
Wet Gas Compression
with Twin Screw Pumps
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Definition
Multiphase pumping should be called
‚Wet Gas Compression‘ when:
• the GVF (Gas Void Fration) exceeds 98%.
• only a few liquid slugs occur, if any.
• the associated liquid is of low viscosity.
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Type MWType MPC
Multiphase Pump Types Bornemann
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Twin-Screw Pump
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Sectional Drawing type MW
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C R O S S
E
C
T
V I E W
O
N
A
L
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Internal Recirculation Valve
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Design Features type MW
• Pressure Rating
ANSI 300 lbs
• Replaceable Liner for easy Maintenance
• Engineered Rotor Set
• Single acting Mechanical Seal with atmospheric Quench System
• Welded Construction
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Buffer Fluid System
Upper Buffer Vessel
Lower Buffer Vessel
Mechanical Seals
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Operational Features
• Capacity up to 280.000 BPD / 1800 m³/h
• Inlet Pressure up to 290 psig /20 barg
• Differential Pressure up to 700 psig /50 barg
• GVF up to 97%
• Dry Running approx. 30 min. without external liquid injection or cooling
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• Large scaled internal
separation chamber for liquid storage
• Internal recirculation of liquid for even heat
distribution
• Reverse flow
Pump-Compressor Design
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Sectional Drawing
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C R O S S
E
C
T
V I E W
O
N
A
L
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Design Features MPC type
• Pressure rating ANSI
600 lbs to 1500 lbs
• Replaceable liner and engineered rotor set
• Liquid flooded rotating elements
• Welded construction
• Top connections
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Operational Features MPC type
• Capacity up to 300.000 BPD / 2000 m³/h
• Suction pressure up to 1300 psig / 90 barg
• Differential pressure up to 1350 psi / 95 bar
• Dry running up to 1 hour
• Average GVF up to 99%
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Benefit
What is the benefit of wet gascompression with twin screw pumps:
• Boosting the gas production by
adding energy to an untreated wellstream.
• an increase of the gas production
by reducing the wellhead pressure.
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Pump Design
With little liquid occuring in the wet gas stream, it need to be made available. This can be done by storing it inside the pump
housing itself.
Internal re-circulationLarge scaled internal chamber
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Compression Heat
Compression of gas will generate heat.Therefore the pump filling needs to be cooled.
This can be done by:
• Liquid Recirculation
• Liquid Cooling
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Liquid Recirculation
In case the pump temperature exceed a certain levelliquid can be injected into the inlet side of the pump.
M
M 2 PhaseSeparator
toproduction
fromwells
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Liquid Cooling
M
M
toproduction
from
wells
In case the available volume of liquid is not sufficient to keepthe pump temperature at a reasonable level, the liquid inside the
casing needs to be cooled down.
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Field Cases
Inlet
pressure
Discharge
pressure
% Sm³/m³ m³/h Sm³/h MPa MPa m³/h kW
I - onshore CDN 97 283 30 8480 0.8 2.2 984 799
II - onshore NL 99.5 6895 3 20686 3.5 7.0 585 705
III - offshore NL 99.5 3044 6 18262 1.8 3.5 925 500
Shaft
powerLiquid Gas
ProjectGVF GLR Capacity
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MOBIL, Canada, MPC 335 - 100, 1997
GVF 97 %
GLR 1613 SCF/BBL
p inlet 116 psig
p disch. 319 psig
Capacity 148 MBPD
Speed 2200 rpm
Power 1071 HP
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Liquid Recirculation
from wellsto production
MPP 1
MPP 2
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GVF 99.9 %
GLR 44,841 SCF/BBL
p Inlet 500 psig
p Disch. 1,000 psig
Capacity 68 MMSCFD
Speed 1,800 rpm
Power 1,000 HP
NAM, The Netherlands, MPC 335 – 60, 1999
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Liquid Cooling
to production
from wells
MPP
Cooler
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Heat exchanger for pump filling and gas engine cooling system
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NAM, Offshore Netherlands, MPC 335 – 100, 1999
GVF 99,5 %
GLR 17,038 SCF/BBL
p inlet 220 psig
p disch. 580 psig
Capacity 176 MBPD
Speed 1,800 rpm
Power 670 HP
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MPP
from wells
to production
to production
Liquid Cooling
Cooler
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Heat exchanger sized for pump filling only (K 15 FB)
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• Wet Gas Compression with Twin Screw Pumps is feasible.
• Compression heat is removed by liquid circulation.
• The commercial approach should consider the complete system.
Conclusion
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Thank you
for your attention !
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Multiphase pumps in CSS operations
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Why the Need for Vapor Recovery?
• Annulus gas conservation
• Eliminate flaring & flare emissions
• Maximize the steam cycle
• Recovery of gas affects economics
• Address military concerns
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Why Use a Multiphase Pump?
• Conventional Equipment:
– Reliable, well known to operations
– Individual components inexpensive
– Total installation fairly expensive
• Multiphase Pump
– Overall capital cost reduction
– Wide operating range
– Less overall maintenance support
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Minimum Maximum
Ambient Temperatures
- 40 deg. F + 95 deg. F
Annulus Gas 50 deg. F
3 psig 10% Water Vapour
320 deg. F 150 psig +
60% Water Vapour
Bitumen Emulsion 0.5 cP Viscosity
122 deg. F 25,000 cP Viscosity
320 deg. F
Challenges
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Norman Wells
Sable Island
CanadaU.S.A.
Calgary
Edmonton
PEACERIVER
ATHABASCASyncrude
Cold Lake
100 mile
125 km
WABASCA
ALBERTA
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Cyclical Steam Stimulation (CSS):
– Huff and Puff operation -wet gas collected from casing annulus.
– Sour gas composition changes during the cycle from 80% CO2 - 20%.
– Temperature is close to saturated steam, ~ 266°F at typical suction pressure.
– 20 - 30 wells on a pad.
– Pad level gas design rate of 30,000 sm3/d (~ 1 MM scf/d).
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Inlet Pressure 1.6 barg 23 psigDischarge Pressure 14.0 barg 203 psigTemperature 90 o C 194 °FVolume 600 m3 / hr 91 MBEPDSpeed 1785 rpmMotor 300 kW 400 hpGas Volume Fraction 95 %
Pump Type MW 8.5 zk - 85
Design Conditions IOR
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Vent Gas PFD and Equipment Summary
Discharge Scrubber
Vent Separator
Blackmeredischarge to trunk line
Shell and Tube
Condensate Separater
Grundfossdischarge to trunk line
Nash Liquid Ring Compresser (2)
Seal Water Cooler
Gas to
trunk line
Glycol Aerial Cooler
Glycol PumpGlycol to shell & tube, and plate& frame
Aerial CoolerVent Gas
Multiphase Pump
Liquid Trap
Recycle Liquid
Liquid
Overflow to Group
Liquid Level
Compressed Gasto Group
Conventional Process Flow3 pumps
3 vessels
3 exchangers
2 compressors
Multiphase Process Flow1 pump1 vessel1 exchanger
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GVF 95 %
GLR 279
p inlet 24 psig
p disch. 131 psig
Capacity 93 MBPD
Speed 1780 rpm
Power 373 HP
IOR Operating Parameter
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Drawing Key
PrimroseSteam Plant
CSS Well Pad
Pipeline Corridor
CSS Well Horizontal Leg
CSS Well Build Leg
Field Lay-Out
CNRLCANADIAN NATURAL RESOURCES
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Inlet Pressure 1.1 barg 16 psigDischarge Pressure 15.0 barg 217 psigTemperature 125 o C 257 °FVolume 630 m3 / hr 95 MBEPDSpeed 1785 rpmMotor 225 kW 300 hpGas Volume Fraction 96 %
Pump Type MW 8.5 zk - 85
Design Conditions CNRL
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VFD
TY
PY
FY
500 HP MW 8.5-67
Multiphase Pump
3 Phase Separator
Recycle Water Cooler
The Process
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CoolerManifold
BuildingMultiphase Pump
Building
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Thank you
for your attention !