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Development of Multiphase Pumps for Extreme Applications
Development of Multiphase
Pumps for Extreme Applications

Alejandro Fratini, P. Eng Jelenko Krsmanovic

Calgary Pump Symposium 2015 Calgary Pump Symposium 2013 1 Screw Pump and Seals images provided
Calgary Pump Symposium 2015
Calgary Pump Symposium 2013
1
Screw Pump and Seals images provided courtesy of Flowserve Corporation, all rights reserved.
Presenters
Presenters

Jelenko Krsmanovic is the Product Engineer for Twin Screw and Multiphase Pumps for Flowserve Corporation, based in Brantford, ON. He has worked with Twin Screw and Multiphase Pumps for the past fifteen years, he has been involved in the design, R&D and testing of multiphase and liquid twin screw pumps. Prior to this he worked in design of mobile equipment and power hydraulics. He holds a Mechanical Engineering degree from UNSA in Bosnia and Herzegovina.

Alejandro Fratini is the Product Manager for Twin Screw and Multiphase Pumps and Subsea Equipment for Flowserve Corporation, based in Vernon, CA. He has worked with Twin Screw and Multiphase Pumps for the past twelve years. In addition to this latest experience, he has lead a field service team specializing in repairing reciprocating compressors and began his career as an Applications Engineer working with centrifugal pumps. He holds a Mechanical Engineering degree from UTN in Buenos Aires, Argentina, and a P. Eng. certification from Ontario, Canada.

Argentina, and a P. Eng. certification from Ontario, Canada. CalgaryCalgary PumpPump SymposiumSymposium 20132015 2
Argentina, and a P. Eng. certification from Ontario, Canada. CalgaryCalgary PumpPump SymposiumSymposium 20132015 2
Argentina, and a P. Eng. certification from Ontario, Canada. CalgaryCalgary PumpPump SymposiumSymposium 20132015 2
CalgaryCalgary PumpPump SymposiumSymposium 20132015 2
CalgaryCalgary PumpPump SymposiumSymposium 20132015
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Agenda
Agenda

Why R&D?

Increased Capacity

Wet Gas Compression

Sleeved on Screws

Shaft Deflection vs. P

Mechanical Seals

Erosion Mitigation

Key TakeAways

Q & A

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CalgaryCalgary PumpPump SymposiumSymposium 20132015
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Objectives of R&D
Objectives of R&D
Objectives of R&D Extreme applications: • GVF range from 0 to 100% – Longer batches of

Extreme applications:

GVF range from 0 to 100%

Longer batches of gas

Higher gas inlet temperatures

Operation as Wet Gas Compressor

Lower CAPEX Lower OPEX

Upset conditions of service

– • – – – High WHSIP High start‐up suction pressure Spikes of differential pressure
High WHSIP
High start‐up suction pressure
Spikes of differential pressure
Large viscosity swings based on WC
• Increased erosion caused by sand
• Corrosive environments
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Objectives of R&D
Objectives of R&D
• Full range of GVF testing: 100% water to 100% air and everything in between
• Full range of GVF testing: 100% water to 100% air
and everything in between
• Almost 12 hours of recorded testing in phase 1
83 variables monitored live and
recorded every second over
whole length of the test
A total of 3.4 million data points
to analyze after test was
completed
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Double Start Screws
Double Start Screws

Increase throughput

Double Start Screws • Increase throughput Double start Predictions: + More displacement (larger lead) +

Double start

Double Start Screws • Increase throughput Double start Predictions: + More displacement (larger lead) +

Predictions:

+ More displacement (larger lead)

+ Inherently balanced screws Higher slip

(larger lead) + Inherently balanced screws ‐ Higher slip CalgaryCalgary PumpPump SymposiumSymposium 20132015 6
(larger lead) + Inherently balanced screws ‐ Higher slip CalgaryCalgary PumpPump SymposiumSymposium 20132015 6
CalgaryCalgary PumpPump SymposiumSymposium 20132015 6
CalgaryCalgary PumpPump SymposiumSymposium 20132015
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Double Start Screws
Double Start Screws

Created a CFD model before test

Double Start Screws • Created a CFD model before test CalgaryCalgary PumpPump SymposiumSymposium 20132015 7
CalgaryCalgary PumpPump SymposiumSymposium 20132015 7
CalgaryCalgary PumpPump SymposiumSymposium 20132015
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Double Start Screws
Double Start Screws

1800 rpm test results

Double Start Screws • 1800 rpm test results CalgaryCalgary PumpPump SymposiumSymposium 20132015 8
CalgaryCalgary PumpPump SymposiumSymposium 20132015 8
CalgaryCalgary PumpPump SymposiumSymposium 20132015
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Double Start Screws
Double Start Screws

1200 rpm test results

Double Start Screws • 1200 rpm test results CalgaryCalgary PumpPump SymposiumSymposium 20132015 9
CalgaryCalgary PumpPump SymposiumSymposium 20132015 9
CalgaryCalgary PumpPump SymposiumSymposium 20132015
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Double Start Screws
Double Start Screws

Multiphase test

Double Start Screws • Multiphase test • Drastic drop in flow with minimal differential pressure even

Drastic drop in flow with minimal differential pressure even at low GVF

No temperature rise indicate low compression ratio

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CalgaryCalgary PumpPump SymposiumSymposium 20132015
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Wet Gas Compression
Wet Gas Compression
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary
Wet Gas Compression Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary

Suction Pressure (P s )

Discharge Pressure (P d )

Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium
Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium
Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium
Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium
Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium
Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium
Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium
Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium
Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium
Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium
Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium
Suction Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium

Fluid Movement

Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium 20132015 11
Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium 20132015 11
Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium 20132015 11
Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium 20132015 11
Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium 20132015 11
Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium 20132015 11
Pressure (P s ) Discharge Pressure (P d ) Fluid Movement CalgaryCalgary PumpPump SymposiumSymposium 20132015 11
CalgaryCalgary PumpPump SymposiumSymposium 20132015 11
CalgaryCalgary PumpPump SymposiumSymposium 20132015
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Wet Gas Compression • 100% GVF test – 1200 rpm
Wet Gas Compression
• 100% GVF test – 1200 rpm
Wet Gas Compression • 100% GVF test – 1200 rpm • Different methods used to maintain

Different methods used to maintain the temperature of the liquid inside the outer casing under control

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CalgaryCalgary PumpPump SymposiumSymposium 20132015
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Wet Gas Compression • 100% GVF test – 1800 rpm CalgaryCalgary PumpPump SymposiumSymposium 20132015 13
Wet Gas Compression
• 100% GVF test – 1800 rpm
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Sleeved‐on Screws • Alternative to pinned screws
Sleeved‐on Screws
• Alternative to pinned screws
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CalgaryCalgary PumpPump SymposiumSymposium 20132015
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Shaft Deflection
Shaft Deflection
• Measurement Probe mounting
• Measurement
Probe mounting
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CalgaryCalgary PumpPump SymposiumSymposium 20132015
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Shaft Deflection
Shaft Deflection

2.125 single pitch – 900 rpm

DRVN DRV 2‐ start
DRVN
DRV
2‐ start
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CalgaryCalgary PumpPump SymposiumSymposium 20132015
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Shaft Deflection
Shaft Deflection

Double start 2.875 lead – 1800 rpm

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CalgaryCalgary PumpPump SymposiumSymposium 20132015
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Mechanical Seals
Mechanical Seals

Use of single mechanical seals

Mechanical Seals • Use of single mechanical seals Basic cartridge pusher design * Comments and exceptions
Mechanical Seals • Use of single mechanical seals Basic cartridge pusher design * Comments and exceptions
Mechanical Seals • Use of single mechanical seals Basic cartridge pusher design * Comments and exceptions

Basic cartridge pusher design

* Comments and exceptions apply

pusher design * Comments and exceptions apply Heavy duty API 682 compliant * CalgaryCalgary PumpPump
pusher design * Comments and exceptions apply Heavy duty API 682 compliant * CalgaryCalgary PumpPump
pusher design * Comments and exceptions apply Heavy duty API 682 compliant * CalgaryCalgary PumpPump

Heavy duty API 682 compliant *

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CalgaryCalgary PumpPump SymposiumSymposium 20132015
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Mechanical Seals
Mechanical Seals

Mechanical seal support system

Mechanical Seals • Mechanical seal support system Modified API Plan 31 CalgaryCalgary PumpPump SymposiumSymposium

Modified API Plan 31

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CalgaryCalgary PumpPump SymposiumSymposium 20132015
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Mechanical Seals
Mechanical Seals

Liquid levels

NDE DE Bottom of seal chamber Bottom of suction chamber Diff. P. [psi] Liquid Level
NDE
DE
Bottom of seal chamber
Bottom of suction chamber
Diff. P. [psi]
Liquid Level [in]

Test Time [sec]

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CalgaryCalgary PumpPump SymposiumSymposium 20132015
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Mechanical Seals
Mechanical Seals

Single seals in high GVF

Basic seal Indication of poor lubrication

in high GVF Basic seal Indication of poor lubrication Heavy duty seal Indication of poor lubrication
in high GVF Basic seal Indication of poor lubrication Heavy duty seal Indication of poor lubrication

Heavy duty seal Indication of poor lubrication

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CalgaryCalgary PumpPump SymposiumSymposium 20132015
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Erosion
Erosion

Effect of sand on mechanical seals not tested

Drain to suction presents less chances of clogging cyclones

Effect on volumetric efficiency is minimal

Further new developments are on the work to address this issue.

More to come at next year’s symposium…

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CalgaryCalgary PumpPump SymposiumSymposium 20132015
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Key Take‐Aways
Key Take‐Aways

Maintain consistency between tests

Use high quality instruments – Noise makes it more difficult to analyze results

Test one feature at a time

Cooling methods for high GVF work

MPP for wet gas compression is versatile, but not efficient

Multiphase pumps can handle liquid slugs that compressors cannot

Single mechanical seals suffer in high GVF, without external support systems

Pump limits can be pushed when measuring deflection during testing

Double start screws:

Great for increasing pump displacement

Less volumetric efficiency, but marginally

No effect on deflection

Sleevedon screws:

Take care of run out during manufacturing

Use non corrosive materials

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Thank You!
Thank You!

“It’s not that I’m so smart, it’s just that I stay with problems longer.”

Albert Einstein

“Let me tell you the secret that has led to my goal. My strength lies solely in my tenacity.” Louis Pasteur

“It does not matter how slowly you go as long as you do not stop.”

Confucius

“If you are going through hell, keep going.” Winston Churchill

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