Heavy Crude Oil Applications

CAMARA PETROLERA DE VENEZUELA CAPITULO MONAGAS
Heavy Crude Oil Applications
A Success Story for

Multiphase Pump Technology
in Venezuela
Andreas Heinrich
Maturín Feb. 13th, 2008
What to talk about
What about the Company?

What is Multiphase Boosting?
What are the Applications?
What are the Multiphase Experiences in
Venezuela?
Company – History
From a locksmith’s
F l k ith’ shop
h tto a global
l b l player
l
1853 2007
Company – History
¾ Founded 1853, – locksmith’s shop
¾ 1934 development of twin-screw
pumps, patent granted
¾ More
1988 Joined
than 70POSEIDON Multiphase
Years Experience in
P j t (Statoil,
Project (St tPumps
Twin-Screw il Total)
T t l)
¾ More
¾ 1993 Multiphase
then 90.000Pump
Pumps Type MPC,
(liquid and
Patent granted
multiphase) in Operation worldwide
¾ Today:
⇒ 1999 first Wet Gas Compressor
Technology and marked leader
¾ 2000 SMPC
multiphase
Sub Seaboosting pumps
Multiphase
Module and
d systemswaterdepth
(Kvaerner), (with
( i h more145
than
h m440 pumps))
¾ 2002 first Multiphase High Pressure Booster with

two Pumps in Series
¾ 2006 SMPC Sub Sea Multiphase
Module (Kvaerner), water depth 5.500 feet = 1.675 m
Company – History of Multiphase Technology

1934 Development of Twin-Screw Pumps, Patent granted
1950 first Pump with external Bearings
Bearings, Patent granted
1971 very first Multiphase Pump Installation, Germany
since 1985 continuous Field Installations
1988 joined POSEIDON Project (Statoil, Total)
1993 Multiphase Pump Type MPC,
MPC Patent granted
1999 first Wet Gas Compressor
2000 SMPC Sub Sea Multiphase Module (Demo 2000,
2000 Kvaerner)
2002 first Multiphase High Pressure Booster with two Pumps in
Series
2007 world record in subsea Multiphase pumps
(water depth 5.500 feet = 1.675 m)
Company – Bornemann Today

Company – Bornemann Today

Bornemann Factory 1
Turnover Increase
2007 17%
Bornemann Factory 2)
• Represented in more than 65 Countries

• 2007 Turnover 93 Mio Euro
• 600 Employees
E l (worldwide)
( ld id )
• Privately owned
Company – Service – In-House

In House Test Bed
Bornemann iis the

B th unique
i pump supplier
li
who is able to realize a full multiphase
test
Investment volume 2.500.000,-- Euro
Power up to 2,5 MW
Company –
Multiphase Development & Research Projects
MPA P
Project
j t Multiphase
M lti h P
Pump A
Aggregates
t
Sponsoring:
Company – Results MPA Project

CNRI, Balmoral-Lyell, UK North Sea,
1x SMPC 335 - 100, 2004 (26.12.2005)
Capacity: up to 1300 m3/h
GVF design point: 70%
Differential pressure: up to 20 bar
Shaft power: limited to 1000 kW
Water depth: 145 m
BP-King, Golf of Mexico,

1x SMPC 335 - 50, 2007 (04.12.2007)
Capacity: up to 550 m3/h
GVF design point: 70%
Differential pressure: up to 50 bar
Shaft power: limited to 1000 kW
Water depth: 5.500 feet = 1.675 m
world record
Company –
Power
Transmission
P MBS
Power GP
Project
jti t
Generation MBornemann
Multiphase
lti h B
Boosting
•ti S t
System
Speed Variation
• Multiphase • Power Train
Twin-Screw Motor ((MTM)) MBS Subsea • Flow Control
Deep Water
Ultra Deep Water
Shallow Water
Power Enhancement
Sponsoring:
• Two Stage Wet Gas
Compression
• Multiphase Jet Booster (MJB)
Company –
Bornemann MBS-
MBS-Project
Power
Transmission
P
Power GMultiphase
Generation
ti Boosting System
• Speed Variation
• Multiphase Subsea • Power Train
Twin-Screw Motor ((MTM)) Deep Water • Flow Control
Ultra Deep Water
Shallow Water
Sponsoring Power Enhancement

• Two
T Stage
St Wet
W t Gas
G Compression
C i
• Multiphase Jet Booster (MJB)
What is Multiphase Boosting?

Multiphase Boosting Reservoir

R i BBehaviour
h i
Pipe
p Resistance
Pinlet mpp Poutlet mpp Separator
Pwellhead
Multiphase
Pump Gathering Station
Positive
Line inlet pressure
Reduce the
Transport
is crude
required!!!
of wellhead
oil,pressure,
natural gas,
Resistance Add energy to the untreated wellstream,
i.e.
i.e.increase
formation the
water
boosting total
theand production
sand
total in a single
production
pipeline. Without separation!
Preservoir
Multiphase Boosting Definition

Pinlet mpp
PWellhead
Multiphase
• Tri-Phase Mixture, Pump
– Liquid (oil and water), Gas and Solids.
Line
Resistance
• Average Gas Volume Fraction (GVF) > 50%
– i.e. slugs with GVF from 0% to 100% gas.
• Transient conditions
conditions,
P
– i.e. no useReservoir
of homogenizing equipment, e.g. slug
catcher sand filter etc
catcher, etc.
Multiphase Boosting Definition
Oil field
p
practice:
Oil Viscosity: 1 to more than 6.000 cSt

Water Watercut: 0 to 100%
Gas Gas content: 0 to 100%
Dirt
“Dirt” Particles: < 1 µm to > 1 cm
cm,
and salt, toxic gas, paraffin, ...
Multiphase Boosting Tri-Phase

Tri Phase mixture
100% Situation inside pipeline: Gas + Oil
Product Volume at Inlet Pressure
e
50%
Gas
Liquid
0%
0 5 10 15 20
Inlet Pressure in barg
What are the Applications?

Applications –
Why to use Multiphase Technology
1. Increase your Production
2. Decrease your Investment
3. Environmental considerations
Applications – Increase Production

sure
Press
Well Production Pipeline

Pressure
MPP Performance Envelope
pout
pact
WH Presss.
Decreasee
pin
Multiphase Boosting
Production Increase
Actual Production Optimal Production Volume Flow

Applications – MP Field Development

Tie-in Marginal Fields to Existing Facilities
MPP
30 km MPP 15 km
MPP MPP MPP
MPP
Applications –
Replacement of separation facilities in the field
for each facility
to one central
facility
Applications – Environment
E i t Protection
P t ti
Multiphase boosting contributes to protect the environmental

sustainable
t i bl development.
d l t No
N flaring
fl i gas exists.
i t
Applications – Special Solutions

In-Situ Recovery / Wet Gas Compression
• Main
M i focus
f on gas
– Production without accessories for well flow
e.G. Slug
g catcher,, re-heater,, etc.
• “Normal operation” for multiphase pump compressor
• Issue to be considered
– Heat generation inside pump – depending on pressure ratio
⇒ cooling of product, i.E. Liquid only.
– Cooling by air, external cooler or external injection.
– In-Situ Recovery high inlet temperature occurs
What are the Multiphase Experiences in

Venezuela?
Multiphase Experiences in Venezuela

Basics
• Venezuela Orinoco Belt with heavy crude oil:
Gravity 8°
8 - 12
12° API
• The crude may be diluted with light crude or naphta.
• Water is difficult to separate from heavy crude and
the water has a tendency to retain sediments / solids
• Many Fields are located in areas with hardly any
production infrastructures.

Basics
PDVSA (national oil company)
¾ Several applications in Anzoátegui, Barinas and
Monagas states
• Orinoco Oil Belt Joint Ventures:
¾ PETRO ANZOATEGUI former Petrozuata

Petrozuata:: 120 MBD
¾ PETRO CEDEÑO former Sincor:
Sincor: 190 MBD
¾ PETRO PIAR former Ameriven
Ameriven:: 190 MBD

Problems
• Major accident due to:

– Missing check valve
– Hand operated ball valves
– Erection at wrong location
– Header not suitable for multiphase mixtures
– ⇒ Only experiences guarantee you
SAFETY !
Pump Station After Fire in December 1996


Solutions
• Screw pumps were selected because of the
high-viscosity crude oil and sand content
• Bornemanns patented Pump design
• Moderate speed and larger pitch ensure that the
chambers of the p
pump
p are filled to minimize noise and
vibration
• Hardened screws and liners
• A lot of Multiphase pumps are supplied as completely
packaged units
• Control system packaged by venezuelan contractors
• Efficient support from our local specialists (CTG21).

Solutions
Joined effort between BORNEMANN - operators and CTG 21
Repair Technical Start- up &
Services Consultancy Commissioning
Trouble Shooting & Operation

Warranty issues S
Supportt ffor
Bornemann
Pump Systems
Overhaul Services
Equipment
- Total (screws,
Inspection for
liner, seals, bearings)
Maintenance
- Mechanical Seals Planning &
only Routine Maintenance
Maintenance Consultancy

Start
In 1994, the first MW8.5 was installed by PDVSA in Arecuna, to handle
Heavy Crude, with the following operational conditions:
Capacity: 53.400
53 400 BEPD
Viscosity: 550 cSt
GVF: 88.3
88 3 %
Suction Pressure: 30 psig
g Pressure: 595 p
Discharge psig
g
Velocity: 1.785 rpm
Power: 633 HP
These wells discharged directly to the MPP, because it was not
feasible to use clusters.

Field Development
In 1997, PETRO ANZOATEGUI (Petrozuata) developed with
Multiphase pumps the first heavy crude oilfield
(8–10 API) in the world,
world changing the traditional practices.
practices
Currently they have
bought 17 MPP Petrozuata Field
(mostly MW 9.5-90). Original Development
56.000 acres
38 Clusters
38 MPM
11 MPP
230 Horizontal Wells

Results
• 80 Multiphase pumps are in operation in Venezuela in
2008.
• The many installations in the Orinoco Belt have made
possible a standardized multiphase boosting system for
th fields.
the fi ld
• Bornemann Multiphase Pump Technology has been
successfully proven with heavy crude oil in Venezuela.

Results
1 PDVSA
1.
2 pumps MW8.5 in Arecuna- Anzoátegui (1994)
11 pumps MW8.5/9.5 in Bare / Arecuna – Anzoátegui (1995)
1ppumpp MW8.5 in Morichal - Monagas
g ((1995))
1 pump MW8.5 in Oritupano – Anzoátegui (1996)
1 pump MW7.3 in Barinas (1997)
4 pumps MW9.3 in Melones – Anzoátegui (2002)
Total bought: 22 pumps
2. PETRO ANZOATEGUI former PETROZUATA - Orinoco Oil Belt (since 2007)

17 pumps
p p
3. PETRO CEDEÑO former SINCOR – Orinoco Oil Belt (2000)
7 pumps
4 PETRO PIAR former AMERIVEN – Orinoco Oil Belt (since 2001)
4.
34 pumps

Field applications
Typical Requirements:
- Capacity: up to 150.000 BPD
- Absorbed Power: up to 2.000 kW
- Differential Pressure: up to 600 psi
- Pressure
Press re Rating
Rating: 300 lbs
- Gas Void Fraction: 80 – 96 %
- Heavy Slugging Product
PETRO PIAR former

f Ameriven,
A i
MW 9.3zk-53

Field applications - PETRO PIAR former Ameriven
PETRO PIAR –
Hamaca Multiphase
Boosting
The pump station
gathers the multiphase
production of different
clusters.
Multiphase
M ltiphase Experiences
E periences in Venezuela
Vene ela
Field applications – PDVSA Melones (Melem-1)
• 4 MPP
MW9.3zk-90
• Wells with
different lifting
modes (ESP,
(
PCP, Beam
pumps)
• MPP
installation
recommended
for existing
fields
Source: PDVSA

Field applications – PDVSA Melones
MPP station
Power House equipped with:
- VFD – Syncronized
S i d Transfer
T f
- MCC – Motor Control Center
Control and Automatization System for Low and Medium Voltage

Field applications – PDVSA- Bare y Arecuna
Source: PDVSA

Field applications – PETRO ANZOATEGUI
PETRO ANZOATEGUI former Petrozuata MW9.5


Evolution of the Multiphase Boosting Systems
1994 1997 2000

Local Assistance – Corporación Tecnología

Global 21, C.A.
9 Local representative in Venezuela CTG 21 with more than
17 years experience in the oil & gas industry.
9 Local Service: diagnosis, preventive maintenance, major

maintenance, commissioning, start up and training.
9 Cooperation with national companies.
9 T
Technical
h i l assistance
i t d
during
i engineering
i i and
dddesign
i off
pumping stations and systems.
9 Spare parts supply and after sale service.

www.ctg21.com
Thank you very much

for your attention !

Heavy Crude Oil Applications - A Success History Multiphase Pump Technology in Venezuela - BORNEMAN PUMPS

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CAMARA PETROLERA DE VENEZUELA CAPITULO MONAGAS

A Success Story for

What to talk about

 What about the Company?

¾ 2002 first Multiphase High Pressure Booster with

Company – History of Multiphase Technology

Company – Bornemann Today

Company – Bornemann Today

• Represented in more than 65 Countries

Company – Service – In-House

Bornemann iis the

Investment volume 2.500.000,-- Euro

Company – Results MPA Project

BP-King, Golf of Mexico,

Sponsoring Power Enhancement

What is Multiphase Boosting?

Multiphase Boosting Reservoir

Multiphase Boosting Definition

Multiphase Boosting Definition

Oil Viscosity: 1 to more than 6.000 cSt

Multiphase Boosting Tri-Phase

What are the Applications?

1. Increase your Production

2. Decrease your Investment

Applications – Increase Production

Well Production Pipeline

Actual Production Optimal Production Volume Flow

Applications – MP Field Development

for each facility

Multiphase boosting contributes to protect the environmental

Applications – Special Solutions

• “Normal operation” for multiphase pump compressor

What are the Multiphase Experiences in

Multiphase Experiences in Venezuela

Multiphase Experiences in Venezuela

• Orinoco Oil Belt Joint Ventures:

¾ PETRO ANZOATEGUI former Petrozuata

Multiphase Experiences in Venezuela

• Major accident due to:

Pump Station After Fire in December 1996

Multiphase Experiences in Venezuela

Multiphase Experiences in Venezuela

Trouble Shooting & Operation

Multiphase Experiences in Venezuela

Multiphase Experiences in Venezuela

Multiphase Experiences in Venezuela

Multiphase Experiences in Venezuela

2. PETRO ANZOATEGUI former PETROZUATA - Orinoco Oil Belt (since 2007)

Multiphase Experiences in Venezuela

PETRO PIAR former

Multiphase Experiences in Venezuela

Multiphase Experiences in Venezuela

Multiphase Experiences in Venezuela

Multiphase Experiences in Venezuela

PETRO ANZOATEGUI former Petrozuata MW9.5

Multiphase Experiences in Venezuela

1994 1997 2000

Local Assistance – Corporación Tecnología

9 Local Service: diagnosis, preventive maintenance, major

9 Cooperation with national companies.

9 Spare parts supply and after sale service.

Thank you very much

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What about the Company?