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PE4863

Surface Facility
Course Introduction
Chapter 4.1
Pumps

PE4863 Fall 2016

Course Content
Outline
1. General Considerations
2. Centrifugal Pumps
3. Positive Displacement Pumps
4. Pump System Design
5. Other Practical Considerations
6. Multiphase Pumps

General Considerations
Pressure Head
Head:
The vertical distance between two horizontal levels in a liquid
A measure of the pressure exerted by a column or body of
liquid because of the weight of the liquid
Since a pump may be installed above, at, or below the surface
of the source of supply, the pump must be able to overcome
the net static head in order to pump from one elevation to
another

General Considerations
Pressure Head

NET STATIC
HEAD

STATIC
DISCHARGE
HEAD

STATIC SUCTION
PRESSURE

PUMP

General Considerations
BERNOULLIS THEOREM
The Bernoulli equation is a special statement of the
general energy equation
Work added to the system is referred to as pump head
(h)
Losses from the system are referred to as head loss
(hL)
Pressure (lbf/in2) is a form of work
Strictly Mechanical Energy so we get the equation:
P1 + PE1 + KE1 + WK = PE2 + KE2 + WKFRIC
+ P2

General Considerations
Bernoullis Equation

hP: pump head (ft)


hL: Head Loss (ft)
= f(L/D)(V2/2Zg)
where
f : friction factor
L: Length
D: Diameter
K: loss coefficient

z : Elevation (ft)
p : Pressure (lb/ft2)

: Density (lb/ft3)
V : Velocity (ft/sec)
g : acceleration (32.2 ft/sec2)
SG : Specific gravity [-]

P = 0.434
[psi]
[psi/ft]

hP
[ft]

SG
[-]

General Considerations
Types of Pumps
Pumps are divided into two fundamental types
based on the manner in which they transmit
energy to the pumped media:
1. Kinetic
2. Positive displacement

General Considerations
Types of Kinetic Pumps

General Considerations
Types of Positive Displacement Pumps

Course Content
Outline
1. General Considerations
2. Centrifugal Pumps
3. Positive Displacement Pumps
4. Pump System Design
5. Other Practical Considerations
6. Multiphase Pumps

Centrifugal Pumps

There

are many types, sizes, and designs from


various manufacturers who also publish operating
characteristics of each pump in the form of
performance (pump) curves.

Pump

curves describe head delivered, pump


efficiency, and net positive suction head (NPSH)
for a properly operating specific model pump.

Centrifugal pumps are generally used where high


flow rates and moderate head increases are
required,

Centrifugal Pumps

Munson, Young and Okiishi (2002)

Centrifugal Pumps

Open Impeller

enclosed or shrouded
Impeller

Munson, Young and Okiishi (2002)

Centrifugal Pumps
Impeller

Centrifugal Pumps
Pump motor

Centrifugal pump body

A double-suction, horizontal split-case, single-stage centrifugal pump


(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)

Centrifugal Pumps
Actual head rise (ha)

For negligible elevational and frictional losses

: Fluid density

Munson, Young and Okiishi (2002)

Centrifugal Pumps
Power gained by the fluid
Expressed in horse power (water horse power)

Density [lb/ft3]

Flow rate [ft3/s]

ha

Head in [ft]
Munson, Young and Okiishi (2002)

Centrifugal Pumps
Overall efficiency,

The denominator represents the total power applied


to the shaft of the pump and is often referred to as
brake horsepower bhp

Munson, Young and Okiishi (2002)

Centrifugal Pumps
Pump performance characteristic

Munson, Young and Okiishi (2002)

Centrifugal Pumps
Pump performance characteristic

Munson, Young and Okiishi (2002)

Centrifugal Pumps
Net Positive Suction Head (NPSH)
s

suction

NPSHR:

required
NPSH,
denoted that must be maintained,
or exceeded, so that cavitation
will not occur

NPSHA:

available
NPSH
represents the head that actually
occurs for the particular flow
system
Munson, Young and Okiishi (2002)

Centrifugal Pumps
Available (NPSHA)

For
proper
operation

pump

Munson, Young and Okiishi (2002)

Cavitation Damage
Impeller inlet blades cavitation on a suction side.

As bubbles flow from low pressure to higher, they implode against metal
surfaces. These micro-hammer-like impacts erode the material, creating
cavities thus cavitation

Centrifugal Pumps
Example 4.1
A centrifugal pump is to be placed above a large, open water tank, as shown in
figure, and is to pump water at a rate of 0.5 ft 3/s. At this flowrate the required net
positive suction head, NPSHR, is 15 ft, as specified by the pump manufacturer. If the
water temperature is ,80 F and atmospheric pressure is 14.7 psi, determine the
maximum height, that the pump can be located above the water surface without
cavitation. Assume that the major head loss
Assume that the head loss by fittings
between the tank and the pump inlet is
due to filter at the pipe inlet having a
loss coefficient of KL=20. Other losses
can be neglected. The pipe on the
suction side of the pump has a diameter
of 4 in.
Consider that the water vapor pressure
at 80F is 0.5069 psia and =62.22 lb/ft3
Munson, Young and Okiishi (2002)

Centrifugal Pumps
Example 4.1 - Solution
The available net positive suction head, is given by the equation

The maximum value for will occur when Thus

Since the only head loss to be considered is the loss

Munson, Young and Okiishi (2002)

Centrifugal Pumps
Example 4.1 - Solution
The maximum value for will occur when Thus

Thus, to prevent cavitation, with its accompanying poor pump


performance, the pump should
not be located higher than 7.65 ft above the water surface.
Munson, Young and Okiishi (2002)

Centrifugal Pumps
System Characteristics and Pump Selection
The energy equation between point 1 and 2 is

hP: actual head gained by the fluid


hL varies approximately as the flow
rate squared, thus

Munson, Young and Okiishi (2002)

Centrifugal Pumps
System Characteristics and Pump Selection

Munson, Young and Okiishi (2002)

Centrifugal Pumps
Example 4.2
Water is to be pumped from one large, open tank to a second large, open tank as
shown in Figure. The pipe diameter throughout is 6 in. and the total length of the
pipe between the pipe entrance and exit is 200 ft. Minor loss coefficients for the
entrance, exit, and the elbow are shown on the figure, and the friction factor for the
pipe can be assumed constant and equal to 0.02.
A certain centrifugal pump
having the performance
characteristics shown in
next slide is suggested as a
good pump for this flow
system. With this pump,
what would be the flowrate
between the tanks? Do you
think this pump would be a
good choice?
Munson, Young and Okiishi (2002)

Centrifugal Pumps
Example 4.2 Pump Curve

Munson, Young and Okiishi (2002)

Centrifugal Pumps
Example 4.2 - Solution
Application of the energy equation between the two free surfaces, points (1) and (2)

With p1=p2=0, V1=V2=0, z2-z1= 10ft. f=0.02, D=6/15 ft. And l=200 ft. The energy
equation become:

where the given loss coefficients have been used.

Munson, Young and Okiishi (2002)

Centrifugal Pumps
Example 4.2 - Solution
Fluid velocity

The energy equation can be simplified to

Converting Q to gpm (gal/min)

(Eq. 4)
Munson, Young and Okiishi (2002)

Centrifugal Pumps
Example 4.2 - Solution

Munson, Young and Okiishi (2002)

Centrifugal Pumps
Example 4.2 - Solution
Another concern is whether or not the pump is operating efficiently at the operating
point. As can be seen from previous figure, although this is not peak efficiency,
which is about 86%, it is close 1about 84%2. Thus, this pump would be a
satisfactory choice, assuming the 1600 galmin flowrate is at or near the desired
flowrate.
The amount of pump head needed at the pump shaft is

The power needed to drive the pump is

Munson, Young and Okiishi (2002)

Coverage Chart for Centrifugal Pumps


makes it possible to do a preliminary pump selection by looking at a wide range
of pump casing sizes for a specific impeller speed. This chart helps narrow down
the choice of pumps that will satisfy the system requirements

Pump Performance Curve

for a given
Model
Casing size (volute)
Impeller rotational speed
(Source: City College of New York,
Department of Civil Engineering)

Pump selection diagram


shaft hp
impeller
diameter

impeller
speed

System
curve

efficiency
contours
Possible operating
points

Figure 15.15

Course Content
Outline
1. General Considerations
2. Centrifugal Pumps
3. Positive Displacement Pumps
4. Pump System Design
5. Other Practical Considerations
6. Multiphase Pumps

Positive Displacement Pumps


Fixed volume of fluid is displaced
during each cycle regardless of static
head/pressure pumping against.
Uses either a piston, gear, or screw
type (reciprocating, rotary gear,
rotary screw, etc).

Positive Displacement Pumps

Positive Displacement Pumps


Rotary Pumps (gear, lobe,
screw, vane)
Most popular: gear pumps
90%+ mechanical eff.
Relatively constant output

Positive Displacement Pumps


Characteristic Pump

N1[rpm]

N2[rpm]

hp

GPM

Positive Displacement Pumps


Progressive cavity pump (PCP)

The PCP pump is comprised of a rubber stator and a rotating metal rotor

The cavity move in helicoidally trajectory from the suction to discharge

Sucction
Rotor

Discharge

Stator

Homokinetic
Joint

coupling excentrical
axle

Bearing

Seal

Positive Displacement Pumps


Progressive cavity pump (PCP)

To create the cavity it is required

The stator must have one more teeth than the


rotor.

Every rotor teeth always is in contact with the


stator surface.

The rotor and stator conform a longitudinal gear

Positive Displacement Pumps


Progressive cavity pump (PCP)
Slippage

Fluid leakage across the rotor/stator seal lines between cavities


results in actual flow rates that are lower then the theoretical

Theoretical Flow Rate = CapacityxPump Speed)

Slippage increases with differential pressure and also depends


on the rotor/stator fit, pump speed and fluid viscosity

Positive Displacement Pumps


PCP Design
Define the maximum (qMax) and minimum (qMin) flow rates
Define the differential pressure across the pump
This is define by the pressure losses across the system

Goto the Seepex website:


www.rotatingright.com/pdf/seepex/resources/seepex_curves.h
tml
6 is referring to 1 stage,
in general one stage
will rise the pressure in
about 90psi

12 is referring to 2
stage, in general one
stage will rise the
pressure in about 180
psi (90psi each stage)
Model V can rise in a
larger value.

For 90 psi differential


pressure

Maximum flow rate


(always give a safety
factor)

Check pump dimensions on

www.seepex.com/fileadmin/userfun
ctions/download.php?file=DIN_e_2
013_03.pdf

Consider BN range for the project

Minimum flow rate


(always give a
safety factor)

Maximum
Power

Course Content
Outline
1. General Considerations
2. Centrifugal Pumps
3. Positive Displacement Pumps
4. Pump System Design
5. Other Practical Considerations
6. Multiphase Pumps

Pump System Design


Input data
Maximum and minimum flow rates
Pressure drop required
Liquid density and viscosity
Fraction of solids

Pump System Design


Centrifugal Pumps-Series
Series (called staging):

2 pumps

hP2 = 2hP1

hP

q2 = q1

1 pump

GPM

What will happen if we use a progressive cavity pump?

Pump System Design


Centrifugal Pumps-Parallel

Head

Flow
500

500x2 = 1000

52

Pump System Design


Centrifugal Pumps-Parallel

Double the pumps But will Flow Double for sure?!

Pump System Design


Centrifugal Pumps-Parallel
It depends on a System!

1000 ft (static head)

long pipe, elbows, valves


a lot of friction

Case A

Case B

Pump System Design


Centrifugal Pumps-Parallel
Case A mostly static head

head, ft

h0 = 1000 ft
Flow, gpm
500

500x2 = 1000

Pump System Design


Centrifugal Pumps-Parallel
Case B mostly friction

head, ft

If the system can not handle it more


pumps will not add any more flow!

Flow, gpm
1000
500

550 !?

Can this happen if we use a progressive cavity pump?

Course Content
Outline
1. General Considerations
2. Centrifugal Pumps
3. Positive Displacement Pumps
4. Pump System Design
5. Other Practical Considerations
6. Multiphase Pumps

Intake Distance

Same issue as vortex braking in separation


Same logic applies

Course Content
Outline
1. General Considerations
2. Centrifugal Pumps
3. Positive Displacement Pumps
4. Pump System Design
5. Other Practical Considerations
6. Multiphase Pumps

Introduction

As its name indicates, multiphase pumps are able to boost a fluid


combining multiple phases, typically liquid and gas phases. In some
cases the pumps must also handle solids like sand, which are often
produced by hi&-rate wells or unconsolidated formation.
Emergence from research labs 19 years ago, multiphase pumping has
become a viable solution to a wide number of field development plans.
While the technology is seen to be particularly beneficial in remote
locations such as the deepwater Gulf of Mexico, pumps have also been
deployed to a number of onshore locations ranging from Alaskan North
Slope to Columbia and from West Africa to the Middle East.

Introduction
Conventional Oil Production
Conventional oil production involves the separation of the gas and
liquid phases at some point before sending he production to a
gathering or processing facility.

Gas
Pipeline

Compressor
Gas

From Wells

Well Test
Separator
Separator
Liquid

Oil
Pipeline

Tank
Pump

Introduction
Multiphase Production Systems
Multiphase production systems eliminate the need of separation and
instead boost the produced stream directly to the gathering facility. A
muItiport valve diverts the production from each well to a multiphase
flow meter.

From Wells

Multiphase
Flow Meter

To Main
Station
Multiphase
Pipeline

Multiphase
Pump

Introduction
Multiphase Production Systems
Advantages and Disadvantages:
By eliminating this equipment, the cost of a multiphase pumping
facility is about 70% that of a conventional facility (Dal Porto, 1996)
and significantly more savings can be realized if the need for an
offshore structure is eliminated altogether.
Increased production through lowering backpressure on wells.
Elimination of vapor recovery systems
Reduction in footprint of operations
However, multiphase pumps do operate less efficiently (30-50%,
depending on Gas volume fraction and other factors) than
conventional pumps (60- 70%) and compressors (70-90%).

Introduction
Multiphase Production Systems

Different production options affect the maximum distance achieved from


well to separator in a remote well (after Leggate et al. 1996).

Multiphase Pump Technologies


Multiphase Pumps
Positive Displacement
Twin Screw
Progressive Cavity Pump (PCP)
Piston
Diaphragm
Gear
Vane

Rotodynamic
Helico-Axial
Side Channel
Multi Stage
Centrifugal Pump

Multiphase Pump Technologies

Multiphase Pump Technologies


Twin-Screw Pumps
The twin-screw is by far the most popular multiphase pump in use and is
manufactured by Bornemann, Flowserve and Nuovo Pignone. Twin-screws are
particularly adept at handling high Gas Volume Fractions (GVF) and fluctuating
inlet conditions. These pumps remain functional even at GVFs of 95% and with
recirculation systems can function at 100% GVF for short periods of time.

Multiphase Pump Technologies


Progressing Cavity Pumps (Single-Screw)
Widely used in shallow wells as an artificial lift method, the Progressing Cavity
Pump (or Moyno pump) has been adapted for surface multiphase pumping. The PCP
pump is comprised of a rubber stator and a rotating metal rotor. This pump is
effective for low flow rates (less than 30,000 bbl/day total volume of gas, oil and
water) and for lower discharge pressures (maximum of 400 psig). This pump has the
unique ability to tolerate considerable amounts of solids (sand). However, high sand
production rates result in the need to replace the stator on a regular basis.

Multiphase Pump Technologies


Piston Pumps
One of the simplest forms of multiphase pumping is the use of a large double-acting
piston to compress the multiphase oil, water and gas mixture. This approach is
effective in the low and moderate flow rate ranges with a maximum capacity of
approximately 110,000 bbl/day (total volume of gas, oil and water) and maximum
discharge pressure of approximately 1,400 psig. The first type of piston pump, the
Mass Transfer Pump, was installed June 1998 by National Oil Well in Canada. This
pump makes use of the same gear box and prime mover that is utilized in
conventional sucker rod pumping units.

Multiphase Pump Technologies


Diaphragm Pumps
The diaphragm pump is a reciprocating
pump consisting of two pumping
chambers. The piston and motor are
immersed in hydraulic oil supplied by a
conventional axial-piston hydraulic
pump. An elastomeric diaphragm
separates the hydraulic oil from the
pumped fluids. While these pumps have
been primarily associated with the
liquid-solids flow associated with
deepwater drilling operations, they can
be modified to accommodate 100%
GVF fluids with high efficiency. Rates
of up to 30,000 BPD and differential
pressures of 550 psi have been
achieved with prototype pumps (Beran,
1995).

Multiphase Pump Technologies


Helico-axial Pumps
The Helico-axial pump is a type of rotodynamic pump developed by the Poseidon
Group (IFP, Total and Statoil) and manufactured by Framo and Sulzer.
The fluid flows horizontally through a series of pump stages, each consisting of a
rotating helical shaped impeller and a stationary diffuser . This configuration is akin
to a hybrid between a centrifugal pump and an axial compressor. Each impeller
delivers a pressure boost with the interstage diffuser actingto homogenize and
redirect flow into the next set of impellers. This interstage mixing prevents the
separation of the gas-oil mixture,
enabling stable pressure-flow
characteristics and increased
overall efficiency. As the gas
is compressed though
successive stages, the geometry
of the impeller/diffuser changes
to accommodate the decreased
volumetric rate.

Multiphase Pump Technologies


Multistage Centrifugal Pumps
Downhole Electric Submersible Pumps (ESPs), manufactured by companies such as
Schlumberger-Reda and Baker-Centrilift, are widely used as an artificial lift method
in oil wells. So far, this technology has tended to focus on liquid pumping with
incidental amounts of entrained gas. Recently, these pumps have been adapted for
surface pumping applications and their ability to handle gas has been extended.

Multiphase Pump Technologies


Multiphase Gas Compression
If 94% <GVF < 99% use a wet gas
compressor

Multiphase Pump Technologies


Multiphase Dual System

Operational Ranges
Operational Envelop

Question

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