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Abstract
The paper reports on developmental research on the
effects of viscosity and two phases, liquid gas flow on
Electrical Submersible Pumping (ESP) which are multistage centrifugal pumps for high rate and high boost applications.
Multiphase viscous performance of a full-scale electrical submersible pumping (ESP) system at Shells Gasmer facility has been studied experimentally. The objective of this study is to predict the operational conditions
that cause degradation and gas lock for light and high
viscosity fluids to support ESP operation in Shell International E&P Inc (Shell) Deepwater major Projects BC-10
and Perdido. The ESP systems studied used a 1025 series
tandem WJE 1000 mixed flow type pump. The test facility work was performed using pumps with 32 stages moving fluids with viscosity from 2 to 450 cP at various
speed, intake pressure and gas void fractions (GVF, aka
gas volume fractions). ). Additional tests with 4 stage
WJE1200 were conducted at the Centrilift facility in Claremore using single phase viscous fluid.
The ESP system is an important artificial lift method
commonly used for medium to high flow rate wells. Multiphase flow and viscous fluids cause problems in pump
applications. Free gas inside an ESP causes many operational problems. Under two-phase flow conditions, loss of
pump performance or gas lock condition can be observed.
Under viscous fluids, the pump performance degrades as
well.
No work has been carried out on ESP performance in
viscous fluid for multiphase flow. The testing at Shells
Gasmer facility revealed that the ESP system is robust
and performance tracked theoretical predictions over a
wide range of flow rates and light viscosity oils
The main technical contributions of this study are the
data collection and analysis of pump head degradation
under two important variables, high viscosity and twophase flow inside the ESP.
Background
Shell is the operator in two major projects where
there has been significant advancements in deepwater
subsea boosting technology, operations, and surveillance:
Perdido in the Gulf of Mexico (on stream since March
2010) and BC-10 offshore Brazil (on stream since July
2009). These novel projects continue the long tradition of
Shells leadership in the challenging deepwater environment by development and application of a novel seafloor
boosting system [1].
Electrical submersible pumps (ESP) were selected as
the subsea boosting system used by both the Perdido and
BC-10 assets for increased ultimate recovery and higher
production rates. The subsea boosting system is located in
a seafloor caisson. the caissons inside are used to collect
production fluids from the manifolded subsea wells. Extensive testing and qualification of the subsea boosting
system was undertaken prior to final configuration selection including construction of the worlds only 1500-hp
ESP test facility capable of controlling multi-phase fluid
viscosities and temperatures in Shell Gasmer Prototype
test facility in Houston [1].
Pump performance degrades due to friction losses resulting from the fluid viscosity. As the viscosity increases,
the maximum flow capacity of the pump is reduced and
the required brake horsepower (BHP) increases. Furthermore, multiphase flow causes several problems in pump
application in gassy oil fields. Most critical behavior under two-phase flow is pump gas locking which is related
to a potential unstable conditions where ESP system can
be damaged and/or even cause a system failure.
To mitigate the risks further, Shell performed fullscale tests of caisson ESP systems to validate the performance of the ESP components over the range of fluids
viscosity, GVF and flow rates expected in the field. These
tests were conducted at a land-based facility rather than
offshore to reduce costs and minimize delays due to logistics. A full-scale ESP system and test loop were constructed in 2006 at Shells Gasmer Facility to test subsea
boosting technologies.
A comprehensive test plan was implemented and performance tests had been carried out for these systems.
This paper considers configuration G and H testing
and analysis only. Test results of the configuration A to
C were discussed by Gilyard [1].
Details of the ESP equipment used for the testing, is
given in table 1. The ESP system included a 1025 series
tandem, 32 stage, WJE 1000 pump. This ESP system
used 875 series tandem seals, a single 2000 hp variable
speed drive (VSD) and a 1500 tandem hp motor. A
Lissett Barrios, Charles Deuel, David Knowles, Sandeep Patni, Stuart Scott and Ketan Sheth
shroud was used to ensure that fluids are directed past the
motor to ensure adequate cooling of the motor.
ESP was tested for various parameters including, inlet
pressure, viscosity, speed, flow rate, % GVF and its effect
on the ESP performance and reliability. Testing provided
guidelines for the field operations. Various test parameter
envelope is given in table 2. Three different oils were
used for viscosities varying from 1 to 450 cP. For safety
considerations the injected gas was restricted to nitrogen.
The primary test objectives were to:
Validate hydraulic performance maps of the caisson
ESP systems
Establish ESP system performance curves (flow rate,
head, speed curves) over a wide range of GVFs and
viscosities
Determine ESP performance at high GVF and predict
gas locking and/or instable behavior
System Schematic
The test facility consisted of the caisson ESP system and
the supporting surface facilities. The caisson ESP system
consisted of:
A 300-foot deep cased hole, 45-inch ID
A 300-foot caisson vessel, 36-inch OD suspended in
the cased hole
One of a number of configurations of ESP suspended
inside the caisson from its top tubing hanger
Power and instrument cables running to and from the
ESP, including medium-voltage, subsea electrical
power connectors
Instruments connected to the ESP and to the production tubing to measure pressure, temperature, flow,
level and vibration at various locations within the
caisson
A control system for operating the ESP through its
variable-frequency drive
Variable-frequency drives to power the ESP(s)
Test loop schematic is shown in Fig 1. It uses pneumatic and motorized flow control, Coriolis flow metering,
and variable speed drive control. The system is charged
with either a low, medium or high viscosity oil depending
on the test requirements. Fluid viscosity delivered to the
caisson from the supply vessel ranged from 2-450 cP and
was controlled by a heat exchanged located downstream
of the supply vessel.
Coriolis flow meters ELITE series, with +/-0.05%
mass and volume flow accuracy; +/-.35% gas flow accuracy; +/-0.0002g/cc density accuracy were used to measure incoming liquid to the caisson and multiphase fluid
from the ESP discharge. Pressure and temperature transmitters used were located at the pump intake and discharge to measure pump total differential pressure. Horse
power was calculated from motor KW and efficiency and
RPM were measured from variable speed drive control
unit.
Once a targeted single phase (liquid) flow rate, intake
pressure, RPM, temperature etc. at the test pump is estab-
Large-Scale Experimental Investigation of ESP Performance With High Viscosity Fluids and Gas
Testing
The main objective of this study is to evaluate the performance of the pump under two-phase conditions and
viscous fluids. Therefore, the working fluids selected
were mineral oil for the liquid phase and nitrogen for the
gas phase. The viscosity of the oil is shown in table 3.
To investigate the behavior of gas/oil mixture viscous
flow inside the ESP, pump performance is determined as
a function of liquid and gas flow rates, inlet pressure, outlet pressure, and physical properties of the fluid.
Test Results/Data Analysis
Single Phase Viscous Flow.
WJE 1200 4 stage pump was tested in water at 3500
rpm (60 Hz) speed. Viscosity correction factors for the
pump were developed by testing at two speed 2625 and
3500 rpm, up to 2500 cP, in the R&D viscous test loop of
pump plant in Claremore, OK. The pump performance
curves for the head and BHP at 2625 rpm, up to 2500 cP
is shown in the Figs. 3 and 4. The ESP pumps were also
tested in Gasmer test facility to verify the viscous pump
performance. Pump overperformed at the very low viscosities on the head flow performance. This is due to higher
reduction in leakage losses than the increase in viscous
losses. Overall, viscous performance did match with the
previous testing. As viscosity increases, the head flow
performance deteriorates and BHP performance increases,
resulting lower efficiency and reduced performance.
Two Phase Viscous Flow.
Effect of Speed.
In viscous applications, affinity laws for speed
changes to the pump performance are not accurate and
hence cannot be directly applied. [2]. As speed increases,
(a) The Reynolds number increases and the friction factors move from laminar to transition to turbulent region,
resulting in lower friction and smaller flow correction
factors; (b) Mixing losses at the impeller and diffuser inlet
and exit are often considered as little dependent on the
Reynolds Number; (c) Disk friction losses grow with decreasing Reynolds Number or increasing viscosity; and
(d) mechanical losses are essentially independent from the
viscosity of the fluid pumped; (e) head increases with the
square of the speed; (f) friction losses increases by the
power of 2.5, and not cubic ration of the speed. Because
of the above reasons, at constant viscosity, BHP does not
increase by cubic ration of the speed. This fact is also
supported by the increase in the efficiency of the pump
with the increase in the operating speed at constant viscosity [3, 4].
Effect of GVF.
Addition of gas has considerable effect on the pump
performance, depending upon the viscosity of the fluid.
Fig 5 shows the two-phase pump performance at 50 Hz
for light oil (2 to 6 cP) and 500 psia pump intake pressure
Lissett Barrios, Charles Deuel, David Knowles, Sandeep Patni, Stuart Scott and Ketan Sheth
Conclusions
Pump manufacturer need to supply guidelines for
predicting performance of multistage pump in
viscous and two phase flow conditions.
Stage by stage performance calculation of multistage pump is recommended for viscous multiphase flow applications. Viscosity and gas volume should be calculated from first stage as a
one stage pump, corrected by pressure and temperature rise, and then should be used for second
stage and so on.
As intake pressure increases, gas behaves more
as liquid than as a gas and chances of gas going
back to solution increases, (a) lowering fluid viscosity if gas miscible in liquid or (b) if gas not
miscible, then mixture viscosity will increase by
creating emulsion.
An increase in GVF will decrease the BHP requirement of the pump due to reduction in the
mixture density. However, it may increase the
BHP requirement if it creates emulsion.
At constant viscosity, minimum % GVF handling capacity of the pump increases as intake
pressure increases. Also due to increase in viscosity, from 2 to 100 to 225 cP viscosities, gas
handling capabilities of the pump increases.
At constant intake pressure, minimum GVF handling capacity of the pump increases with increase in viscosity. Also due to increase in take
pressure from 290 to 550 to 900 psi, gas handling capabilities of the pump increases
At constant viscosity, stable operation of minimum flow limits and % GVF handling capabilities is further expanded to the lower flow rates
(indicating higher stable operation at lower flow
rates) as pressure increases.
At constant intake pressure, stable operation of
minimum flow limits and GVF handling capabilities is further expanded to the lower flow rates
(indicating higher stable operation at lower flow
rates) as viscosity increases.
Pumps should be run at the highest possible operating speed for viscous two phase flow conditions, considering thrust, NPSH, operating flow
range, efficiency and erosion.
Nomenclature
FAT = Factory acceptance test
BEP = Best efficiency point
BHP = Brake horsepower, hp
GVF = Instantaneous gas void fraction (gas volume /
total fluid volume)
cP = Centipoise, dynamic viscosity
cSt = Centistokes, kinematic viscosity
DP = Differential pressure across the pump
Acknowledgments
The authors would like to acknowledge Shell and Baker
Hughes for permission to publish this paper.
Large-Scale Experimental Investigation of ESP Performance With High Viscosity Fluids and Gas
Figures
Motor
Seal Chamber
Section
Configuration
G and H
Pump
Motor Jacket
Maximum
7000 11000
35000 40000
250
1000
% GVF
10
60
Viscosity (Cp)
350
Speed (Hz)
50
70
Pump hp
300
1225
45 %
110 %
Amps
98
235
150 %
Light
Medium
Heavy
Degrees F
Conosol C 201
Hygold L201
AC 2501
70
2.8
110.2
1756.9
104
1.9
35.2
432.0
150
1.2
11.9
102.9
Lissett Barrios, Charles Deuel, David Knowles, Sandeep Patni, Stuart Scott and Ketan Sheth
Table 5Effect of Viscosity and Intake Pressure on Minimum Two Phase Flow Handling Capabilities
Blowdown to
Atmosphere
Discharge
Gas
Pressure Control
Compressor
Valve
Gas Cooler
M
Density
Meter
M
Vent Drum
Primary
Separator Balance
Line
Oil Cooler
Recirculation
Pump
Supply
Vessel
Flow
Control
Valve
Relief
M
Clamp-on GVF
Meter
Electric
Heater
Choke
Flow
Development
Spool
Caisson
Separator
& Pump
Drain Line
Drain Line
Warm-up
Valve
Spec Break
600# 5000 psi
Gas Booster
Electric
Heater
Drain Line
Liquid Carryover
Separator
Flow
Control
Valve
M
M
Mix Point
Service Line
Recycle Valve
Drain Line
ESP
Suction
Scrubber
Liquid
Carry-over
Meter
M
Motor
N2Supply
Vent to
Atmosphere
Subsea
Equipment
Large-Scale Experimental Investigation of ESP Performance With High Viscosity Fluids and Gas
DP stage, psi/stg
140
120
100
80
`
60
40
20
0
0
2800 CP
670 cp
210 Cp
10000
2200 CP
535 Cp
155 cp
20000
30000
Total flow, bpd
1790 CP
445 Cp
129 Cp
1225 CP
410 Cp
107 Cp
995 CP
380 Cp
80 Cp
40000
835 Cp
313 Cp
49 Cp
50000
765 Cp
280 Cp
Water
Lissett Barrios, Charles Deuel, David Knowles, Sandeep Patni, Stuart Scott and Ketan Sheth
20
`
15
10
5
0
0
5000
10000 15000
2800 CP
670 cp
210 Cp
2200 CP
535 Cp
155 cp
1790 CP
445 Cp
129 Cp
1225 CP
410 Cp
107 Cp
995 CP
380 Cp
80 Cp
40000
45000 50000
835 Cp
313 Cp
49 Cp
765 Cp
280 Cp
Water
BHP, Hp/stg
25
1500
1000
500
0
0
10000
20000
30000
40000
50000
GVF= 10-13%
GVF=25-27%
GVF=40-44%
GVF=14-18%
GVF= 30-32%
GVF=45-46%
Fig. 532 Stage WJE1000 Pump Performance 500 Psia Intake Pressure At 2-6 Cp And 50 Hz.
Large-Scale Experimental Investigation of ESP Performance With High Viscosity Fluids and Gas
BHP (HP)
800
700
600
500
400
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
25% GVF
30% GVF
40% GVF
45% GVF
FAT Oil
Fig. 6Comparison Of Viscous Two Phase BHP - Flow Pump Performance For 32 Stage WJE1000 Pump At 500 Psi Intake Pressure,
50 Hz and 1 cP Oil (Light Oil).
2500
2000
1500
1000
500
0
0
10000
20000
30000
Total Inlet flow (Oil+Gas), bpd
FAT- 180cp
GVF=22-24%
GVF=25-27%
GVF=36-38%
GVF=39-43%
GVF=50-55%
40000
Fig. 7 32 Stage WJE1000 Pump Two Phase Performance 500 Psia Intake Pressure At 180 Cp And 50 Hz.
10
Lissett Barrios, Charles Deuel, David Knowles, Sandeep Patni, Stuart Scott and Ketan Sheth
1600
1400
Total DP , psi
1200
1000
800
600
400
200
0
0
10000
20000
30000
Total Inlet flow (Oil+Gas), bpd
40000
2 cp GVF=25-27%
2 cp GVF=34-37%
2 cp GVF=40-44%
180 cp GVF=25-27%
180 cp GVF=36-38%
180 cp GVF=39-43%
Fig. 8Comparison Of 32 Stage WJE1000 Pump Performance For 2 And 180 Cp At 500 Psia And 50 Hz.
2000
1500
1000
Total D P , psi
500
0
0
10000
20000
30000
40000
Fig. 9Comparison Of 32 Stage WJE1000 Pump Performance At 250, 500 And 900 Psia, 2 To 6 Cp And 50 Hz.
Large-Scale Experimental Investigation of ESP Performance With High Viscosity Fluids and Gas
Total DP , psi
2000
1500
1000
500
0
0
10000
20000
30000
40000
50000
GVF=40-44% 500psia
GVF=40-43% 900 psia
Fig. 10Comparison of 32 Stage WJE1000 Pump Performance At Higher GVF At 500 And 900 Psia, 2-6 Cp And 50 Hz.
Total DP , psi
1800
1600
1400
1200
1000
800
600
400
200
0
0
5000
10000
15000
20000
25000
30000
35000
40000
Fig. 11Comparison of 32 Stage WJE1000 Pump Performance At 250 And 900 Psia, 80 Cp And 50 Hz.
11
12
Lissett Barrios, Charles Deuel, David Knowles, Sandeep Patni, Stuart Scott and Ketan Sheth
Total DP , psi
2000
1500
1000
500
0
0
10000
20000
30000
Total Inlet flow (Oil+Gas), bpd
GVF=25-27% 250 psia
GVF=25-27% 500 psia
FAT- 180cp
40000
Fig. 12Comparison of 32 Stage WJE1000 Pump Performance At 250 And 500 Bar, 180 Cp And 50 Hz.
BHP, Hp
750
700
650
600
550
500
450
400
0
10000
20000
30000
Total Inlet flow (Oil+Gas), bpd
40000
50000
Fig. 13Comparison Of 32 Stage WJE1000 Pump In Viscous Two Phase BHP - Flow Pump Performance At Various Intake Pressures, 50 Hz And 180 Cp Oil (Heavy Oil).