Development of a High Boost, High Power, Ultra-deep Twin Screw Multiphase Pump System

Abstract

Between 2005 and 2010 Shell has been working with Flowserve and other specialty contractors to develop a next generation pumping system requiring a complete review and redesign of all major components. The work has been performed at multiple locations in Europe and the Americas by an integrated team. It has now reached the level of maturity that it can be shared within the industry. In 2004, Shell performed a comprehensive assessment of industry capability for subsea pumping. This study concluded that boost pressures available at the time were insufficient to meet future project needs, particularly for ultra-deep, heavy oil applications with large gas volumes. As a result the high boost, high power, ultra-deep twin screw multiphase pump development was initiated.The development included building and testing the subsea twin screw pump, a submersible motor, subsea electrical high power connectors, a pressure compensation system and high bandwidth fiber optic health monitoring system in addition to a purpose-built high capacity test loop. The project is now reaching its conclusion with integration of the core components due to take place by the end of 2010. Individual components such as the pump have already been tested up to 4 MW shaft power, 2400 psi differential pressure, flow rates up to 90,000 barrels per day, with viscosities ranging from 2 -2,000 centipoise, an order of magnitude greater than any similar existing machine. This paper describes the work performed, the major challenges addressed and the methodology used to overcome them. One particular challenge was the implementation of rigorous HSE requirements for such high energy, heavy equipment.

Failure Mode and Effect Analysis of Subsea Multiphase Pump Equipment

“…[1,4,5] also lists some typical failure effects that can be attributed to electrical submersible pumps in subsea field, [6,7,8] for helico-axial multiphase pump and [6,9,10,11,12] for Twin-Screw Pump.…”