THE APPLICATIONS OF THE APPLICATIONS OF SURFACE JET PUMP TECHNOLOGY TO INCREASE OIL & GAS PRODUCTION D N j B C lt
- Dr. Najam Beg, Caltec
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THE APPLICATIONS OF THE APPLICATIONS OF SURFACE JET PUMP TECHNOLOGY - - PowerPoint PPT Presentation
THE APPLICATIONS OF THE APPLICATIONS OF SURFACE JET PUMP TECHNOLOGY TO INCREASE OIL & GAS PRODUCTION D N j Dr. Najam Beg, Caltec B C lt www.caltec.com Contents 1. Jet pump principle of operation 2. Design and performance of jet pumps g p
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– Production boosting – LP back out – De‐bottlenecking compressors – De‐liquification wells De liquification wells – Flare gas
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HP Discharge
Nozzle Mixing tube Diffuser
1 3 4 5 6 7 2 8
LP
HP Flow LP Flow Combined Flow
Velo sure Press
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1 4 P2 P1 2 3 5 6 Deck level 6 GAS 7 8 9 GAS OIL WATER WATER
Oil and Gas Production Flow Path
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Jet Pump Low Pressure ( ) S High Pressure (HP) Stream Discharge Stream
Typical jet pump
(LP) Stream Jet Pump High Pressure (HP) Stream Discharge Stream
Jet pump for just pressure boosting
Low Pressure (LP) Stream Jet Pump Low Pressure High Pressure (HP) Stream Discharge Stream
Jet pump for just backpressure lowering
(LP) Stream Jet Pump High Pressure (HP) Stream Discharge Stream Low Pressure (LP) Stream ( )
Jet pump for backpressure lowering and pressure boosting
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Pressure Flowrate e Flowrate sure Pressure Flowrate Pressure Press Flowrate
Low Pressure (LP) Discharge
e Flowrate
( )
Pressure Flowrate Pressure Flowrate Pressure
High Pressure (HP)
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5
COMMERCIAL-IN-CONFIDENCE
4.5 PR=2 PR=3 PR=5 PR=7
Gas Jet Pump/Ejector Performance Curves
3.5 4
ssure Ratio
PR 7 PR=10 PR=15 PR=20 HP to LP Pressure Ratios Curves
Oth F t
2 5 3
arge to LP Pres
Other Factors;
Molecular weight, Cp/Cv ratio t
2 2.5
Discha
etc.
1 1.5 0.5 1 1.5 2 2.5 3 3.5 4
LP to HP Mass Flow Ratio www.caltec.com
110
100 110
Nozzle # 1 Design conditions HP Pressure = 84 barg HP Fl t 35MM fd & 53 bbl/d
90 ure (barg)
HP Flow rate = 35MMscfd & 53 bbl/d
70 80 HP Press 60
Nozzle # 2 Design conditions HP Pressure = 62 barg HP Flow rate = 33MMscfd & 45 bbl/d
50 20 25 30 35 40 45 HP Gas Flowrate (MMscfd)
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11 12
Jet Pump Performance
LP pressures vs. LP intake flowrates at three HP pressures
9 10 11 Jet Pump Required Discharge Pressure = 11.5 barg 7 8 essure (barg) Maximum flow through jet pump before choking 4 5 6 Inlet LP pre Jet Pump design point :
HP = 65.2 MMscfd @ 75barg
Operating curve 1 Operating curve 2
2 3 5 10 15 20 25 30 35 40
@ g LP = 25.5 MMscfd @ 4 barg Discharge = 11.5 barg
Operating curve 3
Inlet LP flowrate (MMscfd)
HP=65.2 MMscfd @ 75barg HP=57 MMscfd @ 65barg HP=70 MMscfd @ 80barg
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High Pressure Side (Removable HP Nozzle) Discharge Side (Removable Diffuser)
Patented Universal Design Ejector / Jet Pump
Diffuser Low Pressure Side Nozzle
Removable Nozzle Removable Mixing tube / Diffuser
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Nozzle Diffuser
EXAMPLE JET PUMP LAYOUT
(TOP / PLAN VIEW) High Pressure (HP) Gas Jet Pump Discharge Line (TOP / PLAN VIEW) Jet pump orientation where LP comes from side Discharge Silencer LP Optional Acoustic LP Silencer EXAMPLE PROJECT NORTH jacket Low Pressure (LP)
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p
Boost production from LP wells
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Solution: Solution: Used HP recycled gas to power jet pump, to draw-in low pressure Shell ll Benefits wells Benefits
Shell wells into the exiting
Export Davy Line Compressor
g facilities.
Jet Pump
Export Bessemer
Separator Line
compressor
Low Pressure Gas Wells
Dp
compressor
Kilo Subsea Line
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Multi Awards winning solution
Solution Using high pressure gas from the well to power the jet pump enabled to draw-in the backed-out low pressure wells Benefits p
bar giving extra 22 MMscfd of gas (production increased by 110% ).
minimum modification to the existing piping.
wnstream s/Pipelines
the LP wells.
To Dow Process Gas Eductor
higher downstream pressure.
High Pressure Wells Low Pressure Wells (initially backedout) www.caltec.com
Solution ; HP gas from the existing compressor Solution ; HP gas from the existing compressor
Benefits
psi enabling loaded wells to produce consistently
Higher gas velocities, lowered liquids accumulated in the pipeline, causing a further 140psi drop at the wellhead %
pressure reduction and lower pipeline loss.
Export 40MMSCFD 400 psig 200 psig 1250 i Sales
2.5 Bscf of otherwise lost reserves recovered.
suction increased compressor throughput.
Ejector 1250 psig Recycle gas process 7.4 MMSCFD 850 psig Sub sea manifold
GEMINI
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Solution Used a jet pump and HP gas from a Used a jet pump and HP gas from a satellite to reduce the operating pressure of the Separator and increase
p p Benefits
JET GAS TO
JET PUMP HP GAS
LP GAS
GAS TO GATHERING STATION 7 miles Platform B
psi.
hi d ith dditi l i t d
LP GAS
OIL TO PUMPING
Separator
pipeline
achieved with additional associated gas
LP WELLS
SYSTEM Platform A
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Solution Wellcom gas system. The high pressure gas well was used as motive flow to boost pressure p
Benefits
p now producing 140,000 Nm3/d using energy from HP well.
compression section, thus allowing the LP compressor to be switched off.
compressor.
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At Gathering Site
High Pressure (HP) Gas Stream cycle line
At Well Site
Existing Gas Jet Pump # 2 Discharge Silencer Discharge Silencer HP Gas Well Gas Jet P #1 LP Silencer Re-c
At Well Site
XX Km
LP Silencer Low Pressure (LP) Gas Stream Existing compressor Silencer Silencer Pump #1 LP Silencer
XX Km
LP Gas Well
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Solution To cover a wide operating range of RS field, three jet pumps were used in parallel. Each jet pump could be switched on/off depending p p p g upon the demand. High pressure gas from the existing compressor was used to power these jet pumps
Benefits
107 MMscfd thus handling LP flow variations.
High Pressure HP
107 MMscfd thus handling LP flow variations.
pressure reduction on RS.
Flow From RS Low Pressure Wells Jet Pump 1 Jet Pump 2 High Pressure HP Discharge Silencer Anti-Surge Flow Control Valve
additional incremental flowrate of 6 to 8 MMscfd.
Low Pressure Wells (LP) Jet Pump 3 LP Silencer LP Flow By- Pass Line Sep & Slug Catcher RS Gas Scrubber and Compressor
compressor suction.
Sep & Slug Catcher Sep & Slug Catcher From ECA1 From ECA2
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Solution Installed a Universal Gas Jet Pump (UJP) in the l li f th i ti C t l th
UJP
recycle line of the existing Compressor to lower the FWHP of the inlet wells whilst also boost FWHP pressure.
COMPRESSOR RECYCLE VALVE EXPOR T
Benefits
JP’ h bl i t l ll d ti t b
maximised as wellhead pressures decline.
p q p g, saving capital and accelerating the benefit
eliminated saving the client £10m capital cost eliminated saving the client £10m capital cost
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Solution
Remove the 1st stage compressor by Remove the 1 stage compressor by utilising the available energy from recycle gas from the HP compressor
Benefits
compressor
Export line
g p
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To Pipelines 2nd Stage Gas Compressor
Solution: Using re‐cycle gas from compressor to de bottleneck 1st
LP Gas Wells Re-cycle Line 1st Stage Gas Compressor
Jet Pump 1
compressor to de‐bottleneck 1st stage compressor Benefits
Jet Pump 2
Benefits
some of the gas from 1st stage to that of 2nd stage
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Solution ; Solution ;
High pressure gas from the 1st stage separator was used to power the jet pump
Benefits ;
delivered at the suction pressure of 2nd stage compressor 2nd stage compressor.
Installed jet pump after compressor removal Existing compressors
from service. It simplified system
costs
1st 3rd 4th
Jet Pump
2nd Route 2nd
costs.
compressor,
1st Stage 2nd Stage 3rd
stag e
4th Stage
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Source of HP flow; HP gas well Source of HP flow; HP gas well Benefits; Gain in gas production by 23 000 sm3/d (0 812MMscfd)For 23,000 sm3/d (0.812MMscfd)For almost two years
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Solution Solution Used HP gas from long-string to off- load the well via surface jet pump Benefits
load the well via surface jet pump
t 7 MM fd f 2 5 MM fd
Gas Jet Pump HP Gas
to 7 MMscfd from 2.5 MMscfd. Production increased by 180%. Liquid loading cycle was reduced
p LP Wet gas HP Gas
hence more sustain production
from casing
Dual Completion Wellhead
from casing.
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Solution Installed a Jet Pump (JP) using HP gas as motive force Installed a Jet Pump (JP) using HP gas as motive force from Export compressor at 150barg. Benefits
gas.
Jet Pump HP Gas
1st Stage
Export / Fuel Gas To flare
2nd / 3rd Stage
Wells
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Solution Using high pressure spare oil pump as the motive source for
B fit
the jet pump to draw in the low pressure flare gas
Benefits
Using 17 000 b/d of oil / water at 60 bar Using 17,000 b/d of oil / water at 60 bar
High Pressure Liquid
Jet Pump
Intermediate
x stage
Low Pressure Wells
Flare LP Gas
Pressure
separator inlet pressure.
g Separator
Oil To Process System Or Pumping System
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Hi h P (HP)
Wellcom System
High Pressure (HP) source [Gas or liquid} Gaslift injection system Well production S f Wellhead To downstream process Surface Production via Tubing Well
l Flowrate
Wellcom system & Gaslift injection Additional production Lift gas
Produced Oil
Gaslift injection
P Gaslift Injection Flowrate
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Well Revival Gas Jet Pump
HP Gas
Well Revival Liquid Jet Pump
HP Liquid LP Wells Test Header
M Gas
Production Header
Test Separator
M
Liquid
REVIV AL APPLIES TO BOTH GAS AND OIL WELLS S O O G S O S
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GVF OF THE LP FLOW GVF OF THE LP FLOW N=(DP-LP)/ (HP-DP)
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Solution Using high pressure oil well and oil pump as the motive source for the Wellcom multiphase system the backpressure on the low pressures oil wells was reduced. Benefits
the well of up to 11 bar was achieved. the well of up to 11 bar was achieved.
parts
additional 1.5 MMscfd of gas was achieved.
the export pipeline pressure of 55 barg
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barg.
Multi Awards winning solution
Wellcom oil system ; multiphase HP wells were used to bring in closed low pressure il ll
Jet Pump
Benefits
I-SEP p
TO PROCESS JET PUMP FROM HP WELL GAS
( 150 b/d )
I-SEP
SYSTEM JET PUMP
COMMINGLER
LIQUID
( 150 b/d )
stabilising production.
FROM LP WELL
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1200 1050 1100 1150
Flowing bottomhole pressure (FBHP) Dp at wellhead=17.4 psi
900 950 1000 1050 800 850 900
FBHP Dp =140 psi
700 750 6:0… 6:5… 7:5… 8:5… 9:4… 0:4… 1:4… 2:3… 3:3… 4:3… 5:3… 6:2… 7:2… 8:2… 9:1… 0:1… 1:1… 2:0… 3:0… 0:2… 1:1… 2:1… 3:1… 4:0… 5:0… 6:0… 7:0… 7:5…
FBHP Dp 140 psi
06 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 00 01 02 03 04 05 06 07 07
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Solution
Gas Jet Pump Optional
By borrowing some of the available high pressure export gas as the motive source for the Wellcom multiphase system, the backpressure on the low pressure oil wells was reduced and the discharge pressure increased.
Gas Jet Pump Commingler LP Gas LP Separation Gas Compressor HP Gas To Downstream Process/ Manifold
Benefits
LP Liquid Separation System Liquid Booster Pump
A backpressure reduction, A boost in the pressure of 8 barg was achieved.
This was installed on two installations
LP Wells Liquid Booster Pump
This was installed on two installations.
pressure on the wells ,but maintaining the discharge at the required value. This also prolonged the life of the the required value. This also prolonged the life of the wells considerably by allowing the wells to continue to produce at the required delivery pressure.
Production increased by 24% and 34% respectively.
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solutions.
Gas Jet Pump Optional Commingler HP Gas Gas Jet Pump Optional Commingler HP Gas Commingler Gas Compressor HP Gas Commingler Gas Compressor HP Gas To Pipelines LP Gas LP Separation System To Pipelines LP Gas LP Separation System LP Liquid Pump LP Liquid Pump LP Wells LP Wells HP Injection Water Liquid Jet Pump HP Injection Water Liquid Jet Pump
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TABLE 1: COMPARING THE PERFORMANCE OF SINGLE AND DUAL WELLCOM SYSTEMS
Case High Pressure (HP) Low Pressure (LP)
Discharge Pressure Pressure Pressure barg
Liquid flowrate m3/h Gas flowrate sm3/d
GVF
(%)
Pressure barg
Liquid flowrate m3/h Gas flowrate sm3/d GVF (%) barg A 70 100 423069 75 30 40 221662 90 34 B-1 70 423069 100 30 221662 100 40 B-2 70 100 30 40 45 Case A: Single WELLCOM system Case B-1 & B-2: Dual WELLCOM system gas & liquid jet pumps
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Discharge Inlet Flow rate Pressure Flow rate Pressure Discharge Pressure Inlet Pressure Outlet Pressure Hydraulic Shaft Power HP LP Liquid Pump Inlet GVF rate [bbl/d] Pressure [barg] rate MMscfd Pressure [barg] Pressure [barg] Pressure [barg] Pressure [barg] P [bar] Hydraulic Power [kW] Shaft Power [kW] 70% 5000 155 0.66 10 40 10 155 145 133 222 50% 5000 120 0.29 10 40 10 120 110 101 169 30% 5000 105 0 13 10 40 10 105 95 87 146 30% 5000 105 0.13 10 40 10 105 95 87 146 10% 5000 96 0.033 10 40 10 96 86 79 132 70% 5000 40 0.66 10 13 10 40 30 28 46 50% 5000 40 0.29 10 15.5 10 40 30 28 46 30% 5000 0 13 10 17 3 10 40 30 28 30% 5000 40 0.13 10 17.3 10 40 30 28 46 10% 5000 40 0.033 10 18.8 10 40 30 28 46
LP Gas + Liquid I-SEP / HI-SEP Multiphase Liquid Jet Pump www.caltec.com
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F th l li f
compressor
p
y p
t ( d ti /T t)
by site conditions separator (production/Test)
line
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Jet Pump Gas Jet Pump High Pressure Gas
1 t S
Jet Pump Gas Compressor HP Gas Gas to process / pipeline Gas Jet Pump Low Pressure Gas High Pressure Gas Discharge Gas
1st Stage Separator 2nd / 3rd Stage Separator
LP Wells To flare To pipeline/export Re-cycle Line High Pressure Gas Low Pressure Wells LP Gas Jet Pump Intermediate Pressure Gas Gas Eductor HP Gas Discharge Gas Silencer Gas Compressor LP Gas X Stage Separator Oil To Process Gas Compressor Separator LP Gas Silencer System Or Pumping System Liquid to downstream process/liquid pump Wells Manifold www.caltec.com
HP Well
1
HP Well
2
LP Wells LP Wells
Lowering the whole mainfold pressure with HP well Assisting weaker LP wells with with HP well
HP Well
3
HP Well
4
LP Wells LP Wells
Lowering the whole line pressure with compressor re-cycle Lowering LP manifold pressure with compressor re-cycle, And by-passing the HP well
Note: Above illustrations are valid for gas and multiphase (oil) jet pump applications. The intermediate separators/KOV/pumps/valves are ignored here. www.caltec.com The intermediate separators/KOV/pumps/valves are ignored here.
HP Well HP Well
LP HP Well LP LP Wells
5
LP Wells
6
D b ttl ki 1st St ith t De-bottlenecking 1st Stage compressor with next stage compressor re-cycle (taking part of the gas) Removing 1st Stage compressor with next stage compressor re-cycle
HP Well
7
HP Well
8
LP Wells LP Wells
I i d ti LP ll ith HP ll l i i li Increasing production on LP wells with HP well, lowering pipeline pressure with compressor while providing required compressor suction pressure De-bottlenecking compressor Some LP+HP wells by-pass
Note: Above illustrations are valid for gas and multiphase (oil) jet pump applications. The intermediate separators/KOV/pumps/valves are ignored here. www.caltec.com The intermediate separators/KOV/pumps/valves are ignored here.
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Discharge Jet Pump P T P T HP Gas Vent Flow Discharge Silencer Drain LP Silencer P T
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HP MP Gas HP LP MP Gas A
PT
LP Gas LP B C Gas Separator PT Gas Liquid
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In-line acoustic silencers
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Pressure rating ANSI 1500#
Material LTCS NACE CTP sizes (Jp-6) HP 3”, LP 4”, Discharge 6”
Jet Pump Skid
~ 1.5 m ~ 4 m ~ 2.4 m
Silencers Skid
~ 1.5 m ~ 3 5 m ~ 2.4 m
CTP sizes (Jp-10) HP 6”, LP 8”, Discharge 10” CTP sizes (Jp-16) HP 8”, LP 12”, Discharge 16”
Discharge Silencer V t 3.5 m Vent Jet Pump Discharge Silencer HP Gas Vent Drain CTP Tie-in Point (CTP) Vent LP Gas LP Silencer Drain CTP Point (CTP) Drip Pan www.caltec.com
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