Professional Documents
Culture Documents
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Surface Jet Pump Applications
De-bottleneck compressors
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Caltecs Surface Jet Pump (SJP)
(Otherwise known as an Eductor or Ejector or Velocity Spool)
HP sources:
HP wells
HP gas from process system
Compressor re-cycled gas
HP oil / water (injection water)
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Surface Jet Pump Internal Flow Dynamics
Nozzle Mixing tube Diffuser
Discharge
HP
LP
1 2 3 4 5 6 7 8
HP Flow
LP Flow
Velocity
Combined Flow
Pressure
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Surface Jet Pump Typical Performance
5
Key Factors:
HP/LP pressure ratio
4.5
LP/HP flow ratio
Discharge / LP pressure ratio
4
Other Factors :
Temperature,
Discharge to LP Pressure Ratio
3.5
Z factor, Cp/ Cv ratio
Molecular Weight
3
HP:LP Pressure Ratio
2 3
2.5 5 7
10 15
20
2
1.5
1
0 0.5 1 1.5 2 2.5 3 3.5 4
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SJP Performance - Liquid driving Gas
Maximum discharge pressure when using HP water to boost 1 MMscfd of LP gas at 1 barg
60
Discharge pressure (barg)
50
40
30
20
HP = water at 70 barg
10
HP = water at 140 barg
0
0 5000 10000 15000 20000 25000 30000 35000 40000
Water flow rate (bbl/d)
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Typical nozzle performance curve
90
Pressure = 75 barg
80 Flowrate = 65.2 MMscfd
Operating point
3
Operating point
70 1
Operating point
60 2
50
50 55 60 65 70 75 80
Inlet HP Gas Flowrate (MMscfd)
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Surface Jet Pump Performance Curves
Surface Jet Pump Performance
LP pressures vs. LP intake flowrates at three HP pressures
12
11
urface Jet Pump Required Discharge Pressure = 11.5 barg
10
9
Inlet LP pressure (barg)
8
Maximum flow through
SJP before choking
7
S
6 Operating curve 2
5
SJP Pump design point :
4 Operating curve 1
HP = 65.2 MMscfd @ 75barg
LP = 25.5 MMscfd @ 4 barg
3 Discharge = 11.5 barg
Operating curve 3
2
0 5 10 15 20 25 30 35 40
Inlet LP flowrate (MMscfd)
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Avoid LP wells` Back-Out
UKCS - Offshore
Issue
New HP wells would have backed-out LP
wells by increasing pipeline pressure
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Production Boosting & Avoiding Re-Wheeling
UKCS - Offshore
Issue
Near-by low pressure satellite wells liquid
loaded & could not produce against the
existing pipeline back pressure
Indonesia - Offshore
Issue
1st stage compressor bottlenecked,
restricting production
Client option to purchase new or re-
wheel compressor
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Compressor Replacement and Prolonging
Field Life
SJP
UK - Onshore
Issue LP WELLS
gas consumption
MP WELLS EXPORT
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Production Boosting and Reviving LP wells
Malaysia - Offshore
Issue
Multiple wells shut-in
TEST SEPARATOR
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Well Deliquification / Revival
Gulf of Mexico - Offshore
Issue
Subsea wells 50 km away from platform
and in 1000m depth shut-in and liquid
loaded
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Production Separator Pressure Reducing with HP Well
Issue
Benefits
Good use of available wasted energy
Lowered separator pressure by 105 psi.
Extra oil production of 400 bbl/d was
achieved with additional associated gas
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Reviving Backed Out Wells ,with
Production Gains
Europe Onshore
Issue
LP wells backed out by the manifold
pressure
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Two SJPs in Series for Sustaining Wells
Initial solution
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Vent Gas Recovery
Mexico - Onshore
Issues
Gas venting from crude storage tank
Environmental emissions
Safety risk from electrical storms
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Flare Gas Recovery
Nigeria
Issues
Aim was to recover flare gas since
there is no on site compressor
available.
Benefits
Flare gas pressure is boosted by 4 bar.
No flaring
Recovered 0.7 MMscfd of flare gas
Use existing spare oil and water
pumps.
The total production delivered at the
separator inlet pressure.
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Multiphase Boosting
Malaysia - FPSO
Issue
Shut-in LP wells
140psi
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Multiphase Boosting System( WELLCOM System )
Issue
Benefits
Up to 11 bar backpressure reduction was
achieved on the LP wells.
Net extra oil gain of 550 bbl/d with additional
2.5 MMscfd of gas was achieved.
The total production was delivered at the
export pipeline pressure of 55 barg.
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Extra Production gain with SJP System
and Gas lift
High Pressure (HP) source SJP/ Wellcom
[Gas or liquid] System
Production
Additional
via Tubing
production
Wellcom system &
Gaslift injection
Lift gas
Gaslift injection
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Multiphase Boosting Using Part of Gaslift as
the HP Source
Gas SJP Commingler
Issue Gas Compressor
HP Gas
Benefits
Backpressure reduction of 8 barg was achieved
Production increased by 24% and 34%
respectively
Net extra oil gain of 700 bbl/d with additional 2.5
MMscfd of gas was achieved
Low power consumption compared to alternative
solutions such as MPH pumps
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Prevent New HP Well Backing-out Production
from LP Wells & LP Well Revival
Test
Header Commingler
M
LP Wells Test Cooler
Test
Separator
M
Production
M
Header
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Subsea SJP Application for Production Boosting
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Surface Jet Pump solutions
Discharge Side
Low Pressure Side
Material of construction;
High Pressure Side - Carbon steel to various grades of
duplex
- dictated by fluids compositions
and compatibility with
interconnecting pipework
Nozzle
Replaceable
Diffuser
Mixing tube / Diffuser
Removable
Nozzle
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In-line Acoustic Silencers
Flow
Silencers needed for the LP and discharge lines to reduce noise at 1m from the SJP
Below 80 dBA
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SJPs Typical Instrumentation & Controls
HP Gas P T P T
SJP Discharge Flow
Discharge
Silencer
P T LP Silencer
Gas A
Gas HP MP
HP MP
LP B
LP
C
Gas PT
Gas PT
Separator
Liquid
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Caltec Commingler Technology
Caltec
Commingling
Solutions
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How to Identify SJP Applications Locations
At the wellhead
At the manifold
At the transportation line
At pipes connections ( e.g. Tee)
At the by-pass line
Upstream, inlet of a separator
Downstream, at the outlets of a
separator (production/Test)
Upstream of compressor suction line
From the re-cycle line of compressor
Downstream of compressor
Between compressor stages
- SJP Application Locations
Upstream of a pump
Location in most cases dictated by the
site conditions
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How to Identify SJP Applications (1 / 2)
1
HP
Well
LP
Well
s
HP Well
2
LP
Well
s
HP 3
Well
LP
Wells
HP Well
LP
Well
s
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How to Identify SJP Applications (2 / 2)
HP Well
5
LP
Wells
HP Well
6
LP
Wells
HP Well
7
LP
Wells
8
HP Well
LP
Wells
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Re-Cap on SJP design and applications
Passive system
Utilises energy otherwise wasted
Designed to international codes and standards
Low weight
Minimal footprint /Can be installed in various orientations
No moving parts, hence near zero maintenance
Low CAPEX, very low to no OPEX
Minimal control and instrumentation
Easy and quick to install
Low risk
Short payback period
Robust in handling liquid slugs
Can be easily modified if operation conditions change
No operator is needed
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Compact Cyclonic Separation Caltecs I-SEP
Technology inspired by nature
Light
Outlet
Heavy
Inlet Outlet
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I-SEP Compact Separator Applications
Gas-liquid separation
De-gassing liquids
GAS+LIQUID
LIQUID
INLET
LIQUID outlet
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Multiphase Boosting
Malaysia - FPSO
Issue
Shut-in LP wells
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Well Test/Multiphase Metering
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I-SEP System in UBD Operation
Issue
Conventional UBD physically large units
Loosing Tungsten Carbide Chokes every 4 hours
Large gas pressure drops
Benefits
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Debottlenecking 1st Stage Production Separator
Issue
Restricted production due to production separator TT PT (Optional)
PT Eductor
I-SEP / Gas
being bottle-necked HI-SEP-1 M Scrubber LT
PT To Flare
LT
(Optional) PT
Gas
M 1
Scrubber LT
0
Using CALTECs patented I-SEP technology, a 1st Stage
LT
vertical separator was supplied taking part of the Separator
PT
Benefits
Pump Dedicated to I-
Smaller size and foot print compared to SEP System
alternative solutions
Debottlenecking existing 1st stage production
separator, hence increase separation quality
Increased total throughput of the production site
Ability to withstand slug flow type flow conditions
Handling 20000 bbl/d of liquid with 17 MMscfd of
gas
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I-SEP System in Severe Slugging Mitigation
Inlet
Liquid
Outlet Gas Outlet
0.5 No ISEP
Mitigation 2.5
CV
2.45
0.4 Choke
slugging Valve
2.4
2.35
0.3 I-SEP Riser base
Liquid 2.3
velocity pressure
2.25
0.2
(m/s) [bara]2.2
No slugging 2.15
0.1 2.1
2.05
0.0 2
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 50 55 60 65 70 75 80 85 90 95 100
Gas velocity (m/s) Time [t]
Flow regime map comparing I-SEP to CV and no mitigation. SS Time series data comparison of I-SEP to CV during a 3 hours
region to the left of each respective boundary. period.
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Oil-Water Separation Wx Technology
1 2 3
Samples obtained:
1) Fluid from Final Polishing Unit
2) Wx water outlet sample
3) Wx oil outlet sample
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De-Gassing Liquids using I-SEP
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I-SEP in Sand Separation Duty
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Re-Cap on I-SEP Compact Separator
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Thank you
Questions welcome