Bornemann Subsea Brochure

BORNEMANN SUBSEAHELPING IMPROVE THE WORLD ́S ENERGY SUPPLYSUBSEA MULTIPHASE PUMPS

Onshore, offshore or subsea, Borne-mann has the solution to improve pro-duction and process control through the use of its multiphase boosting technolo-gy. Multiphase boosting allows the pum-ping of gas and liquids at the same time. Production improvement and accurate process control are the main advantages of this approach.

Bornemann specializes in twin-screw pumping technology with more than 75 successful years in moving difficult and unconventional types of fluids. The company’s success has been in a diversi-ty of markets: oil industry, on- and off-shore, food and the chemical industry.

Due to the robustness and process flexi-bility, and the ability to handle all kinds of fluids including large particles and gas, the twin-screw technology is the perfect system for multiphase boosting.

With more than 500 installations Bor-nemann has cumulated more than 25 million operating hours during the last 25 years, resulting in the world’s lar-gest experience in operation and supply of multiphase pump systems for the oil and gas industry. Besides the unique and proven pump design the understan-ding and control of the well production

is essential to improving and stabilizing the production rates. Safe, reliable and operator friendly control systems, in-cluding oil field proven control logics, are a vital part of each multiphase pump system – onshore as well as offshore and subsea.

In 1997 Bornemann’s activities in the subsea market started with German Government approved R&D projects, followed by the Norwegian DEMO 2000

project which finally led to the first twin-screw pump subsea installations in the North Sea and Gulf of Mexico.Based on the level of experience gained, the new vertical subsea pump SMPC se-ries 4 is now available. Bornemann’s vision is to support the oil and gas indus-try in tackling technically challenging applications by utilizing its exceptional expertise in twin-screw pump technolo-gy to improve the production and opti-mize recovery of the reservoirs.

PROVEN TECHNOLOGYFROM THE PUMP EXPERTS

Multiphase boosting is not only pumping liquid and gas at the same time, it is a complex process of handling the untrea-ted well stream, a variable mixture of oil, gas and water.

Production improvement, increased re-covery, reduced environmental impact and accurate process control by provi-ding constant flow rates and well pressu-res make this technology a clear choice.

Each reservoir has its own specific pro-duction characteristics in regard to oil production, gas production and water-cut minimization. The optimum produc-tion can be achieved by adjusting the flow to provide the optimal well head pressure, following the natural changes in reservoir performance over the years. Twin screw multiphase pumps can be ins-talled in line with electrical submersible pumps, gas lift or other down hole arti-ficial lift methods to improve the overall reliability and process efficiency.

Green field production controlUnfortunately exact production data is not always available in the early field life. Therefore pump systems for green

fields have to be designed for the highest future flexibility in regard to flow rates, pressures and gas content.

Brown field production improvementHowever, during the later field life, the flow characteristics of the reservoir is well known. Non-producing wells can be revitalized. Reduction of the well back-pressure can lead to significant improved production on flowing wells. Slug flow, high gas content, increasing water cut and the associated risk of emulsion build up with higher fluid viscosities must be

incorporated into the system design.

Multiphase Power Generation

In the early field life surplus reservoir pressure will typically be choked in to control the flow rate. Instead of using only the choke, the SMPC can run as a multiphase motor to control the well head pressure and to produce electrical energy.Depending on the hydraulic energy available the Multiphase Motor can pro-duce some 10 kW for subsea control sys-tems, or some 100 kW to feed other sub-sea consumers with energy.

MULTIPHASE BOOSTING - INTELLIGENT SOLUTIONS FOR THE OIL AND GAS INDUSTRY

Pres

sure

Actual Volume Flow (Oil + Gas)

Gas + Oil Flow(GOR constant)

Multiphase MotorPower Generatorreduce flow ratecontrol well pressure

Multiphase Pumpincrease flowratecontrol well pressure

Pipeline Performance

well free flow at given choke setting

MPPs in series MPPs in parallel installation Redundancy in remote area Offshore northsea Offshore gulf of Thailand 2MW teststand with King SMPC

2 3

Bornemann is the leading manufacturer of twin-screw pumps worldwide.

The Bornemann unique twin screw pumps are rotary positive displacement pumps. Its engineered rotors are hydraulically balanced and shafts and screws are made separately from the highest grade of ma-terials available.

They can handle virtually any type of fluids, regardless of viscosity, lubricity or gas content so an obvious choice for multiphase applications.

Multiphase Pumps have to handle oil, gas and water at constantly changing compositions, pressures and tempera-tures. Bornemann’s depth of experience with multiphase applications enables proper design of the pump and controls to handle these varying conditions.

Pump capacity primarily is not determi-ned by gas content, density or differen-tial pressure but by rotor diameter, pitch of the rotor-screws and, directly and li-near by rotational speed.

Bornemann’s patented solutions for internal liquid separation and recircu-lation of some liquid back to the inlet prevent the rotors from running dry and

provide enough cooling when operating the pumps with high gas contents.

SMPC series 4The Subsea Multiphase Pump SMPC series 4 is the result of continuous deve-lopment and improvement of the subsea MPP’s and all heavy duty topside multi-phase pumps installed.

This improvement by Bornemann occurs because of permanent R&D activities and the diversity of Multiphase Pumps installed and operated throughout the world on various oil and gas fields.

The lube oil filled, pressure compensa-ted pump-motor-cartridge is integrated into a simple, separator style pressure casing. All potential problem interfaces between the pressure casing and the pump cartridge are eliminated.

The large liquid storage volume inside the pressure casing provides an excellent dry run capability for the SMPC series 4.

TWIN-SCREWMULTIPHASE PUMP

The SMPC series 4 is a very robust pump, designed for 5 years maintenance free operation. The wide speed and capacity range of the series 4 allows for a long operating period on wells without the need for mechanical adjustments to ac-count for changing production require-ments.

The positive displacement characteristic of the SMPC ensures constant flow velo-city in the pipelines, dampens slug flow and transports the multiphase mixture without influencing the fluid properties.

Integrated subseaspeed variationThe Hydraulic Speed Control (HSC) can be installed in the SMPC series 4 instead of the conventional mechanical coupling between pump and motor.

The SMPC series 4 utilizes the proven technology of the VOITH TURBO coupling series EL as the foundation of the HSC design. The design approach eliminates the need for electrical frequency con-verters and separate umbilicals for each pump, a significant cost savings.

Consequently the simplification of the electrical power supply now enables se-

veral SMPCs to run on one power cable at different speeds.

The overall system efficiency will be sig-nificantly improved by this Bornemann technology and longer step out distan-ces will become feasible.

SMPC series 2SMPC series 1 SMPC series 3 SMPC series 3 SMPC pump cartridgeSMPC series 2

Installation of SMPC series 4

VOITH TURBO coupling series EL

MULTIPHASE GOES SUBSEA

- MULTIPHASE PUMP SMPC SERIES 4

4 5

The twin-screw subsea pump type SMPC series 4 is characterized by the following advantages:

■ Wide operating range• capacity not depending on fluid

density• variable gas content from 0% gas

to 95% gas without any influence on capacity

• high compression ratio - up to 1:50

• wide viscosity range - from 1 to 5000 cSt

• high differential pressure - more than 250 bar (multiphase) with two pumps in series

• variable flow rates - from 100 to 5000 m3/h(15 to 750 MBPD) with two pumps in parallel

■ constant flow rate - stable operation on long pipelines

■ full self priming and gas handling capability up to 100% gas

■ high efficiency at high liquid viscosity and gas content

■ level control of upstream separator or pressure control of pipeline and well head

■ extension of operating range possi-ble by serial and parallel installation of SMPCs

■ minimized footprint: vertical design and no additional process equipment required

■ integration of hydraulic speed con-trol (HSC) possible

ADAPTABILITY AS A PARTOF THE CONCEPT

Out of the ten frame sizes (2 to 12) Bor-nemann provides for topside pumps, the most approved five pump sizes (6 to 10) have been selected for subsea boosting.Each frame size is defined by the power rating and the rotor diameter. Within

the frame size the conventional high ca-pacity rotors can be installed. Different pitches can be selected to optimize the pump performance. Alternatively the high differential pressure rotor design (HDP) can be chosen.

In all cases the larger pitch will provide higher flow rates, the smaller pitch will allow more differential pressure. The to-tal flow rate is the mixture of oil, water and gas at pump inlet temperature and pressure.

SMPC series 4 400bar SMPC series 4 HSC Test tank Installation of SMPC series 4 Underwater testing

High DP: Operation of Pumps in SeriesHigh Flow: Operation of Pumps in Parallel

MPP

MPP

E-M

otor

E-M

otor

Serial and parallel installationMany topside installations have two or more twin-screw multiphase pumps ope-rating in parallel or in series to provide the highest reliability, flexibility and ef-ficiency.

PERFORMANCE RANGEOF THE SMPC SERIES 4

bar

150

100

50

0

0 500 1000 1500 2000 m3/h

SMPC 10SMPC 9SMPC 8SMPC 7SMPC 6

Diff

eren

cial

Pre

ssur

e

Pump Capacity

Graphic above is valid for: gas content 0 to 100 %, water cut 0 to 100 %,viscosity 1 to 100 cSt.Higher viscosities will allow for more differential pressure.

Underwater testing

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Joh. Heinr. Bornemann GmbH

Industriestraße 231683 ObernkirchenGermany

Fon: +49 5724 390-0Fax: +49 5724 [email protected]

Germany – Headquarter

UNIQUE SOLUTIONS MADE BY THE SPECIALIST

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CANADABornemann Inc.320 441, 5th Avenue S.W.Calgary, AlbertaCanada T2P 2V1CANADAFon: +1 403 294 0777Fax: +1 403 262 [email protected]

USABornemann Pumps, Inc.10375 Richmond Ave,Suite 1575Houston, Texas 77042USAFon: +1 832 320 25 [email protected]

Parts and new pump stockingBornemann Inc.P.O. Box 1769Matthews, NC 28106USAFon: +1 704 849 86 36Fax: +1 704 849 86 [email protected]

ARGENTINABombas Bornemann S.R.L.Armenia 2898B1605CDP MunroProv. Buenos AiresARGENTINAFon: +54 11 475 680 08Fax: +54 11 475 655 [email protected]

MEXICOBornemann S.A. de C.V.Castillo de Cantburry 1652938 Atizapan, Estado de MexicoMEXICOFon: +52 55 5808 0875Fax: +52 55 5808 [email protected]

SINGAPOREBornemann Pumps Asia Pte. Ltd.25 Intern. Business ParkGerman Centre, # 04-11/12Singapore 609916SINGAPOREFon: +65 656 167 82/3Fon: +65 656 159 78Fax: +65 656 167 [email protected]

CHINABornemann Pumps & Systems(Tianjin) Co., Ltd.Jinbin General Building No. 6,No. 45 Muning RoadTEDA, TianjinP. R. China 300457CHINAFon: +86 22 662 978 00Fax: +86 22 253 267 [email protected]

Bornemann Pumps InternationalTianjinRoom 1101Tianjin Binjiang International HotelNo. 105 Jianshe RoadHeping District, TianjinCHINAFon: +86 22 5881 2997Fax: +86 22 5881 [email protected]

OR GET IN DIRECT CONTACT WITH OUR SUBSEA EXPERTS: [email protected]

Bornemann Subsea Brochure

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