1、Powerful multiphase pumps for increased oil growth was broadly-based, with increases in all regions except Europe growth was above average in all regions, although Asia Pacific countries accounted for the majority (54 %) of global consumption growth. (Graphic: source BP)生产地区：世界石油生产量在2010年时已经从1,000,0
2、00桶/天增长到1，800,000桶/天；增长基数非常大，并发生在除了欧洲和欧亚大陆的所有地区。同时，OPEC和非OEPC国家之间增长的也存在大范围差别。世界石油消费增长到2.7百万桶/天；尽管亚太国家占绝大多数（54%）的全球消费增长。但仍然高于所有地区的平均水平，（图示：来源于 BP）.These new reservoirs, however, are not easy to produce and the oil companies are faced with many challenges. Most of the remaining oil and gas reserves of
3、 the world are located close to the arctic circle, in the oceans in shallow, deep or ultra-deep water, in deserts and other not easily accessible areas. Many of these areas are not developed and a suitable infrastructure must be created to allow successful exploration and production of these oil and
4、 gas fields. A large growth in new oil and gas field discoveries has been in South and Central America. Particularly Mexico and Brazil developed assets which will guarantee sufficient national reserves for many years.然而对石油公司来说他们仍面临着新石油储备不易开采的难题。世界上大多数剩余的石油和气储量在靠近北极圈的浅、深和非常深的的海域，或是在沙漠中以及其他不容易获得的地区。这些
5、地区中许多地方是还是尚未开发的，必须建立合适的基础设施才能将这些油和气成功地勘探和开采出来。现在在美国南部和中部已经发现大量的新的油气田。墨西哥和巴西丰富的资源储备也将会保证多面国家能源储备的充足。A large number of todays oilfields are maturing fields. The reservoir pressure has decreased over the years and artificial lift by means of gas or water injection or ESPs (Electrical Submersible Pumps)
6、 must be used to bring the well-flow to the surface and create sufficient pressure to operate conventional separation equipment. The use of multiphase pumps with their ability to operate at very low well head pressures can economically increase the production life of matured wells. 现有的成熟油田已经开采多年，由于油
7、层压力下降，必须通过注入气体，水或者使用ESP(电脱潜水电泵)等人工方法提供足够的压力将井流输送到传统分离设备上。而多相泵具有可以在低井口压力下运行的工作能力，从而能提高已开采油井的生产寿命，提高生产经济性。Many oil producing countries have not yet developed sufficient infrastructures to use the associated gas produced as feed stock, automotive fuel, power generation or heating purposes. This gas is
8、still widely flared or vented after separation and contributes significantly to the global warming by releasing CO2 or even worse CH4 emissions to the atmosphere. Most countries are taking statutory measures to ban all flaring and venting during the next few years. Multiphase pumps contribute to the
9、 successful achievement of this target by transferring the untreated well flow to centralized treatment facilities were the petroleum gas can be economically processed.许多石油生产国还没有开发足够的基础设施将生产出来的气来作为汽车燃料，发电或供热的原料。目前石油气仍然广泛用于燃烧用途，燃烧后的废气排放到大气中废气中的CO 2会大大增加使全球变暖的温室效应的形成，更糟糕的是废气中的CH 4也会排放到大气中污染空气。现如今大多数国家
10、正在采取法律措施在未来几年内来禁止所有石油气燃烧和废气的排放。多相泵通过输送未处理的井流到集中处理施设，为使石油气能够经济的管理目标的成功实现做出了贡献。The twin screw pump as multiphase system双螺杆泵作为多项系统Twin screw multiphase pumps are rotary positive displacement pumps of double volute design. They are hydraulically balanced with no thrust loads on the pump bearings.内部After
11、 entering through the suction port of the pump the flow splits to either side and is pressurized within the screw packages with opposed thread. The screws are machined from single piece bar stock for maximum stiffness in order to maintain minimum shaft deflection under all operating conditions. They
12、 are installed in the replaceable cast steel casing insert. The surface of the screws is nitrided for wear protection. The torque from the drive screw is transmitted to the idler screw via oil lubricated timing gears. An external lube oil system provides well temperate lube oil to the timing gears a
13、nd the heavy duty and lifetime optimized tapered roller bearings which carry the drive screws and the idler screws.。The bearing span is kept as short as possible in order to minimize the shaft deflection. 双螺杆多相泵是双吸正排量转子泵液压平衡的在泵轴承上没有推力作用。工作介质进入泵入口之后会分流到两侧并且被加压进相反螺旋组成的密封腔内。为实现在所有的操作工况下维持最小的挠度，螺杆从单件棒料加
14、工保证最大刚度。并将它们安装在可替换的铸铁衬套内，螺杆表面经过氮化处理用作磨损保护。通过油润滑的同步齿轮驱动主动螺杆的并且传递扭矩到从动螺杆。外部润滑系统为同步齿轮重载和优化寿命的圆锥滚子轴承提供良好温度的润滑油。为使轴的挠度最小，使轴承的跨距尽可能的小There is no contact between pump screws and casing insert. To maintain a clearance between the pump screws and the casing insert under all operating conditions is a basic an
15、d essential design criteria for twin screw multiphase pumps. The screw shafts are sealed by double acting mechanical seals with SiC vs. SiC seal faces on both product and atmospheric side. An external seal system in accordance with the Requirements of API Plan 54 provides clean and cool seal oil to
16、each seal.。All mechanical seals are installed on the suction side of the pumps and hence, exposed to suction pressure only.泵螺杆与衬套没有接触。保持泵螺旋与衬套在任何工况下的间隙对于双螺杆多相泵是一个基本的关键设计标准。螺杆轴通过双端面机械密封在介质侧和大气侧的碳化硅密封面进行密封。附加的密封系统依照API Plan 54 为每个密封提供干净清洁的密封油所有的机械密封安装在泵的入口侧，仅收到入口压力的作用。A large multiphase production sys
17、tem in the Gulf of Mexico一个大型多项生产系统在墨西哥湾The Gulf of Mexico is historically the most important area in North America for providing oil and gas and raw material in the petrochemical industry to the USA and Mexico. From the start with oil and gas production offshore in the 1960s its importance is conti
18、nuing to grow with new larger hydrocarbon deposits discovered every year. Initially, shallow water reservoirs at water depth up to 100 m were produced along the US and Mexican coastlines. Development of new exploration and prospecting technologies made it possible to go deeper and deeper. Today rese
19、rvoirs at a water depth of 3000 m can be economically produced. Despite the belief that the Gulf would run out of hydro carbon deposits one day, actually more oil and gas are discovered and made economically possible to produce, thanks to 3-D seismic imaging, directional drilling and deep water tree
20、s and production manifolds.墨西哥湾是历史上给美国和墨西哥等北美地区提供油和气和化工原料最重要区域。19世纪60年代开始对石油和石油气的近海开采，同时随着每年新的更大的碳氢储备的发现，墨西哥湾重要性愈加提高。最初沿着美国和墨西哥海岸线在水深到达100m处被开采浅水储备。新的勘探和开采技术的发展提高了深水储备开发的可能性。如今水深3000m的油储已经能够很经济地开采出来。尽管墨西哥湾的油田储备终会枯竭，但仍要归功3-D震波成像技术，定向钻井技术，深水树管技术和生产阀组技术使更多的石油和石油气被发现，经济地开采出来。In the Mexican territorial w
21、aters significant findings of oil and gas have been done in the last 30 years. The largest reservoir ever found in the western hemisphere was Cantarel, which only recently lost its first place to the pre-salt Tupi field in Brazil. Besides Cantarel there are other significant fields in the shallow wa
22、ter (up to 100 m) depth in Mexico. The giant Ku-Maloob-Zaap field started to develop in the 1980s and 1990s. It is a large complex of fixed platforms in 6080 m water depths. Some platforms are wellhead platforms whereas others have processing and power generation equipment. Also, an FPSO is anchored
23、 nearby and serves as an extended production and storage facility. 在过去的30年在墨西哥领海内已经完成了大量的油和气的发现。西半球发现的最大的油田Cantarel代替了给到巴西的图皮盐层下油田第一的位置，除了Cantarel，墨西哥浅水区域有其他的大储量油田，Ku-Maloob-Zaap油田于19世纪80和90年代开始开发开采。他是一个在60-80米水深上的复杂固定平台。一些平台仅仅是井口平台，而其他类型的平台还会带有输送和发电设备。同样,一个浮式生产储存储油轮作为一个扩展的开采和存储的设施。也会在油田在附近抛锚, The o
24、il is typically heavy with an API grade of 18 to 22 with significant amounts of gas produced as associated gas with the oil. The oil and some gas is exported to shore from pipelines. A lot of the gas is used in power generation with gas turbine driven pumps and compressors and in the processing of t
25、he crude oil. When the wells started to flow initially, water injection was used to maintain reservoir pressure. As the wells were ageing gas lift was introduced. With gas lift compressed natural gas is sent down the annulus of the well and through a gas lift valve, the gas lightens the column of oi
26、l in the production tubing to lift it to the surface. For some time this method of production is sufficient to bring up the oil and provides enough pressure in the pipelines to overcome line losses and the arriving pressure of the first stage separator.石油通常是沉重的API年级18 - 22与大量的天然气生产天然气与石油有关。石油和天然气与管道
27、出口到岸上。很多天然气用于发电用燃气轮机驱动泵和压缩机和加工的原油。当井开始流最初,注水保持油层压力。随着老龄化介绍了气举井。与气举发送压缩天然气的环,通过气举阀,气体减轻石油的列在生产油管解除它浮出水面。一段时间生产这种方法能充分打开石油和提供足够的压力管道克服线损失和到达的第一阶段分离器的压力。Gradually the gas lift is not enough to recover the oil in the reservoir and bottom hole pressure of well reaches a point where the oil cannot any lon
28、ger move from the formation to the well bore.逐渐气举并不足以恢复石油储层和井的井底压力达到某一程度时,油不能再从井孔的形成。At that moment there are some few remedies left to save the reservoir from abandonment and one of these is the fast developing technique of multiphase pumping.为数不多在那一刻有一些补救措施拯救遗弃的水库,其中一个是多相泵的迅速发展的技术。In the case of t
29、he Ku-Maloob- Zaap field the production from the wells were estimated to drop very quickly and in the next few years reach a point where they would have to be abandoned. After lengthy studies it was decided by the Mexican State Oil Company that three of the wellhead platforms were going to be equipp
30、ed with multiphase pumps.的Ku-Maloob Zaap领域的生产井估计很快下降,在未来几年内,他们将不得不被放弃。经过漫长的研究是由墨西哥国家石油公司决定三个井口平台将配备多相泵。The objective was to be able to continue production for many years to come and delay the abandonment of the reservoir and dramatically increase the total recovery of hydrocarbons from the formation
31、.目的是能够继续生产多年来推迟水库的遗弃,大大增加总复苏的碳氢化合物的形成。The multiphase pumps propositioned was analysed in detail. Production curves were showing a pressure draw down at the wellhead of 12 bar would have a significant positive impact on the bottom hole pressure and the ability of the wells to continuous producing. At
32、 this low well head pressure the associated gas will expand significantly which means at pump inlet the gas fraction (GVF) can be up to 97 % with the wells sometimes intermittent liquid production (oil and water) it was necessary to provide the pumps with a liquid recirculation system to keep the pu
33、mp primed at all times even with long gas slugs coming from the wells. Each of the three platforms have 24 producing wells tied to a common suction manifold which in turn is connected to either five or six of the multiphase pumps, depending on the platform. The pumps operate in parallel driven by 19
34、00 kW variable frequency controlled electrical motors. The speed of the motors which control the pumping capacity and thereby the pressure in the suction manifold are automatically set to follow the desired optimal manifold pressure.详细分析了多相泵调情。生产曲线显示出井口的压力减少12小节将产生重大的积极影响井底压力和井连续生产的能力。在这个低井口压力相关的气体会
35、显著扩大这意味着在泵吸入口气体分数(预防)可以高达97%的水井有时间歇生产液体(油和水)有必要提供泵的液体再循环系统保持泵启动时刻即使长气蛞蝓来自井。每个三个平台有24口生产井与一个共同的进气岐管依次连接到5或6的多相泵,根据平台。并行泵操作由1900千瓦电机变频控制。电机的速度控制泵送能力,从而在进气岐管的压力自动设置遵循所需的最佳管道内压力。All pumps are packaged in modules, including controls and instrumentation per the customer specification. The packaging was do
36、ne on the U.S. Gulf coast and each pump module was transported by barge to the platform for direct installation. In addition to the pumps (16 in total), three so-called E-buildings were supplied which contains all the frequency converters, automation, switchgear and controls. The E-buildings are air
37、 conditioned although each platform is specified for unmanned operation.所有泵都打包在模块,包括控制和仪表/客户规范。美国墨西哥湾和包装是每个泵模块被驳船运输平台直接安装。除了泵(总共16日),三个所谓的E-buildings提供包含所有变频器,自动化、开关和控制。E-buildings空调虽然是指定为每个平台无人操作。Pump operating data and design details泵的操作数据和设计细节The twin screw multiphase pumps installed on each of t
38、he three platforms are designed for the following parameters:双螺杆多相泵安装在每个三个平台设计的以下参数:The pump casing is manufactured from fabricated carbon steel with the suction port on side and the discharge port on top. All welds were subject to extensive quality control by means of non-destructive testing.泵壳是由碳钢
39、制作的吸入口和卸货港。所有的焊接质量控制受到广泛的非破坏性测试。Both pump screws are made from carbon steel nitrided in order to minimize wear. The replaceable casing insert is manufactured from cast carbon steel.两个泵螺丝是由碳钢渗氮,以减少磨损。可更换套管插入从铸造碳钢制造。The construction materials for all wetted and pressurized pump parts meet the requirem
40、ents of the NACE Standard MR 0175 latest edition.所有湿的建筑材料和加压泵零件符合要求的NACE标准先生0175最新版。All pumps are equipped with a liquid management system (recirculation system). These systems are located on the skid downstream the pump discharge but within the skid limits. During the pump operation liquid is const
41、antly separated from the multi phase flow with a minimum efficiency of 97 percent. The separated liquid is collected in the reservoir of the liquid management system. A recirculation volume equal to approx. 3.0 percent of the actual flow rate is constantly injected from the liquid reservoir into bot
42、h suction areas of the pumps. During possible gas slugs this amount of liquid is sufficient to ensure continuous gas compression. The large surface of the liquid reservoir contributes to the quick heat dissipation and renders additional cooling unnecessary. The volume of the reservoir of the liquid
43、management system is adapted to the maximum expected gas slug length specified by the customer.所有泵都装有液体管理系统(循环系统)。这些系统位于下游滑橇装泵出口,但在限制。在泵操作期间液体不断与多相流分离,最低97%的效率。分离液体收集在液体的水库管理系统。再循环体积等于大约。3.0%的实际流量不断从贮液器注入泵的吸入区域。在可能的气体蛞蝓这么大量的液体足以保证连续气体压缩。大型贮液器表面有助于快速散热,使额外的不必要的降温。储层的体积的液体管理系统适应最大预计气体段塞长度由客户指定。Before
44、dispatch all pumps were subject to a witnessed hydrostatic test and a witnessed factory acceptance test.在派遣之前所有泵受到见证水压试验和工厂验收试验。The future未来远景After completion and successful inspection of the skids and all accessories, they have been loaded on barges for transport to their final destinations on the
45、particular platforms. The installation at the three platforms and the commissioning is scheduled for 2012.成功完成后,检查刹车和所有配件,他们已经装上驳船运输的特定平台上的最终目的地。三个平台的安装和调试定于2012年。Engine driven multiphase production systems in the Gulf of Mexico发动机驱动的多相生产系统在墨西哥湾During the past years several twin screw multiphase pum
46、ps have been installed on offshore platforms in the US territorial of the Gulf of Mexico. Lack of electrical power on these platforms required gas engine driven equipment. An independent operator in stalled an twin screw multiphase pump for a flow rate of 880 m3/h, a differential pressure of 19 bar
47、and a GVF of 97 %. The gas engine is rated at 630 kW. A liquid management system to safeguard the operation during gas slugs is an integrated part of the skid.在过去几年几双螺杆多相泵被安装在海上平台在美国领土的墨西哥湾。缺乏这些平台上的电力所需的燃气发动机驱动的设备。停滞不前的一个独立的运营商双螺杆多相泵的流量880 m3 / h,压差19酒吧和 97%的预防。燃气发动机额定在630千瓦。液体管理系统维护操作期间气体蛞蝓是一个集成的打滑
48、的一部分。A large twin screw multiphase pump was installed by a major international operator on another platform in the Gulf of Mexico. The unit is designed to trans fer a mixture of oil, water and gas with a GVF of 95 % at a flow rate of 991 m3/h and differential pressure of max. 44 bar to a centralized
49、 separation facility. With the liquid management system and the 1,500 kW gas engine this is one of the largest multiphase pump skids ever built.大型双螺杆多相泵是由一个主要的国际运营商安装在另一个平台在墨西哥湾。单位是为了反式带的混合油,水和气体养狐业95%的流量991 m3 / h和最大压差。44条集中分离设备。液体管理系统和1500千瓦燃气发动机,这是有史以来建造的最大的多相泵橇之一。The objectives to use twin screw multiphase pumps versus conventional equipment on both applications were: The reduction of the well pressure to increase the oil recovery The reduction of the gas lift requirements Smaller footprints Less equipment Less weight Lower capital costs Quick amortization
