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DEMO2000-Prosj.ret tekn.utv. petro.virk

OTECHOS CRP: ROBUST, COMPACT MULTI-PHASE PUMP FOR SUBSEA BOOSTING AND WELL ARTIFICIAL LIFT (PHASE 2)

Alternative title: OTECHOS CRP: ROBUST, KOMPAKT FLERFASEPUMPE FOR HAVBUNNS-TRYKKØKNING OG KUNSTIG LØFT (FASE 2)

Awarded: NOK 11.9 mill.

Project Number:

309737

Application Type:

Project Period:

2020 - 2022

In the current phase of the project (2020-22), OTECHOS have built and tested a multiphase pump (CRP-10K) for 10,000 barrels per day oil/gas wellstream to qualify as a subsea pump to TRL 4 (API) for field piloting by Lundin, now Aker BP. The operator intends to utilize power from shore to the Edv. Grieg platform by replacing today’s gas lift by a simple, robust subsea well pump for increased recovery. The pump design is based on the previous small prototype (CRP-2000). Testing at Equinor P-Lab in Porsgrunn demonstrated pump flow capacity well above design, high gas volume fraction tolerance and high efficiency. In CRP-10K, OTECHOS have implemented several significant design modifications to improve performance and reliability, such as shaft bearings by SKF and mechanical circular seals from company John Crane (JC). A complete flow loop with slurry/feeder pump and air compressor for multiphase testing with water, air and introducing sand was built in our facilities at Akland (Risør). In cooperation with TechnipFMC, OTECHOS carried out a sand test to verify that the pump did not suffer abnormal wear from particles. OTECHOS have invested in computer power, ANSYS software and in-house expertise for 3D modelling and fluid simulation (CFD analysis) from suction through pump process chambers to discharge to optimize design. Throughout 2022 we have run a series of tests in our in-hous flowloop. In 1h22 we tested how pressure and flow varied when adding air. Well data from Lundin specified typically 30-80 % free gas in the wellstream at wellhead conditions. This is advantageous for CRP-10K being a displacement pump. Our own test machine was built to test mechanical seals under controlled process conditions and to develop a barrier fluid system to prevent wellstream and impurities in penetrating seals and shafts, while at the same time providing lubrication and cooling to gears, shafts and motor. In close collaboration with the supplier (JC), OTECHOS have developed and adapted the seals to high differential pressure (delta P) and the characteristic rotational pattern of the CRP. In 2022, OTECHOS hired Parat Energy in order to build on leading edge market knowledge. Based on their experience, we rearranged the test facility to a closed loop with high pressure tank, choke valve/nozzle and low pressure tank to simulate realistic flow conditions to allow us to carry out repetitive measurements to be compared with the CFD process simulations. Technical description of a complete subsea pump with subsea motor by IKM, topside power supply and control system designed as a retrievable module was developed as documentation of our plan to reach TRL 4 (API). Together with Aker BP, we are now considering various subsea field candidates (4-well templates or single wells) for piloting. In dialogue with Aker Solutions, we are screening other promising applications for further commercialization, such as “low shear” subsea pumps for produced water treatment. Furthermore, OTECHOS won an order for developing and supplying a special pump for dense-phase CO2 for IFE’s test center at Kjeller. The same technology platform is used in a EU Horizon Europe project to develop an energy efficient hydrogen compressor for the green shift.

More text

OTECHOS PUMPS AS is developing the centric reciprocating pump, CRP, a compact positive displacement pump suitable for multiphase wellstream conditions. As a downhole pump, the CRP differs fundamentally from current ESP technology, solving most of the operational and reliability issues associated with centrifugal ESPs. The project is a continuation of Phase 1, which started 2q 2018 with funding from Aker BP, Lundin, Equinor and Innovation Norway with the objective to develop and demonstrate a fully functional, multiphase pump. Phase 2 (this application) will continue and extend testing with live wellstream, develop a complete system prototype for duration testing, test to TRL 4 (API), package and make ready for field piloting over the period 1Q 2020 - 1Q 2022. The oil and gas industry has high demands in terms of reliability and durability in extreme conditions, such as high pressures and temperatures in wells, and harsh climates offshore. The CRP technology is a disruptive innovation, offering higher efficiency, robustness and simplicity as well as small footprint physically and environmentally. CRP has low internal friction and slip rate compared to other pumping technologies which results in its high efficiency. The value creation and market potential is huge, and can be approached with the support of the partner oil companies as "first movers". OTECHOS has secured patent for the Centric Reciprocating Technology in several countries. OTECHOS recently completed the second phase of an R&D grant for SME businesses under the Horizon 2020 program to bring to market the CRT technology for compressor (CRC) applications with Air Products AS as a launch customer. The CRC and CRT are based on the same technology platform and will provide the basis for future development of the CRR heat expander/engine as a key component in the renewable energy transition.

Funding scheme:

DEMO2000-Prosj.ret tekn.utv. petro.virk