SPE

Society of Petroleum Engineers

SPE 23624
Field Tests of the Poseidon Pump
P. Gie. Total
Copyright 1992, Society of Petroleum Engineers, Inc
'I

nis paper was presented at the Second Latin American Petroleum Engineering Conference, II LAPEC, of the Society of Petroleum Engineers held in Caracas, Venezuela, March 8

1i, t992

This paper was selected for presentation by an SPE Program Committee following review of information contained in an abstract submitted by the author(s). Contents of the paper,
as presented, have not been reviewed by the II LAPEC or the SPE and are subject to correction by the author(s). The material, as presented, does not necessarily reflect any
position of the II LAPEC or the SPE, its officers, or members. Papers presented at SPE meetings are subject to pub6cation review by Editorial Committees of the Society of
Petroleum Engineers. Permission to copy is restricted to an abstract of not more than 300 words. Illustrations may not be copied. The abstract should contain conspicuous
acknowledgment of where and by whom the paper is presented.
Write Publications Manager, SPE, P.O. Box 833836 RiChardson TX 750833836 U.S.A. Telex 730989 SPEDAL.

AllSTRACT
Since May 1991 a POSEIDON pump of the
rotodynamic type has been running on the SIDI EL
IT A YEM field in TUNISIA, logging more than 3500
operating hours (end of November 91) without a
major problem. This pump is one of the practical
results of the POSEIDON project, launched in 1984
by TOTAL, IFP and STATOlL. to develop the concept
of multiphase pumping: the final target being a
subsea multiphase boosting station.
Prior to the Tunisian test, this pump had been
tested satisfactorily on the two phase loop of IFP at
SOLAIZE (FRANCE),and it was this which decided
the partners to send the prototype, wihout any
modification, to the real active field test rig
specially prepared to accommodate multi phase
equipment.

2. MUL TIPHASE PUMPS

With the current low price for produced oil and
the increasing cost of offshore operations it makes
sense to use the declining fields separation
capacities to receive the effluent coming from the
smaller or marginal fields which do not deserve a
conventionnal development.
Also onshore fields located in remote areas or
locations where it becomes more difficult to flare
the produced gas or to build additional facilities are
cases for using such pumps.
The basic requirement to develop any field is
that the wellhead pressure, may be,assisted by
secondary recuperation means - water llljection, gas
lift - is enough to transfer the multiphase effluent
through a single, multiphase pipeline. Otherwise,a
pump is needed.
A line will be mainly characterised by the flow rate
(bbl/d), the composition of the fluid i.e the gas
fraction GLR [gas to liquid ratio expressed as a
3 3
percentage by volume (%) or as a ratio (m /m ) in
suction condition], the pressure at the pump inlet
and the pressure rise needed to enter the first stage
of the separator at the end of the line. Secondary
data will be PVT parameters such as fluid density,
temperature, viscosity, water cut etc ...
Considering the above,the wide range of possible
combinations must be emphasised,especially for the
gas fraction that vary from zero in the case of a pure
monophase fluid, to 95% for wells where a gas lift
production is in use or if the produced gas has
already reached high GOR, 100% being reached if
there is severe slugging.

1. INTRODUCTION
The choice of the multiphase pump type is the
result of comprehensive knowledge and comparative
studies of the different available or described
pumping systems at commencement of the project
The partners, not being bound to any particular
pump manufacturer, only wished to select or to
improve a known product in order to have a tool
available for their future subsea developments.
In the following paper we will describe the different
types of possible multiphase pumps and the reasons
that lead the partners to the rotodynamic principle
type. We will then present the POSEIDON pump, the
tests performed on a diphasic loop to ascertain its
behaviour with any composition of fluid, then the
tests conducted in real field conditions at SIT and
an intermediate conclusion about these operations
that mark the end of the R and D phase.

69

Field tests of the Poseidon pump

The pressure rise generally needed will be between

20 and 60 bars for an average throughput of 40000
bbl/d (cumulated oil and gas).
Two main types of pump, based on different
principles are available or under development :
these are positive displacement and rotodynamic
pumps.
2.1 Positive displacement pumps
These pumps have a rotating or a reciprocating
movement.

LAPEC 23624

the gas fraction in the fl uid,since available

elastomers cannot withstand extended exposure to
gas This can produce chemical damage to the
elastomer and the loss of its mechanical properties
and the subsequent failure of the pumping system.
2.1.3 Diaphragm pumps
In this system, the fluid is pushed by to the
reciprocating movement of a flexible membrane,
made either of elastomers or metal.
In the case of elastomers, as for the Moineau-type
pumps, it is very difficult to select a product
compatible with liquid hydrocarbons and gaseous
fluids. The wear appears when the dissolved gas in
the elastomer is quickly decompressed, creating
small cracks in the texture,that finally lead to a
mechanical failure under the alternating movement.
The metallic diaphragm on the other hand produces
a very small pressure rise per stage, due to its
mechanical resistance.Thus several stages are
needed, but the capacity of each must be adapted
permanently to the volume produced by the previous
stage. This means that the fluid composition should
be fixed for each pump. Industrial application for
the oil industry therefore seems very difficult.

2.1.1 Twin-screw pumps

Here the fluid is trapped between two
parallel,meshed screws and is pushed towards the
outlet of the pump by the combined rotation of the
screws(fig.l). This pump can give a high discharge
pressure but it works with small clearances between
the two rotating parts(the screws)and between each
part and the casing. To reduce the effect of leaks
and to minimize wear it is necessary to increase the
number of screw pitches. In case of high gas
fraction, internal leaks become larger as the liquid
cannot trap all the gas and increase of rotational
speed is needed to compensate.Then a temperature
rise resulting from both metallic friction and gas
compression occurs that leads to screws vibrations
and shafts bending and finally to the seizing of the
rotating parts to the stator.
Due to the small internal clearances between the
casing and the screws ,this type of pump is also
more susceptible to sand particle damage.
To withstand flow composition variations and
possible gas slugs such pumps need a permanent
monitoring to adapt the rotational speed and thus
keep both mechanical torque and inlet pressure
constant.
In
addition
a permanent
liquid
recirculation device is compulsory to maintain a
continuous liquid film on the screws.
Finally, for a given flow rate, these pumps are the
largest of their type.
These pumps, although imperfect, have reached
the industrial developement stage and are available
from several manufacturers. The high sophistication
needed to operate them makes their use for subsea
application highly umprobable.
However some of them (by Multiphase PLC and
Bornemann) have been tested under real field
conditions (SHELL,EXXON ,BP ,AGIP,TOT AL) with
limited results.

2.1.4 Piston pumps

Different systems are based on the principle of a
linear piston, pushing the multi phase fluid, and
driven either by hydraulic rams or linear electric
motors. Normally in horizontal position they can
have two opposite pistons (Framo Engineering) on
the same rod working in two separate cylinders, or a
single cylinder with one double acting piston,
driven by one or two rods (SINTEF)(fig.2).
IFP is also developing a double chamber piston
pump, with a vertical stroke,and driven by
hydraulic rams .See fig.3 ..
The horizontal piston pumps suffer from the
gravity effect and from seal wear. The upper part of
the cylinder, the colder one, will be covered by the
condensed water vapor, during the suction phase,
which will induce corrosion .. The lower part will
collect water and sediment with subsequent erosioncorrosion effects. For vertical or horizontal pumps,
the seals work under high differential pressures
which accelerate the wear of this elastomeric part.
In addition, for all the devices, the behaviour of the
inlet and outlet valves under multiphase mixture
has still to be validated.

2.1.2 Moineau-type pumps

The idea is to extend the well known Moineau
screw system of pumping heavy oil on the surface or
downhole, to mixtures with a higher gas fraction.
The rotating screw is made of stainless steel while
the rotor is generally made of an elastomer in order
to maintain a good seal between the screw and the
stator. The problem then comes with the increase of 70

Rotodynamic pumps
Those pumps, well known for monophase fluids,
are light and cheap and their running clearances
give a large capability to withstand sand or solid
particles. But any typical centrifugal multIstage
pump, if it can accept a 2 to 4% gas fraction, suffers
from head reduction very quickly when the fraction
increases and at 15-20% loses priming completely .
2.2

LAPEC 23624

Pierre Gie

In this type of machine, at each stage the fluid is

accelerated by the rotating blades of the impeller
and kinetic energy is converted into pressure when
the fluid flow is diverted into the rectifier blades
fixed to the stator(fig.4). But when handling
multiphase flow, the liquid is accelerated but the
gas is not,and hence a gas-liquid separation occurs
and the conversion of the kinetic energy into
pressure cannot occur.
2.2.1 Early days
Scientific researches combined to laboratory
tests conducted by IFP and TOTAL in the seventies,
were completed by the realisation in 1981 of a full
scale model for down-hole applications, able to
pump 15 000 bId with a gas fraction of 30%. In
1980,Pompes Guinard was licensed to use of patents
covering this multiphase technology, generally
known as the first generation hydraulics, with the
view of manufacture of down hole pumps to produce
oil with GLR below three.This pump was selected in
1987 by Shell,to be the heart of a fully marinized
pumping station,when launching the SMUBS project
where Framo Engineering is in charge of the subsea
integration.
2.2.2 The POSEIDON project
In 1984,ST ATOlL joined TOTAL and IFP in a
newly created research group with the ambitious
goal to develop equipment to lower the cost of
offshore hydrocarbon production, particularly in
deep waters and for marginal fields. One important
part of the research was dedicated to the
improvement of the 1st generation of hydraulics, in
order to create a real multiphase pump able to
withstand slugs of 100% gas. The result is the
POSEIDON pump as described later.
2.2.3 Other rotodynamic pumps
Based on the same principle of rotodynamics,
helico-axial stages, different types of pumps are
being developed mainly in Norway.
- a back to back system where two shafts rotate in
opposite direction. The reactive dynamic thrust
forces compensate each other and the design of the
thrust bearing is greatly simplified.
- a contra-rotating pump : the stator (where the
rectifiers are set) rotates in the opposite direction
to the rotor, hence increasing the relative speed of
the particles, between the impeller blades and the
rectifier blades.

3. POSEIDON PUMP
The helico axial concept had already shown its main
advantages which are:
-ability to pump a very gassy fluids
-mechanical simplicity, then reliability
-compactness, and easy future marinization
71

-low sensitivity to solid particles due to the large

running clearances
-self adaptation to flow conditions
-flexibility of the driving system(hydraulic,
electrical, mechanical) depending on the location,
such as onshore ,on platform or subsea.
It needed to be developped to make available an
industrial, reliable machine.
It needed to be developped to make available an
industrial, reliable machine.

3.1 The Rand D project

It can be simplified in two phases as follow:
3.1.1. From 1984 to 1986 :Improvement and test of
the first generation of hydraulics.
The first generation pump (1981 patent, by
Guinard) was tested at 6 000 RPM for a GLR of 4.5
(inlet conditions).
Simultaneously a second generation of hydraulics
were developed and new compression cells
(impeller-rectifier) were tested to reduce the
thickness of the blades, improve the surface texture,
and optimize the transfer momentum according to
the number of impeller blades.
To make possible the test of those improved
compression cells in real conditions, a new test
bench was built in SOLAIZE on IFP premises.
A pumping module, fitted with 29 compression
stages (1 st generation) of 122 mm was tested in
1985 at 6000-8000 RPM and GLR of 12.5 (inlet
conditions).
A second module fitted with 15 newly designed
compression cells (2nd generation) of 134 mm was
tested in 1986 with GLR 22 at 40 bars suction
pressure, giving a very high increase in overall
efficiency (from 40% to 52%).
3.1.2. Second phase after 1986.
Those
promlsmg
intermediate
results
ascertained the feasibility of an industrial unit, the
fabrication of which was decided upon in 1987.
This pump, called P300 and built by Technicatome
has the following design specification (as a matter of
fact,the capacity of the multiphase test loop at
SOLAIZE):
Flow rate 25 000 to 40 000 bbl/d-slug flow.
Inlet pressure 10 to 40 bars.
GLR 10 to 20 at suction pressure.
Pressure rise 20 bars at GLR 10.
Maximum rotation speed 6 600 RPM.
It was designed as a marine version. Its basic
components are an isostatic shaft
1.8 m long
equiped with 13 stages of compression cells (8
impellers of 250 mm, 5 impellers of 232mm), two
pad journal bearing, one pad thrust bearing and two
single and compensated mechanical seals.
The final overall dimensions of this compact pump
is 2.4 m long with a diameter of 0.5 m.

Field tests of the Poseidon pump

A buffer tank was also built and put at the suction

end of the pump in order to damp out and regulate
the large GLR and flow rate fluctuations caused by
severe slugging. It is also used as a liquifier unit to
wet the large gas pocket coming from the well head
during start-up.
3.1.3 Computer model
In parallel with the research on the compression
cells, a computer mathematical model was developed,
with the goal of describing the physico-chemical
behaviour of the multiphase fluid inside the
impeller-rectifier stage and of being helpful in
designing the future hydraulic compression cells.
This model was fed with all the information obtained
from over 2000 points during tests performed on
compression cells and afterwards on the entire
pump.
The semi-empirical correlation, combined with the
mathematical model gives a tool that describes the
results of each compression cell in terms of power,
pressure rise and multiphase efficacy.The term
multiphase efficacy is defined as the ratio of the
experimental pressure rise to the computed
pressure rise obtained in ideal conditions (no
energy loss due to the non-homogeneity of the
fluid). An ideally homogenous fluid would have an
efficacy ratio of 1.
The model can eventually give the results of
compression at each stage, then the cumulate value
for each different series of stages and then for the
entire pump (fig.5). The necessary data are the
geometry of the cells, PVT analysis of the fluid, flow
rates and inlet conditions,including GLR and
pressure.
3.1.4 Bench test
This artificial multi phase loop (fig 6) is the
image of a field manifold handling 35000 bId at
40bar with a gas fraction up to 95%. A slug
generator was added to simulate start-up and
transient conditions, as close as possible to real
field conditions.
The buffer tank, designed and optimised during the
first research phase was installed upstream of the
pump. This device reduce"s the effect of large slugs
and pressure variations at the pump inlet and hence
possible detrimental mechanical effects. In brief, it
is a form of accumulator or capacitor, in which the
flow enters through a perforated pipe, and where the
homogeneity of the mUltiphase fluid is kept as
stable as possible. It is also a static device, without
any moving part.
3.1.5 Bench test results
These tests were the first performed on a
completed pump of the 2nd generation. One aim was
to produce the characteristics of the pump in steady
state conditions and later to investigate thp 72

LAPEC 23624

variations when facing slugging," and transient

conditions. The second aim was to verify the
mechanical behaviour of the unit in view of a
possible field test under more severe conditions.
Steady state flow
A steady state flow, combined with the use of the
buffer tank, was used to plot the characteristics of
the pump(Fig.7). Different set of curves were
obtained depending on the GLR and on the suction
pressure. The behaviour of the pump with different
GLR, gave also an idea of the future reaction during a
slug flow regime.
Transient flow
This regime was tested with and without the
buffer tank in the circuit. Without it, the variation
of the gas content induced important torque
vanatlOns, as the outlet pressure remains stable
while the inlet pressure follows the gas percentage.
Using the buffer tank, torque variations are
drastically lowered,
which proves the real
dampening effect and pOSItIve result for the
mechanical behaviour of the pump.
Well start up
In this simulation(fig.8), the gas pocket was
longer and was completely separated from the liquid
phase.Here the buffer tank has a regulating effect,
its volume being slowly filled up by one phase,
whilst the pump maintains a constant pressure rise
by adjustment of the rotational speed.
Mechanical behaviour
After these tests the pump was dismantled and
no sign of abnormal wear or fatigue could be
detected, neither overheating nor vibration appeared
during the operations.
3.1.6 Intermediate conclusion
Those satisfactory results of tests on an artificial
loop confirmed the following aspects of the design
data:
- Design performances reached
- Ability to handle slugs of pure gas
- Confirmation of the role of the buffer tank in
terms of regulation and smoothening of the flow
- Excellent mechanical behaviour
Following these tests,the partners decided to install
the pumping device on an actual field wit h 0 U t
special
adaptation of the pump to the field
charac teri sti cs.
3.2 Field testing
3.2.1 SIT test rig
This test rig has been built by TOTAL and
STATOIL in 1988 on an onshore field in Tunisia
(SIDI EL IT A YEM), operated by CFTP (Compagnie
Franco Tunisienne des Petroles) in which TOTAL

LAPEC 23624

Pierre Gie

has a 50% share. This multi phase loop gives the

possibility to test equipments under real field
conditions, but without endangering the field
production as an automatic by pass valve isolates
the loop in case of a problem on the rig. This
manifold controls an average of 5000bbl of liquid
effluent per day with a high water content and a gas
ratio of about 95%(fig 9).
The station was used for a multiphase
measurement campaign taking advantage of the
flexibility offered by the two pipe lines of 6" and 4"
diameter(fig.l0. Two campaigns were conducted, one
to record the data of the flowing conditions and the
mass-balance, in order to adjust the transient and
stead y state models developed by ST ATOIL and
TOT AL.The other was to test measurement devices
for slug detection with non-intrusive sensors,
mainly densitometers and vibration sensors. The
second campaign is linked to an EEC backed
research programme performed in cooperation with
the BHRG(Cranfield,England).
While the POSEIDON pump was being tested at
Solaize in 89/90, a Bornemann twin screw pump was
bought and installed at SIT in order to improve the
knowledge on other available equipment.Today SIT is
the only place where it is possible to find different
multiphase equipments, namely two types of
multi phase pumps a twin screw type and a
rotodynamic (POSEIDON) type installed on a living
field,plus various multiphase metering devices.
3.2.2. POSEIDON at SIT
The pump is the prototype built for and tested at
SOLAIZE.It was directly designed in its marine
version including an
integrated lubrication
system.The buffer tank,designed and developed
during the studies,was installed at the suction end
of the pump.
As shown in fig. II,the pump was installed in
parallel with the twin-screw pump.The POSEIDON
pump was eventually put on stream at the end of
May 91.
The first major check-up took place in mid-July 91
after 1000 Hrs of operation. During this 1000 Hrs
period no shut down occured due to a malfunction of
the pump itself.
Compared to the artificial multiphase loop,the
test rig produces more difficult conditions:large gas
fraction,GLR over 30 mainly due to low fluid
production, quicker
flow
rate
and
pressure
variations creating stronger torque variations than
expected.
As a change in the. fluid composition, i.e. a
modification
of the
gas
to
liquid
ratio
( GLR),requires an adjustment of the rotational
speed, a slow reaction induces a rapid torque

increase and then a shut-down due to the preset

protection level on the maximum torque value.
Operation of this protection device necessitates a
re-start of the pump. Improvements have also been
made
to the regulation of the rotating speed in
relation to the torque variation which represents in
fact the GLR variation.
Other shut-downs resulted mainly from the fact that
the pump is now in a place where the external
parameters are not as well controlled as on an
artificial loop (well manifolding, national electrical
network etc ... )
Finally this once again proved that an artificial
bench, simulating
natural field conditions, whatever
the sophistication may be,cannot include all
parameters of
an actual production center.The
human factor
in
particular must not be
underestimated,as one can no longer run the
equipment with the high levelled, specialized
personnel of a research center as at Solaize-IFP but
with the normal field operators of SIT who did not
receive special training when transferred to the
multiphase 100p.The obtained
results will also be
integrated into the design of future stations.
3.2.3.Field test results
Three main objectives were looked at during the
test:
-to check the multi phase behaviour of the pumpbuffer tank system.
-to perform an endurance test on all mechanical
components.
-to improve the knowledge on the complete
multi phase pumping station.
On December 1st 1991,after more than 4000
cumulated running hours,one can draw the following
intermediate conclusions:
-The pump has given with the actual fluid effluent
the same characteristics as those plotted at
Solaize.Hydraulic performances were confirmed
although facing harsh and unstable conditions
(flowrate, pressure,GLR).
-The recirculation of a limited amount of liquid
smooths the inlet conditions (lowering the GLR
from 30 to 10) and brings back the flow parameters
into the design range of the pump.
-The association pump/buffer tank proved to be
satisfactory especially in slug flow regime.The
recorded curves of fig.12 show how the liquid level
in the buffer tank decreases when gas pressure
increases meaning that this gas fraction change has
a major effect on the buffer tank, thus dampening
the pump inlet conditions.
-Regardless of suction pressure variation,the
outlet pressure is kept reasonably stable.
-The systems adapts itself to the outlet conditions
(simulated by a change of the separator inlet
73 pressure) In fig.13 the recorded curve shows how

Field tests of the Poseidon pump

the pressure rise at the pump increases after the

increase of the separator inlet pressure.
-At a constant outlet pressure,the pressure rise
increases
with the
rotational
speed,hence
decreasing the suction pressure on the producing
wellheads.
-For a given outlet pressure,fixed by the separator
and the pipe-line pressure drop, the rotation speed
(RPM) regulates all the up-stream production
parameters,flow rate and pressure.
-From a mechanical standpoint,the motor-pump
group showed no unusual operating phenomenon.

4. CONCLUSION
The operational tests realised with a prototype
pump,not specially designed for the harsh field
condition of Sidi El Itayem in Tunisia have provided
the following conclusions:
-The ability of the pump to be installed easily on a
producing field.
-Confirmation of the design data of the pump,i.e.
its ability to tranport multiphase fluids,whilst
coping with large gas slugs.
-The self-regulating behaviour of the installation.
-The good smoothening effect of the buffer
tank,preventing dangerous torque variations.
All this important information will be integrated
into
the
design
of
the
planned
future
installations:one is to be installed by IFP in France,
one by ST ATOlL on the Gullfaks platform in the
Norwegian sector of the North Sea,and the last one-a
subsea station-by TOTAL in the UK sector of the
North Sea.

ACKOWLEDGEMENTS
The author thanks MM Buvat (Total) Durando,de
Panafieu and Bratu(lFP)for their contribution in the
preparation of this paper.
REFERENCES
1 P ARNAUDEAU:Development of a two-phase oil
pumping
system,Poseidon project.OTC 5648,
Houston,May 1988
2 A LAFAILLE:Poseidon:The multiphase boosting
and transportation system.OSEA 90128,Singapore,
December 1990.
3 E.ENGELMANN T.A.TORP:The Poseidon project and
the future of multiphase production.ONS,Stavanger,
August 1990.
4
P
G IE:The
Poseidon
project,1990-1991
achievements.DOT Monaco,November 1991.

74

LAPEC 23624

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.,
....

.c

c..

~g

--

~8

~6

--

:5
:..;

-"

~J

~2

1:
:0
9

t
!

INLET PRESSURE

(bars)

\
lim e ( h 0 u r s) '"

Fig.13

Adaptation

to the

77

line conditions

~
!

,I

I
1

I
i

i
I

I
llme(hours) '"

Fig.12 Field tesls

.,

J~

""+Wi

~.

Fig.11 Poseidon Pump al SIT

PRESSURE(BARS)

!""""'I~

'"

'"'"

...

i~

results