News 2010

Bornemann will exhibit from September 07- 10, 2010 at the SMM in Hamburg

Wed, 11 Aug 2010 09:47:56 +0200

Economical and reliable pumps and systems for Marine and Shipbuilding – under this motto Bornemann is once again going to show its wares at this year's SMM, the international trade fair for the shipbuilding and ship-supply industry.

You find us in Hall A2, Stand 220.

Bornemann will demonstrate how its intelligent pump solutions are able to meet growing demands in state-of-the-art shipbuilding. This year we present the first time the Bornemann Twin-Screw Pumps, including control system.

Bornemann Twin-Screw Pumps have proven their worth internationally as loading pumps on tankers, transfer pumps for heavy-duty HFO and as lubricating pumps for supplying the main engine.

We inform you about the advantages of our pumps and systems.

The Bornemann team is looking forward to your visit!

SOGS - Subsea Oil and Gas Skimmer

Mon, 02 Aug 2010 12:05:39 +0200

Bornemann is specialist in twin-screw pumping technology, both on- and offshore. Bornemann has the world’s largest experience in supplying pumps and systems to the oil and gas industry for applications related to multiphase boosting, wet-gas-compression and heavy oil pumping. Since 2000 Bornemann is involved in Subsea Multiphase Boosting Projects. In addition to the oil and gas market Bornemann Twin-Screw Pumps are used in the food, pharmacy and chemical industry pumping fluids which are highly complex and difficult to handle.

Some years ago Bornemann was designated to supply the “submerged” drain-pumps to empty the sunken oil tanker “ERIKA” at the French coast.

Subsea oil production requires the conveyance of fluids from the well to the next receiving station at the surface (on- or offshore) through pipeline systems. Subsea boosting and processing stations can be integrated subsea and the fluids in these systems are in most of the cases oil-water-gas mixtures coming with the natural untreated well production.

High safety requirements prevent leaks from occurring. In the very unlikely event of a leakage, the contamination to the environment should be detected and collected as soon as possible. Unfortunately, an operative mobile Subsea Leakage Collection Systems does not exist yet.

In case of a subsea leak, oil and gas will be released into the seawater environment.
The hot oil and gas will be quickly depressurized to seawater pressure, solved gas will come out of solution and lighter hydrocarbon components will vaporize. The oil and gas mixture will cool down rapidly when getting in contact with seawater. The oil viscosity changes and light and heavy oil components will separate. Intensive mixing of oil and water can create highly viscose water-oil-emulsions and should therefore be avoided.
Oil, water and gas mixtures are well known and can be safely handled by well approved multiphase pumps.

The critical parameter is the level of gas hydrates. Gas will cool down almost instantaneously as it gets in contact with cold seawater (typical 4°C). Below a water depth of 300 m the risk of gas hydrates to be generated is high. A gas hydrate is a crystalline solid, consisting of a gas molecule surrounded by a cage of water molecules.
Gas hydrates tend to agglomerate and stick to surfaces.

Gas hydrate equilibrium diagram for methane (a) and natural gas (b) in seawater; seawater temperature of the Gulf of Mexico is presented by the dotted lin (Zheng et al., 2002)

Information about oil/gas leakage investigation is limited, but a comprehensive investigation on oil and gas spilling into the deep-sea was conducted during the “Deepspill” campaign. The published hydrodynamic model (e.g. Chen and Yapa, 2002; Zheng et al., 2002) incorporates the phase changes of gas, associated changes in thermodynamics and its impact on the hydrodynamics of the jet/plume distribution. Hydrate formation, hydrate decomposition, gas dissolution, non-ideal behaviour of the gas, and possible gas separation from the main plume due to strong cross currents are integrated with the jet/plume hydrodynamics and thermodynamics.

Scheme of deep water oil/gas spill (Zheng et al., 2002)

Obviously, the emerging fluids have to be collected as close to the leak as possible. Accordingly the subsea skimmer will operate in the hydrate formation zone.

Gas hydrate formation is not only controlled by its thermodynamic properties but also by kinetic processes. The challenges in hydrate nucleation and growth are related to mass- and heat-transfer effects. The nucleation and growth of hydrates is often associated with a delay or induction time (metastability) from the time the system is thermodynamically favourable to form hydrates. Turbulent mixing of water and gas reduces this phenomenon and gas bubbles sticking to surfaces show also enhanced hydrate skin growth. As the nucleation of hydrates is a stochastic process, a system may be in a metastable state from seconds to hours/days, depending on the mixing conditions, composition, apparatus geometry, etc.

The formation of gas hydrates can be influenced by heating and injection of additives.

Twin-Screw Pumps are well known in the industry being able to handle difficult media, subsea multiphase pumps are one example.

Coming from the typical subsea pump design, the requirements for an emergency tool are different:

Lifetime: less than 1/2 year
Pressure rating inlet: 0 bar
Pressure rating outlet: 100 bar or less
Pressure head: 5 to 50 bar
Able to handle pulpy gas hydrates
Availability: immediately

Still the same requirements to subsea process pumps are:

Handle low to high viscosities
Handle low to high gas content
Oil-water mixtures, do not create emulsion
Pressure compensated electrical motor
Capacity variation of pump from 0 to 100%
Design for water depth up to 3000m

The Operational Concept

When a leakage occurs, the emergency leakage-collecting tool (Subsea HC skimmer) is brought in place and starts to collect as much hydrocarbons as possible through the inlet funnel, as close as feasible at the leak. If possible, the suction lance (snorkel) is placed inside the leaking equipment to reduce the pressure inside the equipment below ambient pressure to eliminate all leakage into the seawater. A good compromise will be a combination of snorkelling from inside the equipment and collecting the remaining leakage outside.

The positioning of the leakage-collecting tool will do by ROV’s.

A leakage detection tool (hydrocarbons sniffer) should be installed on the snorkel to find the centre of the leakage cloud, and an other detector should be installed outside of the suction cone to document how much hydrocarbons are still going into the environment.

The Subsea Skimmer can be hanging from a oil recovery vessel in safe distance from the subsea installations. Later or alternatively the Subsea Skimmer can be installed subsea onto a containment system structure or beside it on a separate structure and connected to the containment system via flying leads. The "Subsea Skimmer" might also be connected directly to an Insertion Tool in order to draw down the pressure in damaged hydrocarbon piping system so that the amount of oil leaking to the environment can be reduced.

Suggested Solution

Based on the Bornemann SMPC series 4 concept, the existing pump-motor module is used as it is. The pressure casing will be modified to a insulated inlet funnel. A short piping connects the suction snorkel to the pump-cartridge. A ROV operated control valve will adjust the flow rate through the snorkel and through the inlet funnel.

Injection of additives (gas hydrate inhibitors) and additional heating of the cone can eliminate the formation of hydrates.

Information from the HC-sniffers, measurement of discharge pressure and cone temperature will be used for optimal flow rate control of the pump.

Speed variation can be done by the use of topside frequency converters or by using a hydraulic speed converter subsea.

Conclusion

The above drawn concept is designed by pump experts with eminent experience in handling unconventional products. It is verified by oil, gas and hydrate experts and considered a viable solution. The technology is available, components are in operation and approved.

Solutions for shallow water (less than 300 m) will be less complex in regard to hydrates and easier to handle. Deep water solutions have to be equipped with hydrate control equipment. Both have to be available within a very short mobilisation time.

A joint industry project under participation of local authorities and the government should be able to develop a working prototype within a very short period of time. It may not be quick enough, but from today the industry must be prepared for a future accident, which hopefully never will happen.

For more information about SOGS please click here

Subsea boosting for oil and gas projects

Thu, 20 May 2010 10:08:26 +0200

Multiphase, according to the general understanding in the oil and gas community, is the oil-watergas mixture coming with the natural untreated well production.
Uncertainties in the production data, slugflow in pipelines and fast variations in pressure and fluid composition are part hereof. As soon as a significant amount of
gas is involved, separation effects in the flowlines have to be considered. Consequently the Multiphase Pump (MPP) has to be designed for slugflow conditions.
In general multiphase pumps can be divided into three groups with its own technical requirements:

Gas tolerant liquid booster: 0% to 30% gas – typically only applicable direct downstream of separators or inside long crudeoil transfer pipelines.
Multiphase pump: up to 100% gas temporary – downstream well and upstream separator.
Wet gas compressor: 99% to 100% gas continuously but with the risk of slugflow (water or condensate) – typically downstream gas wells.

In all cases the MPP shall be able to transport the liquid-gas mixture against the full pipeline backpressure without interruption of the flow.
Bornemann provides the patented solution of internal liquid (product liquid phase) separation and recirculation of a small percentage of liquid back to MPP inlet, preventing MPP rotors running completely dry. Separation and liquid storage inside the MPP discharge casing is vital for the Multiphase Mixture (MP) boosting process.

Improvement of Oil Production

Each reservoir has its own optimal production characteristic in regard to oil production, gas production and water-cut minimisation. The graphic explains the production task of multiphase pumps.

The oil production (orange curve) of wells typically follows a certain known production profile, depending on the wellhead back-pressure. At a certain wellhead pressure the flow velocity in the well is too low to transport the liquid to surface. The well might be “dead” or only gas is coming. If the well is closed, after some time the wellhead shutin pressure will build up. The shut in pressure can be very high compared to the production pressure. There is an optimal oil production at a certain pressure which is fluctuating with the time. Too low pressure draw down might lead to non-optimal production rates and damages in the reservoir. Together with the oil the associated gas is produced – the relation between oil and gas typically is given in GOR (gas-oil ratio at standard conditions). Because the gas is expanding with the pressure going down, the total production curve is expanding to higher flow rates (brown curve) at lower system and pump inlet pressures. The well is producing into a pipeline system. The pipeline backpressure (blue curve) on the production is defined by any static backpressure on the pipeline (geodetic height, separator pressure, etc.) plus pressure losses depending on the medium flowing through the pipeline. The equilibrium between well and pipeline performance (crossing of blue and brown curve) defines the natural production (depending on choke setting, etc.).
During the first years chokes might control the perfect balancing between production and backpressure. By and by the reservoir is depleting and the producing well pressure is declining. Additional wells might be connected to the pipeline system, which can lead to higher pipeline back-pressure on the well. At this moment the installation of multiphase boosting pumps (red arrow) helps to control the well pressure for best production. The pump now unloads well performance characteristics from pipeline behaviour.

Twin Screw Pumping Technology

The Bornemann MPPs are twinscrew pumps. Within these pumps two synchronized rotors are intermeshing and forming closed chambers between the rotor-screwflanks and the surrounding casing insert (liner). Whatever enters into the chamber at screw inlet will be moved to the outlet. Pump capacity depends on rotor diameter, pitch of the rotor-screws and finally the pump speed.
There is no contact between screws and liner. Consequently there will be a gap between the pumping elements and therefore a certain internal backflow (slippage) from pump discharge back to pump suction. At any time the Bornemann internal separation and recirculation ensures enough liquid at the rotors to keep the gaps sealed with liquid and therefore the pump performance is independent on gas content. The rotors are “engineered rotors”. Shaft and screws can be made from materials, best suitable for the task and the pumping process. Heat treatments and coatings can be done separately without influencing the shaft properties.

DPC – Double Pressure Compensated Pump

The Bornemann Subsea Booster (SMPC) is the consequent further development of the subsea MPP and the heavy duty topside Multiphase Pump type MPC. The new Double-Pressure-Compensated (DPC) pump design provides the basis for the new subsea MPPs – the SMPC series 4.1. It basically consists of two main components:

The pressure casing, rated for water depths and process pressure.
The pump-motor-module, including all rotating equipment.

The pump-motor-module is built up from the approved SMPC pump cartridge and a simplified electrical motor cartridge. Power transmission from motor to pump can be achieved by a conventional mechanical coupling. Optionally a hydraulic torque and speed converter can be used. The total cartridge – except the pumping chambers – is filled with pressurised lube oil – the barrier fluid. The pressure of the lube oil is permanently controlled and adjusted to provide to the mechanical seals best operating conditions (constant pressure over the seal). Consequently the casing of the pump-motor-module is fully pressure compensated against the pump discharge pressure which is inside the pressure casing. The pump-motor-module will be inserted into the pressure casing by avoiding all sensitive interfaces between pressure casing and pump-motor-module. Deflections, deformations, mechanical stress, etc. from the casing will not been transmitted to the pump-motormodule. The casing is designed according to the actual requirements. Different materials can be used, coating from inside could be done, composite material might be applied.
The pressure casing is a geometrical simple “separator style” pressure vessel. Therefore it provides good separation and liquid hold up capabilities – required for reliable multiphase operation. The DPC design also allows the vertical installation of the MPP. The diameter of the pump can be minimized – still providing sufficient separation and liquid hold up volume for multiphase-service.

Pump Performance

The pump capacity at a certain speed is not much influenced by the differential pressure over the pump. There is a certain backflow from pump discharge to pump
suction through the gaps between rotors and casing. The backflow depends mainly on viscosity and differential pressure. By speed variation a wide capacity
range at full pressure head (differential pressure) can be provided, 10 to 120 percent of the nominal capacity is typical. The achievable differential pressure is limited by the mechanical load on the rotor. Differential pressure of up to 100 bar in high viscous liquid service with up to 20 percent gas and good efficiency is standard today on twin-screw pipeline transfer pumps. Special designed high pressure multiphase rotors also allow for pressure build up of 100 bar without influence on the rotor integrity in full gas service – but at high gas the efficiency will be limited. Rotors, designed for higher capacity are limited in pressure head due to the fact that the maximal allowable shaft power within one frame size remains constant over all available rotor designs.

High Differential Pressure Booster Systems

For subsea applications more often very high boost pressures will be required to overcome the water depth while the wellhead pressures shall be reduced to its limits.
Practically this will require multiphase pumps or gas tolerant liquid boosters being able to increase the production pressure from almost 0 bar up to 200 to 300 bar.
The Bornemann solution is the installation of two or more multiphase pumps in series. The first is controlling the system inlet pressure and providing a certain precompression. The second pump is controlling the outlet pressure of the first pump by speed variation – picking up the compressed volume flow at the outlet of the first stage MPP at the required pressure – and overcomes the remaining pipeline backpressure. Each single pump is operating with a better efficiency and the total power consumption will be significant reduced. On a project in Abu Dhabi, the total power requirement could be reduced from 1 MW for the single pump concept to 500 kW (2 x 250kW) with the serial installation that was finally selected.

Bornemann exhibits at OTC Houston, May 03.- 06, 2010

Thu, 15 Apr 2010 11:05:14 +0200

Offshore Technology Conference is the leading event in the oil & gas industry, proposing high quality technical conferences and an international exhibition. Bornemann will be happy to welcome you on its booth to present new developments in Multiphase Boosting and Pump Technology.

Visit us on the German Pavillon!

Exhibition floor plan
Booth # 4527-5 German Pavillon
Venue
Reliant Center
1 Reliant Park
8400 Kirby Drive Houston
Texas 77054 - USA
Opening hours:
3 May, 9:00 am - 5:30 pm
4 May, 9:00 am - 5:30 pm
5 May, 9:00 am - 5:30 pm
6 May, 9:00 am - 2:00 pm

Link to OTC website

IFFA 2010

Wed, 07 Apr 2010 10:55:17 +0200

International meat-processing industry to meet at IFFA in Frankfurt am Main from 8 to 13 May 2010
Visit us in Hall 9.1, Booth A 88

The next leading international trade fair for processing, packaging and sales in the meat industry will open its doors in Frankfurt am Main from 8 to 13 May 2010. Around 900 companies from 48 countries are expected to present their latest innovations on around 100,000 square metres of exhibition space (seven halls). IFFA has been the international meeting place for the meat-processing industry and the foremost forum for investment decisions since 1949. The range of products and services to be seen is unique and covers the entire meat-production chain from slaughtering, dismembering and processing to packaging and sales. The exhibitors, which include all international market leaders, produce their latest products in readiness for the fair and launch their innovations there. Don’t miss this opportunity to see the latest products, technologies and processes, e.g., for energy efficiency and resource conservation in the mechanical-engineering segment, meat-processing automation, process documentation and traceability, hygiene and occupational safety. The products on show will be rounded off by an attractive complementary programme with competitions, conferences and special shows.

EMBT-Conference 2010, 24.-25. März 2010 in Hannover

Wed, 24 Mar 2010 11:54:25 +0100

The EMBT Conference is one of the most important expert meeting places for Multiphase Boosting Technology.

While a substantial growth of this technology is expected, this event offers the entire spectrum of all applications in onshore, offshore and subsea areas.

As with the two events before in 2006 and 2008, the 3^rd EMBT Conference on March 23- 25, 2010 in Hannover will inform you about the latest developments in Multiphase Boosting Technology first hand and from experts – onshore, topside and subsea.

The conference’s international orientation will ensure a high level of personal exchange and professional discussion. While we will concentrate on research and development in various areas, three highly profiled workshops will make sure that we do not miss out on operational issues and experience.

Download Conference Program.pdf