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Viscous Oil Pumping Technology Viscous Oil Pumping Technology

and Annular Water Injection Techniquesand Annular Water Injection Techniques

Presented to:Presented to:NATO CCMS Oil Spill Technology Development WorkshopNATO CCMS Oil Spill Technology Development Workshop

The Bedford Institute of Oceanography The Bedford Institute of Oceanography Dartmouth, Nova Scotia, CanadaDartmouth, Nova Scotia, Canada

October 12th October 12th –– 13th, 200613th, 2006

The MotivationThe Motivation

-Increasing use and transport of high viscosity oils

-Availability of Effective Mechanical Feeder Skimmers which are able to recover these materials from the water surface

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The MotivationThe Motivation

Applications Applications –– Pipeline Spill Alaska 2006Pipeline Spill Alaska 2006

The MotivationThe Motivation

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Flow Enhancing TechniquesFlow Enhancing Techniques

• Various high and extreme viscosity pumping techniques have

been developed and tested by Industry and Government

– Bulk heating

– Local bulk heating

– Annular Water Injection

• Discharge side annular water lubrication

• Inlet side annular water lubrication cold water

• Inlet side annular water lubrication steam / hot waterc

Local Bulk HeatingLocal Bulk Heating

• Steam Coil surrounding the

pump inlet

– Lowers viscosity of oil around

the pump to reduce viscosity

and improve inflow.

– Works for all types of pumps.

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Annular Water InjectionAnnular Water Injection

• Oil industry since 1959

• For centrifugal pumps

• Placed after the pump

• CEDRE model tests 1989

• Framo emergency off-loading

in early nineties VOPSCourtesy by GPC/USCG/US NAVY

Annular Water InjectionAnnular Water Injection

NO Water InjectionNO Water Injection WITH Water InjectionWITH Water Injection

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Discharge SideDischarge Side AWIAWI

• First USCG VOPS workshop,

Seattle 1999

• After New Carissa Spill

• 10 – 14 times pressure reduction

• Tests up to 450 m hose

• Viscosities were in 20,000 cSt –

30,000 cSt range

Inlet Side AWI Inlet Side AWI -- Cold WaterCold Water

• Developed in 2001

(flemingCo)

• For non emulsifying pumps

• Reduces friction losses in

pump

• Lubricates flow through

discharge hose

Inlet injection flange

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Inlet Side AWI Inlet Side AWI -- Steam / Hot WaterSteam / Hot Water

• Same benefits as cold water

PLUS:

• Local Bulk Heating Effect for

better inflow to the screw.

• Heats up inner surfaces of

pump and hose for reduced

friction.

Joint Viscous Oil Pumping System (JVOPS) WorkshopJoint Viscous Oil Pumping System (JVOPS) Workshop

• Testing and improving US Coast Guard, Canadian Coast Guard, and Industry Viscous Oil Pumping Systems

• Long distance pump transfer testing on 200,000 cSt oil up to 450 m

• Long distance pump transfer testing on 500,000 cSt oil up to 150 m

• Optimize lubrication water – inlet, outlet, temperatures, and percentages

• Comparative testing between all pumps with their flow enhancing devices

• Effects of local bulk heating alone and in conjunction with most efficient type of water injection

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Joint Viscous Oil Pumping System Joint Viscous Oil Pumping System WorkshopWorkshop

• Participating Pumps:– DESMI DOP-250 PDAS Pump– GT-185 PDAS Pump– FRAMO TK-125 Double Screw Pump– LAMOR GT-A 50 PDAS Pump

• Flow Enhancing Techniques Applied:– Inlet Side Water Lubrication– Discharge Side Water Lubrication– Local Bulk Heating

DESMI DOP-250 Pump w. flemingCo inlet AWIF and USCG/Navy outlet AWIF

Outlet AWIF Inlet AWIF

JVOPS Workshop PumpsJVOPS Workshop Pumps

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GT-185 Pump with flemingCo inlet and outlet AWIFs

Inlet lube device

Outlet AWIF

JVOPS Workshop PumpsJVOPS Workshop Pumps

Framo TK-125 w. 10 mm inlet lubrication tube and Framo outlet AWIF

Outlet AWIF

Inlet water injection tube

JVOPS Workshop PumpsJVOPS Workshop Pumps

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Lamor GT-A 50 w. integrated flemingCo inlet and outlet AWIFs

Integrated inlet AWIF

Outlet AWIF integrated in discharge coupling

JVOPS Workshop PumpsJVOPS Workshop Pumps

GT-A 50 JVOPS Results 200,000 cst oil & 92 meter 6 inch hose

Inlet lube water Outlet lube water Capacity Pump pressure

No water No water 4.5 m3/h 11.9 bar

4 % cold water 4% cold water 44.8 m3/h 2.8 bar

(14oC) (14oC)

4% hot water 4% cold water 45.7 m3/h 0.6 bar

(99oC) (14oC)

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GT-A 50 JVOPS Results 200,000 cst oil & 6 inch hose

6” H ose length

m

V iscosity

cS t

In le t lube

water% / ºC

O utle t lube

water % / ºC

C alcu lated capacity

m 3/h

D rum -fill

capacitym 3/h

Pum p pressure

bar

92.6 202,000 0 0 4.5 6.1 11.9 92.6 210,000 4 / 98 4 / 98 46.7 42.7 0.6 92.6 210,000 4 / 99 4 / 14 45.7 40.5 0.6 92.6 210,000 4 / 14 4 / 14 44.8 43.2 2.8

WITH NO LUBRICATION:

Could pump 50 m3/hr through 23 meters of 6” hose

WITH LUBRICATION (and considering hydraulic motor power limitations):

Could pump 50 m3/hr through 800 meters of 6” hose

4/5

JVOPS Workshop PumpsJVOPS Workshop Pumps

Positive Displacement Pumps performed as expected both with, and

without Flow Enhancement Techniques.

Hot water on the inlet and cold water on the outlet worked best. Hot

water on the inlet only worked nearly as well.

Water lubrication percentages as low as 1.7% would work once the

annulus water ring had been established

Efficient water lubrication could be maintained with cold water once the

annulus water ring had been established using hot water on inlet

JVOPS Workshop JVOPS Workshop IMPORTANT OBSERVATIONS 1IMPORTANT OBSERVATIONS 1

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No requirement for additional lube water for increased hose length

Re-starting the fully water lubricated pumping process after a stop was

only possible when using hot water on the inlet (max. 90 m hose in test)

Up to 360 m of hose could be pigged in one step using discharge WL

pump or compressed air. Final decon by diesel flushing

JVOPS Workshop JVOPS Workshop IMPORTANT OBSERVATIONSIMPORTANT OBSERVATIONS

Positive Displacement ArchimedesPositive Displacement Archimedes’’ Screw PumpsScrew Pumps

- Simple, robust geometry.

- Plate wheel engages with screw and seals against backflow to develop high pressure.

- End Suction Screw for efficient inflow to the pump.

- Very gentle, low shear pumping - Will not emulsify oil and water.

- Knife system on inlet - Cuts most debris found in oil spills. Large Solids can pass through pump.

- Predictable and reliable performance in a wide range of fluids from water to bitumen.

PDAS PumpsPDAS Pumps

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Positive Displacement ArchimedesPositive Displacement Archimedes’’ Screw PumpsScrew Pumps

PDAS Pumps PDAS Pumps –– How they workHow they work

TORQUE TORQUE --VSVS-- CAPACITY (PUMP SCREW DIAMETER) OF PDAS CAPACITY (PUMP SCREW DIAMETER) OF PDAS PUMPS IS A KEY INDICATOR OF EXTREME VISCOSITY PUMPS IS A KEY INDICATOR OF EXTREME VISCOSITY PERFORMANCE!PERFORMANCE!

THE IMPORTANCE OF TORQUETHE IMPORTANCE OF TORQUE

5.363751000160OMTS 16070DESMI DOP DUAL-200

6.00180100080OMSS 8030DESMI DOP-160

6.053751000160OMTS 16062LAMOR GT-A 50

9.00180100080OMSS 8020LAMOR GT-A 20

9.50475800160OMTS 20050LAMOR GT-A 50H

Torque/CapacitydeltaP 175 bar RPMflow (L/m)MotorCapacityPump Model

Performance IndicatorTorque (Nm) at Maximu

mMaximum Hydraulic

Danfoss HydraulicPump Max

TO TO MAXIMIZE PERFORMANCEMAXIMIZE PERFORMANCE, CHOOSE THE PDAS PUMP , CHOOSE THE PDAS PUMP

BY TORQUE AND PRESSURE CAPABILITY, THEN SIZE BY TORQUE AND PRESSURE CAPABILITY, THEN SIZE

ACCORDING TO REQUIRED CAPACITY.ACCORDING TO REQUIRED CAPACITY.

JVOPS Workshop JVOPS Workshop IMPORTANT OBSERVATIONSIMPORTANT OBSERVATIONS

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Viscous Oil Pumping PackageViscous Oil Pumping Package

AWIF technology for existing PDAS Pumps AWIF technology for existing PDAS Pumps

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Hot Water/Steam Flow Control Hot Water/Steam Flow Control

Higher pressure hose systems Higher pressure hose systems

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Steam Cleaner/Pressure Sprayer for Steam Cleaner/Pressure Sprayer for AWIF on smaller pumps AWIF on smaller pumps

Steam and Hot Water Generators for Local Bulk Steam and Hot Water Generators for Local Bulk Heating and AWIF on larger pumps Heating and AWIF on larger pumps

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Steam Coils for Local Bulk Heating Steam Coils for Local Bulk Heating

Further Development Further Development

Quantify the relationship of Torque to Pump Performance –vs-Viscosity

Decision Making tools for responders

Optimization of Local Bulk Heating System - Pump end

Optimization of Injection Water Heating Systems and pumping systems

New technologies for local viscosity reduction

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Thank you.

Jim Mackey

Hyde Marine, Inc.

28045 Ranney Parkway, Suite G

Cleveland, Ohio 44145 USA

www.hydemarine.com

T: +1.440.871.8000 x156

F: +1.440.871.8104

JMackey@hydemarine.com