fmc subsea pumping - gas/electric · pdf file4/15/2013 direct drive systems 1 agenda •...
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1Direct Drive Systems4/15/2013
Agenda
• Subsea pumps by technology and power• Multiphase motors and pumps• Key Technologies
Motor Barrier fluid Hydraulic bundle
• FMC Technologies is the leader in subsea systems integration Collaborating with Sulzer Pumps Ltd. and acquired Direct
Drive Systems to provide integrated multiphase boosting systems
2Direct Drive Systems4/15/2013
Subsea pump units by technology
22
51
47
28
6
30
2
15
8
0 10 20 30 40 50 60
ESP
Helico-axial
Tech not selected/installed
Centrifugal
Twin Screw
Hybrid H-A
Source: INTECSEA-Offshore
FMC Technologies installed 1994 – 2012
• FMC integrating 34% of the MPP installations for 18 years• Vertical integration best practices focus on safety, simplicity,
efficiency, barrier fluid system, service & support
3Direct Drive Systems4/15/2013
Subsea pumps by power - all years
24
6
12
56
4 3
9
25
38
52
-4
6
16
26
36
46
56SSPMM3.0
OfferingSSPMM6 Concept
15,000 psi
SSPMM3.5 Offering
Source: INTECSEA-Offshore1994-2012
93 units: 0.50 – 1.5MW 41 units: 1.75 – 2.5MW 47 units: 2.75 – 3.5MW
Megawatts
SSPMM2 Offering
FMC offering one qualified 5,000 psi motor design
Three motor rotor diameters to optimize efficiency
4Direct Drive Systems4/15/2013
Subsea pumps by technology
Source: INTECSEA-Offshore
0
50
100
150
200
250
300
0 10 20 30 40 50 60 70 80 90 100
Diff
eren
tial H
ead
Pre
ssur
e (b
ar)
GVF (%) at suction condition
GVF vs differential pressureOperational and conceptual capabilities
Centrifugal
Helico-axial
Hybrid centrifugal-helico-axial
Twin screw
Wet gas compressor
Dry gas compressor
5Direct Drive Systems4/15/2013
Motor/pump design – cross section
FilterMotor
ROV panel
Penetrators
Cooler
Barrier fluid pipe work
Balance lineDischarge nozzle
PT/TT sensors
Pump
Coupling
Mechanical seals
Balance drum
Thrust bearings
Barrier fluid manifold
Suction nozzle
18 ft
26T wt
8 ft
6Direct Drive Systems4/15/2013
Key technologies – Permanent magnet motor
• High efficiency Synchronous motor performance, 3 x 'air gap' and small diameter PM rotor increase efficiency ~10% liberating surface power for other uses
• High Speed Selections at 5,000rpm with 6,000rpm capability allow for changes in production and GVF
• Sealed Cable wound stator and carbon sleeve rotor allow use of more environmental friendly water-based barrier fluid
• Eliminates subsea moisture control systems because barrier fluid is not part of motor insulation system
• Modular construction allows same motor and unit concept for all pump types
7Direct Drive Systems4/15/2013
Key technologies – Barrier fluid system
• Purpose Protects motor from process fluid Motor cooling Lubrication of seals and bearings
• Features Environmentally friendly barrier fluid
(Water/Glycol) Pure mechanically-based system
• Reduced complexity• No control system delay
Redundant system• Components
Topside hydraulic pressure unit (HPU)
Subsea regulation mechanical valves
8Direct Drive Systems4/15/2013
Key technologies – Pump hydraulic bundle
• 10 years Experience Sulzerbuilding and installing helico-axial technology for over 10 years
• Tolerant Large axial flow path and clearances tolerate large particles and sand production
• High Speed Compressor-style assembly guarantees machine balance
• Resistant SUME HVOF coatings provide combination of corrosion and erosion resistance
• Thrust Balance piston application in multi-phase flow unique to Sulzer over 10 years
9
Collaboration
2006 - Sulzer Pumps sanctions R&D activity into subsea pumping
2008 - Joint development agreement with FMC Technologies• Develop a subsea pump module to meet market requirements
• Completion for qualification of first prototype
2012 – FMC Technologies and Sulzer Pumps enter long-term exclusive supply agreement
10
Collaboration – Scope of supply
• Integration into subsea station• Pipe connection• Wet mateable connector• Pump motor unit control system• Drive system including umbilical• High pressure barrier fluid supply unit
• Pump motor unit• ROV panel• Control logic• Penetrator (same make as wet
mateable connector)• Instrumentation attached to pump
11Direct Drive Systems4/15/2013
Hydraulic
• Pump performance on single phase and two phase complete• High boost (+100 bar dP) confirmed
Cooling
• Sufficient margin on design to accommodate higher losses and provide cooling flexibility
Mechanical• Motor and pump integrated system is predictable and stable
Electrical
• VSD starting / running algorithm confirmed• Long step out simulations confirmed• Motor power at step loading confirmed
Pressurizing
• Overpressure limits tested• Mechanical seal leakage rate as expected
Subsea Qualification
Test summary
Total 2013 unit running time: 1,000 h, 250 start/stops
12Direct Drive Systems4/15/2013
Summary
• FMC Technologies is the leader in subsea systems integration Collaborating with Sulzer Pumps Ltd. and acquired Direct
Drive Systems to provide 1.5MW-6MW integrated multiphase pumping systems
• Key technologies Motor: efficiency, speed, modular Barrier fluid: environmentally friendly, eliminates moisture
control Hydraulic bundle: experience, tolerant, balanced and
resistant
FMC Integration marinizing best of all technologies