Publications

Zulu area and its surface facilities are being operated under a flowing fluid type of heavy oil production with 19 degAPI gravity. This given condition leads to a unique intermittent and foaming oil flow phenomenon followed by daily process parameter fluctuation, to be specific, along pressure and water cut. The unsteady operational parameter reduces oil flow continuity, flow assurance effectiveness, which resulting a severe pump cavitation. Pump cavitation escalates to a unit pump failure and systemic oil processing instability. Consequently, maintenance cost increases due to unplanned pump breakdown. This paper conducted a complete analysis using mathematical composition approach to clearly define the phenomenon of cavitation from its early beginning. Using a custom-made data acquisition, four operational parameters of pump, such as: pressure suction-discharge and vibration vertical-horizontal are being captured separately for advance polynomial regression. The main challenge is to synthesize four high order polynomial equations using composite function approach in order to be able clearly interpret the phenomenon along pump during: normal condition, recirculation, and early to severe cavitation in mathematical ways. This step is resulting two main equations for further sensitivity polynomial analysis which is important to be done to distinguish the higher response equation prior to cavitation generation. All mathematical results have been simplified onto a matrix as an input data for a module unit, responsible in activating the process recirculation valve control to eliminate cavitation fast. Moreover, a manual valve is being operated as a bursting valve to compensate any gas trap accumulation along pump which leads to a severe cavitation. These are value creation from this solution: - A higher reliability of pump with a stable discharge pressure > 230 psig - Cavitation prevented less than ten minutes - Production increment of oil by 11 BOPD and increase company revenue > 70,000 USD (yearly average 2018).