FLOW BOOSTER CELL (FBC™)
Hydraulically Powered Production Boosting for Downhole and Subsea Applications
Current development focus: FBC™ for downhole artificial-lift and production-boosting applications
FBC™ is a proprietary production-boosting technology that transfers hydraulic power from the surface and converts that energy near the production source into mechanical pumping power.
Originally developed for subsea production boosting, the FBC™ architecture has evolved into a broader technology platform capable of being adapted to different production environments. Its current engineering program is focused on a downhole configuration for artificial lift, heavy-oil and multiphase production, while the original subsea configuration remains an active application of the FBC™ platform.
Surface-generated hydraulic power. Local mechanical conversion. Direct production boosting.
From Subsea Production Boosting to a Broader FBC™ Platform
The FBC™ concept originated from the challenge of providing production boosting close to the source in subsea environments while reducing dependence on complex prime-drive equipment located at the production point.
That development led to an earlier subsea FBC configuration and physical 3D prototype, establishing the original architecture around surface-supplied hydraulic power, local hydraulic-to-mechanical energy conversion and production boosting.
As development progressed, the underlying FBC™ principle demonstrated potential beyond a single installation environment.
Different applications require different architectures, mechanical layouts, completion interfaces, hydraulic arrangements and operating envelopes. Rather than replacing the original subsea concept, these adaptations have expanded FBC™ into a broader production-boosting platform.
The current engineering focus is the FBC™ Downhole Flow Booster Cell, adapted specifically for well production and artificial-lift applications.
A Common Power-Conversion Principle
One Core Architecture — Adapted to the Application
Across its different configurations, FBC™ is based on a common operating principle.
Surface equipment generates and controls hydraulic power. Pressurized motive fluid transmits that energy to the FBC™, where a compact hydraulic power-conversion system transforms pressure and flow into mechanical torque.
That torque is transferred directly to an integrated production booster designed for multiphase service.
This architecture eliminates the need for a conventional downhole electric motor and high-voltage power cable at the FBC itself and allows the primary power-generation equipment to remain at the surface or another more accessible location.
Depending on the application and fluid compatibility, the motive-fluid circuit can also provide an additional production-conditioning function.
Current Development Focus
FBC™ — Downhole Flow Booster Cell
The current FBC™ development program adapts the platform for installation within the wellbore.
Surface-generated hydraulic power is delivered downhole and converted within the FBC™ into controlled mechanical torque for an integrated multiphase production booster.
The downhole FBC™ is being developed particularly for wells where combinations of heavy fluids, multiphase production, intervention exposure and downhole electrical constraints create additional operating challenges.
Heavy Oil & Viscous Production
The FBC™ pumping architecture is being developed around viscous and heavy-oil applications where fluid properties can significantly influence artificial-lift performance.
A compatible lighter motive or conditioning fluid may also be selectively incorporated into the production stream when beneficial, reducing effective viscosity before or during pumping.
Multiphase Production
The production booster is designed around oil, water and gas mixtures, rather than assuming ideal single-phase production.
This makes multiphase behavior an integral part of the FBC™ engineering and validation program.
Solids & Sand
The multiphase pumping architecture is intended to accommodate entrained solids within the production stream. The allowable particle size, solids concentration, erosion rate and resulting operating envelope remain part of the planned qualification and testing program.
Intervention-Sensitive Applications
FBC™ relocates the prime-drive function to the surface and eliminates the conventional downhole electric motor and high-voltage cable. The resulting architecture is intended to reduce dependence on downhole electrical drive equipment and improve accessibility of major power-generation and control components.
Operational Challenges Across Artificial-Lift & Production Systems
Artificial-lift technologies are application-specific. ESPs, PCPs, gas lift, hydraulic and jet systems each provide important advantages within their respective operating envelopes.
FBC™ is not intended to suggest that one artificial-lift technology is universally superior to another.
Instead, the FBC™ architecture is being developed for applications where combinations of viscosity, multiphase behavior, intervention cost, downhole electrical exposure or production-conditioning requirements create a different set of priorities.
Conventional electrically driven systems may place motors, cables and associated electrical components deep within the production environment. Hydraulic systems can avoid some of those components but may introduce other efficiency, erosion or fluid-management considerations. PCP and gas-lift systems provide strong solutions in appropriate operating windows but likewise depend on fluid properties, completion configuration and available infrastructure.
FBC™ targets another architecture within this landscape: surface-generated hydraulic power converted locally into mechanical production-boosting torque.
High Viscosity Fluids
Multiphase Flow (and solids)
High Lift and High Pressure
Reliability & Interventions
More Than a Hydraulically Driven Pump
The FBC™ is being developed as an integrated production architecture, not simply as another hydraulic pump.
Its potential value comes from the combination of surface power generation, local hydraulic-to-mechanical conversion, direct multiphase boosting and optional production conditioning.
Current engineering objectives include:
- Surface-accessible prime-drive and control equipment.
- No conventional downhole electric motor or high-voltage power cable at the FBC.
- Heavy-oil and multiphase production capability.
- Pump architecture intended to accommodate entrained solids.
- Optional heavy-oil conditioning using compatible motive fluid.
- Application-specific downhole and subsea configurations.
- Reduced exposure to intervention-sensitive downhole drive components.
- Potential equipment and lifecycle economic advantages where intervention cost, viscosity or electrical limitations are significant.
Energy & Economic Positioning
The FBC™ Value Case Is Not Based on Energy Efficiency Alone
Energy performance depends strongly on the specific production conditions, including fluid properties, production rate, lift requirement, multiphase behavior and the operating point of each artificial-lift system.
Under some conditions, the FBC™ surface power requirement may be slightly higher than that of a representative ESP system. For this reason, FBC™ is not being positioned as inherently more energy efficient.
Its broader value proposition is architectural, operational and economic.
Current preliminary engineering screening indicates an FBC™ equipment-cost target approximately 30% below the midpoint of the representative ESP equipment basis used in the study.
Potential lifecycle value is expected to be most significant where downhole interventions, heavy-fluid handling, serviceability or electrical-system exposure materially influence operating economics.
These estimates remain preliminary engineering targets and require validation through prototype testing, pilot operation and application-specific economic analysis.
FBC™ for Subsea Production Boosting
Current Development & Validation
Developing the FBC™ Platform
The Original Application Remains Part of the Platform
Subsea production boosting was the original application behind the development of FBC™ and remains a valid configuration of the technology.
The subsea concept was developed to place hydraulic-to-mechanical power conversion and production boosting closer to the subsea production source while allowing the primary drive function to remain at a more accessible location.
Earlier development work included a physical 3D prototype of the subsea FBC configuration, supporting the evolution of the broader platform.
Future subsea FBC™ configurations can be adapted to different production architectures, tieback requirements, water depths, fluid conditions and project-specific operating requirements.
The current focus on downhole production therefore represents an expansion of FBC™ applications, not the replacement of its subsea origin.
Engineering Design → Prototype → Validation → Pilot
FBC™ is currently in engineering design and prototype development.
The system architecture and principal hydraulic and mechanical functions have been defined, and purpose-built engineering software is being used to integrate hydraulic power conversion, multiphase pumping, motive-fluid and system-level calculations.
Earlier prototype work has been completed for the subsea configuration, while the current downhole configuration is progressing through mechanical integration and prototype development.
The planned validation path includes bench hydraulic testing → integrated FBC™ prototype testing → viscous and multiphase-fluid testing → solids/erosion qualification → model calibration → representative field pilot → qualification and commercial deployment.
Performance, operating envelope, run life, solids capability and economic benefits will be established progressively through this validation program.
Wirbeln Energy Production LLC is advancing FBC™ as a production-boosting platform for applications where hydraulic power transmission, multiphase pumping, heavy-fluid handling and reduced dependence on downhole electrical drive equipment may create operational value.
We welcome engagement with operators, service companies, technology organizations and strategic collaborators interested in evaluating potential FBC™ applications.
Collaboration Opportunities
Technical Review • Bench Validation • Prototype Testing • Pilot Candidate Identification • Strategic Development
A different architecture: surface-powered, integrated, and designed to reduce downhole complexity and intervention exposure.
1301 rue Fannin.
Suite 2440
Houston, TX 77002
USA
Courriel : contact@wirbeln.com
Téléphone : +1-832-741-0784
12224 Rosslyn Rd.
Suite B
Houston, TX 77086
USA
Courriel : contact@wirbeln.com
Téléphone : +1-832-741-0784
Non-confidential technology overview. FBC™ performance, operating envelope,
reliability and solids-handling capability are engineering objectives subject to prototype,
laboratory and field validation. Economic benefits are preliminary estimates.