Crossover Two-Phase Flow Pump Segmentation
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Solution Overview
Problem
Centrifugal pumps struggle to efficiently handle two-phase fluids in hydrocarbon wells due to significant density differences between liquid and gas, leading to gas pockets forming and blocking the flow, which reduces pressure creation ability.
Innovation Solution
A downhole well pumping apparatus with a central rotary pump section for liquids and an annular turbine section for gases, separated by a cylindrical wall, where both sections rotate in unison, increasing pressure for both components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a centrifugal pump is used to pump two-phase fluids, then liquid pumping efficiency is improved, but gas pockets form and block flow reducing pressure creation
Solution Approach 1:
The pump is divided into two separate pumping sections: an inner centrifugal pump section for liquid and an outer axial flow pump section for gas. This segmentation allows each section to handle its designated phase independently, preventing gas pockets from blocking liquid flow while maintaining pressure creation capability for both phases.
Solution Approach 2:
Different pumping mechanisms are applied to different spatial zones within the pump housing. The inner centrifugal pump uses radial flow impellers optimized for liquid, while the outer axial flow pump uses propeller-type impellers optimized for gas. Each zone has tailored flow characteristics matching the local fluid phase properties.
2Reliability
If a gas separator is used to separate gas from liquid, then gas pockets are removed, but the system becomes more complex and requires additional equipment
Solution Approach 1:
The gas separation and pumping functions are merged into a single dual-section pump unit. The inner centrifugal pump handles liquid while the outer axial flow pump handles gas, and both sections operate simultaneously within the same housing. This eliminates the need for separate gas separators and reduces system complexity.
Solution Approach 2:
The pump housing serves multiple functions: it contains both the inner centrifugal pump and outer axial flow pump, provides structural support, and facilitates simultaneous processing of both liquid and gas phases. This multi-functionality reduces the number of separate components needed in the system.
3Stress or pressure
If the impeller increases velocity for pressure creation, then liquid pressure increases, but gas requires much higher velocity and cannot achieve it
Solution Approach 1:
The pumping action is segmented into two independent velocity systems: the inner centrifugal pump generates high velocity for liquid pressure creation, while the outer axial flow pump generates even higher velocity specifically for gas compression. Each section operates at velocity levels appropriate for its designated phase.
Solution Approach 2:
Different impeller designs with different velocity characteristics are used for different phases. The centrifugal impeller generates radial velocity components optimized for liquid, while the axial flow impeller generates axial velocity components optimized for gas. The velocity parameters are changed to match the requirements of each fluid phase.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration effectively separates and increases the pressure of both liquid and gas components, preventing gas pockets from forming and enhancing the overall pumping efficiency by maintaining separate flow paths for liquids and gases.
Implementation Method 1
The impeller rotates and imparts velocity to the well fluid while the diffuser converts the kinetic energy to pressure
Implementation Method 2
the diffuser converts the kinetic energy to pressure
Implementation Method 3
The gas separator locates below the pump and separates gas from the liquid, typically by a forced vortex. The forced vortex forces the heavier components to the outer portions of the gas separator housing
Implementation Method 4
The turbine section has blades for compressing the gaseous components
Data Source
AI summary
A hydrocarbon well pump has impellers and diffusers configured with inner and outer sections. The central section contains impeller passages configured for pumping liquid. The outer section contains turbine blades for compressing gas. A cylindrical sidewall separates the two sections. A driven shaft rotates the central and outer sections in unison.