ESP Gas Separator Impeller Diffuser Design
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Solution Overview
Problem
Conventional fluid movers in electric submersible gas separators are inefficient in handling high gas volume fraction fluids, leading to decreased efficiency and capacity due to gas lock issues, as they fail to effectively impart momentum to multiphase fluids.
Innovation Solution
A fluid moving apparatus comprising a rotatable shaft with an impeller and diffuser, featuring funnel-shaped vanes with regressive pitch and alternating angles, which homogenizes and imparts axial momentum to the fluid, reducing the likelihood of gas lock by directing higher-density fluid inward and breaking up gas bubbles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a helical auger is used to facilitate fluid flow through the gas separator, then the device complexity is reduced, but the fluid moving efficiency deteriorates due to inability to effectively impart momentum to multiphase fluids
Solution Approach 1:
The patent replaces the conventional helical auger (screw-based mechanical system) with an impeller-diffuser system that uses centrifugal force and fluid dynamics to move multiphase fluid. The impeller rotates to impart centrifugal force, while the diffuser converts kinetic energy to pressure, effectively handling gas-liquid mixtures without the gas lock issues of screw-based systems.
Solution Approach 2:
The patent changes the operational parameters by using a rotating impeller with specific blade angles and a diffuser with controlled geometry to optimize fluid flow. The impeller rotates at controlled speeds, and the diffuser angle is designed to match the impeller outlet flow, creating efficient momentum transfer to multiphase fluid while preventing gas accumulation.
2Productivity
If a traditional centrifugal pump stage is used inside the gas separator, then the fluid moving efficiency improves, but the reliability deteriorates due to susceptibility to gas lock in high GVF applications
Solution Approach 1:
The patent segments the fluid moving function into two distinct components: an impeller for imparting centrifugal force and a diffuser for converting kinetic energy to pressure. This segmentation allows each component to be optimized independently - the impeller handles high-GVF multiphase flow while the diffuser ensures smooth, gas-free delivery to the pump, preventing gas lock.
Solution Approach 2:
The diffuser acts as an intermediary component between the impeller and the pump inlet. It receives the multiphase fluid from the impeller, allows gas bubbles to separate and escape, and delivers homogenized liquid to the pump. This intermediary function prevents gas lock while maintaining high fluid moving efficiency.
3Reliability
If well fluid must gain sufficient momentum to travel through the long separation chamber, then the gas separation effectiveness improves, but the energy consumption increases due to the difficulty of moving multiphase fluid
Solution Approach 1:
The patent uses a rotating impeller that dynamically adapts to the flow conditions of multiphase fluid. The impeller blades are designed with optimal angles to efficiently transfer energy to gas-liquid mixtures, and the system can operate at varying speeds to match different fluid conditions, reducing energy consumption while maintaining separation effectiveness.
Solution Approach 2:
The patent optimizes the diffuser geometry parameters (angle, length, inlet/outlet diameters) to maximize pressure recovery and minimize energy losses. The diffuser angle is specifically designed to match the impeller outlet flow, creating efficient momentum transfer that reduces the energy needed to move fluid through the separation chamber while maintaining effective gas separation.
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
The solution effectively reduces gas lock occurrences and enhances the efficiency of gas separation, improving the quality of fluid delivered to the pump and increasing production rates by ensuring homogenous fluid flow through the gas separator.
Implementation Method 1
an impeller coupled to the shaft so as to rotate with the shaft inside a separation chamber of the gas separator
Implementation Method 2
impart axial momentum to the fluid, reducing the likelihood of gas lock by directing higher-density fluid inward
Implementation Method 3
a non-rotatable diffuser paired to the impeller on a downstream side of the impeller
Implementation Method 4
the diffuser including a body, the body including a central aperture, a wall circumferentially enclosing the body, and a plurality of diffuser blades extending radially between the body and the wall
Implementation Method 5
Both vortex and rotary type separators separate the well fluid centrifugally before it enters the pump. Such centrifugal separation induces higher-density, gas poor fluid outward, while the lower density, gas rich fluid moves inward near the shaft
Data Source
AI summary
A fluid moving system and apparatus for an electric submersible pump (ESP) is described. A fluid moving system includes a gas separator between an electric submersible pump and an ESP motor, the gas separator including a separation chamber including an impeller and a diffuser, the impeller including a plurality of regressively pitched main vanes interspersed between a plurality of mixer vanes, each of the plurality of main and mixer vanes extending along the hub with a positive slope and a concave top face, and a diffuser, the diffuser including blades extending along a diffuser body in a sloped direction substantially opposite the slope of the impeller main vanes, the blades having a concave top face and a regressive pitch that mirrors the pitch of the impeller main vanes, wherein the impeller vanes and diffuser blades serve to homogenize the well fluid while facilitating downstream movement.