Multi-phase crude oil pressure boosting system
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Solution Overview
Problem
Conventional surface pumping systems in the oil and gas industry face challenges with high gas-volume fractions at the inlet, leading to issues like slugging flow, high vibrations, and insufficient boost pressure, which can result in equipment failure and increased production costs.
Innovation Solution
A pressure-boosting system comprising a separation section, a mixing section, and a pumping section, where the separation section separates a feed mixture into gas and liquid using gravity or centrifugal forces, the mixing section combines the separated gas and liquid in a fluid suction chamber, and the pumping section uses a diffuser to direct the mixed fluid to a pump for pressure boosting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional surface pumping systems handle high gas-volume fraction mixtures, then the system can process multiphase fluids, but slugging flow and high vibrations occur leading to insufficient boost pressure and equipment failure
Solution Approach 1:
The system divides the multiphase flow handling into separate phases: a separation section that divides gas and liquid, a mixing section that recombines them in controlled proportions, and a pumping section that handles the mixed flow. This segmentation allows each section to be optimized for its specific function, enabling reliable handling of high gas-volume fraction mixtures without slugging or excessive vibrations
Solution Approach 2:
The mixing section acts as an intermediary between the separation section and pumping section. It takes separated gas and liquid phases, mixes them in controlled proportions using mixing elements, and delivers a stabilized mixed flow to the pump. This intermediary mixing process prevents direct handling of high gas-volume fraction mixtures by the pump, eliminating slugging and vibration problems while maintaining the ability to process such mixtures
2Productivity
If conventional pumping systems operate with high gas-volume fraction inlet mixtures, then production can be maintained, but high vibrations generate high stress on structure and components leading to equipment failure
Solution Approach 1:
The separation and mixing sections perform preliminary actions before the fluid reaches the pump. The separation section divides the phases, and the mixing section recombines them in controlled proportions, creating a stabilized flow pattern. This preliminary conditioning of the fluid eliminates the high vibrations and stress that would otherwise occur in the pump and structural components during high gas-volume fraction handling
Solution Approach 2:
The mixing section serves as a protective intermediary that shields the pump and structural components from the harmful effects of high gas-volume fraction mixtures. By controlling the mixing process and delivering a stabilized flow to the pump, it prevents the high vibrations and stress that lead to equipment failure, while still enabling continuous production
3Adaptability or versatility
If conventional pumping systems experience slugging flow and high vibrations, then handling capability is reduced, but remedial expenses and production loss increase negatively impacting economics
Solution Approach 1:
By segmenting the system into separation, mixing, and pumping sections, each optimized for its specific function, the system achieves reliable handling of high gas-volume fraction mixtures without slugging or excessive vibrations, eliminating costly remedial expenses and production losses while maintaining pumping capability
Solution Approach 2:
The mixing section acts as a protective intermediary that prevents harmful slugging and vibrations from reaching the pump, thereby eliminating equipment failures and associated costs. This intermediary function maintains pumping capability with high gas-volume fraction mixtures while avoiding the negative economic impacts of remedial expenses and production loss
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 system effectively increases the pressure of multiphase fluid mixtures, enhances operational stability by preventing slugging and high vibrations, and improves the pump's ability to handle high gas-volume fraction mixtures, leading to increased operational efficiency and reduced maintenance costs.
Implementation Method 1
separating the feed mixture into a gas and a liquid in the separation tank
Implementation Method 2
separates the feed mixture into a gas and a liquid in the separation tank
Implementation Method 3
flowing the mixed fluid through a diffuser to a pump
Data Source
AI summary
A system (200) for pumping a multi-phase feed mixture includes a separation section (230) having a separation tank (206), a mixing section (240), and a pumping section (250). The separation tank (206) has a feed mixture entrance (204) and a liquid outlet (215) located at different axial positions along a wall of the separation tank (206). A gas line (212) extends through the separation tank (206) from a gas inlet (217) located in an interior of the separation tank to a gas outlet (218) located outside of the separation tank (206). The mixing section (240) includes a fluid suction chamber (220) surrounding the gas outlet (218), and a liquid line (216) fluidly connects the liquid outlet (215) to the fluid suction chamber (220). The pumping section (250) includes a pump (226), and a diffuser (222) fluidly connects the fluid suction chamber (220) to a pump inlet (224).