Multi-Phase Pump Recirculation for Wear Reduction
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Solution Overview
Problem
Multiphase pumps face issues with increased wear and clogging due to recirculation of solids in the flow-calmed area, especially when dealing with high solid content in multiphase mixtures, leading to inefficiencies and potential system failures.
Innovation Solution
A method that separates the gas, liquid, and solid phases in a pressure-side separation chamber, where the liquid phase is recirculated through a bypass line with a valve for startup and adjusted based on operating conditions, and the solid phase is separated and removed to prevent clogging and wear, using a separation device with a settling space and reservoir to manage phase separation effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the recirculation line is positioned deep within the pressure chamber to ensure continuous liquid circulation, then liquid sealing and cooling are improved, but solids that sink to the bottom are also recirculated leading to increased wear and clogging
Solution Approach 1:
The pressure chamber is segmented into an upper recirculation zone and a lower settling zone. The recirculation line is positioned to draw liquid only from the upper zone, while the lower zone allows solids to settle and be discharged separately through a solids discharge line. This spatial segmentation prevents solids from entering the recirculation line while maintaining liquid circulation for sealing and cooling.
Solution Approach 2:
The harmful solid particles are extracted from the recirculating liquid stream by providing a separate solids discharge path at the bottom of the pressure chamber. This allows the recirculation line to transport only liquid, eliminating wear and clogging issues while maintaining the beneficial sealing and cooling effects of liquid recirculation.
2Power
If the valve in the recirculation line is closed after startup to increase pressure, then pumping efficiency is improved, but the system loses the ability to dissipate compression heat and lubricate components
Solution Approach 1:
The recirculation valve is designed to be dynamically adjustable rather than simply open or closed. During operation, the valve can be partially opened to allow controlled amounts of liquid to recirculate, providing continuous cooling and lubrication while maintaining sufficient pumping pressure. This dynamic control allows the system to adapt to varying thermal and lubrication requirements.
Solution Approach 2:
The system incorporates feedback control where the recirculation flow rate is adjusted based on operating conditions such as temperature, pressure, and load. Sensors monitor these parameters and automatically adjust the valve position to maintain optimal balance between pressure generation and heat dissipation, ensuring both pumping efficiency and thermal management.
3Ease of operation
If a separator is used to separate gas and liquid phases before pumping, then pump operation is simplified, but equipment complexity and logistical effort increase significantly
Solution Approach 1:
The separation function is merged with the pumping function by integrating a separation chamber directly into the pump housing. The separation chamber is positioned upstream of the pump inlet, allowing gas-liquid separation to occur within the same equipment assembly. This eliminates the need for separate external separator equipment while maintaining simplified pump operation with multiphase mixtures.
Solution Approach 2:
The pump system is designed with multi-functionality, combining phase separation, pumping, and recirculation cooling in a single integrated unit. The separation chamber serves both as a gas-liquid separator and as part of the overall fluid handling system, while the recirculation line provides additional functions of cooling and lubrication. This universal design reduces equipment complexity while maintaining operational simplicity.
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 approach reduces wear on pump components, prevents clogging, and enhances energy efficiency by allowing controlled recirculation of a solid-free liquid phase for lubrication and heat dissipation, ensuring stable operation even under varying conditions.
Implementation Method 1
a gas phase is separated from a liquid phase and a solid phase in the separation chamber
Implementation Method 2
the liquid phase is further separated from the solid phase in the separation chamber
Implementation Method 3
a portion of the liquid phase freed from the solid phase is fed to the suction side in order to, on the one hand, create a gap seal within a screw pump and, on the other hand, to facilitate the dissipation of the heat of compression
Data Source
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AI summary
The invention concerns a method and an apparatus for operating a multi-phase pump which has a suction-side inlet (10) and a discharge-side outlet (20) and which pumps a multi-phase mixture charged with solids, comprising the following steps: a. pumping a multi-phase mixture into a discharge-side separation chamber (45), b. separating a gaseous phase from a liquid phase and a solid phase in the separation chamber (45), c. separating the liquid phase from the solid phase in the separation chamber (45), d. feeding a portion of the liquid phase released from the solid phase to the suction side.