Multiphase Pump Self-Lubrication via Phase Separation
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Solution Overview
Problem
Multiphase pumps used in oil and gas fields face challenges in maintaining efficient cooling and lubrication with minimal external circuits, especially in difficult-to-access locations like underwater pumps, where maintenance is complex and costly.
Innovation Solution
A multiphase pump with a separation system that separates the multiphase mixture into phase-enriched components, using a liquid-enriched liquid component for lubrication and a gas-enriched gas component for cooling, eliminating the need for external lubricant circuits and seals, and incorporating a centrifuge for effective separation and compact operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external lubricant circuits and seals are used for pump units, then reliable lubrication and cooling can be achieved, but device complexity and maintenance requirements increase
Solution Approach 1:
The pump system uses itself to provide lubrication and cooling. The multiphase mixture pumped by the pump is separated into phases, and the liquid phase is recirculated through the separation system to automatically lubricate and cool the pump units, eliminating the need for external lubricant circuits and seals.
Solution Approach 2:
The multiphase mixture serves multiple functions: it is both the product being pumped and the lubricant/coolant for the pump system. The separation system enables the liquid phase to be extracted and reused for lubrication purposes, making the pumped fluid serve dual purposes.
2Reliability
If external lubricant circuits are used for underwater pumps, then adequate lubrication can be provided, but maintenance complexity and cost increase due to difficult accessibility
Solution Approach 1:
The system eliminates external lubricant circuits that would require maintenance by using the pumped multiphase mixture itself for lubrication. The separation system automatically extracts the liquid phase and recirculates it to lubricate pump units, creating a self-maintaining system suitable for underwater applications.
3Reliability
If seals are used to separate lubricant and pumped product, then contamination can be prevented, but device complexity and potential failure points increase
Solution Approach 1:
The separation system extracts the liquid phase from the multiphase mixture through phase separation. This extraction process naturally prevents contamination between lubricant and product without requiring seals, as the separated phases are handled in distinct pathways within the separation system.
4Device complexity
If multiphase mixture is used directly for lubrication without separation, then external lubricant circuits can be eliminated, but lubrication effectiveness decreases due to presence of gas and solid components
Solution Approach 1:
The separation system segments the multiphase mixture into distinct phases (gas, liquid, and solid components). This segmentation allows the liquid phase to be isolated and used for lubrication in a purified state, while other phases are handled separately or returned to the product stream.
Solution Approach 2:
The system applies different quality requirements to different phases. The liquid phase is processed to high purity for lubrication applications, while gas and solid components are handled differently. This local quality approach ensures optimal lubrication effectiveness where needed without unnecessarily processing all phases to the same standard.
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 solution reduces maintenance needs, minimizes the number of special operating media circuits, and enables efficient lubrication and cooling of pump elements, enhancing the pump's operational efficiency and reliability in harsh environments.
Implementation Method 1
a separation system having a first separation stage for at least partly separating at least some of the multiphase mixture into a plurality of phase-enriched components
Implementation Method 2
incorporating a centrifuge for effective separation and compact operation
Data Source
AI summary
A product-lubricated multiphase pump for pumping a multiphase mixture containing hydrocarbon includes a separation system and a supply system. To achieve a good cooling and lubrication of pump elements without a lot of operating media and operating medium circuits, the separation system has a first separation stage for at least partly separating at least a portion of the multiphase mixture into a plurality of phase-enriched components and the supply system supplies a liquid-enriched liquid component as lubricant to a pump element to be lubricated.