Perforated Flow Conditioner for Multiphase Pump Slug Flow
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Multiphase pumps malfunction under slug flow conditions due to segregation of liquid and gas phases, leading to pump overheating and failure, as they run 'dry' without sufficient liquid.
Innovation Solution
A Flow Conditioning System (FCS) that includes a concentric perforated pipe within an outer shroud pipe, designed to transition slug flow into well-mixed bubbly or continuous churn flow regimes, ensuring thorough mixing of phases upstream of the pump by breaking gas pockets and promoting liquid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If slug flow conditions occur with long gas pockets, then gas-liquid multiphase flow pumps can handle the flow, but the pumps run dry without sufficient liquid leading to overheating and failure
Solution Approach 1:
The flow conditioner segments the continuous gas pockets into smaller bubbles by forcing the flow through a perforated pipe. The perforations create multiple small openings that break up large gas slugs into dispersed bubbles, ensuring liquid is present between gas phases and preventing the pump from running dry.
Solution Approach 2:
The flow conditioner acts as an intermediary device installed upstream of the pump to condition the flow before it reaches the pump. This mediator transforms the harmful slug flow pattern into a safer flow pattern that protects the pump from overheating and failure.
2Productivity
If slug flow with segregated liquid and gas phases occurs, then the flow can be transported, but the phases become segregated causing pump malfunction
Solution Approach 1:
The flow conditioner promotes homogeneity by mixing the segregated gas and liquid phases. The perforated pipe forces the flow through multiple small openings that disperse gas bubbles uniformly throughout the liquid, creating a more homogeneous mixture that prevents phase segregation and ensures stable pump operation.
3Stability of the object's composition
If a flow conditioner with perforated pipe is installed to mix phases, then phase mixing is improved, but device complexity increases
Solution Approach 1:
The flow conditioner is a passive device that uses the kinetic energy of the flowing fluid itself to achieve mixing. The perforated pipe geometry and flow dynamics create turbulence and dispersion without requiring external power sources, moving parts, or complex control systems. The structure serves itself by using the flow to condition the flow.
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 FCS effectively prevents pump failure by ensuring continuous liquid flow and well-mixed phases, preventing overheating and enhancing the operational reliability of multiphase pumps under slug flow conditions.
Implementation Method 1
The bubbly or continuous churn flow that occur in the shroud section are forced to pass through the perforations of the perforated smaller pipe, which promote a more thorough mixing of the phases upstream of devices such as multiphase pumps
Data Source
AI summary
Embodiments of a Flow Conditioning System (“FCS”) of this disclosure may be used for homogenizing a fluid containing a gas phase and a liquid phase. In some embodiments the FCS may be applied to a fluid containing hydrocarbons. The FCS may be located where appropriate, including but not limited to subsea. The FCS may be used for homogenizing slug flow. In embodiments, the FCS may be composed of an outer shroud pipe section, into which a concentric perforated smaller pipe is inserted at the top. The inlet slug flow regime is changed at the shroud section whereby the slugs are broken, transitioning to well-mixed flow regimes, such as bubbly flow or continuous churn flow. The bubbly or continuous churn flow that occur in the shroud section are forced to pass through the perforations of the perforated smaller diameter pipe, which promote a more thorough mixing of the phases upstream of devices such as multiphase pumps.