Subsea Multiphase Pump Magnetic Coupling and Fluid Separator Cooling
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Solution Overview
Problem
Operating fluid systems submerged in deep seawater is challenging due to harsh conditions such as corrosion, extreme temperatures, and high hydrostatic pressures, making maintenance and repair difficult and costly.
Innovation Solution
A submersible fluid system design that includes an electric machine and a fluid-end with a magnetic coupling, magnetic bearings, and a fluid separator system, which operates in a pressure vessel to withstand ambient pressures and thermal loads, and uses a gas environment to minimize heat generation and facilitate efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the system operates submerged in deep seawater, then it can perform fluid processing in remote locations, but the harsh environment causes corrosion, thermal stress, and high maintenance costs
Solution Approach 1:
The system divides the fluid processing equipment into modular components (pump or compressor units, separation systems, cooling apparatus) that can be independently sealed and maintained. Each module is contained within its own pressure-resistant housing, allowing individual replacement without complete system retrieval.
Solution Approach 2:
A fluid separator system acts as an intermediary between the multiphase process fluid and the bearing lubrication system. It extracts liquid from the process fluid and directs it to lubricate bearings, while separating out gas and solids. This intermediary mechanism protects the bearing system from direct exposure to corrosive process fluids while enabling lubrication.
2Power
If traditional mechanical coupling is used between motor and fluid rotor, then power transmission is efficient, but maintenance requires complete system access which is costly and complex
Solution Approach 1:
The patent replaces direct mechanical coupling between the motor rotor and fluid rotor with magnetic coupling. Magnets on the motor rotor interact with magnets on the fluid rotor through a non-contact magnetic field, eliminating the need for physical shafts, seals, and mechanical connections that would require disassembly for maintenance.
Solution Approach 2:
The harmful mechanical connection elements (shafts, seals, gears) are extracted from the system entirely. The power transmission function is achieved through electromagnetic interaction, removing the components that would otherwise require maintenance and create failure points.
3Temperature
If the system uses conventional cooling methods, then heat dissipation is effective, but it generates additional heat from mechanical friction and requires complex cooling infrastructure
Solution Approach 1:
The system uses the process fluid itself as the cooling medium. The multiphase fluid passing through the system absorbs heat from the motor and fluid rotor, eliminating the need for separate cooling systems. The fluid serves dual purposes: process material and thermal management medium.
Solution Approach 2:
The patent converts the thermal energy that would normally be waste heat into a useful cooling function. The process fluid, which must pass through the system anyway, absorbs thermal energy from the motor and fluid end, reducing the need for additional cooling infrastructure and converting a potential problem (heat generation) into a beneficial cooling effect.
4Ease of repair
If magnetic coupling is used to eliminate mechanical contact, then maintenance is simplified, but heat generation from magnetic fields increases energy consumption
Solution Approach 1:
The magnetic coupling system operates continuously without mechanical wear or friction losses. The magnetic field interaction maintains constant efficiency over time, unlike mechanical systems where friction and wear increase energy consumption during operation. The non-contact nature ensures continuous efficient power transmission.
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 operates in deep water environments with reduced heat generation and energy consumption, enabling efficient fluid processing and maintenance while minimizing the need for complex and costly maintenance procedures.
Implementation Method 1
The drive-end of the fluid rotor is coupled to an electric machine rotor of the electric machine by a magnetic coupling
Implementation Method 2
the fluid separator system communicates a liquid flow extracted from the multiphase flow to the first mentioned bearing and the second bearing
Implementation Method 3
operates in a pressure vessel to withstand ambient pressures and thermal loads, and uses a gas environment to minimize heat generation
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A submersible fluid system for operating submersed in a body of water includes an electric machine and a fluid-end. The fluid-end includes a fluid-end housing having an inlet to a fluid rotor, the fluid rotor coupled to the electric machine and carried to rotate in the housing by a bearing in the housing. A fluid separator system receives a multiphase fluid and communicates a flow of the fluid to the inlet and a substantially liquid flow extracted from the multiphase fluid to the bearing.