Increase In Inlet Gas Volume Fraction Research Articles

Bubble breakage and aggregation characteristics in a vortex pump under bubble inflow

The behaviors of bubbles in a vortex pump play a crucial role in its performance when handling gas–liquid flows. However, not much research has been done on the distribution of the gas–liquid phases and the characteristics of bubble breakage and aggregation in vortex pumps. This lack of understanding hinders the improvement of pump performance in gas–liquid flow transport. This study aims to investigate the bubble characteristics in a vortex pump using the population balance model, focusing on the variation of bubble size and the influence of the inlet gas volume fraction (IGVF) on bubble breakage and aggregation. The results show that as the IGVF increases, the gas volume fraction in the impeller becomes larger than that in the bladeless chamber. The majority of bubbles in the impeller are concentrated near the hub, while they also remain in the circulating-flow zone of the bladeless chamber. Under low IGVF conditions, the average diameter of bubbles decreases from the pump inlet to the outlet. The bladeless chamber has a larger average bubble diameter and a higher percentage of large bubbles compared to other parts of the pump. Moreover, the bubble number density at the pump outlet increases with the IGVF, indicating the production of more bubbles, while the increase in IGVF also results in an increase in the percentage of large bubbles. The study also discusses the mechanism of bubble breakage and aggregation in vortex pumps. It suggests that the effective breakage frequency and effective aggregation frequency are responsible for bubble breakage and aggregation in the vortex pump. The gas volume fraction and turbulent dissipation rate are identified as important parameters affecting the effective breakage and aggregation frequency. These findings provide new insights into understanding the characteristics of bubble breakage and aggregation in vortex pumps.

Research on energy recovery and gas–liquid separation characteristics in diffuser of Helico-Axial Multiphase Pump

An Euler two-fluid model and a Shear Strain Transports (SST) turbulence model were used to study the gas–liquid flow law in a diffuser of a Helico-Axial Multiphase Pump by building a bedstand in this paper and studied energy recovery and gas–liquid separation characteristics of the diffuser in the Helico-Axial Multiphase Pump at different stages. The results show that the pressurization capacity of an impeller decreases gradually when the increase in IGVF (inlet gas volume fraction), and static pressure drops slightly in a dynamtic–static interface. Energy recovery characteristics are more complex at medium and high IGVF in the diffuser. The pressure gradient change perpendicular to the flow direction is the main factor causing two-phase separation on the back surface of the diffuser. The gas–liquid separation is mainly caused by the pressure gradient difference perpendicular to the flow direction on the working surface of the diffuser under the low IGVF, while the pressure gradient difference in the two directions is jointly influenced by the pressure gradient difference at medium and high IGVF.

Numerical investigation of gas–liquid two-phase performance in a mixed-flow pump by using a modified drag force model

As key devices to lift deep-sea oil and gas, mixed-flow pumps can transport multiphase flow with high inlet gas volume fraction (IGVF). Performance parameters of mixed-flow pumps may be disturbed by the complex flow and gas–liquid distribution under various conditions that need an accurate two-phase flow numerical methodology for prediction. In this work, the gas–liquid mixed flow performance of a mixed-flow pump is investigated based on the modified drag force model, which considers the bubble deformation at high IGVF. The effects of the IGVF on pressure increment and gas phase distribution are explored. The influences of flow rate and rotational speed are studied as well. Experiments are conducted to obtain performance parameters and gas–liquid distribution images. The results show that performance parameters and gas–liquid distribution predicted in simulations are consistent with those obtained in experiments. The pressure increment of the mixed-flow pump is decreased as the IGVF and flow rate increase. Especially when IGVF increases from 5% to 15%, the pressure increment drops sharply, which is the surging phenomenon. The increased speed may improve the performance. The evolution of gas phase distribution is deeply analyzed to improve the understanding of gas–liquid flow characteristics in mixed-flow pumps.

Experimental study of gas–liquid two-phase operating characteristics and bubble evolution law of a semi-open mixed-flow pump

This work experimentally studied the influence of gas and liquid distribution on a semi-open mixed-flow pump performance. High speed photography technology was contributed to obtain the evolution law of bubbles in the impeller. The results show that the inlet gas volume fraction (IGVF) and liquid flow rate are the main factors affecting the performance of the pump. The pressurization capacity linearly decreases with the increase in IGVF when the liquid flow rate is close the best efficiency point. However, this factor suddenly drops when the IGVF reaches a certain critical value under the condition of a low liquid flow rate. The spatiotemporal evolution characteristics of the isolated bubbles and gas column in the segregated flow were investigated. In addition, the bubbles are evenly distributed, and the flow pattern is mainly bubbly flow (BF) or aggregated BF (ABF) in the impeller inlet area without blades. Under small liquid flow rate conditions, the bubbles tend to coalesce into larger-sized gas-pocket with an increase in IGVF. The tip leakage vortex increases the turbulence intensity of the flow field. The results show that the bubbles downstream of the tip leakage vortex in the impeller channels are more easily broken into smaller bubbles and form a BF or ABF.

Effect of Operating Parameters on the Coalescence and Breakup of Bubbles in a Multiphase Pump Based on a CFD-PBM Coupled Model

When the multiphase pump is running, the internal medium often exists as bubble flow. In order to investigate the bubble occurrence characteristics in the pressurization unit of the multiphase pump more accurately, this paper couples computational fluid dynamics (CFD) with a population balance model (PBM) to investigate the bubble size distribution law of the multiphase pump under different operating conditions, taking into account the bubble coalescence and breakup. The research shows that the mean bubble size in the impeller domain gradually decreases from 1.7013 mm at the inlet to 0.6179 mm at the outlet along the axis direction; the average bubble diameter in the diffuser domain fluctuates around 0.60 mm. The bubbles in the impeller region gradually change from the trend of coalescence to the trend of breakup along the axial and radial directions, and the bubbles in the diffuser tend to be broken by the vortex entrainment. The bubble size development law is influenced by the inlet gas volume fraction (IGVF) and the rotational speed, showing a more obvious rule, where the gas phase aggregation phenomenon enhanced by the increase in IGVF promotes the trend of bubble coalescence and makes the bubble size gradually increase. The increased blade shearing effect with the increase in rotational speed promotes the trend of bubble breakup, which gradually reduces the size of the bubbles. In addition, increasing the bubble coalescence probability is a key factor leading to changes in bubble size; the bubble size development law is not very sensitive to changes in flow, and the bubble size is at its maximum under design conditions. The research results can accurately predict the performance change of the multiphase pump and provide technical guidance for its safe operation and optimal design.

On the performance of a centrifugal pump under bubble inflow: Effect of gas-liquid distribution in the impeller

Determining the characteristics of gas-liquid two-phase flow in centrifugal pumps is essential for a better understanding of pump performance. In this study, a visualization investigation was performed to determine the effect of the gas-liquid distribution in the impeller on the performance of a centrifugal pump with a closed impeller. Emphasis was placed on the influences of the inlet gas volume fraction (IGVF), flow rate, and rotational speed on the gas-liquid distribution in the impeller and, thus, on the surging characteristics of the pump. The correlation mechanism between the distribution of the gas-liquid phase in the impeller and the surging characteristics of the pump was revealed. Finally, several surging prediction models were examined. The results show that the gas-liquid two-phase distribution in the impeller has an immediate impact on the pressure increment and efficiency of the pump. The increase in IGVF directly induced pump surging by changing the flow pattern in the impeller. Surging occurred when the flow pattern changed from gas pocket flow to segregated flow. It was also found that pump surging could be eliminated by adjusting the flow rate and increasing the rotational speed, which changed the flow pattern inside the impeller. Compared with the experimental results, the critical IGVF obtained by the existing surging prediction model exhibits some deviation. The surging prediction model dedicated to the volute centrifugal pump requires further investigation. The results reported here can provide better insight into the performance of volute-type centrifugal pumps and provide a reference for developing corresponding surging prediction models.

Experimental Study on the Performance of a See-Through Labyrinth Seal With Two-Phase, Mainly-Liquid Mixtures

Abstract With the increasing demand of the oil and gas industry, many pump companies are developing multiphase pumps, which can handle liquid–gas flow directly without separating the liquid from a mixed flow. The see-through labyrinth seal is one of the popular types of noncontact annular seals that act as a balancing piston seal to reduce the axial thrust of a high-performance centrifugal pump. The see-through labyrinth seal also generates reaction forces that can significantly impact the rotordynamic performance of the pump. Multiphase pumps are expected to operate from pure-liquid to pure-gas conditions. Zhang and Childs (2019) (Zhang, M., and Childs, D., 2019, “A Study on the Leakage and Rotordynamic Performance of a Long Labyrinth Seal Under Mainly-Air Conditions,” ASME J. Eng. Gas Turbines Power, 141(12), p. 121024) conducted a comprehensive experimental study on the performance (leakage and rotordynamic coefficients) of a see-through labyrinth seal under mainly gas conditions. This paper continues Zhang and Childs (2019) (Zhang, M., and Childs, D., 2019, “A Study on the Leakage and Rotordynamic Performance of a Long Labyrinth Seal Under Mainly-Air Conditions,” ASME J. Eng. Gas Turbines Power, 141(12), p. 121024) research and studies the performance of the see-through tooth-on-stator labyrinth seal under mainly liquid conditions. The test seal's inner diameter, length, and radial clearance are 89.256 mm, 66.68 mm, and 0.178 mm, respectively. The test fluid is a mixture of air and paper silicone oil (PSF-5cSt), and the inlet gas volume fraction (GVF) varies from zero to 12%. Tests are conducted at an exit pressure of 6.9 bars, an inlet temperature of 39.1 °C, three pressure drops (PDs) (27.6 bars, 34.5 bars, and 48.3 bars), and three rotating speeds ω (5 krpm, 10 krpm, and 15 krpm). The seal is always concentric with the rotor, and there is no intentional fluid prerotation at the seal inlet. The air presence in the oil flow significantly impacts the leakage as well as the dynamic forces of the test seal. The first air increment (increasing inlet GVF from 0% to 3%) slightly increases the leakage mass flow rate, while further air increments steadily decrease the leakage mass flow rate. For all test conditions, the leakage mass flow rate does not change as ω increases from 5 krpm to 10 krpm but decreases as ω is further increased to 15 krpm. The reduction in the leakage mass flow rate indicates that there is an increase in the friction factor, and there could be a highly possible flow regime change as ω increases from 10 krpm to 15 krpm. For ω ≤ 10 krpm, effective stiffness Keff increases as inlet GVF increases. Keff represents the test seal's total centering force on the pump rotor. The increase of Keff increases the seal's centering force and would increase the pump rotor's critical speeds. Ceff indicates the test seal's total damping force on the pump rotor. For ω ≤ 10 krpm, Ceff first decreases as inlet GVF increases from zero to 3%, and then remains unchanged as inlet GVF is further increased to 12%. For ω = 15 krpm, Keff first increases as inlet GVF increases from zero to 3% and then decreases as inlet GVF is further increased. As inlet GVF increases, Ceff steadily decreases for ω = 15 krpm.

Distribution and motion characteristics of bubbles in a multiphase rotodynamic pump based on modified non-uniform bubble model

Multiphase rotodynamic pumps are important equipment that transport gas-liquid mixtures in offshore oilfields, suggesting it is necessary to investigate the flow characteristics in such pumps. In this study, the Eulerian two-fluid model is solved to obtain the bubble distribution in the pump, while the non-uniform bubble model is used to predict the break-up and coalescence of bubbles. The gas cavity equation is introduced to capture the rapid coalescence of bubbles near the suction side of the impeller blades, and the interphase forces in the cavities are modified. Compared with the experimental measurements for the gas volume fraction and bubble size, it is found that the simulations with the modification have better accuracies than without it. The effects of the inlet gas volume fraction (IGVF) on the bubble distribution are analyzed. Due to the formation of vortices, a large bubble number density is observed near the shroud of the impeller inlet, which increases with greater IGVF. The gas-liquid separation in the diffuser becomes more significant as the IGVF increases. Bubbles from the impeller inlet are observed to continuously gather near the suction side of the impeller blades. This forms a gas cavity that moves towards the impeller outlet with a low gas volume fraction. The rotor-stator interactions cause the air pockets to discontinuously move along the pressure side of the diffuser blade.

Numerical Investigation on Bubble Distribution of a Multistage Centrifugal Pump Based on a Population Balance Model

This work aimed to study the bubble distribution in a multiphase pump. A Euler-Euler inhomogeneous two-phase flow model coupled with a discrete particle population balance model (PBM) was used to simulate the whole flow channel of a three-stage gas-liquid two-phase centrifugal pump. Comparison of the computational fluid dynamic (CFD) simulation results with experimental data shows that the model can accurately predict the performance of the pump under various operating conditions. In addition, the liquid phase velocity distribution, gas-phase distribution, and pressure distribution of the second stage impeller at a 0.5 span of blade height under three typical working conditions were compared. Results show that the region with high local gas volume fraction (LGVF) mainly appears on the suction surface (SS) of the blade. With the increase in inlet gas volume fraction (IGVF), vortices and low velocity recirculation regions are generated at the impeller outlet and SS of the blade, the area with high LGVF increases, and gas–liquid separation occurs at the SS of the blade. The liquid phase flows out of the impeller at high velocity along the pressure surface of the blade, and the limited pressurization of fluid mainly happens at the impeller outlet. The average bubble size at the impeller outlet is the smallest while that at the impeller inlet is the largest. Under low IGVF conditions, bubbles tend to break into smaller ones, and the broken bubbles mainly concentrate at the blade pressure surface (PS) and the impeller outlet. Bubbles tend to coalesce into larger ones under high IGVF conditions. With the increase in IGVF, the bubble aggregation zone diffuses from the blade SS to the PS.

A Study on the Leakage and Rotordynamic Coefficients of a Long-Smooth Seal With Laminar-Two-Phase, Mainly-Oil Mixtures

Abstract This paper conducts a comprehensive study on the effects of the presence of air in the oil on the leakage and rotordynamic coefficients of a long-smooth seal (inner diameter D = 89.306 mm, radial clearance Cr = 0.140 mm, and length-diameter ratio L/D = 0.65) under laminar-two-phase flow conditions. The mixture consists of air and silicone oil with inlet gas volume fraction (GVF) up to 10%. Tests are performed at inlet temperature Ti = 39.4 °C, exit pressure Pe = 6.9 bars, pressure drop PD = 31, and 37.9 bars, and rotor speed ω = 5, 7.5, and 10 krpm. The test seal is always concentric with the rotor, and no intentional fluid prerotation is provided at the seal inlet. The complex dynamic stiffness coefficients Hij of the test seal are measured and fitted by the frequency-independent direct stiffness K, cross-coupled stiffness k, direct damping C, cross-coupled damping c, direct virtual-mass M, and cross-coupled virtual-mass mq coefficients. Under laminar flow conditions, increasing inlet GVF has negligible effects on K, k, C, and effective damping Ceff, while it decreases c and M. These trends are correctly predicted by San Andrés's bulk-flow model with laminar flow friction formula. As inlet GVF increases, measured leakage flow rate m˙ increases slightly. In general, the predictions of K, k, C, c, Ceff, and m˙ are reasonably close to measurements.

Leakage and Force Coefficients of a Grooved Wet (Bubbly Liquid) Seal for Multiphase Pumps and Comparisons With Prior Test Results for a Three Wave Seal

Abstract In the subsea oil and gas industry, multiphase pumps and wet gas compressors are engineered choices saving transportation and separation facility costs. In these machines, seals handling multiple phase components must be able to operate without affecting the system efficiency and its dynamic stability. This paper, extending prior work conducted with uniform clearance and wavy surface annular seals, presents measurements of leakage and dynamic force coefficients in a grooved seal whose dimensions are scaled from an impeller wear ring seal in a boiler feed pump. The 14-grooves seal has diameter D = 127 mm, length L = 0.34 D, and clearance c = 0.211 mm; each groove has shallow depth dg ∼2.6 c and length Lg ∼ 3.4% L. At a shaft speed of 3.5 krpm (surface speed = 23.3 m/s), a mixture of air in ISO VG 10 oil with inlet gas volume fraction (GVF) ranging from 0 (just oil) to 0.7 (mostly air) lubricates the seal. The pressure ratio (inlet/exit) is 2.9. The flow is laminar since the liquid is viscous and the pressure drop is low. The measured mixture mass flow decreases continuously with an increase in inlet GVF. The seal stiffnesses (direct K and cross coupled k), added mass (M), and direct damping (C) coefficients are constant when the supplied mixture is low in gas content, GVF ≤ 0.1. As the gas content increases, 0.2 ≤ GVF ≤ 0.5, the seal direct dynamic stiffness becomes nil with an increase in excitation frequency, whereas k and C reduce steadily with GVF. In general, for GVF ≤ 0.5, the direct damping is invariant with frequency; variations appearing for GVF = 0.7. Compared against a three wave annular seal, the grooved seal offers much lower force coefficients, in particular the viscous damping. Thus, for laminar flow operation (heavy oil) with a low pressure drop as in a wear ring seal, a three wave seal is recommended as it also offers a significant centering stiffness.

Numerical Simulation of a Gas-Liquid Centrifugal Pump under Different Inlet Gas Volume Fraction Conditions

In order to study the influence of inlet gas volume fraction (IGVF) on performance of a gas-liquid centrifugal pump, three-dimensional turbulent flow of a single-stage gas-liquid centrifugal pump has been simulated by using computational fluid dynamics (CFD). Both steady and unsteady simulations have been conducted for different inlet gas volume fraction conditions of the pump. The gas phase distribution, the internal flow field and pressure field of the pump were obtained with inhomogeneous two-fluid model. The result showed that many gas accumulation zones accompanied vortices appears in the impeller as IGVF increases, and surge would occur as IGVF reaches a certain value. The change of IGVF would change the magnitude and direction of the impeller radial force.

Leakage and Rotordynamic Force Coefficients of A Three-Wave (Air in Oil) Wet Annular Seal: Measurements and Predictions

In subsea environments, multiphase pumps and compressors add pressure to the process fluid, thus enabling long distance tie back systems that eliminate topside oil and gas separation stations. One challenge to construct a reliable multiphase pump or a reliable wet gas compressor is that the first must handle, without process upset, a mixture whose gas volume fraction (GVF) changes suddenly; while the other must remain stable while working with a liquid volume fraction (LVF) changing over long periods of time. The mixture GVF/LVF affects the static and dynamic forced performance of secondary flow components, namely seals, and which could lead to an increase in both rotor lateral or axial vibrations, thus compromising system reliability and availability. The current research is a planned endeavor toward developing seal configurations amenable to maintain rotor dynamic characteristics during changes in the contents of flow components. This paper extends prior work with uniform clearance annular seals and presents the static and dynamic forced performance of a three-wave surface annular seal designed to deliver a significant centering stiffness. The test element has length L = 43.4 mm, diameter D = 127 mm, and mean radial clearance cm=0.191 mm. At a shaft speed of 3.5 krpm (23 m/s surface speed), an air in ISO VG 10 oil mixture with an inlet GVF, 0 to 0.9, feeds the seal at 2.5 bara pressure and 37 °C temperature. The mixture mass flow rate decreases continuously with an increase in inlet GVF; shaft speed has little effect on it. Dynamic load tests serve to identify the seal dynamic force coefficients. The liquid seal (GVF = 0) shows frequency independent force coefficients. However, operation with a mixture produces stiffnesses that vary greatly with excitation frequency, in particular the direct one that hardens. The direct damping coefficients are not functions of frequency albeit dropping rapidly in magnitude as the GVF increases. The work also compares the performance of the wavy seal against those of two other seals: one with clearance equal to the mean clearance of the wavy seal, and the other with a large clearance emulating a fully worn wavy seal. The small clearance seal leaks 20% less than the wavy seal, whereas the leakage of the worn seal is twofold that of the wavy seal. For the three seals, the leakage normalized with respect to a pure liquid condition collapses into a single curve. The wavy seal produces the greatest direct stiffness and damping coefficients, whereas the worn seal produces the smallest force coefficients. Derived from a homogeneous mixture bulk flow model, predicted force coefficients for the three-wave seal match well with the test data for operation with a pure oil and an inlet GVF 0.2. For operation with GVF > 0.2, the discrepancy between the prediction and experimental data grows rapidly. The extensive test campaign reveals a wavy-surface seal offers a centering stiffness ability, a much desired feature in vertical submersible pumps that suffer from persistent static and dynamic stability issues.

An investigation of the flow characteristics of multistage multiphase pumps

PurposeNumerical simulations of a multistage multiphase pump at different operating conditions were performed to study the variational characteristics of flow parameters for each impeller. The simulation results were verified against the experimented results. Because of the compressibility of the gas, inlet volume flow rate qi and inlet flow angle ßi for each impeller decrease gradually from the first to the last stage. The volume flow rate at the entrance of the pump q, rotational speed n and inlet gas volume fraction (IGVF) affect the characteristics of qi and ßi.Design/methodology/approachThe hydraulic design features of the impellers in the multistage multiphase pump are obtained based on the flow parameter characteristics of the pump. Using the hydraulic setup features, stage-by-stage design of the multistage multiphase pump for a nominal IGVF has been conducted.FindingsThe numerical simulation results show that hydraulic loss in impellers of the optimized pump is substantially reduced. Furthermore, the hydraulic efficiency of the optimized pump increases by 3.29 per cent, which verifies the validation of the method of stage-by-stage design.Practical implicationsUnder various operating conditions, qi and ßi decrease gradually from the first to the fifth stage because of the compressibility of the gas. For this characteristic, the fluid behavior varies at each stage of the pump. As such, it is necessary to design impellers stage by stage in a multistage rotodynamic multiphase pump.Social implicationsThese results will have substantial effect on various practical operations in the industry. For example, in the development of subsea oilfields, the conventional conveying equipment, which contains liquid-phase pumps, compressors and separators, is replaced by multiphase pumps. Multiphase pumps directly transport the mixture of oil, gas and water from subsea oilwells through a single pipeline, which can simplify equipment usage, decrease backpressure of the wellhead and save capital costs.Originality/valueCharacteristics of a multistage multiphase pump under different operating conditions were investigated along with features of the inlet flow parameters for every impeller at each compression stage. Our simulation results have established that the change in the inlet flow parameters of every impeller is mainly because of the compressibility of the gas. The operational parameters q, n and IGVF all affect the characteristics of qi and ßi. However, the IGVF has the most prominent effect. Lower values of IGVF have an insignificant effect on the gas compressibility. Higher values of IGVF have a significant effect on the gas compressibility. All these characteristics affect the hydraulic design of the impellers for a multistage multiphase pump. In addition, the machining precision should also be considered. Considering all these factors, when IGVF is lower than 10 per cent, all the impellers in the pump can be designed uniformly. When IGVF varies from 10 to 30 per cent, the first two stages should be designed separately, and the latter stages are uniform starting with the second stage. When IGVF varies from 30 to 50 per cent, the first three stages should be designed separately, and the latter stages are going to be similar to the third stage. An additional increase in IGVF results in degeneration of the differential pressure of the pump, which will reduce the compressibility of the gas. As such, it can be deduced that only the first three stages should be designed separately, and the latter stages will be similar to the third stage. In addition, for the pump working under a lower volume flow rate than 25 m3/h, the first three stages should be designed individually while keeping the geometrical structure of the subsequent stages the same as the third stage.