An investigation of the flow characteristics of multistage multiphase pumps

Abstract

Purpose Numerical 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/approach The 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. Findings The 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 implications Under 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 implications These 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/value Characteristics 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.