Multiphase pump

Abstract

A multiphase pump includes a housing having a pump inlet and a pump outlet for a process fluid, an inlet annulus configured to receive the process fluid from the pump inlet, a discharge annulus configured to discharge the process fluid into the pump outlet, a pump rotor configured to rotate about an axial direction and arranged within the housing, the pump rotor being configured to convey the process fluid from the inlet annulus to the outlet annulus, and a return line configured to return the process fluid from the high pressure side to the low pressure side, the return line including an inlet configured to receive the process fluid, an outlet configured to discharge the process fluid and a control valve configured to open and close the return line, the inlet of the return line arranged directly at the discharge annulus.

Claims

1. A multiphase pump for conveying a multiphase process fluid from a low pressure side to a high pressure side, the multiphase process fluid including liquid components and gas components, the multiphase pump comprising: a housing having a pump inlet and a pump outlet for the process fluid and configured to be connected to a pipe to deliver the process fluid to another location; an inlet annulus configured to receive the process fluid from the pump inlet; a discharge annulus configured to discharge the process fluid into the pump outlet; a pump rotor configured to rotate about an axial direction and arranged within the housing, the pump rotor having an impeller and being configured to convey the process fluid from the inlet annulus to the discharge annulus with the discharge annulus being a chamber separate from the pump rotor; and a return line configured to return the process fluid from the high pressure side to the low pressure side, the return line comprising an inlet configured to receive the process fluid, an outlet configured to discharge the process fluid and a control valve configured to open and close the return line, the inlet of the return line arranged directly at the discharge annulus so as to enable the liquid components and gas components of the process fluid to be in a homogenous state when entering the return line and the outlet of the return line arranged directly at the inlet annulus, the return having a length to enable the liquid components and gas components of the process fluid to be mixed at the outlet of the return line, and at least a portion of the inlet annulus surrounding the impeller in a radial direction.

2. The multiphase pump in accordance with claim 1, wherein the inlet of the return line and the pump outlet are disposed in a spaced relationship at the discharge annulus.

3. The multiphase pump in accordance with claim 1, wherein the outlet of the return line is in fluid communication with the inlet annulus.

4. The multiphase pump in accordance with claim 1, wherein the outlet of the return line and the pump inlet are disposed in a spaced relationship at the inlet annulus.

5. The multiphase pump in accordance with claim 1, wherein the return line directly couples the discharge annulus with the inlet annulus.

6. The multiphase pump in accordance with claim 1, wherein the return line has a length, which is at most two times the distance between the pump inlet and the pump outlet.

7. The multiphase pump in accordance with claim 1, wherein the return line is detachably connected with the housing.

8. The multiphase pump in accordance with claim 1, wherein the return line is an external pipe arranged at an outside of the housing.

9. The multiphase pump in accordance with claim 1, wherein the return line is arranged inside the housing.

10. The multiphase pump in accordance with claim 1, wherein the multiphase pump is a vertical pump with the pump rotor extending in a vertical direction.

11. The multiphase pump in accordance with claim 1, further comprising a driver operatively connected to the pump rotor and configured to rotate the pump rotor, the driver arranged inside the housing.

12. The multiphase pump in accordance with claim 1, wherein the multiphase pump is configured for subsea oil and gas conveyance.

13. The multiphase pump in accordance with claim 1, wherein the multiphase pump is configured for installation on a sea ground.

14. The multiphase pump in accordance with claim 1, wherein the return line has a length, which is at most 1.5 times the distance between the pump inlet and the pump outlet.

15. The multiphase pump in accordance with claim 1, wherein the inlet of the return line and the pump outlet are arranged diametrically opposed at the discharge annulus.

16. The multiphase pump in accordance with claim 1, wherein the outlet of the return line and the pump inlet are arranged diametrically opposed at the inlet annulus.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will be explained in more detail hereinafter with reference to the drawings.

(2) FIG. 1 is a cross-sectional view of a first embodiment of a multiphase pump according to the invention;

(3) FIG. 2 is a cross-sectional view of a second embodiment of a multiphase pump according to the invention;

(4) FIG. 3 is a cross-sectional view of a third embodiment of a multiphase pump according to the invention; and

(5) FIG. 4 is a cross-sectional view of a fourth embodiment of a multiphase pump according to the invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

(6) FIG. 1 shows a cross-sectional view of an embodiment of a multiphase pump according to an embodiment of the invention which is designated in its entity with reference numeral 1. The multiphase pump 1 is designed as a centrifugal pump for conveying a multiphase process fluid from a low pressure side LP to a high pressure side HP. The multiphase pump 1 has a housing 2 designed as a pressure housing, which is able to withstand the pressure generated by the pump 1 as well as the pressure exerted on the pump 1 by the environment. The housing 2 may comprise several housing parts, which are connected to each other to form the housing 2.

(7) In the following description reference is made by way of example to the important application that the multiphase pump 1 is designed and adapted for being used as a subsea pump in the oil and gas industry. In particular, the multiphase pump 1 is configured for installation on the sea ground, i.e. for use beneath the water-surface, in particular down to a depth of 100 m, down to 500 m or even down to more than 1000 m beneath the water-surface of the sea. In such applications the multiphase process fluid is typically a hydrocarbons containing mixture that has to be pumped from an oilfield for example to a processing unit beneath or on the water-surface or on the shore. The multiphase mixture constituting the process fluid to be conveyed can include a liquid phase, a gaseous phase and a solid phase, wherein the liquid phase can include crude oil, seawater and chemicals, the gas phase can include methane, natural gas or the like and the solid phase can include sand, sludge and smaller stones without the multiphase pump 1 being damaged on the pumping of the multiphase mixture.

(8) It goes without saying that the invention is not restricted to this specific example but is related to multiphase pumps in general. The invention may be used in many different applications, especially in such applications where the multiphase pump 1 is installed at locations which are difficult to access.

(9) The housing 2 of the multiphase pump 1 comprises a pump inlet 3 through which the multiphase process fluid enters the pump 1 at the low pressure side LP as indicated by the arrow I, and a pump outlet 4 for discharging the process fluid with an increased pressure at the high pressure side HP as indicated by the arrow O. Typically the pump outlet 4 is connected to a pipe or a piping (not shown) for delivering the process fluid to another location. The pressure of the process fluid at the pump outlet 4, i.e. at the high pressure side HP, is typically considerably higher than the pressure of the process fluid at the pump inlet 3, i.e. at the low pressure side LP. A typical value for the difference between the high pressure and the low pressure side is for example 50 to 200 bar.

(10) The pump 1 further comprises an inlet annulus 5. The pump inlet 3 opens into the inlet annulus 5, so that the inlet annulus 5 receives the process fluid through the pump inlet 3. The pump 1 further comprises a discharge annulus 6 for discharging the process fluid into the pump outlet 4, through which the process fluid leaves the pump 1. The pump outlet 4 opens into the discharge annulus 6.

(11) The multiphase pump further comprises a pump rotor 7 for rotating about an axial direction A. In a manner known per se the pump rotor 7 is configured for conveying the process fluid from the inlet annulus 5 at the low pressure side LP to the discharge annulus 6 at the high pressure side HP. The details of the pump rotor 7 are not shown in FIG. 1. Typically, the pump rotor 7 comprises a shaft 71 (see for example FIG. 2) rotatable about the axial direction A and one impeller 72 (single stage pump) or a plurality of impellers 72 (multistage pump) arranged in series along the axial direction A for conveying the process fluid from the inlet annulus 5 to the discharge annulus 6 and thereby increasing the pressure of the process fluid. Each impeller 72 is fixed to the shaft 71 in a torque-proof manner. Each impeller 72 may be designed for example as a radial impeller or as an axial impeller or as a semi-axial impeller.

(12) For rotating the shaft 71 of the pump rotor 7, the shaft 71 is operatively connected to a drive unit 8, which might be a separate unit located outside the housing 2 of the pump, or which might be integrated into the housing 2. For subsea applications the drive unit 8 is usually arranged inside the housing 2.

(13) By the drive unit 8 the pump rotor 7 is driven during operation of the pump 1 for a rotation about the axial direction A that is defined by the longitudinal axis of the pump rotor 7.

(14) The multiphase pump 1 further comprises a return line 9 for recycling a part of the process fluid from the high pressure side HP to the low pressure side LP. The return line 9 comprises an inlet 91 for receiving the process fluid to be recycled, an outlet 92 for discharging the process fluid to be recycled, and a control valve 93 for opening and closing the return line 9. The control valve 93 may be designed for example as a minimum flow valve, which opens the return line 9 when the flow generated by the pump 1 drops below a minimum flow.

(15) According to the invention, the inlet 91 of the return line 9 is arranged directly at the discharge annulus 6, so that the return line 9 receives the process fluid directly from the discharge annulus 6. The multiphase process fluid in the discharge annulus 6 is strongly homogenized by the action of the pump rotor 7, which thoroughly mixes at least the liquid and the gaseous phase of the multiphase fluid.

(16) In the embodiment shown in FIG. 1 the inlet 91 of the return line 9 opens into the discharge annulus 6, so that the process fluid may directly enter the inlet 91 of the return line 9 from the discharge annulus 6.

(17) The inlet 91 of the return line 9 and the pump outlet 4 are disposed in a spaced relationship at the discharge annulus 6. Typically, the discharge annulus 6 is an annular chamber. As shown in FIG. 1 the inlet 91 of the return line 9 and the pump outlet 4 are arranged diametrically opposed at the discharge annulus 6.

(18) It has to be noted that the distance between the inlet 91 of the return line 9 and the pump outlet 4 at the discharge annulus 6 may be different from 180 when viewed in the circumferential direction of the discharge annulus 6. However, the opening of the inlet 91 into the discharge annulus 6 is a different opening than the opening of the pump outlet 4 into the discharge annulus 6.

(19) The outlet 92 of the return line 9 is in fluid communication with the inlet annulus 5 of the pump 1. According to the embodiment shown in FIG. 1, the outlet 92 of the return line 9 is arranged directly at the inlet annulus 5. The outlet 92 opens into the inlet annulus 5.

(20) The outlet 92 of the return line 9 and the pump inlet 3 are disposed in a spaced relationship at the inlet annulus 5. Typically, the inlet annulus 5 is an annular chamber. As shown in FIG. 1 the outlet 92 of the return line 9 and the pump inlet 3 are arranged diametrically opposed at the inlet annulus 5.

(21) It has to be noted that the distance between the outlet 92 of the return line 9 and the pump inlet 3 at the inlet annulus 5 may be different from 180 when viewed in the circumferential direction of the inlet annulus 5. However, the opening of the outlet 92 into the inlet annulus 5 is a different opening than the opening of the pump inlet 3 into the inlet annulus 5.

(22) The return line 9 is designed as a pipe connecting the discharge annulus 6 with the inlet annulus 5. In the first embodiment shown in FIG. 1 the return line 9 is designed as an external pipe and arranged at the outside of the housing 2. The return line 9 is fixed to the housing 2 by means of a first flange connection 94 connecting the inlet 91 of the return line 9 with the discharge annulus 6, and by means of a second flange connection 95 connecting the outlet 92 of the return line 9 with the inlet annulus 5.

(23) The return line 9 is designed as a pipe having the shortest length that is possible or technically reasonable when considering constructional or structural aspects. Ideally, the length of the pipe constituting the return line is essentially the same as the distance between the discharge annulus 6 and the inlet annulus 5. In practice, the return line 9 is somewhat longer than the distance between the discharge annulus 6 and the inlet annulus 5 due to constructional reasons. It is preferred that the return line 9 has a length which is at most two times and particularly preferred at most 1.5 times the distance between the pump inlet 3 and the pump outlet 4. The short and compact design of the return line 9 has the advantage that the pressure loss caused by friction losses in the return line 9 is very low. In addition the short length of the return line 9 reduces any separation effects in the recycled process fluid, such as phase separation, stratification or slug generation. Furthermore, by the short length of the return line 9 considerable temperature variations between the recycled process fluid and the main stream of process fluid are avoided. Due to the low pressure losses and the low thermal variations the formation of hydrates, in particular in the return line 9, is prevented

(24) As already said, the return line 9 further comprises the control valve 93 for opening and closing the return line 9. When the control valve 93 is in the open position the fluid communication through the return line 9 is open, so that the process fluid is recycled from the discharge annulus 6 to the low pressure side LP. When the control valve 93 is in the close position the fluid communication through the return line 9 is closed, so that no process fluid is recycled from the discharge annulus 6 to the low pressure side LP. The control valve 93 may be designed as a shut-off valve having only an open and a close position or the control valve 93 may be designed as a flow control valve for regulating the flow of the process fluid through the return line 9.

(25) The control valve 93 may be configured for example as an electrically actuated valve or as a hydraulically actuated valve.

(26) The method for operating the return line 9, in particular how and when the return line 9 is opened or closed by the control valve 93, per se is not particularly relevant for the invention. In principle, each method known in the art for operating a return line 9 in a pump, in particular in a multiphase pump 1, is suited for operating the multiphase pump 1 according to the invention. As an example reference is made to EP-A-3 037 668 where a method is described for operating a pump having a return line for recycling the process fluid from the high pressure side to the low pressure side or the suction side of the pump.

(27) The basic function of the return line 9 is to avoid, that the multiphase pump 1 is operating at a flow, which is lower than the minimum flow the multiphase pump 1 is designed for. This minimum flow is a known value, which is given by the design of the pump 1 or the pump installation.

(28) During operation of the multiphase pump 1 the hydraulic performance of the pump 1 is monitored. For example the flow generated by the pump is detected, for example by determining the flow of process fluid discharged through the pump outlet 4. The flow may be directly measured by means of one or more appropriate sensors or the flow may be determined by means of other operational parameters of the pump 1 which are indicative for or related to the flow generated by the pump 1.

(29) When the flow approaches or reaches the minimum flow the return line 9 is partially or fully opened by means of the control valve 93. Now, the process fluid is at least partially recycled from the high pressure side HP to the low pressure side LP or the suction side, respectively, of the pump 1. Of course, it is also possible that the entire flow of process fluid conveyed to the discharge annulus 6 is returned to the inlet annulus 5.

(30) By returning the process fluid from the high pressure side HP to the pump inlet 3 or to the inlet annulus, respectively, the volume flow at the pump inlet 4 or through the inlet annulus 5 is increased, whereby the flow through the pump 1 from the inlet annulus 5 to the discharge annulus 6 is increased, which moves the actual operating pump away from the minimum flow condition back towards the best efficiency point. As soon as the flow of process fluid generated by the pump 1 is sufficiently higher than the minimum flow, the return line 9 can be closed by means of the control valve 93, so that the process fluid is no longer recycled from the discharge annulus 6 to the low pressure side LP of the pump.

(31) For recycling the process fluid from the discharge annulus 6 to the low pressure side LP of the pump it is not necessary to supply the recycled process fluid directly to the inlet annulus 5 through an opening that is different from the orifice of the pump inlet 3 into the inlet annulus 5.

(32) In other embodiment of the pump 1 the outlet 92 of the return line 9 is connected to the pump inlet 3.

(33) In addition, it is also possible that the return line 9 is connected to a buffer tank and the buffer tank is connected with the pump inlet 3. In such embodiments the process fluid recycled from the discharge annulus 6 is supplied to the buffer tank. From the buffer tank the process fluid is supplied to the pump inlet 3.

(34) The embodiment shown in FIG. 1 is configured as a vertical pump with the pump rotor 7 extending in the vertical direction. During operation of the pump the pump rotor 7 is oriented in the direction of gravity and the axial direction A extends vertically.

(35) It goes without saying that the multiphase pump according to the invention may also be designed as a horizontal pump with the pump rotor 7 extending in the horizontal direction, i.e. perpendicular to the direction of gravity.

(36) In the following description of further embodiments of the multiphase pump 1 according to the invention only the differences to the first embodiment are explained in more detail. The explanations with respect to the first embodiment are also valid in the same way or in analogously the same way for the other embodiments. Same reference numerals designate features that have been explained with reference to FIG. 1 or functionally equivalent features. In addition, the features explained referring to a specific embodiment may also be implemented in an analogous way in the respective other embodiments. In particular each of the embodiments may be designed as a vertical pump or as a horizontal pump.

(37) FIG. 2 shows a cross-sectional view of a second embodiment of a multiphase pump 1 according to the invention. The second embodiment is designed as a horizontal pump 1. The multiphase pump 1 is designed as a multistage pump 1, wherein the pump rotor 7 comprises a plurality of impellers 72 arranged in series on the shaft 71. The impellers 72 are designed as semi-axial impellers 72. Between adjacent impellers 72 in each case a stationary diffuser 73 is provided for directing the process fluid to the next stage impeller 72. The drive unit 8 for rotating the pump rotor 7 is not shown in FIG. 2.

(38) FIG. 3 shows a cross-sectional view of a third embodiment of a multiphase pump 1 according to the invention. The third embodiment is here designed as a vertical pump. The drive unit 8 for rotating the pump rotor 7 is not shown in FIG. 3.

(39) According to the third embodiment the return line 9 is fixedly connected to the housing 2 in a non-detachable manner. The return line 9 is for example welded to the housing 2 as indicated by the welding seams 96 in FIG. 3.

(40) FIG. 4 shows a cross-sectional view of a fourth embodiment of a multiphase pump 1 according to the invention. The fourth embodiment is here designed as a vertical pump. The drive unit 8 for rotating the pump rotor 7 is not shown in FIG. 4.

(41) In the fourth embodiment the return line 9 is an internal line, i.e. the return line 9 is arranged inside the housing 2 of the multiphase pump 1.