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Research Papers: Energy Systems Analysis

Predictive Erosion Model for Mixed Flow Centrifugal Pump

[+] Author and Article Information
Sahand Pirouzpanah

Department of Mechanical Engineering,
3123 Texas A&M University,
College Station, TX 77843

Abhay Patil

Department of Mechanical Engineering,
3123 Texas A&M University,
College Station, TX 77843
e-mail: abhyapatil@tamu.edu

Yiming Chen

Department of Mechanical Engineering,
3123 Texas A&M University,
College Station, TX 77843
e-mail: yimingchen@tamu.edu

Gerald Morrison

Department of Mechanical Engineering,
3123 Texas A&M University,
College Station, TX 77843
e-mail: gmorrison@tamu.edu

Contributed by the Advanced Energy Systems Division of ASME for publication in the Journal of Energy Resources Technology. Manuscript received December 14, 2018; final manuscript received March 4, 2019; published online March 27, 2019. Assoc. Editor: Esmail M. A. Mokheimer.

J. Energy Resour. Technol 141(9), 092001 (Mar 27, 2019) (9 pages) Paper No: JERT-18-1891; doi: 10.1115/1.4043135 History: Received December 14, 2018; Accepted March 05, 2019

Electrical submersible pumps (ESPs) are widely used in upstream oil production. The presence of a low concentration solid phase, particle-laden flow, in the production fluid may cause severe damage in the internal sections of the pump which reduces its operating lifetime. To better understand the ESP pump's endurance, two different designs of commonly used mixed flow ESPs were studied numerically to determine the pump's flow behavior at its best efficiency point. Computational fluid dynamics (CFD) analysis was conducted on two stages of one design type of pump's primary flow path employing Eulerian–Granular scheme in ANSYS FLUENT. The key parameters affecting the erosion phenomena within the pump such as turbulence kinetic energy, local sand concentration, and near wall relative sand velocity were identified. The predictive erosion model applicable to pumps was developed by correlating the erosion key parameters with available experimental results. It is concluded that the use of an erosion model on the second design of ESP proves the model's versatility to predict the erosion on different designs of ESPs.

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References

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Figures

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Fig. 1

Experimental setup to investigate the erosion rate in pumps [20]

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Fig. 2

Mesh generated on single-stage pump: (a) impeller shroud and inlet, (b) impeller and diffuser shroud, and (c) balance holes and impeller hub

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Fig. 3

Single stage noneroded blades and hub of the ESP pump

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Fig. 4

ESP-shrouded impeller and balance holes

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Fig. 5

Single-phase pressure contours for (a) the first-stage ESP and (b) second-stage ESP

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Fig. 6

Water streamlines for the first stage (a) span: 0.1, (b) span: 0.5, and (c) span: 0.9 and for the second stage (d) span: 0.1, (e) span: 0.5, and (f) span: 0.9

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Fig. 7

Distribution of (a) sand volume fraction and (b) water turbulence kinetic energy at the first-stage outlet diffuser

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Fig. 8

(a) Turbulence kinetic energy for the first stage, (b) turbulence kinetic energy for the second stage, (c) sand volume fraction for the first stage, and (d) sand volume fraction for the second stage

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Fig. 11

Erosion rate for the computed erosion factor values

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Fig. 10

Sand concentration for the first stage (a) span: 0.1, (b) span: 0.5, and (c) Span: 0.9 and for the second stage (d) span: 0.1, (e) span: 0.5, and (f) span: 0.9

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Fig. 9

Turbulence kinetic energy for the first stage (a) span: 0.1, (b) span: 0.5, and (c) span: 0.9 and for the second stage (d) span: 0.1, (e) span: 0.5, and (f) span: 0.9

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Fig. 16

Split vane pump impeller geometry

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Fig. 15

Comparison between the computed erosion rates with the erosion at different locations

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Fig. 14

Comparison between the computed erosion rates with the eroded locations in the first and second impellers

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Fig. 13

Computed erosion rate on the second stage from different views

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Fig. 12

Computed erosion rate on the first stage from different views

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