Search Results (114)

A twin-screw multiphase pump is essential equipment for the transfer of gas-liquid multiphase mixtures in oil and gas operations. This work addresses rotor deformation in real applications by correcting the rotor profile using the arc transition approach, eliminating teeth tips, mitigating local stress concentration, and reducing the danger of rotor deformation. Simultaneously, in conjunction with the oil and gas mixed transportation requirements of the Changqing Oilfield, the MPC208-67 twin-screw mixed transportation pump was engineered, and the essential structural specifications were established. This paper employs the Mixture multiphase flow model and the SST k-ω turbulence model to simulate the internal flow field of the pump in Changqing Oilfield, aiming to examine the impact of high-gas-content conditions on the pump’s performance and ensure it aligns with design specifications. The modeling findings indicate that the pressure in the pump progressively rises along the axial direction and remains constant within the chamber. As the void fraction of the medium increases, the pressure differential between the inlet and exit of the rotor fluid domain progressively diminishes, resulting in high-velocity fluid emerging in the interstice between driving and driven rotors. The simultaneous increase in rotational speed elevates the overall fluid velocity while diminishing the pressure value. Under rated conditions, the output pressure and flow rate of the planned multiphase pump achieve 1.8 MPa and 300 m³/h, respectively, thereby fully satisfying the design specifications. This work employs the response surface approach to optimize multi-objective performance parameters, including leakage and pressurization capacity, to enhance the pump’s operational performance under high gas content situations. The optimization results indicate a 17.87% reduction in pump leakage, an 8.86% rise in pressurization capacity, and a substantial enhancement in pump performance. Full article

The high energy consumption and cost of operation which result from substantial pressure losses during the transportation of crude oil over long-distance pipelines due to frictional drag created by turbulence are fundamental issues. In order to cope with such challenges, the current research intends to develop a simulation-based study that employs MATLAB R2016b and Minitab 21 to assess the effectiveness of drag-reducing agents (DRAs). An effective mathematical representation of the use of basic fluid mechanics with a semi-empirical correlation on the DRA performance is therefore created and its performance compared to actual pipeline data, showing good compatibility with experimental results. The findings show that DRA addition can produce a significant reduction in the pressure drop by 30–35% with an increase in the overall flow efficiency by 40–60%. Using 25 ppm DRA concentration at a Reynolds number of 323,159 enables an optimised prediction of 33.43% in drag reduction with an efficiency of 45.13%. Moreover, it is also found that there are considerable energy savings, flatter radial velocity profiles, and enhanced particle transport, which highlights the radical effect of DRAs on the hydrodynamics of flows. More importantly, it is determined that DRAs are one of the most effective and cost-efficient solutions to improve throughput and decrease the pumping power in the oil pipeline. However, further research is required to generalise the model to multiphase flows and use the newest optimisation algorithms to control the dosage dynamically. Full article

Pumped storage power stations commonly adopt impermeable linings at reservoir bottoms to reduce seepage losses. However, these linings significantly weaken the current dissipation capability of grounding grids, particularly in high-resistivity bedrock areas. To address this problem, a pipeline-type grounding grid (PTGG) with seepage holes is proposed for installation beneath impermeable reservoir basins. By enabling controlled water seepage, the PTGG increases bedrock moisture content and reduces its electrical resistivity, thereby improving grounding performance. A coupled seepage–resistivity–grounding model is established by integrating multiphase flow simulation in porous media with grounding impedance calculations using CDEGS. Simulation results indicate that controlled seepage can reduce the effective resistivity of initially dry bedrock from approximately 38,000 Ω·m to about 500–2000 Ω·m within the primary current-dissipation zone. For a typical pumped storage power station, the proposed PTGG reduces the overall grounding resistance by approximately 11.3–14.0% within 0.5–2 years of operation. Parametric analyses show that decreasing the spacing of seepage holes from 10 m to 1 m significantly enhances resistance reduction, whereas the influence of hole diameter (5–20 cm) on grounding resistance is relatively minor when the spacing is fixed. These results demonstrate that the PTGG provides an effective and site-specific resistance reduction solution for impermeable basin pumped storage power stations, where conventional grounding measures exhibit limited effectiveness. Full article

Semi-open impeller sewage pumps are widely used for transporting solid-laden fluids due to their anti-clogging properties. However, unlike extensive research on clear water conditions, the specific mechanisms governing pressure instabilities under solid–liquid two-phase flows remain underexplored. This study investigates the unsteady flow field and pulsation characteristics of a Model 80WQ4QG pump using unsteady CFD simulations based on the Standard k−ϵ turbulence model and the Eulerian–Eulerian multiphase model. The effects of flow rate, particle size, and volume fraction were systematically analyzed. Results indicate that the blade-passing frequency (95 Hz) dominates the pressure spectra, with the volute tongue and impeller outlet identified as the most sensitive regions. While increased flow rates weaken fluctuations at the volute tongue, the presence of solid particles significantly amplifies them. Specifically, compared to single-phase flow, the pulsation amplitudes at the volute tongue increased by 68.15% with a 3.0 mm particle size and by 97.73% at a 20% volume fraction. Physically, this amplification is attributed to the intensified momentum exchange between phases and the enhanced turbulent flow disturbances induced by particle inertia at the rotor–stator interface. These findings clarify the particle-induced flow instability mechanisms, offering theoretical guidelines for optimizing pump durability in multiphase environments. Full article

Solid–liquid stirred tanks are widely used in multiphase processes, including bioreactors for mesenchymal stem cell (MSC) culture, yet simultaneous experimental data for both dispersed and carrier phases remain limited. Here, a refractive index-matched (RIM) suspension of PMMA microparticles ($d_p=168\mathrm{\mu m}$, ${\rho }_p/{\rho }_l\approx 0.96$) in an NH₄SCN solution is studied at an intermediate Reynolds number ($Re\approx 5000$), low Stokes number ($St=0.078$), and particle volume fractions $0.1\le {\alpha }_p\le 0.5$ v%. This system was previously established and studied for the effect of addition of particles on the carrier phase. In this work, a dual-camera PIV set-up provides simultaneous velocity fields of the liquid and particle phases in a stirred tank equipped with a three-blade down-pumping HTPGD impeller. The liquid mean flow and circulation loop remained essentially unchanged with particle loading, whereas particle mean velocities were lower than single-phase and liquid-phase values in the impeller discharge. Turbulence levels diverged between phases: liquid-phase turbulent kinetic energy (TKE) in the impeller region increased modestly with ${\alpha }_p$, while solid-phase TKE was attenuated. Slip velocity maps showed that particles lagged the fluid in the impeller jet and deviated faster from the wall in the upward flow, with slip magnitudes increasing with ${\alpha }_p$. An approximate axial force balance indicated that drag dominates over lift in the impeller and wall regions, while the balance is approximately satisfied in the tank bulk, providing an experimental benchmark for refining drag and lift models in this class of stirred tanks. Full article

Sewage pumps often handle complex multiphase flows containing rigid solid particles and flexible fibrous debris. These fibers can deform, entangle, and alter the flow, leading to clogging and the uneven erosion of pump components. In this study, we use coupled CFD–DEM simulations (validated by experiments) to analyze how short flexible fibers move within a model sewage pump and how they influence pump erosion. We show that fibers injected near the inlet center tend to remain in the impeller region longer, especially as fiber diameter increases, causing greater contact with the impeller surface. When fibers coexist with sand-like particles, fibers become trapped near the impeller inlet and deflect incoming particles, creating additional collisions and irregular erosion patterns. In general, fibers alone induce minimal erosion, but their interaction with particles substantially amplifies impeller wear, producing more random pitting as fiber concentration rises. These findings highlight how fiber–particle interactions must be considered for reliable pump operation and design. Full article

Electric Submersible Pumps (ESPs) serve as the primary artificial lift technology in offshore oilfields and play a crucial role in ensuring stable and efficient marine oil and gas production. However, the harsh offshore operating environment—characterized by high temperature, complex multiphase flow, and frequent load fluctuations—makes ESPs highly susceptible to accelerated degradation and unexpected failure. To enhance the operational reliability and efficiency of offshore production systems, this study develops a Remaining Useful Life (RUL) prediction method for offshore ESP systems using a Dual-Stage Attention-Based Recurrent Neural Network (DA-RNN). The model integrates an input-attention mechanism to identify degradation-relevant offshore operating variables and a temporal-attention mechanism to capture long-term deterioration patterns in real marine production data. Using field data from a representative offshore oilfield in the Bohai Sea, the proposed method achieves an average prediction error of less than 28 days, demonstrating strong robustness under complex offshore conditions. Beyond prediction, an RUL-driven operation optimization strategy is formulated to guide controllable parameters—such as pump frequency and nozzle size—toward extending ESP lifespan and improving offshore production stability. The results show that combining predictive maintenance with operational optimization provides a practical and data-driven pathway for improving the safety, efficiency, and sustainability of offshore oil and gas development. This work aligns closely with the goals of marine resource development and offers a valuable engineering perspective for advancing offshore oilfield operations. Full article

The aim of this study is to compare submerged vortical structures for a pump mounted in a pump intake without any anti-vortex devices (AVDs), with a trident-like AVD or with a cone AVD. Another aim is to compare the pump characteristics (head, efficiency, power input and radial forces) of these pump arrangements via CFD simulation along with experimental measurements in a closed circuit. The numerical simulation of unsteady multiphase flow is established by means of computational fluid dynamics (CFD) and the volume of fluid (VOF) method. To predict vortical structures in the vicinity of the pump suction bell, the unsteady Reynolds-averaged Navier–Stokes equations (URANS) are solved together with the scale-adaptive simulation (SAS) turbulence model. For each AVD configuration, integral characteristics like the head, power input, efficiency and forces acting on the pump rotor are also evaluated. The numerical results show that the configuration with the cone AVD exhibits the best performance (from the point of view of both hydraulic efficiency and vorticity strength), but it requires a larger distance between the intake bottom wall and the pump bellmouth. The submerged vortices are quite stable when using an AVD, but rather unsteady without any anti-vortex tool. Full article

A coupled CFD-DEM model was adopted to investigate the floating ice accumulation mechanism and its disturbance to the flow field in the pump house of coastal nuclear power plants in cold regions. Based on numerical simulations, the motion, accumulation, and flow interaction characteristics of floating ice under various release positions and heights were analyzed. The results indicate that the release height significantly governs the accumulation morphology and hydraulic response. The release height critically determines ice accumulation patterns and hydraulic responses. For inlet scenarios, lower heights induce a dense, wedge-shaped accumulation at the coarse trash rack, increasing thickness by 57.69% and shifting the accumulation 38.16% inlet-ward compared to higher releases. Conversely, higher releases enhance dispersion, expanding disturbances to the central pump house and intensifying flow heterogeneity. In bottom release cases, lower heights form wall-adhering accumulations, while higher releases cause ice to rise into mid-upper layers, thereby markedly intensifying local vortices (peak intensity 79.68, approximately 300% higher). Spatial release locations induce 2.7–4.8-fold variations in flow disturbance intensity across monitoring points. These findings clarify the combined impact of the release height and location on the ice accumulation and flow field dynamics, offering critical insights for the anti-ice design and flow safety assessment of pump houses. Full article

Reliable water access in remote and desert-like regions remains a challenge, particularly in areas with limited infrastructure. Solar-powered submersible pumps offer a promising solution; however, optimizing their performance under variable environmental conditions remains a challenging task. This research presents an Artificial Intelligence (AI)-driven digital twin framework for modeling and optimizing the performance of a solar-powered submersible pump system. The proposed system has three core components: (1) an AI model for predicting the inverter motor’s output frequency based on the current generated by the solar panels, (2) a predictive model for estimating the pump’s generated power based on the inverter motor’s output, and (3) a mathematical formulation for determining the volume of water lifted based on the system’s operational parameters. Moreover, a dataset comprising 6 months of environmental and system performance data was collected and utilized to train and evaluate multiple predictive models. Unlike previous works, this research integrates real-world data with a multi-phase AI modeling pipeline for real-time water output estimation. Performance assessments indicate that the Random Forest (RF) model outperformed alternative approaches, achieving the lowest error rates with a Mean Absolute Error (MAE) of 1.00 Hz for output frequency prediction and 1.39 kW for pump output power prediction. The framework successfully estimated annual water delivery of 166,132.77 m³, with peak monthly output of 18,276.96 m³ in July and minimum of 9784.20 m³ in January demonstrating practical applicability for agricultural water management planning in arid regions. Full article

Horizontal annular flow channels are widely applied in various fields, including thermal engineering, drilling engineering, and food engineering. Investigating their internal flow patterns is crucial for optimizing pipeline design, selecting appropriate equipment, and understanding the sedimentation and migration modes of multiphase flows within annular geometries. In practical engineering applications, the operational conditions of annular flow channels during gas drilling are the most complex, involving parameters such as eccentricity, rotation, surface roughness, and multiphase flow interactions. This study focuses on the flow characteristics of horizontal annular channels under real-world engineering conditions, examining variations in operational parameters. The pressure drop in annular pipelines is influenced by factors such as flow velocity, eccentricity, and rotational speed, exhibiting complex variation patterns. However, previous studies have not fully considered the impact of rough wellbore walls and the interactions among various factors. Employing experimental methods, this research analyzes the pressure drop characteristics within annular geometries. The results reveal that surface roughness significantly affects pressure drop, with the inner pipe’s roughness having a greater impact when the outer pipe surface is rough compared to when it is smooth. An increase in eccentricity substantially reduces pressure drop, with both positive and negative eccentricities demonstrating symmetric pressure drop patterns. Moreover, a significant positive correlation exists between the total rough area of the annular channel and pressure drop. Furthermore, this study establishes a predictive model through dimensional analysis. Unlike existing models, this new model incorporates the influences of both roughness and eccentricity, achieving a prediction accuracy of over 99%. This research confirms the critical role of roughness in annular flow systems and provides practical implications for selecting more reliable pump power equipment in engineering fields. Full article

The optimization of pump setting depth in low-permeability oil wells remains a persistent challenge, as conventional inflow performance relationship (IPR) curves fail to capture the coupled effects of downhole pump intake depth and reservoir productivity. To address this limitation, this study proposes a novel Low-Permeability Intake Inflow Performance Relationship (LIIPR) framework. The method establishes a theoretical link between pump depth and production by integrating low-permeability reservoir inflow models with multiphase wellbore flow calculations. On this basis, a series of derivative concepts and analytical tools are introduced, including (i) a three-zone classification of inflow curves to distinguish effective, inefficient, and abnormal production regimes; (ii) a multi-pump-depth analysis to determine the feasible range and optimal boundaries of pump setting depth; and (iii) a three-dimensional deep-pumping limit map that couples inflow and outflow dynamics through nodal analysis, providing a comprehensive criterion for system optimization. The proposed LIIPR methodology enables accurate identification of optimal pump depth and intake pressure conditions, overcoming the ambiguity of traditional IPR-based approaches. Unlike previous IPR- or EIPR-based methods, LIIPR introduces for the first time a unified inflow–outflow coupling framework that quantitatively links pump intake depth with well productivity. This integration represents a novel theoretical and computational advance for deep-pumping optimization in low-permeability reservoirs. Applications for field cases in Shengli Oilfield confirm the theoretical findings and demonstrate the practical potential of the method for guiding efficient deep pumping operations in low-permeability reservoirs. Full article

This study investigates premature fatigue failure in rocker arm gears of large-mining-height shearers operating at alternating ±45° working angles, where insufficient lubrication generates non-uniform thermal -stress fields. In this study, an integrated multiphysics framework combining transient thermal–fluid–structure coupling simulations with fatigue life prediction is proposed. Transient thermo-mechanical coupling analysis simulated dry friction conditions, capturing temperature and stress fields under varying speeds. Fluid–thermal–solid coupling analysis modeled wet lubrication scenarios, incorporating multiphase flow to track oil distribution, and calculated convective heat transfer coefficients at different immersion depths (25%, 50%, 75%). These coupled simulations provided the critical time-varying temperature and thermal stress distributions acting on the gears (Z6 and Z7). Subsequently, these simulated thermo-mechanical loads were directly imported into ANSYS 2024R1 nCode DesignLife to perform fatigue life prediction. Simulations demonstrate that dry friction induces extreme operating conditions, with Z6 gear temperatures reaching over 800 °C and thermal stresses peaking at 803.86 MPa under 900 rpm, both escalating linearly with rotational speed. Lubrication depth critically regulates heat dissipation, where 50% oil immersion optimizes convective heat transfer at 8880 W/m²·K for Z6 and 11,300 W/m²·K for Z7, while 25% immersion exacerbates thermal gradients. Fatigue life exhibits an inverse relationship with speed but improves significantly with cooling. Z6 sustains a lower lifespan, exemplified by 25+ days at 900 rpm without cooling versus 50+ days for Z7, attributable to higher stress concentrations. Based on the multiphysics analysis results, two physics-informed engineering optimizations are proposed to reduce thermal stress and extend gear fatigue life: a staged cooling system using spiral copper tubes and an intelligent lubrication strategy with gear-pump-driven dynamic oil supply and thermal feedback control. These strategies collectively enhance gear longevity, validated via multiphysics-driven topology optimization. Full article

Electric submersible pumps (ESPs) are among the most widely used artificial lifting systems, and their operational stability is crucial to the production capacity and lifespan of oil wells. However, during the operation of ESP systems, they often face complex flow issues such as gas lock and insufficient liquid carry. Traditional control strategies relying on liquid level monitoring and electrical parameter alarms exhibit obvious latency, making it difficult to effectively guide the adjustments of key operating parameters such as pump frequency, valve opening, and on/off strategies. To monitor the flow state of ESP systems and optimize it in a timely manner, this paper proposes an innovative profile recognition method based on multiphase flow fitting in the wellbore, aimed at reconstructing the flow state at the pump’s intake. This method identifies flow abnormalities and, in conjunction with flow characteristics, designs targeted operating parameter optimization logic to enhance the stability and efficiency of ESP systems. Research shows that this optimization method can significantly improve the pump’s operational performance, reduce failure rates, and extend equipment lifespan, thus providing an effective solution for optimizing production in electric pump wells. Additionally, this method holds significant importance for enhancing oil well production efficiency and economic benefits, providing a scientific theoretical foundation and practical guidance for future oil and gas exploration and management. Full article

With increasing global energy demand and depletion of onshore oil–gas resources, deep-sea hydrocarbon exploration and development have become strategically vital. As core subsea transportation equipment, the performance of helico-axial multiphase pumps directly determines the efficiency and economic feasibility of deep-sea extraction. However, non-uniform inflow patterns caused by uneven gas–liquid distribution in pipelines degrade pressure-boosting capability and reduce pump efficiency under actual operating conditions. To address this, an optimization method employing helical static mixers was developed. A mixer with a 180° helical angle was designed and installed upstream of the pump inlet. Numerical simulations demonstrate that the mixer enhances gas-phase distribution uniformity in stratified flow, improving efficiency and head across varying gas void fractions (GVFs). At a stratification height ratio (Ψ) of 0.32, efficiency increased by 15.41% and head rose by 15.64 m, while turbulent kinetic energy (TKE) at the impeller outlet decreased by up to 50%. For slug flow conditions, the mixer effectively suppressed gas volume fraction fluctuations, consistently improving efficiency under different slug flow coefficients (φ) with a maximum head increase of 9.82%. The optimized flow field exhibits uniform gas–liquid velocity distribution, stable pressure boosting, and significantly reduced TKE intensity within impeller passages. Full article