Leakage, Drag Power, and Rotordynamic Force Coefficients of an Air in Oil (Wet) Annular Seal

Author(s):  
Luis San Andrés ◽  
Xueliang Lu

Wet gas compression systems and multiphase pumps are enabling technologies for the deep sea oil and gas industry. This extreme environment determines both machine types have to handle mixtures with a gas in liquid volume fraction (GVF) varying over a wide range (0–1). The gas (or liquid) content affects the system pumping (or compression) efficiency and reliability, and places a penalty in leakage and rotordynamic performance in secondary flow components, namely seals. In 2015, tests were conducted with a short length smooth surface annular seal (L/D = 0.36, radial clearance = 0.127 mm) operating with an oil in air mixture whose liquid volume fraction (LVF) varied to 4%. The test results with a stationary journal show the dramatic effect of a few droplets of liquid on the production of large damping coefficients. This paper presents further measurements and predictions of leakage, drag power, and rotordynamic force coefficients conducted with the same test seal and a rotating journal. The seal is supplied with a mixture (air in ISO VG 10 oil), varying from a pure liquid to an inlet GVF = 0.9 (mostly gas), a typical range in multiphase pumps. For operation with a supply pressure (Ps) up to 3.5 bar(a), discharge pressure (Pa) = 1 bar(a), and various shaft speed (Ω) to 3.5 krpm (ΩR = 23.3 m/s), the flow is laminar with either a pure oil or a mixture. As the inlet GVF increases to 0.9 the mass flow rate and drag power decrease monotonically by 25% and 85% when compared to the pure liquid case, respectively. For operation with Ps = 2.5 bar(a) and Ω to 3.5 krpm, dynamic load tests with frequency 0 < ω < 110 Hz are conducted to procure rotordynamic force coefficients. A direct stiffness (K), an added mass (M), and a viscous damping coefficient (C) represent well the seal lubricated with a pure oil. For tests with a mixture (GVFmax = 0.9), the seal dynamic complex stiffness Re(H) increases with whirl frequency (ω); that is, Re(H) differs from (K−ω2M). Both the seal cross coupled stiffnesses (KXY and −KYX) and direct damping coefficients (CXX and CYY) decrease by approximately 75% as the inlet GVF increases to 0.9. The finding reveals that the frequency at which the effective damping coefficient (CXXeff = CXX − KXY/ω) changes from negative to positive (i.e., a crossover frequency) drops from 50% of the rotor speed (ω = 1/2 Ω) for a seal with pure oil to a lesser magnitude for operation with a mixture. Predictions for leakage and drag power based on a homogeneous bulk flow model match well the test data for operation with inlet GVF up to 0.9. Predicted force coefficients correlate well with the test data for mixtures with GVF up to 0.6. For a mixture with a larger GVF, the model under predicts the direct damping coefficients by as much as 40%. The tests also reveal the appearance of a self-excited seal motion with a low frequency; its amplitude and broad band frequency (centered at around ∼12 Hz) persist and increase as the gas content in the mixture increase. The test results show that an accurate quantification of wet seals dynamic force response is necessary for the design of robust subsea flow assurance systems.

Author(s):  
Luis San Andrés ◽  
Xueliang Lu

Wet gas compression systems and multiphase pumps are enabling technologies for the deep sea oil and gas industry. This extreme environment determines both machine types have to handle mixtures with a gas in liquid volume fraction (GVF) varying over a wide range (0 to 1). The gas (or liquid) content affects the system pumping (or compression) efficiency and reliability, and places a penalty in leakage and rotordynamic performance in secondary flow components, namely seals. In 2015, tests were conducted with a short length smooth surface annular seal (L/D = 0.36, radial clearance = 0.127 mm) operating with an oil in air mixture whose liquid volume fraction (LVF) varied to 4%. The test results with a stationary journal show the dramatic effect of a few droplets of liquid on the production of large damping coefficients. This paper presents further measurements and predictions of leakage, drag power, and rotordynamic force coefficients conducted with the same test seal and a rotating journal. The seal is supplied with a mixture (air in ISO VG 10 oil), varying from a pure liquid to an inlet GVF = 0.9 (mostly gas), a typical range in multiphase pumps. For operation with a supply pressure (Ps) up to 3.5 bar (a), discharge pressure (Pa) = 1 bar (a), and various shaft speed (Ω) to 3.5 krpm (ΩR = 23.3 m/s), the flow is laminar with either a pure oil or a mixture. As the inlet GVF increases to 0.9 the mass flow rate and drag power decrease monotonically by 25% and 85% when compared to the pure liquid case, respectively. For operation with Ps = 2.5 bar (a) and Ω to 3.5 krpm, dynamic load tests with frequency 0 < ω < 110 Hz are conducted to procure rotordynamic force coefficients. A direct stiffness (K), an added mass (M) and a viscous damping coefficient (C) represent well the seal lubricated with a pure oil. For tests with a mixture (GVFmax = 0.9), the seal dynamic complex stiffness Re(H) increases with whirl frequency (ω); that is, Re(H) differs from (K-ω2M). Both the seal cross coupled stiffnesses (KXY and −KYX) and direct damping coefficients (CXX and CYY) decrease by approximately 75% as the inlet GVF increases to 0.9. The finding reveals that the frequency at which the effective damping coefficient (CXXeff = CXX-KXY/ω) changes from negative to positive (i.e., a crossover frequency) drops from 50% of the rotor speed (ω = 1/2 Ω) for a seal with pure oil to a lesser magnitude for operation with a mixture. Predictions for leakage and drag power based on a homogeneous bulk flow model match well the test data for operation with inlet GVF up to 0.9. Predicted force coefficients correlate well with the test data for mixtures with GVF up to 0.6. For a mixture with a larger GVF, the model under predicts the direct damping coefficients by as much as 40%. The tests also reveal the appearance of a self-excited seal motion with a low frequency; its amplitude and broad band frequency (centered at around ∼12 Hz) persist and increase as the gas content in the mixture increase. The test results show that an accurate quantification of wet seals dynamic force response is necessary for the design of robust subsea flow assurance systems.


Author(s):  
Xueliang Lu ◽  
Luis San Andrés

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 towards 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.


Author(s):  
Xueliang Lu ◽  
Luis San Andrés

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.


Author(s):  
Luis San Andrés ◽  
Jing Yang ◽  
Xueliang Lu

Subsea pumps and compressors must withstand multiphase flows whose gas volume fraction (GVF) or liquid volume fraction (LVF) varies over a wide range. Gas or liquid content as a dispersed phase in the primary stream affects the leakage, drag torque, and dynamic forced performance of secondary flow components, namely seals, thus affecting the process efficiency and mechanical reliability of pumping/compressing systems, in particular during transient events with sudden changes in gas (or liquid) content. This paper, complementing a parallel experimental program, presents a computational fluid dynamics (CFD) analysis to predict the leakage, drag power, and dynamic force coefficients of a smooth surface, uniform clearance annular seal supplied with air in oil mixture whose inlet GVF varies discretely from 0.0 to 0.9, i.e., from a pure liquid stream to a nearly all-gas content mixture. The test seal has uniform radial clearance Cr = 0.203 mm, diameter D = 127 mm, and length L = 0.36 D. The tests were conducted with an inlet pressure/exit pressure ratio equal to 2.5 and a rotor surface speed of 23.3 m/s (3.5 krpm), similar to conditions in a pump neck wear ring seal. The CFD two-phase flow model, first to be anchored to test data, uses an Euler–Euler formulation and delivers information on the precise evolution of the GVF and the gas and liquid streams' velocity fields. Recreating the test data, the CFD seal mass leakage and drag power decrease steadily as the GVF increases. A multiple-frequency shaft whirl orbit method aids in the calculation of seal reaction force components, and from which dynamic force coefficients, frequency-dependent, follow. For operation with a pure liquid, the CFD results and test data produce a constant cross-coupled stiffness, damping, and added mass coefficients, while also verifying predictive formulas typical of a laminar flow. The injection of air in the oil stream, small or large in gas volume, immediately produces force coefficients that are frequency-dependent; in particular the direct dynamic stiffness which hardens with excitation frequency. The effect is most remarkable for small GVFs, as low as 0.2. The seal test direct damping and cross-coupled dynamic stiffness continuously drop with an increase in GVF. CFD predictions, along with results from a bulk-flow model (BFM), reproduce the test force coefficients with great fidelity. Incidentally, early engineering practice points out to air injection as a remedy to cure persistent (self-excited) vibration problems in vertical pumps, submersible and large size hydraulic. Presently, the model predictions, supported by the test data, demonstrate that even a small content of gas in the liquid stream significantly raises the seal direct stiffness, thus displacing the system critical speed away to safety. The sound speed of a gas in liquid mixture is a small fraction of those speeds for either the pure oil or the gas, hence amplifying the fluid compressibility that produces the stiffness hardening. The CFD model and a dedicated test rig, predictions and test data complementing each other, enable engineered seals for extreme applications.


Author(s):  
Luis San Andrés ◽  
Jing Yang ◽  
Xueliang Lu

Subsea pumps and compressors must withstand multi-phase flows whose gas volume fraction (GVF) or liquid volume fraction (LVF) varies over a wide range. Gas or liquid content as a dispersed phase in the primary stream affects the leakage, drag torque, and dynamic forced performance of secondary flow components, namely seals, thus affecting the process efficiency and mechanical reliability of pumping/compressing systems, in particular during transient events with sudden changes in gas (or liquid) content. This paper, complementing a parallel experimental program, presents a computational fluid dynamics (CFD) analysis to predict the leakage, drag power and dynamic force coefficients of a smooth surface, uniform clearance annular seal supplied with an air in oil mixture whose inlet GVF varies discretely from 0.0 to 0.9, i.e., from a pure liquid stream to a nearly all gas content mixture. The test seal has uniform radial clearance Cr = 0.203 mm, diameter D = 127 mm, and length L = 0.36 D. The tests were conducted with an inlet pressure/exit pressure ratio equal to 2.5 and a rotor surface speed of 23.3 m/s (3.5 krpm), similar to conditions in a pump neck wear ring seal. The CFD two-phase flow model, first to be anchored to test data, uses an Euler-Euler formulation and delivers information on the precise evolution of the GVF and the gas and liquid streams’ velocity fields. Recreating the test data, the CFD seal mass leakage and drag power decrease steadily as the GVF increases. A multiple-frequency shaft whirl orbit method aids in the calculation of seal reaction force components, and from which dynamic force coefficients, frequency dependent, follow. For operation with a pure liquid, the CFD results and test data produce a constant cross-coupled stiffness, damping, and added mass coefficients, while also verifying predictive formulas typical of a laminar flow. The injection of air in the oil stream, small or large in gas volume, immediately produces force coefficients that are frequency dependent; in particular the direct dynamic stiffness which hardens with excitation frequency. The effect is most remarkable for small GVFs, as low as 0.2. The seal test direct damping and cross-coupled dynamic stiffness continuously drop with an increase in GVF. CFD predictions, along with results from a bulk-flow model (BFM), reproduce the test force coefficients with great fidelity. Incidentally, early engineering practice points out to air injection as a remedy to cure persistent (self-excited) vibration problems in vertical pumps, submersible and large size hydraulic. Presently, the model predictions, supported by the test data, demonstrate that even a small content of gas in the liquid stream significantly raises the seal direct stiffness, thus displacing the system critical speed away to safety. The sound speed of a gas in liquid mixture is a small fraction of those speeds for either the pure oil or the gas, hence amplifying the fluid compressibility that produces the stiffness hardening. The CFD model and a dedicated test rig, predictions and test data complementing each other, enable engineered seals for extreme applications.


2020 ◽  
Vol 142 (3) ◽  
Author(s):  
Luis San Andrés ◽  
Xueliang Lu ◽  
Tingcheng Wu

Abstract Subsea multiphase pumps must operate reliably with a process fluid transitioning from a pure liquid, to a mixture of gas and liquid, and to eventually just gas; and pressure seals controlling secondary leakage paths are important for both pump efficiency and dynamic stability considerations, in particular, for flows with a sizable gas volume fraction (GVF). Early work advances a three-wave shape seal that generates significant direct stiffness and hence aids to increase the natural frequency of a vertical pump. This paper details dynamic load tests and produces rotordynamic force coefficients for the wavy-seal operating with a gas in liquid mixture made of air in light ISO VG 10 oil. For operation with pure liquid, GVF = 0, a stiffness (K), damping (C), and added mass (M) model fully characterizes the test article. For operation with a mixture, the seal dynamic stiffness coefficients vary greatly with excitation frequency; the direct dynamic stiffness hardens while the cross coupled stiffness decreases as the whirl frequency approaches shaft speed and then increases for super synchronous frequency. For operation with GVF from 0.1 to 0.8, the seal produces a large positive centering dynamic stiffness. Notably, the seal direct damping coefficient does not depend on frequency though reduces continuously as the inlet GVF increases from 0 to 1 (all gas). The current research adds relevant test data and unique dynamic force coefficients to the design selection of seals in multiphase pumps.


2005 ◽  
Vol 40 ◽  
pp. 179-184 ◽  
Author(s):  
C. Bock ◽  
H. Eicken

AbstractThe microstructural evolution of brine inclusions in granular and columnar sea ice has been investigated through magnetic resonance imaging (MRI) for temperatures between –28 and –3˚C. Thin-section and salinity measurements were completed on core samples obtained from winter sea ice near Barrow, Alaska, USA. Subsamples of granular (2–5cm depth in core) and columnar sea ice (20–23 cm depth) were investigated with morphological spin-echo and diffusion-weighted imaging in a Bruker 4.7T MRI system operating at field gradients of 200 mTm–1 at temperatures of approximately –28, –15, –6 and –3˚C. Average linear pore dimensions range from 0.2 to 1 mm and increase with bulk liquid volume fraction as temperatures rise from –15 to –3˚C. Granular ice pores are significantly larger than columnar ice pores and exhibit a higher degree of connectivity. No evidence is found of strongly non-linear increases in pore connectivity based on the MRI data. This might be explained by shortcomings in resolution, sensitivity and lack of truly three-dimensional data, differences between laboratory and field conditions or the absence of a percolation transition. Pore connectivity increases between –6 and –3˚C. Pore-number densities average at 1.4±1.2mm–2. The pore-number density distribution as a function of cross-sectional area conforms with power-law and lognormal distributions previously identified, although significant variations occur as a function of ice type and temperature. At low temperatures (< –26˚C), pore sizes were estimated from 1H self-diffusivity measurements, with self-diffusivity lower by up to an order of magnitude than in the free liquid. Analysis of diffusional length scales suggests characteristic pore dimensions of <1 μm at < –26˚C.


2021 ◽  
pp. 1-31
Author(s):  
Xueliang Lu ◽  
Luis San Andres ◽  
Jing Yang

Abstract Seals in multiple phase rotordynamic pumps must operate without compromising system efficiency and stability. Both field operation and laboratory experiments show that seals supplied with a gas in liquid mixture (bubbly flow) can produce rotordynamic instability and excessive rotor vibrations. This paper advances a nonhomogeneous bulk flow model (NHBFM) for the prediction of the leakage and dynamic force coefficients of uniform clearance annular seals lubricated with gas in liquid mixtures. Compared to a homogeneous BFM (HBFM), the current model includes diffusion coefficients in the momentum transport equations and a field equation for the transport of the gas volume fraction (GVF). Published experimental leakage and dynamic force coefficients for two seals supplied with an air in oil mixture whose GVF varies from 0 (pure liquid) to 20% serve to validate the novel model as well as to benchmark it against predictions from a HBFM. The first seal withstands a large pressure drop (~ 38 bar) and the shaft speed equals 7.5 krpm. The second seal restricts a small pressure drop (1.6 bar) as the shaft turns at 3.5 krpm. The first seal is typical as a balance piston whereas the second seal is found as a neck-ring seal in an impeller. For the high pressure seal and inlet GVF = 0.1, the flow is mostly homogeneous as the maximum diffusion velocity at the seal exit plane is just ~0.1% of the liquid flow velocity. Thus, both the NHBFM and HBFM predict similar flow fields, leakage (mass flow rate) and drag torque. The difference between the predicted leakage and measurement is less than 5%. The NHBFM direct stiffness (K) agrees with the experimental results and reduces faster with inlet GVF than the HBFM K. Both direct damping (C) and cross-coupled stiffness (k) increase with inlet GVF &lt; 0.1.Compared to the test data, the two models generally under predict C and k by ~ 25%. Both models deliver a whirl frequency ratio (fw) ~ 0.3 for the pure liquid seal, hence closely matching the test data. fw raises to ~0.35 as the GVF approaches 0.1. For the low pressure seal the flow is laminar, the experimental results and both NHBFM and HBFM predict a null direct stiffness (K). At an inlet GVF = 0.2, the NHBFM predicted added mass (M) is ~30 % below the experimental result while the HBFM predicts a null M. C and k predicted by both models are within the uncertainty of the experimental results. For operation with either a pure liquid or a mixture (GVF = 0.2), both models deliver fw = 0.5 and equal to the experimental finding. The comparisons of predictions against experimental data demonstrate the NHBFM offers a marked improvement, in particular for the direct stiffness (K). The predictions reveal the fluid flow maintains the homogeneous character known at the inlet condition.


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