Not Applicable.
Not Applicable.
This disclosure relates to the field of centrifugal fluid pumps. More specifically, this disclosure relates to centrifugal pumps used to lift fluids from subsurface wells.
Subsurface deployed (“downhole”) multi-stage centrifugal pumps are used in wells drilled through subsurface earthen formations for the purpose of lifting fluids to surface. Such pumps are known to have a selected number of “stages”, that is sections each having an impeller and a diffuser, disposed longitudinally in a housing. The number of such stages is related to the amount of lift required of the particular pump such that it may be operated under efficient conditions. To assemble such pumps, it is known in the art to insert and compress a stack of stages into a pump housing. Due to diameter, design and application restrictions, obtaining the best possible pump performance is challenging with these existing assembly methods. This assembly method also requires the inefficient use of valuable design/flow area, especially for very small diameter pumps such as those sold by Zilift Ltd., Aberdeen, Scotland.
Such known assembly method also requires long and specialized tooling to enable assembly and repair or resizing (changing the number of stages) of a particular pump. The space required for this assembly, repair or resizing is typically a minimum of twice the length of the pump housing or drive shaft.
It is desirable to have a centrifugal pump system that can be readily reconfigured to have a different number of stages, to repair or replace individual stages and assemble the pump without the need for lengthy assembly apparatus.
One aspect of the present disclosure is a well pump. The pump includes a plurality of diffusers, wherein each diffuser comprises a first threaded coupling on one longitudinal end and a second threaded coupling on an opposed longitudinal end. An impeller is disposed in each diffuser. The plurality of diffusers are coupled end to end to form a pump housing, in which the first threaded coupling on one diffuser is threadedly engaged to the second threaded coupling on adjacent diffuser.
The first threaded coupling on one diffuser and the second threaded coupling on another diffuser may form a metal to metal seal when threadedly engaged to each other.
The first threaded couplings may be sealed with an O-ring or similar elastomeric seal, or may be sealed with an elastomer seal and a metal-metal seal.
The well pump may further comprise a drive shaft inserted into the impeller in each diffuser.
The well pump may further comprise a protector coupled to one end of the plurality of diffusers.
The well pump may further comprise a motor coupled to an end of the protector opposed to the end of the protector coupled to the one end of the plurality of diffusers.
The motor may comprise an electric motor.
Each diffuser may comprise a separate diffuser body and diffuser vanes, wherein the diffuser vanes may fit into each diffuser body.
Each impeller may be axially movably attached to a drive shaft. Each impeller and each diffuser may comprise a respective axial thrust face, wherein axial force generated by the impellers may be transferred to the diffusers.
The first threaded coupling may be a male threaded connector and the second threaded coupling may be a female threaded connector.
A method for assembling a well pump according to another aspect of the present disclosure includes disposing an impeller in each of a plurality of diffusers. Each diffuser comprises a first threaded coupling on one longitudinal end and a second threaded coupling on an opposed longitudinal end. The plurality of diffusers is threadedly coupled end to end and the threadedly coupled diffusers are deployed in a well.
The first threaded coupling on one diffuser and the second threaded coupling on another diffuser may form a metal to metal seal when threadedly engaged to each other.
The first threaded coupling on one diffuser may be sealed to the second threaded coupling on another diffuser using an elastomer seal.
The method may further comprise inserting a drive shaft into the impeller in the plurality of diffusers.
The method may further comprise assembling a protector to one end of the plurality of diffusers.
The method may further comprise assembling a monitoring and star point sub and at least one motor to an end of the protector opposed to the end of the protector coupled to the one end of the plurality of diffusers.
The at least one motor may comprise an electric motor.
Each diffuser may comprise a separate diffuser body and diffuser vanes, wherein the diffuser vanes may fit into each diffuser body.
The method may further comprise assembling each impeller axially movably to a drive shaft. Each impeller and each diffuser may comprise a respective axial thrust face, wherein axial force generated by the impellers may be transferred to the diffusers.
The first threaded coupling may be a male threaded connector and the second threaded coupling may be a female threaded connector.
Other aspects and possible advantages will be apparent from the description and claims that follow.
The top sub 12 may be followed successively by one or more motor(s) 13, which in the present example may be electric motor(s) and a “monitoring and star point sub” 14. The “monitoring and star point sub” 14 may include one or more sensors and control devices (not shown separately) related to operation of the ESP system 10 and the motor(s) 13. The monitoring and star point sub 14 may also be positioned above the motor(s) 13 and used to make electrical connection between a cable (not shown) and the motor(s) 13. The motor(s) 13 may be coupled at the lower end thereof to a solid enclosed driveshaft, a flexible shaft, magnetic gearing or any other rotational motion transmission. In the present example, the rotational motion transmission may be a solid driveshaft disposed inside the “monitoring and star point sub” 14 which accepts rotational input from the motor(s) 13, and transmits such rotational motion to the pump 26, which may be a rotary pump. A protector 18, may be similar in operating principle to the protector ordinarily used in ESP systems, and may be configured to exclude well fluids at existing well pressure and temperature from entering the motor(s) 13. Not shown in
The present example of ESP system 10 may be of modular design and deployed in the well as separate subassemblies, or the entire ESP system 10 may be lowered into the well as an assembled unit, e.g., as shown in
In order to better understand the structure of a well pump according to the present disclosure,
While in the present example embodiment, the first threaded coupling is described as a female threaded connector, and the second threaded coupling is described as a male threaded connector. It will be appreciated that it is fully within the scope of the present disclosure for the first threaded coupling to be either male or female thread, and the same applies to the second threaded coupling. If the first and second threaded couplings are both male threaded connectors or are both female threaded connectors, a respective double female or double male connector may be used to connect adjacent diffusers.
In the embodiment of
Such thrust surfaces 42B, 46A may comprise bearing material suitable for transfer of such axial thrust forces. In this way, thrust applied to a thrust bearing (not shown) will be reduced as contrasted with conventional pumps having axially fixed impellers. The example embodiment shown in
Diffuser vanes 46C may be formed as a separate component. The diffuser vanes 46C may be shrink fit or press fit into the diffuser body 46B to assemble a complete diffuser 46, which may be assembled as explained above. The diffuser body 46B may include an integral annular shoulder 52 disposed at an axial offset distance from an axial end 54. The diffuser body 46B may include a tapered annular surface 46 that extends directly from the integral annular shoulder 52 to the axial end 54 of the diffuser body 46B.
A wellbore pump system 10, substantially as explained with reference to
The TEC 70 may be stored on and deployed from a drum, reel or spool forming part of a winch such as a wireline winch 80. The wireline winch 80 may be mounted on a vehicle 78 for on road transportation. In other embodiment the winch 80 may be a “skid” mounted unit for use on offshore well service units. The TEC 70 may be extended into the wellbore 60 through suitably positioned sheave wheels 76 positioned as would ordinarily be used in deployment of wireline wellbore measuring instruments or intervention instruments.
A wireline pressure control head 82 may be coupled to the top of the wellhead 66. The wireline pressure control head 82 may include an hydraulically compressible seal element 84 disposed in a bladder 86. The bladder 86 may be inflated by hydraulic pressure using equipment (not shown) known in the art for such purpose. The seal element 84 may have an internal opening sized to seal on an exterior surface of the TEC 27 to substantially prevent escape of fluid under pressure as the ESP system 10 and the TEC 70 are extended into the wellbore 60 or withdrawn from the wellbore 60. The seal element 84 may also substantially prevent fluid from escaping around the exterior of the TEC 70 during operation of the ESP system 10.
A centrifugal pump made according to the present disclosure herein does not require a separate housing and multiple diffusers, and instead combines the diffusers longitudinally to form an equivalent structure to the housing. The diffusers thread together end to end and seal between each other, isolating the pump discharge from the pump inlet. The pump can be re-staged much quicker as the thrust assembly and discharge does not need to be dismantled. Possible advantages of this design may include one or more of the following.
Improved pump performance (head and/or flow) may result from increased flow/design area with respect to a conventional multiple stage centrifugal pump with the same external diameter. The same length of pump can be used for higher flow rate applications and/or higher head applications.
A well pump made according to the present disclosure may be easier to re-stage for different well applications. The space needed and tooling required to change the number of stages in the pump is greatly reduced, providing possible faster turnaround between each job or between applications. Such feature may be particularly useful for short term well intervention which requires frequent restaging of the centrifugal pump, preferably in the field.
The pump thrust assembly, discharge and connections between subassemblies do not need to be disassembled in order to re-stage a pump, saving time, cost, consumable components and motor oil. This is because the pump can be split and dismantled at any diffuser without having to remove the entire pump stage stack from a housing.
Such a well pump can provide reduced pump weight for the same head and/or flow as a correspondingly sized (outer diameter) pump. A lighter pump aids assembly and handling as well as increasing maximum running depth.
Diffuser casting or 3D-print may be shortened in length considerably, thereby reducing material used, casting/printing complexity, casting/printing cost and time, and final machining cost and time.
The threaded diffuser bodies may be machined from billet or coupling stock to ensure material properties for strength, hardness and chemical resistance etc. The diffuser vanes may be printed/cast and press fit or shrink fit into the diffuser bodies. The machined diffuser bodies are then threaded together end to end to create the required length of assembly and numbers of stages to match application requirements. By avoiding the diffusers being stacked, inserted then compressed inside a separate housing, the pump can be stripped from the inlet end, meaning the thrust and discharge section at the top of the pump can stay in place or be attached to the rest of the assembly during re-stage for quick turnaround well intervention applications. As long, specialized tooling for pump assembly and disassembly of conventional well pumps is not required, re-staging operation can take place in a smaller area and with simple, readily available hand tools such as may be available at a well location. Such make possible re-stage of a well pump at a well location.
In light of the principles and example embodiments described and illustrated herein, it will be recognized that the example embodiments can be modified in arrangement and detail without departing from such principles. The foregoing discussion has focused on specific embodiments, but other configurations are also contemplated. In particular, even though expressions such as in “an embodiment,” or the like are used herein, these phrases are meant to generally reference embodiment possibilities, and are not intended to limit the disclosure to particular embodiment configurations. As used herein, these terms may reference the same or different embodiments that are combinable into other embodiments. As a rule, any embodiment referenced herein is freely combinable with any one or more of the other embodiments referenced herein, and any number of features of different embodiments are combinable with one another, unless indicated otherwise. Although only a few examples have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible within the scope of the described examples. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims.
Continuation of International Application No. PCT/EP2021/051522 filed on Jan. 22, 2021. Priority is claimed from U.S. Provisional Application No. 62/964,811 filed on Jan. 23, 2020. Both the foregoing applications are incorporated herein by reference in their entirety.
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Number | Date | Country | |
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20230012388 A1 | Jan 2023 | US |
Number | Date | Country | |
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62964811 | Jan 2020 | US |
Number | Date | Country | |
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Parent | PCT/EP2021/051522 | Jan 2021 | WO |
Child | 17871361 | US |