Embodiments of the invention described herein pertain to the field of electric submersible pump diffusers. More particularly, but not by way of limitation, one or more embodiments of the invention enable a diffuser anti-rotation system and apparatus.
Fluid, such as gas, oil or water, is often located in underground formations. When pressure within the well is not enough to force fluid out of the well, the fluid must be pumped to the surface so that it can be collected, separated, refined, distributed and/or sold. Centrifugal pumps are typically used in electric submersible pump (ESP) applications for lifting well fluid to the surface. Centrifugal pumps impart energy to a fluid by accelerating the fluid through a rotating impeller paired with a stationary diffuser that sits outward of the impeller. A rotating shaft runs through the central hub of the impeller and diffuser. The pump's motor turns the pump shaft, and the impeller is keyed to the pump shaft, causing the impeller to rotate with the shaft. In multistage centrifugal pumps, multiple impeller and diffuser stages are stacked one above the other around the pump shaft, with each successive diffuser sitting on a diffuser of the previous stage.
A conventional vertical ESP assembly includes, from bottom to top, a motor, seal section, intake section, and multi-stage centrifugal pump. Production tubing carries the pumped fluid from the centrifugal pump to the well's surface. The assembly components each have a shaft running longitudinally through their centers that are connected and rotated by the motor. In gassy wells, a gas separator or charge pump may also be included in the assembly, typically between the intake and the pump, or in place of the intake. For example, a gas separator may act as the intake of the assembly. In such instances, the gas separator compresses the gaseous fluid and then attempts to separate any unsaturated gas before the fluid passes into the centrifugal pump. Gas separators sometimes include impeller and diffuser stages to increase the pressure of the fluid during compression and separation of gases. Similarly, charge pumps are also sometimes used in tandem with a primary centrifugal pump in gassy wells, and may also employ stages.
Conventional diffusers have an overlapping locating-feature to allow for stacking of the diffusers. The overlapping feature consists of a female and male register that mate together. The female register is located around the circumference of one end of a diffuser and fits around the male register on the opposing end of the adjacent diffuser.
Diffusers in multi-stage centrifugal pumps should not rotate. If the diffusers spin, the ESP pump loses its pressure lift and fails to produce fluid to the surface of a well. A problem that arises in high temperature or gassy wells, is that thermal expansion within the pump assembly can result in lost compression on the diffuser stack, allowing for diffuser spin. For example, in gassy wells, less cooling fluid passes through the pump, causing the pump to run hotter than wells with more liquid. In another example, steam assisted gravity drainage (SAGD) wells operate with injected steam raising the well temperature to temperatures of up to 550° F. (287.8° C.). In general, ESP pump assemblies operating above 300° F. may experience production problems resulting from diffuser spin.
To date, some attempts have been made to mechanically lock diffusers together in a stack in order to prevent spin. However, these mechanical lock attempts suffer from the drawback of creating complicated casting geometries or difficult machining operations that are costly and impractical to implement.
As is apparent from the above, current approaches to prevent diffuser rotation in ESP stages are inadequate. Therefore, there is a need for an improved diffuser anti-rotation system and apparatus.
One or more embodiments of the invention relate generally to a diffuser anti-rotation system and apparatus.
A diffuser anti-rotation system and apparatus is described. An illustrative embodiment of a centrifugal pump includes at least two diffusers including a first diffuser and a second diffuser, the first diffuser adjacent the second diffuser, each of the first diffuser and the second diffuser including a first end including a plurality of male register tabs dispersed around the first end, and a second end including a plurality of female register slots dispersed around the second end, a coupling ring extending circumferentially between the first diffuser and the second diffuser, the coupling ring including a plurality of projections, each projection of the plurality of projections mated around one of the male register tabs of the first diffuser, and inside one of the female register slots of the second diffuser. In some embodiments, the centrifugal pump further includes a first impeller rotating with a shaft of the centrifugal pump inside the first diffuser, and a second impeller rotating with the shaft of the centrifugal pump inside the second diffuser. In certain embodiments, the coupling ring interlocks the first diffuser and the second diffuser against rotation. In some embodiments, the coupling ring is configured to prevent rotation of the first diffuser with respect to the second diffuser. In certain embodiments, a radially extending portion of each projection of the coupling ring abuts a wall of the one of the male register tabs on a first side of the radially extending portion, and abuts a wall of the one of the female register slots on a second side of the radially extending portion. In some embodiments, each projection includes an arch, and an intrados of the arch surrounds the male register tab of the first diffuser, and an extrados of the arch is flush with and follows an outer diameter of the first diffuser. In certain embodiments, the coupling ring seats around a circumference of a rim of one of the first diffuser or the second diffuser. In some embodiments, the at least two diffusers are compressed in a stack. In certain embodiments, there are two male register tabs in the plurality of male register tabs spaced 180° apart, two female register slots in the plurality of female register slots and two protrusions in the plurality of protrusions. In some embodiments, each male register tab is axially aligned with a female register slot.
An illustrative embodiment of a diffuser anti-rotation system includes a circumferential coupling ring interlocked between a top of a first diffuser and a bottom of an adjacent diffuser. In some embodiments, the top of the first diffuser includes at least one male register tab, the bottom of the adjacent diffuser has at least one female register slot, and the coupling ring interlocks with the at least one male register tab and the at least one female register slot. In certain embodiments, one of the at least one male register tabs and one of the at least one female register slots are aligned axially and one projection from the coupling ring interlocks with both the one of the at least one male register tabs and the axially aligned one of the at least one female register slots. In some embodiments, the one projection mates around the one of the at least one male register tabs and inside the one of the at least one female register slots. In certain embodiments, the diffuser anti-rotation system further includes a first impeller mated with and rotating within the first diffuser, and a second impeller mated with and rotating within the adjacent diffuser. In some embodiments, the interlocked coupling ring is configured to prevent rotation of the first diffuser with respect to the adjacent diffuser. In certain embodiments, the diffusers with mated impellers form a multi-stage centrifugal pump. In some embodiments, the diffuser anti-rotation system further includes a plurality of first diffusers and a plurality of adjacent diffusers forming a diffuser stack compressed by a centralizer bearing. In some embodiments, the bottom of the first diffuser includes at least one male register tab, the top of the adjacent diffuser has at least one female register slot, and the coupling ring interlocks with the at least one male register tab and the at least one female register slot.
In further embodiments, features from specific embodiments may be combined with features from other embodiments. For example, features from one embodiment may be combined with features from any of the other embodiments. In further embodiments, additional features may be added to the specific embodiments described herein.
Advantages of the present invention may become apparent to those skilled in the art with the benefit of the following detailed description and upon reference to the accompanying drawings in which:
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and may herein be described in detail. The drawings may not be to scale. It should be understood, however, that the embodiments described herein and shown in the drawings are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the scope of the present invention as defined by the appended claims.
A diffuser anti-rotation system and apparatus are described. In the following exemplary description, numerous specific details are set forth in order to provide a more thorough understanding of embodiments of the invention. It will be apparent, however, to an artisan of ordinary skill that the present invention may be practiced without incorporating all aspects of the specific details described herein. In other instances, specific features, quantities, or measurements well known to those of ordinary skill in the art have not been described in detail so as not to obscure the invention. Readers should note that although examples of the invention are set forth herein, the claims, and the full scope of any equivalents, are what define the metes and bounds of the invention.
As used in this specification and the appended claims, the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a tab includes one or more tabs.
“Coupled” refers to either a direct connection or an indirect connection (e.g., at least one intervening connection) between one or more objects or components. The phrase “directly attached” means a direct connection between objects or components.
As used herein, the term “outer,” “outside” or “outward” means the radial direction away from the center of the shaft of the electric submersible pump (ESP) assembly element and/or the opening of a component through which the shaft would extend. In the art, “outer diameter” and “outer circumference” are sometimes used equivalently. As used herein, the outer diameter is used to describe what might otherwise be called the outer circumference or outer surface of a pump component such as a diffuser.
As used herein, the term “inner”, “inside” or “inward” means the radial direction toward the center of the shaft of the ESP assembly element and/or the opening of a component through which the shaft would extend. In the art, “inner diameter” and “inner circumference” are sometimes used equivalently. As used herein, the inner diameter is used to describe what might otherwise be called the inner circumference or inner surface of a pump component, such as a coupling ring.
As used herein the terms “axial”, “axially”, “longitudinal” and “longitudinally” refer interchangeably to the direction extending along the length of the shaft of an ESP assembly component such as a multi-stage centrifugal pump, seal section, gas separator or charge pump.
“Downstream” refers to the longitudinal direction through a well substantially with the principal flow of lifted fluid when the pump assembly is in operation. By way of example but not limitation, in a vertical downhole ESP assembly, the downstream direction may be towards the surface of the well. The “top” of a component refers to the downstream-most side of the component. In that vein, a first diffuser that is “above” a second diffuser refers to the first diffuser being downstream of the second diffuser.
“Upstream” refers to the longitudinal direction through a well substantially opposite the principal flow of working fluid when the pump assembly is in operation. By way of example but not limitation, in a vertical downhole ESP assembly, the upstream direction may be opposite the surface of the well. The “bottom” of a component refers to the upstream-most side of the component. In that vein, a first diffuser that is “below” a second diffuser refers to the first diffuser being upstream of the second diffuser.
Illustrative embodiments of the invention described herein may prevent rotation of diffusers in ESP assembly stages, despite operation in gassy and/or high temperature wells that may reach up to 550° F. (287.8° C.). Illustrative embodiments may provide the advantage of a mechanical lock against diffuser spin that does not require complicated casting geometries or complex machining operations, thereby reducing the cost and feasibility of implementing the system of illustrative embodiments.
Illustrative embodiments include a diffuser coupling ring that may provide a mechanical lock between adjacent diffusers in a diffuser stack. The diffuser stack may be employed in stages in a centrifugal pump, gas separator or charge pump of an ESP assembly. One end of a diffuser, either the top or the bottom, may include male register tabs, while the opposing end may include female register slots. The diffuser coupling ring may include projections that interlock with both the male register tabs of a first diffuser and the female register slots of an adjacent diffuser. The interlocked coupling ring may prevent rotation of the diffusers despite high temperature conditions and fast-rotating impellers mated within the diffusers, such as impellers rotating at 3,500 revolutions per minute (rpm).
A coupling and/or lock ring may interlock between adjacent diffusers 200 in a diffuser stack, in between: a first side 300 of a first diffuser 200 with male register tabs 310, and a second side 305 of a second diffuser 200 with female register slots 315. For example, coupling ring 400 may interlock between a bottom of a first diffuser and the top of the diffuser of the previous stage.
Each projection 405 may include radially extending portion 430 that includes radially extending inside surface 420 and radially extending outside surface 425. Radially extending inside surface 420 of projection 405 may abut tab wall 325. A slight clearance may extend between radially extending inside surface 420 of projection 405 and tab wall 325, which slight clearance may close should diffuser 200 attempt to rotate. Radially extending outside surface 425 of projection 405 may abut slot wall 330. A slight clearance may extend between radially extending outside surface 425 of projection 405 and slot wall 330, which slight clearance may close should diffuser 200 attempt to rotate. In an exemplary embodiment, the slight clearance may be about 0.01 cm, 0.023 cm or 0.025 cm on each side of projection 405, between slot wall 330 and radially extending outside surface 425, for example. Abutment between radially extending inside surface 420 and/or radially extending outside surface 425 of projection 405 on the one hand, and slot wall 330 and/or tab wall 325 on the other hand may prevent rotation of diffuser 200 with respect to an adjacent diffuser 200, should one of the interlocked diffusers 200 attempt to rotate.
Illustrative embodiments may provide a mechanical anti-rotation lock between adjacent diffusers in a diffuser stack, preventing or reducing the likelihood of diffuser spin. Illustrative embodiments may be implemented without the need for casting complicated diffuser shapes and/or with only simple machining. Illustrative embodiments may increase the productivity of ESP assemblies operating within high temperature and/or gassy wells, such as for example SAGD wells.
A diffuser anti-rotation system and apparatus is described. Further modifications and alternative embodiments of various aspects of the invention may be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the invention. It is to be understood that the forms of the invention shown and described herein are to be taken as the presently preferred embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features of the invention may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description of the invention. Changes may be made in the elements described herein without departing from the scope and range of equivalents as described in the following claims. In addition, it is to be understood that features described herein independently may, in certain embodiments, be combined.
Filing Document | Filing Date | Country | Kind |
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PCT/US2018/017443 | 2/8/2018 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
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WO2018/148423 | 8/16/2018 | WO | A |
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