The present application is a U.S. National Stage patent application of International Patent Application No. PCT/US2018/035437, filed on May 31, 2018, the benefit of which is claimed and the disclosure of which is incorporated herein by reference in its entirety.
The present disclosure relates generally electrical submersible pumping equipment useful in operations related to subterranean wellbores, e.g., for oil and gas exploration, drilling and production. More particularly, embodiments of the disclosure include bearing assemblies for electric submersible pumps that include a support mechanism for reducing operational wear and fretting.
A variety of pumping systems have been employed to lift fluids from subterranean wellbore locations to the surface. One such pumping system is an Electrical Submersible Pump (ESP), which may be supported within the wellbore and submersed in the fluids to be produced. Generally, an ESP includes a pump and a drive motor, which operate together to pressurize the wellbore fluids and pass them through production tubing to the surface. For example, the pump may include an impeller coupled with a stationary diffuser, and the drive motor may rotate the impeller to impart an upward thrust to the wellbore fluid. Often, impeller and diffuser pairs are stacked in stages along a shaft coupled to the drive motor. An ESP may be operational over a span of months or years in a wellbore, causing extended exposure environmental and operational wear. Accordingly, ESP components must be robust and constructed in a manner to manage the expected wear.
The disclosure is described in detail hereinafter, by way of example only, on the basis of examples represented in the accompanying figures, in which:
The present disclosure includes a diffuser subassembly for use, e.g., in wellbore pumps such as downhole submersible pump assemblies or surface installed pump assemblies fluidly coupled to a wellbore. The wellbore pumps may be operable, e.g., to facilitate production of hydrocarbon or other fluids from a geologic formation through the wellbore, and/or to inject water, CO2 or other fluids into the wellbore. The diffuser assembly includes a sleeve therein for supporting a drive shaft in upward, downward and radial directions. The sleeve includes a central flange captured axially between a pair of bushings press-fit into a diffuser body. Axial loads from the drive shaft may be transferred through the central flange of the sleeve to one or the other of the bushings into the diffuser body. The bushings may be keyed to discourage rotational motion with respect to the diffuser body.
An example embodiment of a wellbore ESP system 10 in accordance with some embodiments of the present disclosure is illustrated in
Wellbore 12 is illustrated in a generally vertical orientation. In other embodiments, the wellbore 12 may include portions in alternate deviated orientations such as horizontal, slanted or curved without departing from the scope of the present disclosure. Wellbore 12 optionally includes a casing string 16 therein, which extends generally from the surface location “S” to a selected downhole depth. Portions of the wellbore 12 that do not include casing string 16 may be described as “open hole.”
Various types of downhole hydrocarbon fluids may be pumped to the surface location “S” with ESP 20 deployed in the wellbore 12. The ESP 20 may be a multi-stage centrifugal pump that functions to transfer pressure to the hydrocarbon fluids (and/or other wellbore fluids present) to propel the fluids from to the surface location “S” at a desired pumping rate. ESP 20 may have any suitable size or construction based on the characteristics, e.g., wellbore size, desired pumping rate, etc., of the subterranean operation for which the ESP 20 is employed. The ESP 20 may operate, e.g., by adding kinetic energy to the hydrocarbon fluids via centrifugal force, and convert the kinetic energy to potential energy in the form of pressure using one or more impellers and diffusers as discussed below in greater detail with reference to
The wellbore ESP system 10 includes a motor 22 for driving the one or more impellers in the ESP 20. A drive shaft 24 may operably connect the motor 22 to transmit the rotation of motor 22 to one or more impellers located in ESP 20 and thereby cause the impellers to rotate. The motor 22 may also be coupled by a cable 28 to a controller 30 at the surface location “S,” which may provide instructions to the motor 22 for operating in a particular manner. In other embodiments, a controller may be disposed at a downhole location.
Other various components of wellbore ESP system 10 include an intake 32, seal chamber 34, and sensor package 36. The intake 32 may allow fluid to enter the bottom of ESP 20 and flow to the first stage of the ESP 20. Seal chamber 34 may extend the life of the motor 22 by, e.g., protecting the motor 22 from contamination, and providing pressure equalization between the motor 22 and the wellbore 12.
The motor 22 may operate at high rotational speeds, such as 3,500 revolutions per minute, to thereby drive the rotation of the impellers in the ESP 20. Rotation of the impellers may cause the ESP 20 to pump fluid to the surface location “S.” The sensor package 36 may include one or more sensors used to monitor the operating parameters of the ESP 20 and/or conditions in the wellbore 12, such as the intake pressure, casing annulus pressure, internal motor temperature, pump discharge pressure and temperature, downhole flow rate, or equipment vibration. The sensor package 36 may be communicatively coupled to the controller 30.
As hydrocarbon fluid travels through the ESP 20, the pressure of fluid may generally increase at each stage due to the fluid traveling through the diffuser. The increase in pressure through each stage of the ESP 20 may result in a down-thrust condition. A down-thrust condition may exist when the pressure is higher in a subsequent stage of the ESP 20 in the direction of the fluid flow (referred to as a “higher stage”) than the pressure in a previous stage of the ESP 20 (referred to as a “lower stage”). In some embodiments, a higher stage may be located uphole from a lower stage.
In some circumstances, an up-thrust condition may occur. An up-thrust condition may exist when the inertial forces of the fluid in ESP 20 toward a higher stage of ESP 20 overcome the downthrust force component. As discussed hereinbelow, upthrust and downthrust forces may be accommodated by diffuser assemblies of the present disclosure.
An impeller and diffuser stack 40 within the ESP 20 defines a longitudinal axis A0 as illustrated in
Bearing set 50 and may include a sleeve 56 and a pair of bushings 58 coupled to the diffuser body 46. The bearing set 50 may be constructed of abrasion-resistant components and may include materials such as tungsten carbide, silicon carbide or titanium carbide. Sleeve 56 and impeller 44 may be secured to the drive shaft 24, such as by a key, and may rotate with the drive shaft 24. The diffuser body 46 and the bushings 58 should not rotate about the axis A0. Bushings 58 may be pressed into the diffuser body 46 by interference fit or may be secured to the diffuser body 46 in an alternate manner recognized in the art. Sleeve 56 may include a central flange 84 (see
The sleeve 56 includes a generally cylindrical body portion 80 extending an axial length 81 of the sleeve 56. A bore 82 extends axially through the body portion 80 for receiving the drive shaft 26 (
The bushings 58 define axially facing thrust surfaces 90 thereon. An outer perimeter 92 of the thrust surfaces 90 may engage the rim 72 of the diffuser body 46 when pressed or otherwise assembled into the central bore 70 of the diffuser body 46. The tabs 76 of the bushings extend axially from the thrust surfaces 90 and extend into the circumferential gaps 74 defined in the rim when the bushings 58 are assembled to the diffuser body 46. An inner perimeter 94 of the trust faces 90 may engage the thrust surfaces 88u, 88l of the sleeve 56 in operation to absorb up-thrust and down-thrust forces from the drive shaft 24. The bushings 58 are illustrated as identical components facing opposite axial directions. In other embodiments (see
The lock rings 68 are arranged to be received in corresponding annular grooves 96 defined in the central bore 70 of the diffuser body 46. The lock rings 68 may have a c-shaped or other cross section to provide some flexibility to the lock rings 68 and permit the lock rings to be radially compressed for installation into the grooves 96. After installation, the lock rings 68 may return to their un-compressed configuration to axially retain the bushings 58 therebetween. The lock rings may be constructed of various materials such as stainless steel, carbon steel, inconel, Ni-resist, etc.
In operation, the sleeve 56 with a central flange 84 provides upward and downward thrust protection utilizing just one sleeve. When an up-thrust condition is encountered, the upper thrust surface 88u of the flange 84 may engage the thrust surface 90 of an upper bushing 58. Similarly, when a down-thrust condition is encountered, the lower thrust surface 88l of the flange 84 engages the thrust surface 90 of a lower bushing 58. The thrust surfaces 88u, 88l and 90 are generally flat and normal to the longitudinal axis A0. Thus, thrust loads may be transferred therebetween while the thrust surfaces 88u, 88l and 90 rotate with respect to one another. With the flange 84 disposed generally in the axial center of the sleeve 56, the deflection of the sleeve 56 due to moments about the radial support, e.g., the inner diameter of the rim 72 (see
A single sleeve 56 arranged to absorb both up-thrust forces and down-thrust force may also lower the cost of a diffuser subassembly 64, as compared to a dual sleeve configuration (see
The diffuser subassembly 64 may be pre-assembled in a stable configuration. Since the flange 84 is entrained or captured between the two bushings 58 (even without being coupled to a drive shaft), the sleeve will be maintained within the diffuser body 46 during transport and assembly, thus facilitating assembly of the ESP 20 (
The diffuser subassembly 64 may be constructed by first securing a first one of the bushings 58 to the diffuser body 46. For example, the bushing 58 may be press fit into the bore 70. Next, the sleeve 56 may be placed in the bore 70 such that the upper thrust surface 88u on the sleeve is adjacent to the complementary thrust surface 90 defined on the first bushing 56. Next, the second bushing 58 may be secured within the bore 70 of the diffuser body 46 such that the thrust surface 90 on the second bushing is adjacent the complementary lower thrust surface 88l defined on the sleeve 56 opposite the upper thrust surface 88u to thereby capture the sleeve 56 within the bore of the diffuser body 46. The lock rings 68 may then be optionally secured in the bore on opposite axial sides of the first and second bushings 58 to further secure the sleeve within the bore 70.
With the sleeve 56 captured, the sleeve 56 may be coupled to the drive shaft 24 of an ESP 20 (
Referring now to
Each of the sleeves 102, 104 includes a key-slot 116 therein, which may facilitate rotationally coupling the sleeves 102 to a drive shaft. The drive shaft may then rotate with respect to the diffuser body 106 housing about the longitudinal axis to drive the rotation of an impeller 44 (
The aspects of the disclosure described below are provided to describe a selection of concepts in a simplified form that are described in greater detail above. This section is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
In one aspect, the disclosure is directed a diffuser subassembly for a downhole submersible pump. The diffuser subassembly includes a diffuser body defining a bore extending along a longitudinal axis, the diffuser body including a fluid flow path around the bore arranged to reduce a velocity of a fluid flowing therethrough while increasing a static pressure of the fluid. An upper bushing is pressed into the bore, and defines a first thrust surface on lower surface thereof within the bore. A lower bushing is pressed into the bore, and defines a second thrust surface on an upper surface thereof within the bore. The diffuser assembly also includes a sleeve for receiving a drive shaft. The sleeve defines upper and lower thrust surfaces thereon disposed axially between the first and second thrust surfaces of the upper and lower bushings.
In some example embodiments, the upper and lower thrust surfaces are defined on a flange extending radially from a sleeve body portion. The flange may intersect an axial center of the sleeve body portion.
In one or more embodiments, the diffuser body defines a circumferential rim extending radially into the bore, and at least one gap is defined within the circumferential rim for receiving a tab of at least one of the first and second bushings to prohibit free rotation of the first and second bushings with respect to the diffuser body. The first and second bushings may be pressed into the diffuser body such that a perimeter of at least one of the first or second thrust surfaces engages the circumferential rim.
In some embodiments the diffuser subassembly further includes a pair of lock rings disposed on opposite axial sides of the first and second bushings and engaged with the diffuser body so as to retain the first and second bushings within the diffuser body. In some embodiments, the diffuser body includes a fluid flow passage therein, and the fluid flow passage extends at an oblique angle with respect to the longitudinal axis into the central bore.
According to another aspect, the disclosure is directed to a downhole submersible pump. The submersible pump includes an electrical motor and a drive shaft operably coupled to the electrical motor for selective rotation of the drive shaft about a longitudinal axis. An impeller is coupled to the drive shaft such that rotation of the drive shaft about the longitudinal axis rotates the impeller about the longitudinal axis. A diffuser body is disposed adjacent the impeller, and the diffuser body defines a bore extending along the longitudinal axis and receiving the drive shaft therein. An upper bushing is disposed within the bore, the upper bushing defining a first thrust surface on lower surface thereof within the bore. A lower bushing is disposed within the bore, the lower bushing defining a second thrust surface on an upper surface thereof within the bore. A sleeve receives the drive shaft therein; the sleeve defines upper and lower thrust surfaces thereon disposed axially between the first and second thrust surfaces of the upper and lower bushings.
In one or more exemplary embodiments, the drive shaft is rotationally coupled to the sleeve by a keyed slot defined on at least one of the drive shaft and the sleeve. At least one of the bushings may be rotationally fixed to the diffuser body by a tab defined on one of the diffuser body and the at least one of the bushings extending into a gap defined on the other of the diffuser body and the at least one of the bushings. In some embodiments, the wellbore pump further includes an impeller and diffuser stack including the impeller and diffuser body and at least one additional impeller coupled to the drive shaft and at least one additional diffuser body circumscribing the drive shaft.
In some example embodiments, the sleeve may be axially captured within the bore by the upper and lower bushings. The sleeve may include a central flange extending radially from a sleeve body portion, and the central flange may define the upper and lower thrust surfaces thereon disposed axially between the upper and lower bushings. In one or more embodiments, the upper and lower bushings may be secured in the diffuser body by at least one of an interference fit with the diffuser body and a lock ring disposed on axial sides of the first and second bushings.
According to still another aspect, the disclosure is directed to a method of assembling a downhole submersible pump. The method includes (a) securing a first bushing within a bore of a diffuser body, (b) disposing a sleeve within the bore of the diffuser body such that an upper thrust surface on the sleeve is adjacent to a complementary thrust surface defined on the first bushing, (c) securing a second bushing within the bore of the diffuser body such that a thrust surface on the second bushing is adjacent a complementary lower thrust surface defined on the sleeve opposite the upper thrust surface to thereby capture the sleeve within the bore of the diffuser body, and (d) coupling, after securing the second bushing, the sleeve to a drive shaft of the submersible pump.
In one or more example embodiments, coupling the sleeve to the drive shaft includes rotationally coupling the drive shaft to the sleeve by engaging a key on one of the drive shaft and the sleeve with a keyslot defined on the other of the drive shaft and the sleeve. Securing the first bushing within a bore of a diffuser body may include rotationally coupling the first bushing with the diffuser body by inserting a tab defined on the first bushing with a gap defined within the diffuser body.
In some embodiments, disposing the sleeve within the bore includes aligning a central flange of the sleeve with the thrust surface defined on the first bushing. Securing the second bushing within the bore may include aligning the thrust surface on the second bushing with the central flange of the sleeve to thereby axially capture the central flange between the first and second bushings. Securing the first and second bushings within the bore may include at least one of forming an interference fit between the first and second bushing with the diffuser body and securing a pair of lock rings on opposite axial sides of the first and second bushings.
The Abstract of the disclosure is solely for providing the United States Patent and Trademark Office and the public at large with a way by which to determine quickly from a cursory reading the nature and gist of technical disclosure, and it represents solely one or more examples.
While various examples have been illustrated in detail, the disclosure is not limited to the examples shown. Modifications and adaptations of the above examples may occur to those skilled in the art. Such modifications and adaptations are in the scope of the disclosure.
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/US2018/035437 | 5/31/2018 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2019/231454 | 12/5/2019 | WO | A |
Number | Name | Date | Kind |
---|---|---|---|
4781531 | James | Nov 1988 | A |
20140050570 | Jayaram | Feb 2014 | A1 |
20150159666 | McManus et al. | Jun 2015 | A1 |
20150226219 | Johnson | Aug 2015 | A1 |
20160115998 | Jayaram et al. | Apr 2016 | A1 |
20180291917 | Webster | Oct 2018 | A1 |
Number | Date | Country |
---|---|---|
WO 2015009428 | Jan 2015 | WO |
Entry |
---|
International Search Report and the Written Opinion of the International Search Authority, or the Declaration, dated Feb. 25, 2019, PCT/US2018/035437, 15 pages, ISA/KR. |
Number | Date | Country | |
---|---|---|---|
20210071683 A1 | Mar 2021 | US |