Patent Application
20240384722
The present disclosure generally relates to electric submersible pumps, and more particularly to a stage design for highly viscous applications.
Various types of artificial lift equipment and methods are available, for example, electric submersible pumps (ESPs). An ESP includes multiple centrifugal pump stages mounted in series, each stage including a rotating impeller and a stationary diffuser mounted on a shaft, which is coupled to a motor. In use, the motor rotates the shaft, which in turn rotates the impellers within the diffusers. Well fluid flows into the lowest stage and passes through the first impeller, which centrifuges the fluid radially outward such that the fluid gains energy in the form of velocity. Upon exiting the impeller, the fluid flows into the associated diffuser, where fluid velocity is converted to pressure. As the fluid moves through the pump stages, the fluid incrementally gains pressure until the fluid has sufficient energy to travel to the well surface.
In some configurations, an electric submersible pump stage includes a rotating impeller and a stationary diffuser. The diffuser can include a curved break water area.
The impeller can include a hub, an upper shroud extending from the hub, a lower shroud generally circumferentially surrounding the upper shroud, a plurality of vanes extending between the lower shroud and the hub and/or upper shroud, and a fluid exit defined between downstream ends of the upper shroud and the lower shroud. The curved break water area can be located proximate the fluid exit of the impeller. The diffuser can include a central hub, a balance ring step radially spaced from and radially or circumferentially surrounding the central hub, a lower plate extending between and connecting the balance ring step and the central hub, an outer housing radially spaced from and radially or circumferentially surrounding the balance ring step, and a plurality of blades extending between the outer housing and the balance ring step and/or lower plate. A radially inner surface of the outer housing can include the curved break water area.
The impeller can include a cutback upper shroud and/or cutback lower shroud. A diameter of the upper shroud can be less than an outer diameter of the vanes of the impeller. A diameter of the lower shroud can be less than an outer diameter of the vanes of the impeller.
In some configurations, an electric submersible pump stage includes a stationary diffuser and a rotating impeller. The impeller includes a hub, an upper shroud extending from the hub, a lower shroud generally circumferentially surrounding the upper shroud, a plurality of vanes extending between the lower shroud and the hub and/or upper shroud, and a fluid exit defined between downstream ends of the upper shroud and the lower shroud. The upper shroud and/or lower shroud is reduced or cut back.
A diameter of the upper shroud can be less than an outer diameter of the vanes of the impeller. A diameter of the lower shroud can be less than an outer diameter of the vanes of the impeller.
The diffuser can include a break water area. The diffuser can include a central hub, a balance ring step radially spaced from and radially or circumferentially surrounding the central hub, a lower plate extending between and connecting the balance ring step and the central hub, an outer housing radially spaced from and radially or circumferentially surrounding the balance ring step, and a plurality of blades extending between the outer housing and the balance ring step and/or lower plate. A radially inner surface of the outer housing can include the curved break water area.
In some configurations, an electric submersible pump stage includes a rotating impeller including an inlet and an outlet, and an associated stationary diffuser configured to receive fluid exiting the outlet of the impeller.
The diffuser can include a central hub configured to surround a shaft; a balance ring step radially spaced from and circumferentially surrounding the central hub; a lower plate extending between and connecting the balance ring step and the central hub; an outer housing radially spaced from and circumferentially surrounding the balance ring step; and a plurality of blades extending between the outer housing and the balance ring step and/or lower plate. At least portions of the outer housing, balance ring step, blades, and/or lower plate define a fluid flow path through the diffuser. A radially inner surface of the outer housing includes a region configured to be contacted by the fluid exiting the outlet of the impeller. The region has a curved profile.
The region can be concave from a perspective inside the fluid flow path through the diffuser. The region can curve or bulge radially outward. The region can be located adjacent or proximate the outlet of the impeller.
The impeller can include a hub, an upper shroud extending from the hub, a lower shroud generally circumferentially surrounding the upper shroud, and a plurality of vanes extending between the lower shroud and the hub and/or upper shroud, the outlet defined between downstream ends of the upper shroud and the lower shroud. The upper shroud and/or lower shroud can be reduced or cut back. A diameter of the upper shroud and/or lower shroud can be less than an outer diameter of the vanes of the impeller.
Certain embodiments, features, aspects, and advantages of the disclosure will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It should be understood that the accompanying figures illustrate the various implementations described herein and are not meant to limit the scope of various technologies described herein.
In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the disclosure. These are, of course, merely examples and are not intended to be limiting. However, it will be understood by those of ordinary skill in the art that the system and/or methodology may be practiced without these details and that numerous variations or modifications from the described embodiments are possible. This description is not to be taken in a limiting sense, but rather made merely for the purpose of describing general principles of the implementations. The scope of the described implementations should be ascertained with reference to the issued claims.
As used herein, the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via one or more elements”; and the term “set” is used to mean “one element” or “more than one element”. Further, the terms “couple”, “coupling”, “coupled”, “coupled together”, and “coupled with” are used to mean “directly coupled together” or “coupled together via one or more elements”. As used herein, the terms “up” and “down”; “upper” and “lower”; “top” and “bottom”; and other like terms indicating relative positions to a given point or element are utilized to more clearly describe some elements. Commonly, these terms relate to a reference point at the surface from which drilling operations are initiated as being the top point and the total depth being the lowest point, wherein the well (e.g., wellbore, borehole) is vertical, horizontal or slanted relative to the surface.
Various types of artificial lift equipment and methods are available, for example, electric submersible pumps (ESP). Electric Submersible Pump (ESP) systems are used in a variety of well applications. ESP systems may comprise centrifugal pumps having a plurality of stages with each stage employing a diffuser and an impeller. Referring generally to
In the example illustrated, submersible pumping system 20 is designed for deployment in a well 28 within a geological formation 30 containing desirable production fluids, such as petroleum. A wellbore 32 is drilled into formation 30, and, in at least some applications, is lined with a wellbore casing 34. Perforations 36 are formed through wellbore casing 34 to enable flow of fluids between the surrounding formation 30 and the wellbore 32.
Submersible pumping system 20 is deployed in wellbore 32 by a conveyance system 38 that may have a variety of configurations. For example, conveyance system 38 may comprise tubing 40, such as coiled tubing or production tubing, connected to submersible pump 22 by a connector 42. Power is provided to the at least one submersible motor 24 via a power cable 44. The submersible motor 24, in turn, powers submersible pump 22 which can be used to draw in production fluid through a pump intake 46. In a variety of applications, the submersible pump 22 may comprise a centrifugal pump. Within the submersible centrifugal pump 22, a plurality of impellers is rotated between diffusers to pump or produce the production fluid through, for example, tubing 40 to a desired collection location which may be at a surface 48 of the Earth.
Many types of electric submersible pumping systems and other types of submersible pumping systems can benefit from the features described herein. Additionally, other components may be added to the pumping system 20, and other deployment systems may be used. Depending on the application, the production fluids may be pumped to the collection location through tubing 40 or through the annulus around deployment system 38. The submersible pump or pumps 22 also may utilize different types of stages, such as mixed flow stages or radial flow stages, having various styles of impellers and diffusers.
Referring generally to
Each rotating impeller 54 moves fluid from the upstream diffuser 56 into and through the downstream diffuser 56 and into the next sequential impeller 54 until the fluid is expelled from centrifugal pump 22. By way of example, each rotating impeller 54 may discharge fluid to the adjacent downstream diffuser 56 which routes the fluid into a diffuser bowl for receipt by the next sequential impeller 54. The fluid flow is routed through the sequential stages 50 of the submersible centrifugal pump 22 until the fluid is expelled from the submersible pump 22.
The illustrated bearing assembly also includes an anti-rotation upthrust ring 256 disposed about the bearing sleeve 252. As shown, the anti-rotation upthrust ring 256 can be disposed adjacent an upstream end of the bushing 254. The bearing sleeve 252 is keyed or rotationally coupled to the shaft 58 such that the bearing sleeve 252 rotates with the shaft 58 in use. The anti-rotation upthrust ring 256 prevents or inhibits the bushing 254 from rotating such that the bushing 254 is stationary or rotationally fixed relative to the diffuser 56. The anti-rotation upthrust ring 256 can also help prevent or inhibit axial movement of the bushing 254 and/or the bushing 254 from dropping out of place from the bearing housing 260. In use, the bearing assembly can help absorb thrust and/or accommodate the rotation of the shaft relative to the diffuser.
The impeller 54 includes a central hub 214, surrounding a bore through which the shaft 58 extends, and a skirt 218 radially or circumferentially surrounding a portion of the hub 214. A space between (e.g., radially between) the skirt 218 and hub 214 defines an intake or inlet 201 of the impeller 54 and a portion of a flow path through the impeller 54. Impeller blades or vanes 213 extend radially outward from the hub 214. In the illustrated configuration, the impeller 54 includes an upper plate, disc, or shroud 217 and a lower plate, disc, or shroud 215. The upper shroud 217 extends radially outward from the hub 214. In the illustrated configuration, the upper shroud 217 extends at an angle radially outward and upward or downstream from the hub 214. The lower shroud 215 extends radially outward from the skirt 218. In the illustrated configuration, the lower shroud 215 extends at an angle radially outward and upward or downstream from the skirt 218. The impeller blades 213 can extend between (e.g., axially between) the lower 215 and the upper shroud 217. The illustrated impeller 54 can therefore be considered a shrouded impeller. The hub 214, blades 213, lower shroud 215, and upper shroud 217 define fluid flow paths through the impeller 54. An outlet or exit 203 of the impeller 54 can be formed or defined between, e.g., at least partially radially between, upper or downstream ends of the lower shroud 215 and the upper shroud 217. As shown, the impeller 54 also includes a balance ring 212 extending upwardly or downstream, e.g., extending longitudinally upwardly or downstream along an axis parallel to a longitudinal axis of the shaft 58, from a top or downstream surface of the upper shroud 217.
In some diffusers 56, the bearing housing 260 can form or define a bore through which the shaft 58 extends. Other diffusers 56 include a central hub 234 that surrounds the bore through which the shaft 58 extends, as also shown in
A radially outer surface of the balance ring 212 of a given impeller 54 can contact or be disposed adjacent or facing a radially inner surface of the balance ring step 236 of the next sequential downstream diffuser 56. The balance ring 212 partially defines a balance ring cavity 220 formed radially between the balance ring 212 and the shaft 58, the bearing housing 260, or the central hub 234 of the diffuser 56. A tip clearance or balance ring clearance 211 is formed or defined axially between an uppermost or downstream-most edge or tip 223 of the balance ring 212 and a lower or generally upstream facing surface of the diffuser lower plate 238, as shown in
Conventional mixed flow stage designs for ESPs typically include a “straight” break water area 270, as shown in
The present disclosure provides a diffuser having a curved break water region 270, for example as shown in
The curved break water region 270 advantageously reduces hydraulic loss and improves pressure recovery of the stage. A stage design optimized for high viscosity applications can include a high impeller blade angle and low blade count, for example 4-6 vanes, to maximize head while reducing viscous frictional loss. The viscous fluid discharges from the impeller and enters the diffuser by following the break water 270 curvature of the diffuser. Such a configuration can reduce or minimize total head loss. In some configurations, a stage according to the present disclosure including a curved break water region 270 also includes a cut back shroud and/or hub impeller to further reduce disk frictional losses due to viscous shear on the shroud and/or hub surfaces.
In some configurations, ESP stages optimized for viscous fluids according to the present disclosure include an impeller having a cut back or reduced shroud (lower shroud 215), as shown in
Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and/or within less than 0.01% of the stated amount. As another example, in certain embodiments, the terms “generally parallel” and “substantially parallel” or “generally perpendicular” and “substantially perpendicular” refer to a value, amount, or characteristic that departs from exactly parallel or perpendicular, respectively, by less than or equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, or 0.1 degree.
Although a few embodiments of the disclosure have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments described may be made and still fall within the scope of the disclosure. It should be understood that various features and aspects of the disclosed embodiments can be combined with, or substituted for, one another in order to form varying modes of the embodiments of the disclosure. Thus, it is intended that the scope of the disclosure herein should not be limited by the particular embodiments described above.
The present application claims priority benefit of U.S. Provisional Application No. 63/261,621, filed Sep. 24, 2021, the entirety of which is incorporated by reference herein and should be considered part of this specification.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2022/044518 | 9/23/2022 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63261621 | Sep 2021 | US |
