This application is a U.S. National Stage Application of International Application No. PCT/US2014/052695 filed Aug. 26, 2014, which designates the United States, and which is incorporated herein by reference in its entirety.
The present disclosure relates generally to well drilling and hydrocarbon recovery operations and, more particularly, to a thrust washer and a diffuser for use in a downhole electrical submersible pump.
Hydrocarbons, such as oil and gas, are commonly obtained from subterranean formations that may be located onshore or offshore. The development of subterranean operations and the processes involved in removing hydrocarbons from a subterranean formation typically involve a number of different steps such as drilling a wellbore at a desired well site, treating the wellbore to optimize production of hydrocarbons, performing the necessary steps to produce the hydrocarbons from the subterranean formation, and pumping the hydrocarbons to the surface of the earth.
When performing subterranean operations, electrical submersible pumps (ESPs) may be used when reservoir pressure alone is insufficient to produce hydrocarbons from a well. ESPs may be installed on the end of a tubing string and inserted into a completed wellbore below the level of the hydrocarbon reservoir. An ESP may employ a centrifugal pump driven by an electric motor to draw reservoir fluids into the pump and to the surface.
For a more complete understanding of the present disclosure and its features and advantages, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:
The present disclosure describes a thrust washer and diffuser for use in a downhole electrical submersible pump (ESP). Modern petroleum production operations use ESPs to pump hydrocarbons from a reservoir to the well surface when the pressure in the reservoir is insufficient to force the hydrocarbons to the well surface. An ESP may include one or more stages, each stage containing an impeller and a diffuser. The impeller and diffuser combinations may increase the velocity and pressure of the hydrocarbon fluid as the fluid travels through the stages of the ESP. The impeller may accelerate the fluid to increase the velocity and kinetic energy of the fluid. The diffuser may transform the kinetic energy of the fluid into potential energy by increasing the pressure of the fluid. In some embodiments, the ESP may be designed such that the impeller and the diffuser are not in contact during normal operating conditions. However at times, such when the actual flow rate is higher than the designed flow rate, the impeller may contact the diffuser located above the impeller. In other embodiments, the impeller may be designed to be in contact with a diffuser during normal operation. To avoid direct contact between the impeller and the diffuser, the ESP may include a thrust washer located between the impeller and the diffuser to prevent wear on the impeller or the diffuser caused by direct contact between the components. The thrust washer may be designed to have a large surface area, covering a majority of the contact area between the impeller and the diffuser, to distribute the frictional forces caused by the impeller and/or diffuser and reduce the wear of the thrust washer. Additionally, the thrust washer and the diffuser may be designed to create a seal to increase the pressure of fluid, such as oil or water, as the fluid travels through the diffuser. The pressure increase may return an impeller to a normal operating position where the impeller is not in contact with the diffuser. The use of a thrust washer designed in accordance with the present disclosure may allow an operating envelope of the ESP to increase. For example, the operating envelope of the ESP may increase from a maximum operating range of approximately 1000 barrels per day to a maximum operating range of approximately 1200 barrels per day. The maximum operating range increase may be caused by the ability of the ESP to maintain normal operating conditions. Embodiments of the present disclosure and its advantages are best understood by referring to
Subterranean operations system 100 may include wellbore 104. “Uphole” may be used to refer to a portion of wellbore 104 that is closer to well surface 102 and “downhole” may be used to refer to a portion of wellbore 104 that is further from well surface 102. Wellbore 104 may be defined in part by casing string 106 that may extend from well surface 102 to a selected downhole location. Portions of wellbore 104 that do not include casing string 106 may be described as “open hole.”
Various types of hydrocarbons may be pumped from wellbore 104 to well surface 102 through the use of ESP 108. ESP 108 may be a multistage centrifugal pump and may function to transfer pressure to the hydrocarbon fluid and/or another type of liquid to propel the fluid from a reservoir to well surface 102 at a desired pumping rate. ESP 108 may transfer pressure to the fluid by adding kinetic energy to the fluid via centrifugal force and converting the kinetic energy to potential energy in the form of pressure. ESP 108 may have any suitable diameter based on the characteristics of the subterranean operation, such as the wellbore size and the desired pumping flow rate. ESP 108 may include one or more pump stages, depending on the pressure and flow requirements of the particular subterranean operation. Each stage of ESP 108 may include one or more impellers and diffusers as discussed in further detail with respect to
Shaft 110 may connect the various components of ESP 108 to other components of the subterranean operation such as intake 112, seal chamber 114, motor 116, and sensor 118. Shaft 110 may have a power cable (not expressly shown) connecting motor 116 to controller 120 at well surface 102. Shaft 110 may transmit the rotation of motor 116 to one or more impellers located in ESP 108 and cause the impellers to rotate, as discussed further with reference to
Intake 112 may allow fluid to enter the bottom of ESP 108 and flow to the first stage of ESP 108. Seal chamber 114 may extend the life of the motor by, for example, absorbing axial thrust produced by ESP 108, dissipating heat created by the thrust produced by ESP 108, protecting oil for motor 116 from contamination, and providing pressure equalization between motor 116 and wellbore 104.
Motor 116 may operate at high rotational speeds, such as 3,500 revolutions per minute and the rotation of motor 116 may cause shaft 110 to rotate. The rotation of shaft 110 may rotate the impellers inside ESP 108 and may cause ESP 108 to pump fluid to well surface 102. Sensor 118 may include one or more sensors used to monitor the operating parameters of ESP 108 and/or conditions in wellbore 104, such as the intake pressure, casing annulus pressure, internal motor temperature, pump discharge pressure and temperature, downhole flow rate, or equipment vibration.
As hydrocarbon fluid travels through ESP 108, 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 ESP 108 results in ESP 108 operating under, and being designed for, downthrust conditions. A downthrust condition may exist when the pressure is higher in a subsequent stage of ESP 108 in the direction of the fluid flow (referred to as a “higher stage”) than the pressure in a previous stage of ESP 108 (referred to as a “lower stage”). In some embodiments, a higher stage may be uphole from a lower stage. ESP 108 may contain thrust bearings (not expressly shown) to support the force exerted on the lower stages during downthrust conditions. However, in some circumstances, an upthrust condition may occur. An upthrust condition may exist when the inertial forces of the fluid in ESP 108 toward a higher stage of ESP 108 overcome the downthrust force component. The upthrust condition may force an impeller against a diffuser and may cause damage to the diffuser and/or impeller because ESP 108 may not be designed to endure upthrust conditions and may not have sufficient bearings to support the frictional forces on the components of ESP 108 during upthrust conditions. While ESP 108 may include thrust bearings to reduce friction between the moving components of ESP 108 during downthrust conditions, the thrust bearings may not engage during upthrust conditions and may not reduce friction between the impeller and the diffuser. Additionally, the upthrust condition may cause the impeller and the diffuser to be in direct contact, where the contact may cause abrasive wear as the impeller spins against the diffuser. Therefore, one or more thrust washers may be affixed to the impeller to prevent direct, metal-to-metal contact between the impeller and the diffuser.
Shaft 204 may be used to transfer rotational energy from a motor, such as motor 116 shown in
As the fluid exits impeller 206, the fluid may enter diffuser 208. Diffuser 208 may convert the kinetic energy of the fluid into potential energy by gradually slowing the fluid, which increases the pressure of the fluid according to Bernoulli's principle. The increased pressure of the fluid causes the fluid to rise to the well surface, such as well surface 102 shown in
After traveling through the stages of ESP 200, the fluid may exit ESP at discharge head 212. In some embodiments, discharge head 212 may be connected to production tubing which may be used to direct the flow of fluid from the wellbore to the well surface. Housing 210 may surround the components of ESP 200 and may align the components of ESP 200.
In some embodiments, there may be open space, or “float space,” between impeller 206 and diffuser 208, located above impeller 206. ESP 200 may be designed to operate in a downthrust condition, where the pressure of the fluid in a higher (e.g., uphole) stage of ESP 200 is higher than the pressure of the fluid in a lower (e.g., downhole) stage of ESP 200. In downthrust conditions, impeller 206 and diffuser 208 are not in contact. However, in some circumstances, ESP 200 may experience an upthrust condition when the inertial forces of the fluid in ESP 200 toward a higher stage of ESP 200 overcome the downthrust force component. During an upthrust condition, impeller 206 may rise up into the float space and come in contact with diffuser 208. Upthrust conditions may be damaging to impeller 206 and diffuser 208 due to the friction caused by the direct contact between impeller 206 and diffuser 208. The frictional wear may decrease the lifespan of impeller 206 and/or diffuser 208.
To prevent damage to impeller 206 and/or diffuser 208 during an upthrust condition, one or more thrust washers (as shown in
Some subterranean operations, the pump may have a larger flow rate than the designed flow rate, which may create an undesirable upthrust condition. Therefore, balance holes 310 may provide pressure balance between the stages of the pump by allowing the fluid to escape the pump stage. While impeller 300 is shown in
Thrust washer 306 may be attached to impeller 300 via a press fit that fastens impeller 300 and thrust washer 306 together through friction between impeller 300 and thrust washer 306. For example, thrust washer component 306a may be pressed against balance ring 304 and thrust washer component 306b may be pressed against hub 302.
In some embodiments, thrust washer 306 may include a phenolic resin. In other embodiments, thrust washer 306 may include a hard, anti-abrasive material, such as a ceramic, a carbide, a composite material, or a composite material embedded with a lubricant. In embodiments where thrust washer 306 includes a hard, anti-abrasive material, the thrust washer may be capable of enduring a greater amount of frictional force than a thrust washer including a phenolic resin.
The dimensions of thrust washer 306 may be bound by various features of impeller 300. For example, an outer diameter of thrust washer 306 may be less than or equal to the inner diameter of the balance ring and an inner diameter of thrust washer 306 may be greater than or equal to the outer diameter of hub 302. In addition, thrust washer 306 may be formed to allow fluid and/or gas to flow through balance holes 310. For example, in the embodiment illustrated in
In another embodiment, the thrust washer may be a single component.
Impeller 410 may rotate about a shaft of the ESP. In some situations, thrust washer 400 may rotate at a rotational speed different from impeller 410. The difference in the rotational speed of thrust washer 400 and impeller 410 may cause thrust washer 400 to wear at the points where thrust washer 400 is in contact with impeller 410 which may cause thrust washer 400 to have a shorter lifespan. Thrust washer 400 may include anti-rotational pegs 404 which may be inserted into anti-rotational notches 414 on impeller 410. Anti-rotational pegs 404 may prevent thrust washer 400 from rotating relative to impeller 410 and may extend the lifespan of thrust washer 400. While thrust washer 400 is shown as a single component thrust washer, a thrust washer 400 with more than one component may also include anti-rotational pegs 404 on each component of thrust washer 400 to prevent relative rotation between the thrust washer component and impeller 410.
Surface 608 of diffuser 600 may contact a thrust washer, such as thrust washer 306 shown in
Area=π(R12−R22)
where
The inner radius of surface 608 may be defined based on the outer diameter of the impeller shaft hub, such as hub 302 shown in
Surface 608 may create a seal with the thrust washer that increases the pressure through diffuser 600 and creates a downward force on the impeller. The increased pressure may assist with returning the pump to downthrust conditions more quickly than a surface that does not create a seal with the thrust washer.
As discussed with reference to
During a downthrust condition, impeller 300 may be spaced away from diffuser 600 creating a float space. However, during an upthrust condition, impeller 300 may be forced up into the float space and may be in contact with diffuser 600, as shown in
The thickness of thrust washer 306 may be determined based on the amount of float space between impeller 300 and diffuser 600 and the proportions of impeller 300. For example, the amount of float space may be between approximately 0.1-inches and approximately 0.25-inches and may vary based on the size of impeller 300. In some embodiments, thrust washer 306 may have a thickness of approximately twenty percent of the float distance between impeller 300 and diffuser 600. In other embodiments, thrust washer 306 may have varying thicknesses across its diameter. For example, in some embodiments component 306b may be thicker than component 306a to provide the initial contact with diffuser 600. In other embodiments, component 306a may be thicker than component 306b. When component 306b provides initial contact with diffuser 600, component 306b may wear a greater amount than component 306a due to the greater frictional forces on component 306b during the initial contact. As component 306b wears and becomes thinner, components 306a and 306b may contact diffuser 600 simultaneously when components 306a and 306b are approximately the same thickness. In an embodiment where thrust washer 306 is a single component, thrust washer 306 may have varying thicknesses across its diameter and the thicker areas of thrust washer 306 may provide initial contact with diffuser 600.
In some embodiments, thrust washer component 306a may be affixed to impeller 300 on surface 308a and thrust washer component 306b may be affixed to impeller 300 on surface 308b. Balance ring 304 may also be affixed to impeller 30 on surface 308b. Surface 308b may be further from the main body of impeller 300 than surface 308a and thrust washer component 306b may sit further away from the main body of impeller 300 than thrust washer component 306a. Thrust washer component 306b may contact diffuser 600 before thrust washer component 306a and thrust washer component 306b may absorb more of the initial force of the upthrust condition. Therefore, thrust washer component 306b may wear more quickly than thrust washer component 306a for a period of time and extend the life of thrust washer component 306a. When thrust washer component 306b wears to a thickness where thrust washer component 306b is the same distance from the main body of impeller 300 as thrust washer component 306a, both components 306a and 306b may contact diffuser 600 virtually simultaneously and may wear at a similar rate.
During an upthrust condition, when impeller 300 is in contact with diffuser 600, thrust washer 306 may contact diffuser 600 at surface 608. Impeller 300 may continue to rotate while diffuser 600 is stationary. The rotation of impeller 300 may cause thrust washer 306 to wear at the points where thrust washer 306 is in contact with the stationary diffuser. In some situations, thrust washer 306 may rotate at a rotational speed different from impeller 300 due to the friction between thrust washer 306 and the diffuser. The difference in the rotational speed of thrust washer 306 and impeller 300 may cause thrust washer 306 to wear at the points where thrust washer 306 is in contact with impeller 300. When thrust washer 306 wears from both sides (the side in contact with the diffuser and the side in contact with impeller 300), thrust washer 306 may have a shorter lifespan. Therefore, thrust washer 306 may have anti-rotational features, such as anti-rotational pegs 404 and anti-rotational notches 414 shown in
Embodiments disclosed herein include:
A. A multi-stage electrical submersible pump that includes a shaft, a motor communicatively coupled to the shaft and operable to rotate the shaft, an intake operable to direct fluid flow into the multi-stage electrical submersible pump, an impeller coupled to the shaft including a balance ring, a balance hole, and a hub, a diffuser disposed adjacent to the impeller, a thrust washer coupled to the impeller located between the balance ring and the hub without blocking the balance hole to allow fluid flow through the impeller and the diffuser, and a discharge operable to direct fluid flow out of the multi-stage electrical submersible pump.
B. A system for distributing force in a multi-stage pump stack that includes a shaft, an impeller coupled to the shaft including a balance ring, a balance hole, and a hub, a diffuser disposed adjacent to the impeller, and a thrust washer coupled to the impeller. The thrust washer is located between the balance ring and the hub without blocking the balance hole to allow fluid flow through the impeller and the diffuser.
C. An impeller in a multi-stage pump stack, the impeller that includes a surface, a balance ring attached on the surface, a hub located in the center of the impeller and aligned with an axis of rotation of the impeller, a balance hole cut into the surface between the balance ring and the hub, and a thrust washer affixed to the impeller on the surface and located between the balance ring and the hub without blocking the balance hole to allow fluid flow through the impeller.
Each of embodiments A, B, and C may have one or more of the following additional elements in any combination: Element 1: wherein the diffuser includes a thrust washer contact surface having a surface area greater than a surface area of a portion of the diffuser that connects the surface to the diffuser. Element 2: wherein the thrust washer includes at least two concentric thrust washer components. Element 3: wherein a height of at least one of the at least two concentric thrust washer components is different from a height of another of the at least two concentric thrust washer components. Element 4: further comprising an anti-rotational notch in the impeller and an anti-rotational peg affixed to the thrust washer where the anti-rotational peg inserted in the anti-rotational notch. Element 5: wherein the balance ring includes a groove in which the thrust washer is inserted. Element 6: wherein the thickness of the thrust washer is variable across the diameter of the thrust washer. Element 7: wherein the thrust washer prevents direct contact between the impeller and the diffuser. Element 8: wherein the thrust washer includes a hard, anti-abrasive material and a surface of the diffuser where the diffuser contacts the thrust washer is coated with a hard, anti-abrasive material.
Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the following claims. For example, while the embodiment discussed describes a thrust washer made of two components, the thrust washer may be made of any number of components. Additionally the thrust washer may be made of any suitable material having sufficient bearing function to lubricate and prevent heat build-up.
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PCT/US2014/052695 | 8/26/2014 | WO | 00 |
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WO2016/032439 | 3/3/2016 | WO | A |
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