Electrical submersible pump and pump system including additively manufactured structures and method of manufacture

Abstract

An electric submersible pump and pump system including additively manufactures structures and method of manufacture are disclosed. The pump system including the electric submersible pump and an electric motor configured to operate the electric submersible pump. The electric submersible pump including a housing, at least one impeller and at least one diffuser disposed within the housing in cooperative engagement. The housing, the at least one impeller, and the at least one diffuser defining an internal volume configured to receive a fluid. At least one of the at least one impeller and the at least one diffuser configured as a monolithic additively manufactured structure comprised of a metal matrix composite. Also provided is an electric submersible pump including an impeller and a diffuser, wherein at least one of the impeller and the diffuser is configured as a monolithic additively manufactured structure comprised of a tungsten carbide (WC) dispersed in a metal matrix.

Description

BACKGROUND[0001]The present disclosure relates to electric submersible pumps. More particularly, the present disclosure relates to electric submersible pumps configured to provide improved contaminant tolerance and resulting increase in life span of the pump and pump components.[0002]Electric submersible pump systems are used in a wide variety of environments, including wellbore applications for pumping production fluids, such as water or petroleum. Electric submersible pump systems typically include, among other components, a submersible pump that provides for the pumping of high volumes of fluid, such as for use in oil wells which produce large quantities of water, or high volume water wells and a submersible motor for operating the electric submersible pump.[0003]A typical electric submersible pump utilizes numerous stages of diffusers and impellers, referred to as pump stages, for pumping fluid to the surface from the well. During operation, the impellers are configured to rotat...

AI Technical Summary

Benefits of technology

The present disclosure provides an electric submersible pump, system, and method of manufacturing that addresses shortcomings of the prior art. Specifically, the invention includes a housing, at least one impeller, and at least one diffuser, which are all made of a metal matrix composite to provide enhanced strength and durability. The impeller and diffuser are designed as a single monolithic structure that reduces costs and complexity, while also improving performance and efficiency of the electric submersible pump. The method of manufacturing involves direct metal laser sintering, which allows for the creation of highly precise and durable structures through a layer-by-layer process. The invention overcomes limitations of current manufacturing techniques and provides a better solution for submersible pumps in high-performance applications.

Problems solved by technology

If a fluid being pumped contains a significant amount of contaminants, and more particularly entrained abrasive contaminants, such as sand, the abrasive particles will abrade and / or erode the components, and in particular the pump impellers and diffusers, and thereby shortening the life of the pump.

However, inclusion of these coating and or wear resistant components is considerably more expensive than conventional pump stage components.

If contaminants have abraded the pump components severely, the pump may potentially have to be removed earlier than the usual life.

The cost for removing an electric submersible pump, including lost production time, can be quite expensive, particularly with regard to wells not easily accessible, such as offshore drilling wells.

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