Anti-spin Pump Diffuser Using Asymmetric Interlocking
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Solution Overview
Problem
Downhole electric submersible pumps face inefficiencies due to diffuser spin, which is exacerbated in multi-stage configurations, as existing compression mechanisms are insufficient to counteract centrifugal forces, leading to reduced pump performance.
Innovation Solution
The implementation of a diffuser design featuring a non-circular recess and lip orientation features that interlock to prevent relative rotation between stacked diffusers, utilizing a lip and recess arrangement that can be easily manufactured by casting, thereby maintaining alignment and preventing spin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a compressive device is used to apply axial force to the diffuser, then diffuser spin is reduced, but the effectiveness decreases significantly in multi-stage configurations
Solution Approach 1:
The patent employs asymmetric interlocking features between diffusers, specifically a non-circular recess in one diffuser and a corresponding non-circular lip protrusion in the adjacent diffuser. This asymmetric geometry creates mechanical engagement that prevents relative rotation between stacked diffusers, directly addressing the spin prevention issue while maintaining effectiveness in multi-stage configurations where traditional compressive devices fail.
2Stability of the object's composition
If traditional compressive devices are used to prevent diffuser spin, then some spin resistance is achieved, but the mechanism becomes insufficient in multi-stage arrangements
Solution Approach 1:
The patent merges the spin prevention function directly into the diffuser structural components themselves. The recess and lip features are integrated parts of the diffuser housing, eliminating the need for separate compressive devices or additional anti-spin mechanisms. This integration simplifies the overall device while maintaining stable diffuser alignment across multiple stages.
3Productivity
If diffusers are stacked in multi-stage configurations, then pump capacity is increased, but diffuser spin is exacerbated
Solution Approach 1:
The patent segments the anti-spin function into individual interlocking pairs between adjacent diffusers in the stack. Each diffuser pair independently engages through its recess-lip mechanism, allowing multi-stage configurations to maintain alignment stability regardless of the number of stages. This segmented approach enables increased pump capacity while preventing the cumulative spin effect that plagues traditional multi-stage designs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances pump efficiency by preventing diffuser spin and maintaining alignment, leading to improved hydrocarbon fluid pressure and flow rates, even in multi-stage configurations.
Implementation Method 1
a lip and recess arrangement that can be easily manufactured by casting, thereby maintaining alignment and preventing spin
Implementation Method 2
the centrifugal force of the fluid exiting the impeller may be transferred to the diffuser, causing the diffuser to rotate or 'spin' within the pump housing
Data Source
AI summary
An electric pump may include a stack of diffusers including a first diffuser and a second diffuser. The first diffuser includes a recess therein defining an inner recess surface substantially circumscribing a primary diffuser axis. The second diffuser includes a lip projecting into the recess of the first diffuser. In response to a differential torque applied to the first and second diffusers about the primary diffuser axis, the lip of the second diffuser may engage the inner recess surface of the first diffuser, and thereby prevent relative rotation of the diffusers with respect to one another. An outer perimeter surface of the lip and the inner recess surface may define polygonal shapes or other non-circular profiles.