Cutter Disk Stator for Solids Handling in Progressing Cavity Pumps

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Solution Overview

Problem

Progressing cavity pumps and power sections lack mechanisms to break up solids that can become jammed or block nozzles, leading to costly downtime in drilling operations.

Innovation Solution

Incorporating cutting surfaces within stators made of multiple cutter disks at the inlet and outlet of progressing cavity pumps and power sections to break up solids into smaller pieces, allowing them to pass through without jamming or plugging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a progressing cavity pump handles fluids containing large solids, then the pump can pass highly viscous fluids and solids, but the solids can get jammed between the rotor and stator causing the pump to lock up

Engineering Contradiction:

Improveability to handle fluids containing solidsVSAvoidpump lock-up prevention

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The stator is segmented into multiple modular sections (first stator section, second stator section, third stator section) that can be independently assembled and replaced. This segmentation allows the pump to handle solids more effectively while maintaining reliability through modular replacement of worn or damaged sections.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cutter disks are positioned at the inlet of the pump to preliminarily break up large solids before they enter the pumping cavity. This preliminary action prevents solids from becoming jammed between the rotor and stator, thereby preventing pump lock-up and maintaining continuous operation.

Inventive Principle:

Principle #10Preliminary action

2Ease of operation

If power section stator is made of rubber, then it can flex to accommodate rotor motion, but the rubber chunks break off due to fatigue and plug the drill bit nozzles

Engineering Contradiction:

Improveflexibility for rotor motionVSAvoidrubber chunking and nozzle plugging

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The cutter disks are extracted as separate removable components from the stator assembly. These cutter disks can be independently removed, replaced, or sharpened without replacing the entire rubber stator, thereby eliminating the harmful effect of rubber chunking while preserving the flexibility needed for rotor motion.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The stator assembly has different local qualities: the rubber stator sections provide flexibility and sealing, while the metal cutter disks provide cutting capability and wear resistance. This local differentiation allows each component to perform its specific function optimally without the drawbacks of using a single material for the entire assembly.

Inventive Principle:

Principle #3Local quality

3Reliability

If cutter disks are added to break up solids, then solids can pass through without jamming, but the device complexity increases

Engineering Contradiction:

Improvecontinuous operationVSAvoidstator structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The stator is divided into multiple modular sections that can be independently assembled and replaced. This segmentation reduces the overall complexity by allowing individual sections to be maintained separately rather than requiring replacement of the entire stator assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cutter disks serve multiple functions: they cut large solids into smaller pieces, guide fluid flow, and can be used in different stator configurations. This multi-functionality reduces the need for additional separate components, thereby managing device complexity while maintaining reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Prevents solids from jamming between the rotor and stator, ensuring continuous operation and preventing drill bit nozzles from being plugged, thus reducing downtime and maintenance costs.

Implementation Method 1

Incorporating cutting surfaces within stators made of multiple cutter disks at the inlet and outlet of progressing cavity pumps and power sections to break up solids into smaller pieces

Methodology Applied

Scientific EffectMechanical cutting: Mechanical Force

Data Source

PatentUS11421693B2Progressing cavity device with cutter disks

Publication Date: 2022.08.23 ROPER PUMP CO

AI summary

A stator for a helical gear device includes a first section having first helically convoluted chamber with a set of radially inwardly extending lobes and a second section adjacent to the first section. The second section includes a stack of cutter disks. Each cutter disk includes a front surface, a rear surface, an interior surface defining a central opening extending from the front surface to the rear surface, a forward cutting edge, and a rearward cutting edge. The interior surface forms a same number of lobes for the central opening as the set of radially inwardly extending lobes in the first section. Each cutter disk is aligned along a common centerline, and each cutter disk is rotated slightly relative to each other to form a second helically convoluted chamber with a same pitch as the first helically convoluted chamber. The second helically convoluted chamber exposes, to materials passing through, portions of the forward cutting edge or the rearward cutting edge of each cutter disk.