Downhole Pump Diffuser Locking for Rotation Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Submersible pumps face operational inefficiencies and potential failure due to internal and external forces causing loosening and rotational movement of diffusers, especially in high-heat and high-gas environments with limited lubrication, affecting the couplings and orientations between components.
Innovation Solution
Implementing locking features such as coupling pins and anchoring mechanisms between diffusers and a pump base to minimize relative rotation, using nonthreaded protrusions for simplified assembly, and securing the diffuser stack to maintain stationary configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If diffusers are coupled using traditional threaded connections, then assembly is simplified, but rotational forces cause loosening and rotational movement of diffusers during operation
Solution Approach 1:
The coupling system is segmented into multiple functional elements: coupling pins for primary connection, locking features (keys and keyways) for rotational prevention, and set screws for additional securing. This segmentation allows each element to address specific aspects of the coupling problem without compromising the others.
Solution Approach 2:
Locking features such as keys and keyways are pre-configured in the coupling structure before operation begins. These features are designed to engage with each other in advance, creating a predetermined mechanical interlock that prevents rotational movement before rotational forces are applied during pump operation.
2Reliability
If locking features are added to prevent rotational movement, then coupling stability is improved, but device complexity increases
Solution Approach 1:
Multiple coupling functions are merged into integrated components. For example, coupling pins simultaneously provide structural support, torque transmission, and rotational constraint through integrated locking features. The diffuser housing and base are merged with built-in keyways and attachment features, eliminating the need for separate locking mechanisms.
Solution Approach 2:
The coupling structure incorporates self-locking features where the geometry of keys, keyways, and set screw holes automatically prevents rotational movement without requiring external locking devices or complex adjustment mechanisms. The structure serves its own locking function through its inherent design.
3Reliability
If diffusers are secured rigidly to prevent rotation, then operational reliability is improved, but assembly and maintenance difficulty increases
Solution Approach 1:
The coupling system is divided into discrete, replaceable components including coupling pins, set screws, and locking features that can be independently accessed and replaced. This segmentation allows maintenance personnel to service individual components without replacing the entire diffuser assembly.
Solution Approach 2:
The coupling features are designed with universal geometries (standard keyways, set screw holes, and coupling pin configurations) that can be replicated across multiple diffusers. This standardization simplifies maintenance by allowing interchangeable parts and reducing the need for specialized tools or procedures.
Data Source
AI summary
Downhole centrifugal pumps and related components and methods may include stationary diffusers housing impellers where the stationary diffusers have radial sidewalls defining a radially outer portion of each of the stationary diffusers. Coupling members may be defined on the stationary diffusers to at least partially transfer a rotational force through the centrifugal pump.