ESP Impeller Diffuser Thrust Distribution
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Solution Overview
Problem
Conventional ESP systems face challenges in efficiently managing thrust forces and fluid flow, particularly during startup and non-uniform fluid flow conditions, due to the free-floating impellers and lack of effective thrust distribution to adjacent diffusers.
Innovation Solution
The ESP system incorporates an annular diffuser with axial and radial passages, a coaxially mounted impeller with a bearing hub, and an annular flow diverter or wear plate with radially projecting vanes, creating a fluid flow path that directs fluid from the impeller to the diffuser, enhancing thrust management and fluid flow efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If impellers float freely on the shaft, then the impellers can accommodate thrust forces, but thrust distribution to adjacent diffusers is ineffective and fluid flow efficiency deteriorates
Solution Approach 1:
The patent introduces a thrust distribution mechanism as an intermediary component between the impeller and adjacent diffusers. This mechanism includes thrust distribution surfaces on the impeller and corresponding surfaces on the diffusers, which mediate the transfer of thrust forces from the impeller to the diffusers, enabling effective thrust distribution while maintaining fluid flow efficiency
Solution Approach 2:
The patent segments the thrust management function by separating the thrust distribution mechanism from the impeller rotation function. The impeller is designed with specific thrust distribution surfaces that interface with adjacent diffusers, allowing thrust forces to be distributed to multiple components rather than being concentrated on a single bearing point
2Reliability
If thrust washers or bearings are located between each impeller and upstream diffuser, then upward and downward thrusts are accommodated, but device complexity increases
Solution Approach 1:
The patent merges the thrust accommodation function with the impeller structure itself. The impeller is designed with integrated thrust distribution surfaces and a bearing hub that combines rotational support with thrust distribution capabilities, eliminating the need for separate thrust washers or bearings between each impeller and upstream diffuser
3Device complexity
If conventional impeller and diffuser configurations are used, then the system structure is simple, but thrust forces are not effectively managed during startup and non-uniform fluid flow conditions
Solution Approach 1:
The patent applies local quality by designing specific regions of the impeller and diffuser with enhanced thrust distribution characteristics. The impeller includes a bearing hub with thrust distribution surfaces at specific locations, and the diffusers include corresponding surfaces positioned to receive thrust forces, creating localized thrust management zones that improve overall system stability
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 configuration improves thrust distribution and fluid flow efficiency, ensuring stable operation during startup and varying flow conditions, and allows for the use of harder materials and coatings not previously permitted, enhancing the overall performance and reliability of the ESP system.
Implementation Method 1
Centrifugal well pumps are commonly used as the submersible pump in an ESP application to pump oil and water from oil wells. Centrifugal pumps typically have a large number of stages, each stage having a stationary diffuser and a rotating impeller driven by a shaft. The rotating impellers exert a downward thrust as the fluid moves upward.
Implementation Method 2
an annular diffuser with passages that extend axially and radially throughout... an annular flow diverter or diffuser wear plate... A fluid flow path extending through the vanes to an outer circumference of the impeller, into the diffuser directed radially toward an axis of the pump
Data Source
AI summary
An electrical submersible pump having a pump section with a stack diffusers and a stack of impellers mounted on a rotatable shaft. Flow paths extends through the pump section directed axially and radially within the impellers and diffusers. Vanes define the flow path through each impeller that provide fluid communication with an upstream side of each impeller and an outer circumference. An annular flow diverting hub is provided on a downstream side of each impeller. The hub has an outer surface that curves radially inward, and having a minimum radius proximate its middle portion. The diffusers are annular members coaxially mounted in a housing of the pump section. Passages define the flow path through each diffuser that extend axially along the pump section and radially between an outer and inner circumference of each diffuser. The outer surface of each hub makes up a portion of an associated passage.