Downhole ESP Labyrinth Seal Upthrust Balance

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Solution Overview

Problem

Electrical submersible pumps (ESPs) face reduced lifespan due to undesirable upward thrust on impellers from pressurized fluids, which existing washers fail to effectively dissipate, leading to premature wear and reduced efficiency.

Innovation Solution

Incorporating labyrinth seals between impellers and diffusers to create a tortuous path for fluid flow, reducing upthrust forces and maintaining impellers in a stable, balanced condition, thereby preventing direct contact with diffusers and extending pump lifespan.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If washers are used to dissipate upthrust forces, then the pump structure is simple, but the washers experience premature wear and reduced efficiency

Engineering Contradiction:

Improvepump structureVSAvoidwasher lifespan

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

A balance piston is introduced as an intermediary component between the impeller and the washer. The balance piston receives upthrust forces from the impeller through fluid pressure acting on its surface, thereby mediating the force transmission and preventing direct contact between the impeller and washer, which reduces wear on the washer

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Fluid pressure is utilized to act on the balance piston surface, generating a counterbalancing force that offsets the upthrust forces. This hydraulic mechanism allows the system to balance forces without direct mechanical contact, extending component lifespan while maintaining structural simplicity

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Device complexity

If impellers are allowed to contact diffusers to balance upthrust, then the device complexity is reduced, but the impeller stability deteriorates

Engineering Contradiction:

Improveupthrust balance mechanismVSAvoidimpeller stability

Core Design Contradiction:

Device complexityVSStability of the object's composition

Solution Approach 1:

The balance piston serves as a mediator that maintains the impeller at a stable equilibrium position. By transmitting fluid pressure forces to the impeller through the piston, the system achieves force balance without allowing direct contact between the impeller and diffuser, thereby maintaining impeller stability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The balance piston creates a counterbalancing force through fluid pressure that opposes the upthrust forces on the impeller. This counterforce mechanism maintains the impeller in a balanced position, preventing instability and unwanted movement while avoiding direct contact with the diffuser

Inventive Principle:

Principle #8Anti-weight (Counterweight)

3Ease of operation

If upthrust forces are not balanced, then the pump operation is simple, but the overall lifespan of the ESP is reduced

Engineering Contradiction:

Improvepump operationVSAvoidESP lifespan

Core Design Contradiction:

Ease of operationVSDuration of action of moving object

Solution Approach 1:

The balance piston system automatically balances upthrust forces through fluid pressure acting on its surface. The mechanism self-regulates based on the operating conditions, with the fluid pressure naturally adjusting to provide the required counterbalancing force without external intervention, thereby extending ESP lifespan while maintaining simple operation

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The balance piston provides preemptive counterbalancing of upthrust forces before they can cause damage to pump components. By establishing force balance in advance through fluid pressure, the system prevents wear and damage to critical components, extending the overall lifespan of the ESP

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

The labyrinth seals effectively balance upthrust forces, reducing wear on washers and maintaining impeller stability, leading to increased ESP efficiency and extended operational lifespan by preventing direct contact between impellers and diffusers.

Implementation Method 1

Incorporating labyrinth seals between impellers and diffusers to create a tortuous path for fluid flow, reducing upthrust forces

Methodology Applied

Scientific EffectLabyrinth seal:

Data Source

PatentUS10260518B2Downhole electrical submersible pump with upthrust balance

Publication Date: 2019.04.16 HALLIBURTON ENERGY SERVICES INC

AI summary

In accordance with embodiments of the present disclosure, a electrical submersible pump includes a pump housing, a shaft extending at least partially through the pump housing and adapted to be driven by a submersible motor, an impeller attached to the shaft and having an impeller passage for fluid to flow therethrough, and a diffuser that is stationary relative to the pump housing and having a diffuser passage, wherein the diffuser is disposed corresponding to the impeller to form a pump stage such that fluid can flow between the impeller passage and the diffuser passage. The electrical submersible pump also includes a labyrinth seal formed between the impeller and the diffuser, wherein the labyrinth seal selectively seals the impeller passage from a cavity formed between the impeller and the diffuser to maintain the impeller in a floating condition relative to the diffuser.