ESP Motor Equalizer Bellows Pressure Control
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Solution Overview
Problem
Existing electrical submersible well pump assemblies (ESP) face challenges in managing pressure differentials between motor lubricant and hydrostatic well fluid pressure, leading to issues with lubricant expansion and contraction, which can result in inefficiencies and potential leakage.
Innovation Solution
The implementation of a below motor pressure equalizer assembly with upper and lower pressure equalizers, each equipped with movable bellows and connection valves, allows for the communication of well fluid pressure to motor lubricant, enabling the expansion and contraction of lubricant while maintaining a sealed system through adaptive valve mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a pressure equalizer with flexible barrier is used to communicate well fluid pressure to motor lubricant, then pressure differential is reduced, but lubricant expansion and contraction causes potential leakage
Solution Approach 1:
The patent employs flexible barriers including bellows and diaphragms to transmit well fluid pressure to the motor lubricant while accommodating thermal expansion and contraction of the lubricant. The flexible elements maintain sealing while allowing volume changes, preventing leakage despite pressure and temperature variations during pump operation.
Solution Approach 2:
The pressure equalizer system uses movable flexible barriers that dynamically adjust to accommodate lubricant expansion and contraction. The bellows and diaphragms move to maintain pressure equilibrium while preventing leakage, adapting to changing operating conditions rather than relying on fixed rigid structures.
2Stress or pressure
If pressure equalizer is located between motor and pump, then pressure equalization is achieved, but device complexity increases with multiple components
Solution Approach 1:
The pressure equalizer assembly is integrated with the motor assembly, combining multiple functions into a unified structure. The flexible barrier is positioned within the motor housing to directly communicate with motor lubricant, eliminating the need for separate external pressure equalization components and reducing overall device complexity.
3Stress or pressure
If connection between upper and lower pressure equalizers is made, then pressure communication is improved, but risk of lubricant leakage during connection increases
Solution Approach 1:
Connection valves are pre-installed in the connection passages between upper and lower pressure equalizers. These valves remain closed during assembly and are only opened after the connection is properly made, preventing lubricant leakage during the connection process. The valves are activated by rotational movement that occurs during normal pump operation.
Solution Approach 2:
Connection valves act as intermediary control elements in the connection passages between pressure equalizers. These valves mediate the flow of lubricant, keeping passages closed during assembly and opening only when properly connected, thereby preventing leakage while enabling pressure communication when needed.
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 solution effectively reduces pressure differentials, allows for thermal expansion of lubricant, and prevents leakage by ensuring continuous communication of motor lubricant between pressure equalizers, enhancing the operational efficiency and reliability of ESP systems.
Implementation Method 1
Each of the pressure equalizers has a movable equalizing element that communicates well fluid pressure exterior of the pressure equalizers to motor lubricant in the motor
Implementation Method 2
allows for thermal expansion of lubricant
Implementation Method 3
the connection valve is spring-biased to a closed position and opens in response to abutment of the lower end of the upper pressure equalizer with the upper end of the lower pressure equalizer
Implementation Method 4
The motor equalizer valve moves to the open position in response to rotation of the shaft
Data Source
AI summary
Upper and lower pressure equalizers couple to a lower end of a motor of an electrical submersible pump assembly. An intermediate connection having a liquid flow passage connects the pressure equalizers. A connection valve located in the liquid flow passage closes the liquid flow passage prior to connecting the pressure equalizers with each other, and opens the liquid flow passage after the connection between the pressure equalizers is made. A sensor lower equalizer wire extends from a sensor unit through the lower pressure equalizer to a lower electrical terminal at the upper end of the lower pressure equalizer. A sensor upper equalizer wire connects to the lower electrical terminal and extends through the upper pressure equalizer to an upper electrical terminal at the upper end of the upper pressure equalizer. A sensor motor wire extends downward from the motor into engagement with the upper electrical terminal.