ESP Stator Slot Insulation With Overlapping Section Joints
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of stator winding insulation for high-temperature electric submersible pump motors is challenging due to the need for rigid insulation materials, which often require multiple lengths to span the motor's significant length, leading to manufacturing difficulties and potential insulation gaps that can cause ground faults and turn-to-turn shorts.
Innovation Solution
The use of overlapping insulation sections and staggered joint arrangements to prevent ground faults and turn-to-turn shorts, with additional overlapping insulators covering the joints between abutting sections, ensuring effective insulation across the motor's length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If multiple lengths of rigid insulation are used to span the motor's significant length, then the insulation can cover the entire stator, but manufacturing difficulties increase and potential insulation gaps can cause ground faults and turn-to-turn shorts
Solution Approach 1:
The insulation system is divided into multiple discrete insulation sections that can be manufactured to standard lengths and then assembled along the stator length. Each section is independently manufacturable, and when properly staggered and overlapped, they collectively provide continuous insulation coverage for the entire motor length without requiring custom long-insulation fabrication
Solution Approach 2:
Overlapping insulation sections are positioned such that one insulation section extends beyond the joint between abutting sections, creating a nested arrangement where the overlapping portion provides continuous insulation coverage. This ensures that no gaps exist at the joints between abutting sections, preventing ground faults and turn-to-turn shorts while maintaining manufacturability with standard-length insulation components
2Length of stationary object
If multiple lengths of rigid insulation are used to span the motor's significant length, then the insulation can cover the entire stator, but insulation gaps can cause ground faults and turn-to-turn shorts
Solution Approach 1:
Overlapping insulation sections are positioned such that one insulation section extends beyond the joint between abutting sections, creating a nested arrangement where the overlapping portion provides continuous insulation coverage. This ensures that no gaps exist at the joints between abutting sections, preventing ground faults and turn-to-turn shorts while maintaining manufacturability with standard-length insulation components
Solution Approach 2:
The insulation sections are pre-positioned in a staggered arrangement during assembly, with overlapping sections placed to anticipate and cover potential gap locations at joints. This preliminary positioning ensures insulation integrity is maintained from the outset, preventing electrical faults before the motor operates
3Reliability
If overlapping insulation sections with staggered joint arrangements are used, then insulation integrity is maintained and electrical shorts are prevented, but the number of different insulation lengths required increases
Solution Approach 1:
The insulation system employs different insulation section configurations at different locations along the stator. Standard-length sections are used in regions where they provide sufficient coverage, while overlapping sections are strategically positioned only at critical joint areas. This localized differentiation maintains insulation integrity where needed most without unnecessarily increasing overall system complexity
Data Source
AI summary
Stators in downhole ESP motors often are used in the sorts of high temperature operations in which rigid, inorganic insulation may prove useful. However, such rigid insulation materials may have inherent manufacturability issues which can limit usage, for example in elongated motors of the sort often used with downhole electrical submersible pumps. Disclosed embodiments provide solutions for effectively insulating conductor portions in the slots of a stator lamination in an ESP motor, and for effectively manufacturing, managing inventory for, and assembling improved stators.