External Rotor Motorized Pump for ESP Rigless Deployment
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Solution Overview
Problem
Electrical submersible pump (ESP) systems face challenges with reliability and high intervention costs due to system complexity and rig dependency, particularly in harsh operating environments.
Innovation Solution
The integration of a motor and pump as a single unit without a shaft or protector section, utilizing magnetic coupling and an external-rotor motor design to enhance reliability and facilitate rigless deployment, with the motor and pump being contained within a housing and the motor rotor integrated with the pump rotor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shaft and protector section are used to couple the motor and pump, then the motor is protected from fluid and power is transmitted, but the system complexity increases and intervention costs increase
Solution Approach 1:
The motor and pump are merged into a single integrated unit where the motor rotor is directly coupled to the pump impeller, eliminating the need for separate shaft and protector components. This integration maintains motor protection while reducing system complexity and intervention requirements.
Solution Approach 2:
The shaft and protector section are extracted/removed from the system by using direct magnetic coupling between the motor rotor and pump impeller, simplifying the overall system while maintaining the essential functions of power transmission and motor protection.
2Power
If a shaft and protector section are used to couple the motor and pump, then power is transmitted from motor to pump, but rig dependency increases and intervention costs increase
Solution Approach 1:
The mechanical shaft coupling system is replaced with a magnetic coupling system where the motor rotor magnetically couples to the pump impeller. This substitution eliminates rig dependency for installation and removal while maintaining effective power transmission from the motor to the pump.
3Volume of moving object
If the motor stator radially surrounds the pump, then compact design is achieved, but manufacturing complexity increases
Solution Approach 1:
The pump is nested within the motor stator assembly, with the pump impeller positioned inside the motor rotor. This nested configuration achieves compact radial design while using standardized manufacturing processes for each component, balancing compactness with manufacturability.
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 reliability, reduces intervention costs, and allows for rigless operation by simplifying system configurations and increasing motor torque capability, while enabling higher head generation and compact system design.
Implementation Method 1
An electrical motor may operate through interaction of the motor magnetic field with motor winding currents to generate force
Implementation Method 2
The interaction between the windings and magnetic fields produces a torque around the axis of the motor rotor to rotate the motor rotor
Implementation Method 3
A multi-stage centrifugal pump having multiple hydraulic stages, each hydraulic stage having an internal diffuser and an external impeller
Data Source
AI summary
An electrical submersible pump (ESP) and method for pumping fluid from a wellbore. The ESP has a motorized pump with an external rotor motor topology. The motorized pump fits into casing in the wellbore. The motorized pump includes a motor having a motor stator and a motor rotor. The motor stator is at a radial center of the motorized pump. The motorized pump has a centrifugal pump radially surrounding the motor stator. The centrifugal pump includes an impeller and a diffuser.