Grinder Pump Assembly for Slag Particle Size Reduction
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Solution Overview
Problem
Existing downhole pumping systems face wear issues due to entrained solid particles, particularly metallic slag, which are not effectively mitigated by prior solutions, leading to component degradation and reduced hydrocarbon recovery efficiency.
Innovation Solution
A grinder pump assembly with multiple stages, each comprising an impeller and diffuser, designed to pulverize solid particles by rotating vanes and contact surfaces, reducing particle size before they reach the primary pump assembly, utilizing hardened metal alloys and adjustable geometry for graduated pulverization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If solid particles are allowed to pass through the downhole pumping system, then the pumping system can handle high volumes of produced fluid, but the solid particles cause accelerated wear on downhole components
Solution Approach 1:
The grinder pump assembly is positioned upstream in the production string to pulverize solid particles before they reach the main pump assembly. This preliminary action of particle size reduction prevents wear on downstream components while maintaining high fluid production volumes.
Solution Approach 2:
The grinder pump assembly acts as an intermediary device between the produced fluid and the main pump assembly. It processes the fluid to remove harmful solid particles through pulverization, allowing the main pump to handle clean fluid without wear damage.
2Reliability
If protective measures are added to prevent solid particle damage, then component wear is reduced, but the device complexity increases
Solution Approach 1:
The harmful solid particle removal function is extracted as a separate grinder pump assembly from the main pump assembly. This modular approach protects the main pump without requiring complex protective features integrated into its design, maintaining simplicity while improving reliability.
Solution Approach 2:
By introducing the grinder pump as an intermediary device, complex protective measures are avoided. The intermediary handles the particle removal function, allowing the main pump to remain simple while still achieving wear protection.
3Object-affected harmful factors
If multiple grinder pump stages are used, then solid particle pulverization is more effective, but the device complexity and manufacturing cost increase
Solution Approach 1:
The grinder pump assembly is divided into multiple stages, with each stage containing impellers and diffusers that progressively reduce particle size. This segmentation allows effective pulverization of tough slag particles through incremental size reduction across stages.
Solution Approach 2:
Multiple grinder pump stages provide excessive pulverization action beyond what a single stage could achieve. This ensures thorough particle size reduction even for the hardest slag particles, with each stage contributing to progressive breakdown.
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
Effectively reduces the size of solid particles, preventing wear on downhole components and enhancing the efficiency of hydrocarbon recovery by maintaining clean formations and equipment, thus prolonging system lifespan and performance.
Implementation Method 1
The upper vanes of the impeller are configured to rotate in proximity with the lower contact surfaces on the diffuser. The lower vanes of the impeller are configured to rotate in proximity with contact surfaces on the diffuser cap.
Implementation Method 2
designed to pulverize solid particles by rotating vanes and contact surfaces
Data Source
AI summary
A grinder pump assembly includes at least one grinder pump stage that has a diffuser and an impeller. The grinder pump assembly also includes a diffuser cap that includes cap contact surfaces. The impeller includes a plurality of upper vanes and lower vanes. The diffuser includes a plurality of lower contact surfaces, a plurality of diffuser vanes and plurality of upper contact surfaces. The upper vanes of the impeller are configured to rotate in proximity with the lower contact surfaces on the diffuser. The lower vanes of the impeller are configured to rotate in proximity with the cap contact surfaces. Multiple grinder pump stages may be used within a single grinder pump assembly.