Integrated ESP Motorized Pump With Shared Rotor for Harsh Wells
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Solution Overview
Problem
Electrical submersible pump (ESP) systems face challenges in reliability and intervention costs due to system complexity and rig dependency, particularly in harsh operating environments.
Innovation Solution
Integration of the 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 rotor and pump rotor sharing the same component and rotating within the pump stator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the motor and pump are integrated as a single unit without a shaft or protector section, then reliability is improved and device complexity is reduced, but the motor protection capability in harsh environments may be compromised
Solution Approach 1:
The motor rotor and pump rotor are merged into a single integrated rotor assembly, eliminating the need for a separate shaft and protector section. This integration reduces the number of components and potential failure points, thereby improving reliability while maintaining motor protection through the unified design.
Solution Approach 2:
The integrated rotor serves multiple functions simultaneously: it acts as both the motor rotor for electromagnetic rotation and the pump rotor for fluid pumping. This multi-functionality eliminates the need for separate protective components while maintaining both motor operation and pump functionality in harsh environments.
2Force
If an external-rotor motor design is used with integrated pump rotor, then high-torque capability is achieved and device complexity is reduced, but the motor stator must radially enclose the pump which increases manufacturing difficulty
Solution Approach 1:
Instead of the conventional design where the pump is external to the motor, this design inverts the arrangement by making the motor stator radially enclose the pump components. This inversion enables the external-rotor configuration that delivers high torque while integrating the pump function, despite the increased manufacturing complexity of the enclosing stator structure.
3Volume of moving object
If the pump radially encloses the motor, then compact configuration is achieved and head generation capability is enhanced, but the motor rotor and pump rotor integration increases manufacturing precision requirements
Solution Approach 1:
The design employs a nested configuration where the pump components are radially enclosed by the motor stator, creating a compact multi-layer structure. The integrated rotor serves as the common rotating element for both motor and pump functions, achieving space efficiency while requiring precise manufacturing to ensure proper electromagnetic and hydraulic performance.
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 compact, high-torque capable systems that can handle corrosive and abrasive fluids, with enhanced head generation capability and simplified system configurations for both surface and downhole applications.
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
A pump may be a submersible pump which is coupled to a submersible or hermetically-sealed motor separate from the pump body
Data Source
AI summary
A motorized pump including a motor and a pump around the motor. The pump rotor is integrated with the motor rotor, wherein the pump rotor has vanes. The motorized pump may be employed as an electrical submersible pump (ESP) in a wellbore.