Integrated ESP Motor-Pump Layout for Stator Isolation
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Solution Overview
Problem
Existing electric submersible pumping systems are complex and prone to failures due to exposure of stator components to well fluids, leading to reduced reliability and efficiency.
Innovation Solution
Integration of a pump and motor within a single housing with a protected stator environment, using a tube to seal the stator from well fluids, and employing magnetic impellers driven by a rotating magnetic field to simplify and compact the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the stator is exposed to well fluids in traditional electric submersible pumping systems, then the system structure is simpler, but the reliability is reduced due to corrosion and damage to stator components
Solution Approach 1:
The patent implements nesting by placing the stator inside a protective tube that is sealed within the pump housing. The tube creates a nested configuration where the stator is protected from well fluids while maintaining the overall system structure. This nesting approach protects the stator from corrosion and damage without requiring complete system redesign.
Solution Approach 2:
The protective tube acts as an intermediary element between the well fluids and the stator. This tube is sealed to the pump housing and creates a barrier that prevents direct contact between corrosive well fluids and the stator components, thereby protecting the stator while allowing the system to maintain its traditional structure.
2Volume of moving object
If separate pump and motor components are used in traditional systems, then each component can be optimized independently, but the overall system becomes more complex and less compact
Solution Approach 1:
The patent merges the pump and motor into a single integrated assembly where the stator serves dual functions as both the motor component and the pump housing element. The impeller is directly coupled to the stator without separate shafts or couplings, creating a compact integrated unit that reduces overall system volume while maintaining functional optimization.
Solution Approach 2:
The stator is designed to perform multiple functions simultaneously: it serves as the motor's magnetic field generator, the pump housing, and the structural support for the impeller. This multi-functionality eliminates the need for separate components and reduces system complexity while achieving compactness.
3Reliability
If traditional electric submersible pumping systems are used, then the system can handle various well conditions, but the exposure of components to well fluids leads to increased failures
Solution Approach 1:
The sealed protective tube serves as an intermediary barrier that isolates the stator from harmful well fluids. This tube is sealed to the pump housing and extends through the pump assembly, creating a protected environment that prevents corrosion and damage while allowing the system to continue operating in challenging well conditions.
Solution Approach 2:
The stator is extracted from the direct exposure to well fluids by placing it inside the sealed protective tube. This extraction removes the harmful interaction between the stator and well fluids, thereby improving reliability while maintaining the system's ability to handle various well conditions through the protected configuration.
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 reduces system complexity, enhances reliability by protecting the stator, and maintains or improves efficiency, allowing for flexible deployment in challenging well conditions.
Implementation Method 1
application of electric power to the stator causes rotation of the impeller relative to the stator
Implementation Method 2
The impeller includes one or more magnetic components, wherein application of electric power to the stator causes rotation of the impeller relative to the stator
Data Source
AI summary
Systems and methods facilitate pumping of various fluids such as well fluids. An electric submersible pumping system is constructed with an outer housing that contains an integrated pump and motor. The pump may include an impeller disposed within a stator of the motor. The integration of the pump and the motor enables elimination of various components of traditional electric submersible pumping systems to thus provide a simpler and more compact system for pumping fluids.