Integrated Motor-Pump Rotor Design for Fluid Bypass Reduction
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Solution Overview
Problem
Existing electrically driven pump/compressor systems in the oil and gas industry face inefficiencies due to separate motor and pump/compressor assemblies, leading to large and heavy setups, with significant process fluid bypassing the impellers, which reduces operational efficiency.
Innovation Solution
An integrated modular, multi-stage motor-pump/compressor device is designed with a rotatable integrated motor/pump rotor and non-rotating shaft, featuring a primary process fluid flow path, diffuser, and journal bearings, which minimizes fluid bypass and optimizes energy transfer through electromagnetic coupling and efficient fluid flow paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate motor and pump/compressor assemblies are used, then the system can be designed independently for each component, but the overall assembly becomes very large and heavy
Solution Approach 1:
The patent combines the motor and pump/compressor into a single integrated assembly where the motor rotor and pump impeller share a common rotating structure. This merging eliminates the need for separate motor and pump assemblies, reducing overall weight and size while maintaining independent design capabilities for each functional component within the integrated structure.
2Adaptability or versatility
If separate motor and pump/compressor assemblies are used, then each component can be optimized separately, but the assemblies end up being very large and heavy
Solution Approach 1:
The motor and pump/compressor are merged into a single integrated assembly, allowing both components to be optimized simultaneously rather than separately. The shared rotating structure enables coordinated optimization of motor and pump parameters, reducing the overall volume while maintaining the adaptability to optimize each component's performance characteristics.
Solution Approach 2:
The pump impeller is nested within the motor rotor structure, with the impeller positioned inside the rotor's rotating components. This nesting arrangement allows the pump functionality to be contained within the motor assembly, significantly reducing the overall volume required for the combined system while enabling independent optimization of both components.
3Ease of operation
If gap is provided between impeller outer surface and housing, then the impeller can rotate freely, but process fluid bypasses the impellers reducing efficiency
Solution Approach 1:
The harmful bypass flow path is extracted and eliminated by redesigning the housing structure. The housing is configured to closely follow the impeller outer surface, removing the gap that allowed fluid bypass. This extraction of the bypass path problem maintains free impeller rotation while preventing energy loss through fluid leakage.
Solution Approach 2:
The housing structure is designed with a thin-walled configuration that closely conforms to the impeller outer surface. This thin film-like housing maintains the necessary clearance for impeller rotation while minimizing the gap volume, thereby reducing fluid bypass and associated energy losses.
4Productivity
If integrated motor-pump rotor is used, then fluid bypass is minimized and efficiency improves, but the design complexity increases
Solution Approach 1:
The motor rotor and pump impeller are merged into a single integrated rotating assembly, which minimizes fluid bypass by eliminating the gap between impeller and housing. While this merging increases design complexity, it simultaneously improves operational efficiency by preventing energy loss through bypass flow.
Solution Approach 2:
The integrated rotor structure serves dual functions: it acts as both the motor rotor for electromagnetic rotation and the pump impeller for fluid propulsion. This multi-functionality reduces the need for separate components and simplifies the overall system architecture, offsetting the increased complexity of the integrated design with functional consolidation.
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
The integrated design enhances operational efficiency by reducing fluid bypass and allowing for independent optimization of motor and pump/compressor components, resulting in a more compact, lightweight, and cost-effective system with improved energy transfer and reduced operational losses.
Implementation Method 1
the rotatable integrated motor/pump rotor comprises at least one electromagnet driver device that is adapted to be electromagnetically coupled with the electric motor stator
Implementation Method 2
As the shaft rotates, the impellers impart the desired energy to the process fluid flowing though the pump/compressor. Due to the rotation of the impellers, the process fluid is forced radially outward
Data Source
AI summary
A novel integrated modular, multi-stage motor-pump/compressor device (10) is disclosed herein. In one example, the device (10) includes an outer housing (12) an electric motor stator (25) positioned within the outer housing (12) and a rotatable integrated motor/pump rotor (18) positioned within the electric motor stator (25). The rotatable integrated motor/pump rotor (18) comprises at least one electromagnet driver device (42, 33, 37) that is adapted to be electromagnetically coupled with the electric motor stator (25) and at least one impeller (28), where an inner surface (34A) of the rotatable integrated motor/pump rotor (18) and the impeller (28) define a primary process fluid flow path (36) within the rotatable integrated motor/pump rotor (18).