Magnetic Coupling Balances Axial Thrust in Submersible Pumps
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Solution Overview
Problem
Submersible well pumps face challenges in balancing axial thrusts, which can lead to increased equipment needs and failure rates due to mechanical contact between the motor and pump shaft, and require lengthy installations in shallow wellbores.
Innovation Solution
The implementation of a downhole-type pump with a magnetic coupling and a balance piston to counteract axial thrusts, reducing the reliance on thrust bearings and eliminating the need for a protector section, thereby encapsulating the motor and reducing failure rates, while maintaining volumetric efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If thrust bearings are used to absorb axial thrust load in the protector, then the axial thrust is supported, but the device complexity and failure rate increase due to mechanical contact
Solution Approach 1:
The patent removes the protector section containing thrust bearings from the ESP system. Instead of using mechanical thrust bearings to absorb axial thrust, the design extracts this component entirely and uses a magnetic coupling system that inherently handles axial thrust without requiring separate bearing support structures.
Solution Approach 2:
The patent replaces the mechanical thrust bearing system with a magnetic coupling system. The magnetic coupling uses magnetic fields to transmit torque while inherently supporting axial thrust loads, eliminating the need for mechanical contact between moving parts and reducing device complexity.
2Force
If thrust bearings with mechanical contact are used in the protector, then axial thrust is absorbed, but the reliability decreases due to increased failure rates
Solution Approach 1:
The patent replaces mechanical thrust bearings with a magnetic coupling system that has no mechanical contact between moving parts. The magnetic coupling uses magnetic fields to transmit torque and support axial thrust, eliminating wear and mechanical failure modes associated with traditional thrust bearings.
Solution Approach 2:
The patent extracts and removes the protector section containing thrust bearings from the system. By eliminating the mechanical contact interface entirely, the design removes the source of mechanical wear and failure, improving overall system reliability.
3Force
If a protector section is included in the ESP system, then thrust bearings are available to support axial load, but the installation time increases due to lengthy installation requirements in shallow wellbores
Solution Approach 1:
The patent removes the protector section from the ESP system configuration. This extraction eliminates the need to install and configure thrust bearings and seal chambers, significantly reducing installation time while the magnetic coupling inherently handles axial thrust support.
4Power
If mechanical contact between motor and pump shaft is used, then torque transmission is achieved, but the reliability decreases due to mechanical wear and failure
Solution Approach 1:
The patent replaces mechanical contact-based torque transmission with a magnetic coupling system. The magnetic coupling uses magnetic fields to transmit torque from the motor to the pump shaft without physical contact, eliminating wear and improving reliability while maintaining efficient power transmission.
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 solution effectively balances axial thrusts, decreases equipment requirements, lowers failure rates, and simplifies field installation by eliminating mechanical contact and shortening the ESP system, thus enhancing operational reliability and ease of deployment.
Implementation Method 1
The implementation of a downhole-type pump with a magnetic coupling
Implementation Method 2
a balance piston to counteract axial thrusts
Data Source
AI summary
A first fluid rotor that has a first fluid intake end and a first fluid discharge end. A second fluid rotor that has a second fluid intake end and a second fluid discharge end. The second fluid rotor is rotatably coupled to the first fluid rotor to rotate in unison with the first fluid rotor along a shared rotational axis. The first fluid intake end and the second fluid intake end are facing opposite directions. A first fluid stator surrounds the first fluid rotor. The first fluid rotor and the first fluid stator form a first fluid stage. The second fluid stator is aligned along the rotational axis. The second fluid stator and the second fluid rotor form a second fluid stage. A flow crossover sub is positioned between the first fluid stage and the second fluid stage.