Protected Bellows Expansion Chamber for ESP Lubricant Isolation

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Solution Overview

Problem

Prior submersible pumping systems face contamination risks and fluid flow restrictions due to the need for the drive shaft to pass through seal sections, which are not effectively addressed by existing designs.

Innovation Solution

The introduction of a fluid expansion chamber with a seal bag and bellows, where the bellows is contained within the seal bag, allowing for the expansion and contraction of motor lubricant without direct fluid communication with the wellbore, thereby preventing contamination and accommodating thermal cycles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the drive shaft passes through the seal section to transfer torque, then torque transmission is achieved, but fluid contamination risk increases

Engineering Contradiction:

Improvetorque transmissionVSAvoidfluid contamination risk

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The seal section is divided into a clean side (motor side) and a contaminated side (wellbore side) separated by a bellows and seal bag. This segmentation allows torque transmission through the drive shaft while preventing fluid contamination by creating distinct fluid zones with appropriate barriers.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bellows and seal bag act as intermediary elements between the clean motor interior and the contaminated wellbore environment. These intermediaries allow the drive shaft to pass through while blocking fluid contamination, thus enabling torque transmission without direct fluid communication between clean and contaminated zones.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If bellows or bags are used to separate clean side from contaminated side, then fluid separation is achieved, but device complexity increases

Engineering Contradiction:

Improvefluid separationVSAvoiddevice complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The bellows and seal bag are combined into a single integrated assembly where the bellows provides the primary separation function and the seal bag reinforces the barrier. This merging reduces the number of separate components needed while maintaining effective fluid separation, thus reducing overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bellows serves multiple functions: it separates clean and contaminated fluids, accommodates thermal expansion of motor lubricant, and maintains the pressure barrier. This multi-functionality reduces the need for additional separate components, thereby simplifying the overall device design.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If the bellows is contained within the seal bag, then protection of the bellows is achieved, but manufacturing complexity increases

Engineering Contradiction:

Improveprotection of the bellowsVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The bellows is nested within the seal bag, creating a protective configuration where the seal bag serves as an outer protective layer. This nesting arrangement protects the bellows from external contaminants and mechanical damage while maintaining a relatively simple assembly process, as the components can be installed in a sequential manner.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 design effectively prevents contamination of the motor lubricant while allowing for the expansion and contraction of lubricant, enhancing the reliability and efficiency of submersible pumping systems by isolating the motor from wellbore fluids.

Implementation Method 1

accommodating the expansion and contraction of motor lubricant as the motor moves through thermal cycles during operation

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

a seal bag filled with a seal bag lubricant and a bellows contained within the seal bag

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS11795795B2Fluid expansion chamber with protected bellow

Publication Date: 2023.10.24 BAKER HUGHES ESP INC

AI summary

An electric submersible pumping system includes a motor filled with motor lubricant, a pump driven by the motor, and a fluid expansion chamber connected to the motor. The fluid expansion chamber includes a seal bag filled with a seal bag lubricant and a bellows contained within the seal bag. The bellows includes an interior in fluid communication with the motor and an exterior in fluid communication with the seal bag lubricant.