Modular Electric Submersible Pump Cooling via Rotor Segmentation
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Solution Overview
Problem
Existing electric submersible pump assemblies for wellbores face inefficiencies due to inadequate design features, particularly in the spacing between the stator and rotor, which affects fluid flow and heat transfer, leading to reduced performance and motor life.
Innovation Solution
The design incorporates a specific radial distance between the inner surface of the stator and the outer surface of the rotor, optimized based on a Reynolds number greater than 1500, along with a bearing assembly configuration that separates the rotor into distinct sections, enhancing fluid flow and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the radial distance between the stator and rotor is reduced to increase power density, then the motor size is reduced, but fluid flow and heat transfer are impaired leading to reduced motor life
Solution Approach 1:
The patent optimizes the radial distance parameter between stator and rotor to a specific value (0.50 mm) that simultaneously achieves high power density and adequate heat transfer. This parameter optimization resolves the contradiction by finding the critical value where both compact size and reliable operation are achieved.
2Reliability
If the radial distance between the stator and rotor is increased to improve fluid flow and heat transfer, then motor life is extended, but the motor size and power density are reduced
Solution Approach 1:
The patent determines the optimal radial distance parameter (0.50 mm) that balances heat transfer requirements with compact size. This parameter change resolves the contradiction by establishing the critical distance needed for adequate cooling while minimizing motor volume.
3Temperature
If the rotor is divided into multiple sections with bearing assemblies to improve heat dissipation, then heat transfer is enhanced, but device complexity increases
Solution Approach 1:
The rotor is segmented into multiple sections with bearing assemblies positioned at strategic locations. This segmentation creates multiple heat dissipation zones along the rotor length, enhancing thermal management while maintaining a modular structure that manages complexity.
Solution Approach 2:
Different sections of the rotor are equipped with bearing assemblies at specific locations where heat generation is highest. This local quality approach concentrates cooling resources where most needed, improving heat dissipation efficiency without uniformly increasing complexity throughout the entire motor.
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 fluid circulation and heat transfer, resulting in increased efficiency and extended motor life by minimizing friction and internal heating, while accommodating the constraints of wellbore dimensions.
Implementation Method 1
improves fluid circulation and heat transfer
Data Source
AI summary
The disclosure herein includes an electric submersible pump assembly for pumping fluids from a wellbore, which electric submersible pump assembly may include: a pump; a housing coupled to the pump; a body disposed in the housing, wherein the body may have a central aperture, an outer surface, and a flow path disposed in the outer surface; and a shaft assembly disposed in the central aperture of the body, wherein the shaft assembly may have a central flow path disposed therethrough and a port in fluid communication with the central flow path, the central aperture of the body, and the flow path disposed in the outer surface of the body.