Self-balancing thrust disk for ESPs
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Solution Overview
Problem
Conventional thrust balancing systems for electric submersible pumps (ESPs) often require a protector to support thrust loads, which can be prone to operational failures and are not effective across a range of operating conditions, especially in environments with solid and abrasive particles.
Innovation Solution
A thrust balancing apparatus comprising a housing, balancing chamber, connecting tube, balancing disk, bushing, washer, and upthrust washers, which balances thrust loads without a protector by establishing fluid communication and adjusting spacings to support the rotatable shaft across various operating conditions, including those with abrasive particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protector is used to support thrust loads in ESPs, then the thrust loads are supported, but the system becomes prone to operational failures especially in environments with solid and abrasive particles
Solution Approach 1:
The patent removes the protector component from the ESP system and replaces it with a thrust balancing apparatus that uses fluid pressure to support thrust loads. The balancing chamber and connecting tube extract the thrust support function from the mechanical protector and implement it through hydraulic means, eliminating the vulnerability to abrasive particles.
Solution Approach 2:
The patent employs a balancing chamber connected to the wellbore through a connecting tube, using wellbore fluid pressure to generate upthrust forces that balance the thrust loads on the rotatable shaft. This hydraulic approach replaces the mechanical protector and provides reliable thrust support without mechanical contact that would be damaged by abrasive particles.
2Reliability
If a protector is used to support thrust loads, then thrust support is provided, but the system is not effective across a range of operating conditions
Solution Approach 1:
The thrust balancing apparatus uses a dynamic fluid pressure system where the balancing chamber responds to varying wellbore pressures and thrust loads. The connecting tube allows fluid communication that automatically adjusts the upthrust force according to operating conditions, providing adaptability across different pumping speeds, flow rates, and load conditions.
Solution Approach 2:
The system changes the pressure parameter of the wellbore fluid to generate varying upthrust forces. As operating conditions change, the fluid pressure in the balancing chamber adjusts accordingly, maintaining effective thrust support across a wide range of operating conditions without requiring mechanical adjustment or protection.
3Reliability
If conventional thrust balancing systems are used, then thrust loads are supported, but the system requires a protector which increases device complexity
Solution Approach 1:
The patent combines the thrust balancing function with the existing ESP structure by integrating the balancing chamber and connecting tube into the pump assembly. The balancing chamber is positioned within the pump housing and works in conjunction with the rotatable shaft and seal assembly, merging multiple functions into a unified system that reduces overall complexity.
Solution Approach 2:
The wellbore fluid serves multiple functions: it provides the pressure source for the thrust balancing apparatus, acts as the balancing medium in the chamber, and eliminates the need for separate protection mechanisms. This multi-functionality reduces the number of components required and simplifies the overall system architecture.
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 apparatus effectively balances thrust loads across a range of operating conditions, improving the reliability and extending the operating life of ESPs, even in the absence of a protector and in environments with abrasive particles, without the need for lubrication.
Implementation Method 1
The connecting tube is configured to establish fluid communication between the balancing chamber and an exterior of the housing, such that an interior of the balancing chamber is exposed to fluid surrounding the housing
Implementation Method 2
A first spacing is defined between the ring and the first disk of the first portion of the balancing disk. A second spacing is defined between the pair of upthrust washers. The first spacing and the second spacing are adjustable to balance a thrust load of the rotatable shaft
Data Source
AI summary
A thrust balancing apparatus for a pump includes a housing, a balancing chamber, a connecting tube, a balancing disk, a bushing, a washer, and a pair of upthrust washers. The balancing chamber defines an upper cavity and a lower cavity. The connecting tube is configured to establish fluid communication between the balancing chamber and an exterior of the housing. A first portion of the balancing disk is disposed within the upper cavity. A second portion of the balancing disk passes through the lower cavity. A third portion of the balancing disk is external to the balancing chamber. The washer is disposed between the balancing disk and the bushing. The pair of upthrust washers are disposed between the balancing disk and the balancing chamber.