Submersible Pump Stage Erosion Control for Sand-Laden Fluids
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Solution Overview
Problem
Electric submersible pumping systems in hydrocarbon wells face erosion issues due to sand in produced fluids, leading to pump failure and reduced reliability.
Innovation Solution
Incorporation of an erosion control system between the impeller and diffuser stages, including thick wall sections, inserts, truncated impeller tips, and protective coatings made of harder materials to mitigate erosion in susceptible zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard pump components are used without erosion protection, then the pump structure remains simple and manufacturing is easier, but the pump components suffer from sand erosion leading to reduced reliability and shorter operational life
Solution Approach 1:
The patent applies local quality by providing erosion control systems only in specific susceptible zones where sand erosion occurs most severely, such as the diffuser inlet and impeller outlet areas. This selective protection approach enhances reliability in critical regions without unnecessarily complicating the entire pump structure, thus resolving the contradiction between improving reliability and maintaining structural simplicity.
Solution Approach 2:
The patent employs composite materials by combining different materials with complementary properties in the erosion control system. For example, using abrasion-resistant materials like tungsten carbide or ceramic coatings on high-erosion areas while maintaining the overall pump structure with standard materials. This composite approach improves component durability against sand erosion without requiring complete material replacement, thereby enhancing reliability while controlling structural complexity.
2Duration of action of stationary object
If erosion control systems with thick wall sections and hardened materials are added, then the operational life of the pump is extended, but the manufacturing cost and complexity increase
Solution Approach 1:
The patent applies segmentation by dividing the erosion control system into modular components that can be manufactured separately and assembled into the pump. The erosion control system is segmented into discrete elements such as protective sleeves, diffuser inserts, or impeller segments that can be produced using standard manufacturing processes and then integrated into the pump assembly. This modular approach extends pump operational life through enhanced erosion protection while simplifying manufacturing by allowing parallel production and easy assembly, thus resolving the contradiction between extending operational life and maintaining ease of manufacture.
Solution Approach 2:
The patent employs parameter changes by modifying the physical and chemical parameters of specific pump components to enhance erosion resistance. This includes changing material hardness, adding protective coatings, or adjusting the geometric parameters of high-stress areas. These parameter modifications extend the operational life of the pump without requiring complete redesign of the entire pump structure, thereby maintaining ease of manufacture while achieving enhanced durability.
3Reliability
If erosion control systems are installed between impeller and diffuser, then sand erosion is reduced and pump life is extended, but the device complexity and potential maintenance requirements increase
Solution Approach 1:
The patent applies the principle of using replaceable erosion control components that can be easily removed and replaced when worn. These disposable or limited-life components, such as protective sleeves or diffuser inserts, are designed to be inexpensive and simple to replace, reducing the overall maintenance complexity. When erosion wears through these protective elements, they can be quickly swapped without requiring complex disassembly or specialized tools, thus maintaining ease of repair while providing continuous erosion protection through the lifecycle of these components.
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
Enhances the longevity and reliability of submersible pumps by reducing erosion, thereby extending the life of the pump and the entire pumping system.
Implementation Method 1
the produced fluid may contain sand which impacts against pump components during the pumping operation. The sand can create unwanted erosion of pump components
Implementation Method 2
The sand can create unwanted erosion of pump components and may ultimately lead to pump failure
Data Source
AI summary
A technique facilitates long-term operation of a submersible pump which may be used in an electric submersible pumping system. According to an embodiment, the submersible pump comprises at least one stage, e.g. a plurality of stages. Each stage uses an impeller which may be rotated within a diffuser to establish a fluid flow through the pump. Additionally, each stage comprises an erosion control system positioned between the impeller and the diffuser to reduce erosion and/or the effects of erosion so as to extend the life of the submersible pump.