Turbine Rotation Locking Mechanism for ESP Restart Protection
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Solution Overview
Problem
Submersible electric centrifugal pumps face issues with motor failure upon restarting due to turbine rotation, fluid leakage through check valves, and electrical hazards during reverse rotation, which existing control systems only partially address.
Innovation Solution
A device comprising interconnected head and base with cam and overrunning clutches allows for torque transmission in both directions while preventing reverse rotation, using a coupling clutch with a spring and pusher mechanism to manage axial movement and prevent turbine rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a check valve is installed at the pump outlet to hold the liquid column and prevent turbine rotation, then the liquid column is held and fluid return is prevented, but mechanical impurities interfere with hermetic closure leading to fluid leakage and turbine rotation
Solution Approach 1:
The patent introduces a turbine rotation prevention device as an intermediary mechanism between the pump and check valve. This device includes a prevention shaft, overrunning clutch, and cam clutch that work together to block reverse rotation of the pump shaft, thereby preventing turbine rotation even when the check valve fails due to mechanical impurities.
Solution Approach 2:
The invention segments the protection function into two independent parts: the check valve for normal operation and the turbine rotation prevention device as a backup mechanical barrier. The prevention device is divided into separate functional components (overrunning clutch for forward rotation, cam clutch for reverse rotation blocking) that can operate independently of the check valve.
2Ease of operation
If control systems with soft start function are used to provide smooth start during turbine rotation, then motor shaft stopping and forward start is enabled, but only two of three problems are solved leaving fluid leakage unresolved
Solution Approach 1:
The turbine rotation prevention device acts as a mechanical intermediary that physically blocks reverse rotation through the cam clutch mechanism. This mechanical intervention works in conjunction with the control system's soft start function, creating a layered protection approach where the control system handles smooth operation while the mechanical device prevents catastrophic failure.
3Reliability
If existing control systems are used to protect from turbine rotation by preventing motor triggering, then motor failure from overloading is prevented, but only one problem is solved leaving fluid leakage and electrical hazards unresolved
Solution Approach 1:
The protection system is segmented into multiple layers: control system protection for motor overload, and mechanical device protection for physical turbine rotation blocking. The mechanical device further segments functions into overrunning clutch for forward rotation and cam clutch for reverse rotation prevention, addressing multiple harmful factors simultaneously.
4Reliability
If a device blocks turbine rotation but needs to provide torque transmission in both forward and reverse directions, then turbine rotation is prevented, but the device complexity increases with multiple clutch mechanisms
Solution Approach 1:
The prevention shaft serves multiple functions: it transmits torque from the motor to the pump during normal operation, and it acts as the rotation axis for the clutch mechanisms during protection mode. The housing serves dual purposes as both structural support and mounting platform for the clutch assemblies, reducing overall device complexity.
Solution Approach 2:
The overrunning clutch and cam clutch are integrated on the same prevention shaft within a single housing, combining multiple protection functions into one compact assembly. The spring mechanism is integrated with the cam clutch to provide automatic engagement and disengagement, eliminating the need for separate actuation systems.
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 reliability and safety of Electric Centrifugal Pumping Units by preventing turbine rotation and ensuring smooth operation during fluid drainage, reducing motor overload and electrical hazards.
Implementation Method 1
coupling of the coupling clutch is provided by a spring
Implementation Method 2
two shafts are mounted on bearing supports: the upper and lower shafts, connected to each other through a cam clutch configured to enable free running in the circumferential direction
Implementation Method 3
an overrunning clutch is installed in the head, providing torque transmission in the forward direction from the lower shaft to the upper one and preventing reverse rotation of the upper shaft
Implementation Method 4
a pusher mounted on the upper shaft for axial movement, and wherein on one side the pusher is connected to the movable part of the coupling clutch and on the other side—to a bush sleeve having an inclined end surface rigidly mounted on the lower shaft
Data Source
AI summary
The invention relates to pumping equipment and can be used in oil industry as part of submersible electric centrifugal pump units. Device for prevention of turbine rotation consists of interconnected head and base, inside of which two shafts are installed on bearing supports—upper and lower ones, connected to each other through a cam clutch with the possibility of free running in the circumferential direction. The overrunning clutch is installed in the head, providing torque transmission in the forward direction from the lower shaft to the upper one and preventing reverse rotation of the upper shaft. The overrunning clutch is connected with the upper shaft via a coupling clutch, movable part of which is mounted on the upper shaft with possibility of axial movement, and stationary part is rigidly connected to the overrunning clutch. Coupling of the coupling clutch is provided by a spring, and disconnection is provided by a pusher mounted on the upper shaft with possibility of axial movement, and on one side the pusher is connected to the movable part of the coupling clutch and on the other side—with a bush sleeve having an inclined end surface rigidly installed on the lower shaft. The technical result is to increase reliability and safety of Electric Centrifugal Pumping Unit due to use of the apparatus for preventing rotation of the turbine.