Patent ID: 12221985

DETAILED DESCRIPTION

FIGS.1-8show an electric submersible pump in accordance with one or more embodiments of the disclosures made herein (i.e., pump100) that is configured for use with flowable fluid material such as, for example, a liquid. The pump100employs a structural arrangement that beneficially reduce pumping pressure loses, reduce pumping energy, provide enhanced volumetric flow efficiency arising from increased flow velocities and mitigate, if not eliminate, common cavitation issues. These enhanced functionalities result in enhanced performance, reliability and durability.

As best shown inFIGS.1,2A and2B, the pump100comprises a rotational assembly102and a rotational assembly housing104. The rotational assembly housing104has an interior space S1extending along a centerline axis A of the rotational assembly housing104. The rotational assembly102is disposed within the interior space S1of the rotational assembly housing104. The rotational assembly102has a rotational axis R1that extends colinearly with the centerline longitudinal axis A of the rotational assembly housing104.

As shown inFIGS.2A-2C, the rotational assembly102has a plurality of in-line flow inducing sections: a flow pressurizing section102A, a rotational flow amplification section102B and a flow outlet section102C. A downstream end portion of the flow pressurizing section102A is engaged with an upstream end portion of the rotational flow amplification section102B. A downstream end portion of the rotational flow amplification section102B is engaged with an upstream end portion of the flow outlet section102C. A centerline longitudinal axis of each of the flow inducing sections (respectively, centerline longitudinal axes A1, A2, A3) extends colinearly with a rotational axis R1of the rotational assembly102.

As discussed below in greater detail, rotation of the rotational assembly102relative to the rotational assembly housing104causes fluid present outside an input end IE of the submersible pump100to be drawn into the interior space S1of the rotational assembly housing104through inlet ports108within the rotational assembly housing104. Filter body109may be provided over the inlet ports108to limit entry of debris. The rotation further causes fluid drawn into the interior space S1of the rotational assembly housing104to be drawn into and pressurized within an interior space S2of the flow pressurizing section102A. The pressurized fluid is urged through the rotational flow amplification section102B for having rotational flow about the rotational axis R1imparted thereon. Thereafter, the rotational fluid flow is focalized by the flow outlet section102C before being outputted via an outlet port112of the flow outlet section102C at an outlet end OE of the rotational assembly housing104. The rotation also causes fluid through the interior space S1of the rotational assembly housing104between the rotational assembly102and inner surface of the rotational assembly housing104for providing cooling and lubrication to points of contact between the rotational assembly102and the rotational assembly housing104.

The submersible pump100may include a motor1for causing rotation of the rotational assembly102relative to the rotational assembly housing104. The motor1may be connected to the rotational assembly102and the rotational assembly housing104by any suitable means that enables rotation of the rotational assembly102relative to the rotational assembly housing104. For example, a main body5(e.g., a housing or casing) of the motor1may be attached to the rotational assembly housing104and a rotational power output portion10of the motor1may be attached to the rotational assembly102for enabling rotational power generated by the motor1to be imparted upon the rotational assembly102. The motor1may be attached to the rotational assembly102via a coupler105that has a first portion engaged with the motor1and a second portion engaged with the rotational assembly102and that inhibits relative rotational movement therebetween.

In one or more preferred embodiments, the motor1, the rotational assembly102and the rotational assembly housing104are jointly configured for maintaining the rotational assembly102in compressive engagement with the rotational assembly housing104. Such compressive engagement serves at least two purposes. The first purpose is such that the rotational assembly102rotates in a controlled manner about the rotational axis R1at one or more rotational speeds. To this end, attachment of the motor1to the rotational assembly housing104may serve to radially constrain the adjacent end portion of the rotational assembly102to rotates in the controlled manner about the rotational axis R1. Optionally or additionally, a support body (e.g., a bracket) may be located between the motor and the rotational assembly102for providing or augmenting such radial constraining of the adjacent end portion of the rotational assembly102. The second purpose is such that, during such rotation of the rotational assembly102, uncontrolled axial movement of the rotational assembly102relative to the rotational assembly housing104along the centerline axis A of the rotational assembly housing104is controlled (e.g., inhibited).

In support of the aforementioned rotational considerations, as best shown inFIG.2A-2C, the submersible pump100preferably includes a plurality of journal bearings114and one or more thrust bearings116. The journal bearings114are axially spaced-apart from each other and are disposed between an outer surface103of the rotational assembly102and an interior (i.e., central passage defining) surface118of the rotational assembly housing104. The journal bearings114and the rotational assembly102and inner surface118of the rotational assembly housing104of the central passage120are jointly configured for radially constraining the rotational assembly102relative to the inner surface118of the rotational assembly housing104—i.e., for providing rotation of the rotational assembly102in a controlled manner about the rotational axis R1. In preferred embodiments, the journal bearings114are integral with the exterior surface103of the rotational assembly102that defines its outer surface103and each engage a mating portion of the interior surface118of the rotational assembly housing104.

As best shown in7, each of the journal bearings114may include one or more flutes115. Each flute115extends across an entire width of the respective one of the journal bearings114. In preferred embodiments, rotation of the rotational assembly102results in the flow pressurizing section102A causing a portion of fluid drawn into the interior space S1of the rotational assembly housing104being urged along the central passage120of the rotational assembly housing104between the rotational assembly102and the interior surface118of the rotational assembly housing104. Each flute115serves as a flow-through passage for readily allowing fluid flow across each of the journal bearings114. Beneficially, fluid flow between the rotational assembly102and the interior surface118of the rotational assembly housing104serves to both cool and lubricate points of contact between the journal bearings114and mating portions of the rotational assembly housing104.

The one or more thrust bearings116are located between an end face122of the rotational assembly102and an interior end face124of the rotational assembly housing104at the outlet end OE of the submersible pump100. The end face122of the rotational assembly102, the interior end face124of the rotational assembly housing104and the one or more thrust bearings116(in combination with an implemented means for forcibly biasing the rotational assembly102in the downstream direction) are jointly configured for axially constraining the rotational assembly102relative to the rotational assembly housing104while enabling uniform and controlled rotational movement about the rotational axis R1. In preferred embodiments, a cylindrical roller thrust bearing is utilized between the end face122of the rotational assembly102and the interior end face124of the rotational assembly housing104for axially constraining the rotational assembly102relative to the rotational assembly housing104.

In regard to the implemented means for forcibly biasing the rotational assembly102in the downstream direction, the rotational assembly102may be biased toward the outlet end OE of the submersible pump100for causing a compressive force at the interface between the one or more thrust bearings116, the rotational assembly102and the rotational assembly housing104. In one example, the motor1may be in direct (e.g., fixed) engagement with the rotational assembly102to forcibly biases the rotational assembly102toward the enclosed end face124of the rotational assembly housing104(i.e., in the downstream direction). In another example, a resilient biasing member (e.g., one or more compression springs such as disc spring washers) are used to apply a balanced torque) may reside between the motor1and the rotational assembly102to forcibly biases the rotational assembly102toward the enclosed end face124of the rotational assembly housing104.

In one or more embodiments, forcibly biasing the rotational assembly102in the downstream direction for causing a compressive force at the interface between the one or more thrust bearings116, the rotational assembly102and the rotational assembly housing104may be accomplished utilizing a motor mount that interlockedly engages the rotational assembly housing104for urging the motor1toward the downstream end portion of the rotational assembly housing104into compressed engagement with the one or more thrust bearings116. The interlocking arrangement of the motor mount and rotational assembly housing104secures the motor mount to the rotational assembly housing104and biases the rotational assembly102against the one or more thrust bearings116. For example, the motor mount may include a body having a threaded portion that engages a mating threaded portion of the rotational assembly housing104through which an axial compressive (i.e., preload) force may be exerted at the interface between the one or more thrust bearings116, the rotational assembly102and the rotational assembly housing104. The motor mount may include a resilient member (e.g., compression spring) that exerts a compressive force on the motor1in response to the motor mount being interlockedly engaged with the rotational assembly housing104.

As best seen inFIGS.2A,3and4, the rotational assembly102comprises an impeller130, a rotational flow amplification body132and an outlet body134. As discussed above, the rotational assembly102has a plurality of in-line flow inducing sections: the flow pressurizing section102A, the rotational flow amplification section102B and the flow outlet section102C. The impeller130is an embodiment of the flow pressurizing section102A. The rotational flow amplification body132is an embodiment of the rotational flow amplification section102B. The outlet body134is an embodiment of the flow outlet section102C.

The impeller130has a sidewall136that extends around the rotational axis R1to define an interior space S2of the impeller. The sidewall136tapers such that the impeller130has a first cross-sectional area adjacent a first end portion EP130-1and a second cross-sectional area adjacent a second end portion EP130-2. The second cross-sectional area is larger than the first cross-sectional area. In preferred embodiments, the impeller130is in the form of an inverted frustum pyramid. A centerline longitudinal axis A1of the impeller130extends colinearly with the rotational axis R1.

The sidewall136includes a plurality of flow-inducing protrusions138each extending outwardly away from the interior space S2of the impeller130. Each of the flow-inducing protrusions138extends from adjacent the first end portion EP130-1of the impeller130to adjacent the second end portion EP130-2of the impeller130. Each of the flow-inducing protrusions138has a leading edge LE and a trailing edge TE relative to a rotational direction RD. Each of the flow-inducing protrusions138has a fluid flow passage140extending therethrough along at least a portion of the leading edge LE.

In one or more embodiments, the inlet ports108may be inclined to have the same or similar inclination as the protrusions138of the impeller130. In one or more embodiments, the inlet ports108may include protrusions at the inner surface of the rotational assembly housing104that have the same or similar profile as the protrusions138of the impeller130. Preferably, the inlet port protrusions of the rotational assembly housing104extend inward from the outer wall of the rotational assembly housing104. Such inlet port inclination and inlet port protrusion arrangement beneficially impact fluid flow from through the inlet ports and into the interior space S of the impeller130.

Each of the flow-inducing protrusions138extends from adjacent the first end portion EP130-1of the impeller130with an upward inclination in the direction opposite a rotational direction RD of the rotational assembly102. The term upward inclination is disclosed herein to include at least a portion of the flow-inducing protrusions extending in a non-parallel direction relative to a reference axis that extends radially from the rotational axis R1—i.e., the leading edge LE is facing upstream. For example, the flow-inducing protrusions138may have a straight longitudinal axis that is skewed with respect to the rotational axis or may have a longitudinal axis that is at least partially curved such that at least a portion of the longitudinal axis is skewed with respect to the rotational axis.

Preferably, as best shown inFIGS.5and6, each flow-inducing protrusion138has an interior surface136A and an exterior surface136B—i.e., opposing surfaces of the sidewall136. The interior surface136A is offset from the exterior surface136Bby an approximately uniform distance (e.g., the thickness of the sidewall136) such that each flow-inducing protrusion138defines a louver-like body outwardly protruding from the exterior surface of the impeller130and forming a respective cavity within the interior surface of the impeller130. Preferably, as best shown inFIG.6, the fluid flow passage140of each of the flow-inducing protrusions138extends along only a central portion of the respective one of the flow-inducing protrusions. In this manner, a first fluid flow stage FFS1of each flow-inducing protrusion138is defined between a first end portion EP130-1of the impeller130and a lower (i.e., first) end portion of the fluid flow passage140, a second fluid flow stage FFS2is defined between the lower end portion of the fluid flow passage140and a second (i.e., upper) end portion of the fluid flow passage140and a third fluid flow stage FFS3is defined between the upper end portion of the fluid flow passage140and the second end portion EP130-2of the impeller130. The first fluid flow stage FFS1is the lowest area on the impeller130, has the smallest diameter, has the least angle cut and the lower corner may be boxed or otherwise closed.

The rotational flow amplification body132has a first end portion EP132-1engaged with the second end portion EP130-2of the impeller130in a manner that inhibits unrestricted rotational movement therebetween. In preferred embodiments, such engagement includes a first interlocking interface142such as in the form of interlocking shoulders142A,142B. The interlocking shoulder142A,142B may have trapezoidal profiles such that the application of torque causes the interface to draw itself into an interlocking configuration—i.e., in view of the mating tapered edge faces of the trapezoidal profiles. Beneficially, interlocking shoulders having trapezoidal profiles provide a positive locking interface that resists section decoupling resulting from vibration within the pump100during operation (i.e., rotational torque application). For certain applications, a rotational flow amplification body in accordance with the disclosures made herein can be configured for being stackable (e.g., via end-to-end mating of opposing interlocking interfaces) such as for increasing the downhole depth pumping capability.

The rotational flow amplification body132has a central passage144. Preferably, the central passage144of the rotational flow amplification body132is round and has a uniform maximum diameter. Preferably, a centerline axis A2of the rotational flow amplification body132extends colinearly with the rotational axis R1and the central passage144of the rotational flow amplification body132extends contiguously with the interior space S1of the impeller130. A plurality of vanes146(e.g., spiral such as a tapered semi-helix) extend from an interior surface148of an exterior wall149that defines the central passage144of the rotational flow amplification body132. Each of the vanes146extends from adjacent the first end portion of the rotational flow amplification body with an upward inclination in a direction opposite the rotational direction RD. Each of the vanes146may extends contiguously along approximately an entire length of the interior surface148of the rotational flow amplification body132. Each vane146is preferably equal in total length and have the same profile.

Preferably, as shown inFIGS.2A and2B, a downstream facing surface146A of each vane146and the interior surface148of the rotational flow amplification body132jointly form a cupped surface150. The cupped surface150may extend along all or a portion of a total length of each of the vanes146. The cupped surface150forms an elongated containment space151in which a portion of the fluid within the central passage144becomes entrapped (at least temporarily) during rotation of the rotational assembly102. Beneficially, this entrapment of fluid results in a greater amount of energy being applied to the entrapped fluid by the rotational flow amplification body132as compared to vanes that do not form a cupped surface and resulting containment space. The greater amount of energy arises from both an increased magnitude of force imparted onto entrapped fluid by virtue of the cupped surface150and the duration of time that such entrapped fluid remains within the containment space151. In one or more embodiments, the cupped surface150and containment space151may be configured in accordance with a Pelton cup shaped blade.

As best shown inFIG.8, each vane146may be inclined at an angle θ (e.g., 45-degrees or more relative to a radial reference line). In addition to the functionality of rotational flow amplification, such an inclination serves to aid in creating a strong axial load during rotation of the rotational assembly102. The width and angle of the vanes146may be such that the inboard edge153of each vane146is spaced away from each other vane146whereby the center area of the rotational flow amplification body132is open (i.e., unobstructed). This open center area is where the fluid flowing through the rotational flow amplification body132merges and allows any suspended particles to freely pass without causing blockage. At the second end portion EP132-2of the rotational flow amplification body132, each vane146may have a radius where each vane146terminates to allow for a broader flow and to aid in rotational flow of the fluid as it flows into the outlet body132.

As best shown inFIGS.2A and2C, the outlet body132has a first end portion EP134-1engaged with the second end portion EP132-2of the rotational flow amplification body132in a manner that inhibits unrestricted rotational movement therebetween. In preferred embodiments, such engagement includes a first interlocking interface152such as in the form of interlocking shoulders152A,152B. The interlocking shoulder152A,152B may have trapezoidal profiles such that the application of torque causes the interface to draw itself into an interlocking configuration—i.e., in view of the mating tapered edge faces of the trapezoidal profiles.

The outlet body134has a central passage154that terminates at the outlet port112(i.e., the fluid outlet of the pump100). Preferably, a centerline axis A3of the outlet body134extends colinearly with the rotational axis R1and the central passage154of the outlet body134extends contiguously with the central passage144of the rotational flow amplification body132. The central passage154of the outlet body134preferably has a uniform diameter portion154A and a convergent portion154B downstream of the uniform diameter portion154A. The uniform diameter portion154A is a flow gate156leading into the convergent portion154B. In preferred embodiments, the convergent portion154B has a convergent taper of 3:1 over its length relative to inside diameter of the central passage144of the rotational flow amplification body132. The convergent portion154B may have a straight-tapered inside wall surface (as shown) or a non-linear inside wall surface, as desired. The flow gate156may be preceded by a similarly uniform diameter portion of the rotational flow amplification body132downstream of the terminal end of the vanes146.

Turning now to operation of the pump100, the motor1serves to rotate the rotation assembly102relative to the rotation assembly housing104. With at least the inlet end IE of the pump100positioned within a fluid (e.g., water) source, this rotation results in uptake, pressurization, rotational flow conversion and output of the fluid from the pump. In contrast of convention ESP's, operation of the pump100(i.e., a pump in accordance with one or more embodiments of the disclosures made herein) advantageously provides for enhanced operational functionalities that result in enhanced performance, reliability and durability. These enhanced operational functionalities arise from structural arrangement of the pump100that beneficially reduce pumping pressure loses, reduce pumping energy and provide enhanced volumetric flow efficiency arising from increased flow velocities.

Advantageously, rotation of the rotational assembly102generates a total dynamic head (TDH) which increases with net positive suction head (NPSH) formed at the fluid inlet of the impeller130. NPSH is a measure of the pressure experienced by a fluid on the suction side of a pump. Thus, for the pump100, the NPSH combined with the siphoning jointly contribute to the acceleration of fluid into the rotational flow amplification body132.

Rotation of the impeller130(i.e., a flow pressurizing section of the rotation assembly102) results in uptake and pressurization of fluid within which at least the inlet end of the pump100is located. As discussed above in reference toFIG.6, the fluid flow passage140of each of the flow-inducing protrusions138extends along only a central portion of the respective one of the flow-inducing protrusions such that the impeller130preferably includes a first fluid flow stage FFS1(i.e., portion of the impeller below lower edge of fluid flow passage140), a second fluid flow stage FFS2(i.e., portion of the impeller extending vertically along length of the fluid flow passage140) and a third fluid flow stage FFS3(i.e., portion of the impeller above top edge of fluid flow passage140). In this respect, each of the flow-inducing protrusions138has three different functions. The first fluid flow stage FFS1creates a siphoning action that promotes flow of fluid from outside the impeller130into the interior space S2of the second fluid flow stage FFS2. In combination with the siphoning action of the first fluid flow stage FFS1, the second fluid flow stage FFS2draws fluid into the interior space S2of the second fluid flow stage FFS2and compresses the fluid. The inside profile of the impeller130at the second and third fluid flow stages FFS2, FFS3pulls the fluid toward the rotational axis R1, begins to impart a rotational flow profile onto the fluid and pressurizes the fluid relative to its inlet pressure. In this respect, after being subjected to the impeller130, the fluid is provided into the rotational flow amplification body132(i.e., a rotational flow amplification section of the rotation assembly102) in a pressurized manner exhibiting at least a partial rotational flow profile (i.e., in contrast to a random or laminar flow profile).

Rotation of the rotational flow amplification body132(i.e., a rotational flow amplification section of the rotation assembly102) results in the continued transformation of fluid to rotational flow and any associated increase in pressurization. To this end, the rotational flow amplification body132creates fluid rotational (e.g., 360-degree fluid rotation) over the total length of the rotational flow amplification body132. Each vane146and the exterior wall149jointly define a respective open-faced flow chamber through which portions of the fluid travel to thereby amplify the rotational flow of the fluid initially generated in the impeller130. The upstream end face of each vane146may be spaced away from the impeller130to aid in uniform mixing of the fluid as it flows into the enters the rotational flow amplification body132.

The outlet body134(i.e., a flow outlet section of the rotation assembly102) is the third and final stage of the pump100. The function of the outlet body134is to merge rotational fluid flow streams exiting the rotational flow amplification body132—i.e., fluid flows from the open-faced flow chambers and open center area of the rotational flow amplification body132. The taper over the lineal length of the convergent portion134B of the outlet body134creates a compression strength within the rotational fluid flow stream. Kinetic energy is accumulated within this lineal length in both its uniform profile and strength. As fluid exits the outlet body134, its rotational flow profile is defined and a focal point of the kinetic energy in the output fluid flow is created. The longevity and flow distance of the focal point is defined and controlled by parameters such as, for example, rotational speed, fluid viscosity, transfer pipe diameter/length, and the like.

Although the invention has been described with reference to several exemplary embodiments, it is understood that the words that have been used are words of description and illustration, rather than words of limitation. Changes may be made within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the invention in all its aspects. Although the invention has been described with reference to particular means, materials and embodiments, the invention is not intended to be limited to the particulars disclosed; rather, the invention extends to all functionally equivalent technologies, structures, methods and uses such as are within the scope of the appended claims.