U.S. patent application number 14/013494 was filed with the patent office on 2015-03-05 for electrical submersible pump and pump system including additively manufactured structures and method of manufacture.
This patent application is currently assigned to General Electric Company. The applicant listed for this patent is General Electric Company. Invention is credited to Farshad Ghasripoor, James William Sears, Vijay Shilpiekandula, Hongqing Sun, Yanzhe Yang.
Application Number | 20150060042 14/013494 |
Document ID | / |
Family ID | 51900515 |
Filed Date | 2015-03-05 |
United States Patent
Application |
20150060042 |
Kind Code |
A1 |
Shilpiekandula; Vijay ; et
al. |
March 5, 2015 |
ELECTRICAL SUBMERSIBLE PUMP AND PUMP SYSTEM INCLUDING ADDITIVELY
MANUFACTURED STRUCTURES AND METHOD OF MANUFACTURE
Abstract
An electric submersible pump and pump system including
additively manufactures structures and method of manufacture are
disclosed. The pump system including the electric submersible pump
and an electric motor configured to operate the electric
submersible pump. The electric submersible pump including a
housing, at least one impeller and at least one diffuser disposed
within the housing in cooperative engagement. The housing, the at
least one impeller, and the at least one diffuser defining an
internal volume configured to receive a fluid. At least one of the
at least one impeller and the at least one diffuser configured as a
monolithic additively manufactured structure comprised of a metal
matrix composite. Also provided is an electric submersible pump
including an impeller and a diffuser, wherein at least one of the
impeller and the diffuser is configured as a monolithic additively
manufactured structure comprised of a tungsten carbide (WC)
dispersed in a metal matrix.
Inventors: |
Shilpiekandula; Vijay;
(Saratoga Springs, NY) ; Sears; James William;
(Niskayuna, NY) ; Yang; Yanzhe; (Niskayuna,
NY) ; Sun; Hongqing; (Niskayuna, NY) ;
Ghasripoor; Farshad; (Berkeley, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
General Electric Company |
Schenectady |
NY |
US |
|
|
Assignee: |
General Electric Company
Schenectady
NY
|
Family ID: |
51900515 |
Appl. No.: |
14/013494 |
Filed: |
August 29, 2013 |
Current U.S.
Class: |
166/65.1 ;
419/53 |
Current CPC
Class: |
C22C 32/00 20130101;
F04D 29/448 20130101; Y02P 10/25 20151101; Y02P 10/295 20151101;
B22F 3/1055 20130101; E21B 43/128 20130101; F05D 2300/20 20130101;
C22C 1/10 20130101; C22C 1/0433 20130101; F05D 2300/10 20130101;
B22F 2003/1057 20130101; C22C 33/02 20130101; F05D 2230/31
20130101; F04D 13/10 20130101; F04D 29/2227 20130101; B22F 3/008
20130101; C22C 32/0026 20130101; C22C 32/0047 20130101; C22C
2200/02 20130101; F04D 29/026 20130101; F05D 2300/6032 20130101;
F05D 2300/2263 20130101 |
Class at
Publication: |
166/65.1 ;
419/53 |
International
Class: |
E21B 43/12 20060101
E21B043/12; B22F 3/105 20060101 B22F003/105; B22F 3/00 20060101
B22F003/00 |
Claims
1. An electric submersible pump comprising: a housing; at least one
impeller disposed in the housing; and at least one diffuser
disposed in the housing and configured in cooperative engagement
with the at least one impeller, wherein at least one of the at
least one impeller and the at least one diffuser is configured as a
monolithic additively manufactured structure comprised of a metal
matrix composite.
2. The electric submersible pump of claim 1, wherein the housing,
the at least one impeller, and the at least one diffuser define an
internal volume within the housing, said internal volume configured
to receive a fluid.
3. The electric submersible pump of claim 1, wherein the electric
submersible pump is configured as a centrifugal pump comprising one
or more pump stages, wherein each of the one or more pump stages
comprises an additively manufactured impeller and an additively
manufactured diffuser.
4. The electric submersible pump of claim 1, wherein the metal
matrix composite comprises a ceramic material dispersed within a
metal matrix.
5. The electric submersible pump of claim 3, wherein the metal
matrix comprises a material selected from the group consisting of
cobalt, nickel, iron, chromium and combinations thereof.
6. The electric submersible pump of claim 3, wherein the ceramic
material comprises a crystalline ceramic material.
7. The electric submersible pump of claim 3, wherein the ceramic
material comprises an amorphous ceramic material.
8. The electric submersible pump of claim 3, wherein the ceramic
material comprises a metal in combination with a non-metal.
9. The electric submersible pump of claim 3, wherein the ceramic
material comprises at least one of an oxide, a nitride, a boride, a
carbide, a silicide, a silica, or a sulfide.
10. The electric submersible pump of claim 1, wherein the metal
matrix composite comprises tungsten carbide (WC) dispersed in a
metal matrix.
11. The electric submersible pump of claim 1, wherein the metal
matrix composite comprises tungsten carbide (WC) dispersed in a
substantially chromium matrix.
12. An electrical submersible pump system, comprising: an electric
submersible pump; and an electric motor configured to operate the
electric submersible pump, wherein the electric submersible pump
comprises: a housing; at least one impeller; and at least one
diffuser, wherein the at least one impeller and the at least one
diffuser are disposed within the housing and configured in
cooperative engagement, wherein the housing, the at least one
impeller, and the at least one diffuser define an internal volume
within the housing, said internal volume configured to receive a
fluid, and wherein at least one of the at least one impeller and
the at least one diffuser is configured as a monolithic additively
manufactured structure comprised of a metal matrix composite.
13. The electric submersible pump system of claim 12, wherein the
metal matrix composite comprises a ceramic material dispersed
within a metal matrix.
14. The electric submersible pump system of claim 13, wherein the
metal matrix comprises a material selected from the group
consisting of cobalt, nickel, iron, chromium and combinations
thereof.
15. The electric submersible pump system of claim 13, wherein the
ceramic material comprises one of a crystalline ceramic material or
an amorphous ceramic material.
16. The electric submersible pump system of claim 13, wherein the
ceramic material comprises at least one of an oxide, a nitride, a
boride, a carbide, a silicide, a silica, or a sulfide.
17. The electric submersible pump system of claim 13, wherein the
ceramic material comprises a material selected from the group
consisting of alumina, silica, aluminum silicate, zirconium oxide,
mica, glass and combinations thereof.
18. The electric submersible pump system of claim 11, wherein the
metal matrix composite comprises tungsten carbide (WC) dispersed in
a substantially chromium matrix.
19. A method of manufacturing an electric submersible pump
comprising: (a) forming at least one impeller disposed in a
housing; and (b) forming at least one diffuser disposed in the
housing and configured in cooperative engagement with the at least
one impeller, wherein at least one of the at least one impeller and
the at least one diffuser is configured as a monolithic structure
comprised of a metal matrix composite, and wherein at least one of
steps (a) through (b) is carried out by direct metal laser
sintering.
20. The method of claim 19, wherein direct metal laser sintering
comprises defining a configuration for the at least one impeller or
the at least one diffuser, depositing a powder into a chamber,
applying an energy source to the deposited powder and consolidating
the powder into a cross-sectional shape corresponding to the
defined configuration.
21. The method of claim 20, wherein the powder comprises metal
matrix composite powder.
22. The method of claim 20, wherein the energy source comprises a
laser or electron beam.
23. The method of claim 20, further comprising programming the
configuration into an additive manufacturing system.
Description
BACKGROUND
[0001] The present disclosure relates to electric submersible
pumps. More particularly, the present disclosure relates to
electric submersible pumps configured to provide improved
contaminant tolerance and resulting increase in life span of the
pump and pump components.
[0002] Electric submersible pump systems are used in a wide variety
of environments, including wellbore applications for pumping
production fluids, such as water or petroleum. Electric submersible
pump systems typically include, among other components, a
submersible pump that provides for the pumping of high volumes of
fluid, such as for use in oil wells which produce large quantities
of water, or high volume water wells and a submersible motor for
operating the electric submersible pump.
[0003] A typical electric submersible pump utilizes numerous stages
of diffusers and impellers, referred to as pump stages, for pumping
fluid to the surface from the well. During operation, the impellers
are configured to rotate within the diffusers. It is known in the
art to make impellers and diffusers from a cast alloy by machining
operations, such as milling, turning, etc.
[0004] During operation of these types of submersible pumps,
tolerance to contaminants in the pumped fluid, and in particular
sand, is of great concern. More particularly, tolerance to
contaminants in the pumped fluid is a critical functionality that
can enhance the lifespan of the electric submersible pumps. If a
fluid being pumped contains a significant amount of contaminants,
and more particularly entrained abrasive contaminants, such as
sand, the abrasive particles will abrade and/or erode the
components, and in particular the pump impellers and diffusers, and
thereby shortening the life of the pump. To minimize the
detrimental effects of these contaminants, recent developments have
provided submersible pumps that include features to reduce material
loss due to contaminants. One of these features includes utilizing
coatings on the component substrate, such as the cast alloy, thus
providing for a harder surface area that is less susceptible to
damage by the impact of these contaminants. In addition, the
inclusion of other wear resistant pump components, comprised of
harder material than the impeller and diffuser, may be utilized
such as bearings formed of hardened material. However, inclusion of
these coating and or wear resistant components is considerably more
expensive than conventional pump stage components.
[0005] In the field of oil and gas, it is typical to remove a pump
from a well for servicing periodically. If contaminants have
abraded the pump components severely, the pump may potentially have
to be removed earlier than the usual life. The cost for removing an
electric submersible pump, including lost production time, can be
quite expensive, particularly with regard to wells not easily
accessible, such as offshore drilling wells.
[0006] Accordingly, it is desired to provide for an electric
submersible pump, including conventional pump stage components
having improved tolerance to contaminants, such as sand, thus
providing for an increase in the lifespan of the pump. Further,
there is a need for an electric submersible pump that allows
continuous operation of the electric submersible pump system for an
extended period of time.
BRIEF DESCRIPTION
[0007] These and other shortcomings of the prior art are addressed
by the present disclosure, which provides an electric submersible
pump, an electrical submersible pump system and a method of
manufacturing an electric submersible pump.
[0008] One aspect of the present disclosure resides in an electric
submersible pump. The electric submersible pump comprising: a
housing; at least one impeller disposed in the housing; and at
least one diffuser disposed in the housing and configured in
cooperative engagement with the at least one impeller. At least one
of the at least one impeller and the at least one diffuser is
configured as a monolithic additively manufactured structure
comprised of a metal matrix composite.
[0009] Another aspect of the present disclosure resides in an
electrical submersible pump system. The electrical submersible pump
system comprising: an electric submersible pump; and an electric
motor configured to operate the electric submersible pump. The
electric submersible pump comprises: a housing; at least one
impeller; and at least one diffuser. The at least one impeller and
the at least one diffuser are disposed within the housing and
configured in cooperative engagement. The housing, the at least one
impeller, and the at least one diffuser define an internal volume
within the housing, said internal volume configured to receive a
fluid. At least one of the at least one impeller and the at least
one diffuser is configured as a monolithic additively manufactured
structure comprised of a metal matrix composite.
[0010] Yet another aspect of the disclosure resides a method of
manufacturing an electric submersible pump. The method comprising:
(a) forming at least one impeller disposed in a housing; and (b)
forming at least one diffuser disposed in the housing and
configured in cooperative engagement with the at least one
impeller. At least one of the at least one impeller and the at
least one diffuser is configured as a monolithic structure
comprised of a metal matrix composite. At least one of steps (a)
through (b) is carried out by direct metal laser sintering.
[0011] Various refinements of the features noted above exist in
relation to the various aspects of the present disclosure. Further
features may also be incorporated in these various aspects as well.
These refinements and additional features may exist individually or
in any combination. For instance, various features discussed below
in relation to one or more of the illustrated embodiments may be
incorporated into any of the above-described aspects of the present
disclosure alone or in any combination. Again, the brief summary
presented above is intended only to familiarize the reader with
certain aspects and contexts of the present disclosure without
limitation to the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0012] These and other features, aspects, and advantages of the
present disclosure will become better understood when the following
detailed description is read with reference to the accompanying
drawings in which like characters represent like parts throughout
the drawings, wherein:
[0013] FIG. 1 is a side view of an electric submersible pump
disposed within a wellbore in accordance with one or more
embodiments shown or described herein;
[0014] FIG. 2 is a schematic sectional view of a portion of an
electric submersible pump assembly in accordance with one or more
embodiments shown or described herein;
[0015] FIG. 3 is a schematic sectional view of a portion of the
electric submersible pump assembly of FIG. 2 in accordance with one
or more embodiments shown or described herein;
[0016] FIG. 4 is an isometric view of an electric submersible pump
diffuser in accordance with one or more embodiments shown or
described herein;
[0017] FIG. 5 is an isometric view of an electric submersible pump
impeller in accordance with one or more embodiments shown or
described herein;
[0018] FIG. 6 is an enlarged view of a portion of a metal matrix
composite material of an electric submersible pump component in
accordance with one or more embodiments shown or described herein;
and
[0019] FIG. 7 is a flowchart depicting an embodiment of an additive
manufacturing method for producing the effusion plate in accordance
with the present disclosure.
DETAILED DESCRIPTION
[0020] The disclosure will be described for the purposes of
illustration only in connection with certain embodiments; however,
it is to be understood that other objects and advantages of the
present disclosure will be made apparent by the following
description of the drawings according to the disclosure. While
preferred embodiments are disclosed, they are not intended to be
limiting. Rather, the general principles set forth herein are
considered to be merely illustrative of the scope of the present
disclosure and it is to be further understood that numerous changes
may be made without straying from the scope of the present
disclosure.
[0021] As described in detail below, embodiments of the present
disclosure provide a system and method for monolithic design and
manufacture of an electric submersible pump. The present disclosure
further provides embodiments of a system and method for monolithic
design and manufacture of an electric submersible pump manufactured
via additive manufacturing techniques. Using such techniques, the
monolithic design so produced may provide improved tolerance to
contaminants.
[0022] The terms "first," "second," and the like, herein do not
denote any order, quantity, or importance, but rather are used to
distinguish one element from another and intended for the purpose
of orienting the reader as to specific components parts.
Approximating language, as used herein throughout the specification
and claims, may be applied to modify any quantitative
representation that could permissibly vary without resulting in a
change in the basic function to which it is related. The modifier
"about" used in connection with a quantity is inclusive of the
stated value, and has the meaning dictated by context, (e.g.,
includes the degree of error associated with measurement of the
particular quantity). Accordingly, a value modified by a term or
terms, such as "about", is not limited to the precise value
specified. In some instances, the approximating language may
correspond to the precision of an instrument for measuring the
value.
[0023] In the following specification and the claims, the singular
forms "a", "an" and "the" include plural referents unless the
context clearly dictates otherwise. As used herein, the term "or"
is not meant to be exclusive and refers to at least one of the
referenced components being present and includes instances in which
a combination of the referenced components may be present, unless
the context clearly dictates otherwise. In addition, in this
specification, the suffix "(s)" is usually intended to include both
the singular and the plural of the term that it modifies, thereby
including one or more of that term (e.g., "the impeller" may
include one or more impellers, unless otherwise specified).
Reference throughout the specification to "one embodiment,"
"another embodiment," "an embodiment," and so forth, means that a
particular element (e.g., feature, structure, and/or
characteristic) described in connection with the embodiment is
included in at least one embodiment described herein, and may or
may not be present in other embodiments. Similarly, reference to "a
particular configuration" means that a particular element (e.g.,
feature, structure, and/or characteristic) described in connection
with the configuration is included in at least one configuration
described herein, and may or may not be present in other
configurations. In addition, it is to be understood that the
described inventive features may be combined in any suitable manner
in the various embodiments and configurations.
[0024] As used herein, the terms "may" and "may be" indicate a
possibility of an occurrence within a set of circumstances; a
possession of a specified property, characteristic or function;
and/or qualify another verb by expressing one or more of an
ability, capability, or possibility associated with the qualified
verb. Accordingly, usage of "may" and "may be" indicates that a
modified term is apparently appropriate, capable, or suitable for
an indicated capacity, function, or usage, while taking into
account that in some circumstances the modified term may sometimes
not be appropriate, capable, or suitable. For example, in some
circumstances, an event or capacity can be expected, while in other
circumstances the event or capacity cannot occur--this distinction
is captured by the terms "may" and "may be".
[0025] Referring to FIG. 1, an exemplary electric submersible pump
(ESP) system 10 including portions manufactured via additive
manufacturing techniques is illustrated wherein the ESP system is
disposed within a wellbore 12. In one embodiment, the wellbore 12
is formed in a geological formation 14, for example, an oilfield.
The wellbore 12 is further lined by a casing 16, as indicated in
FIG. 1. In some embodiments, the casing 16 may be further
perforated to allow a fluid to be pumped (referred to herein as
"production fluid") to flow into the casing 16 from the geological
formation 14 and pumped to the surface of the wellbore 12.
[0026] As illustrated in FIG. 1, the ESP system 10 includes an
electric submersible pump 20, an electric motor 22 configured to
operate the electric submersible pump 20, and an electric cable 24
configured to power the electric motor 22. As noted earlier, the
ESP system 10 according to some embodiments of the invention is
disposed within a wellbore 12 for continuous operation over an
extended period of time. Accordingly, in such embodiments, the ESP
system 10 and the components of the ESP system 10 may be subjected
to extreme conditions such as high temperatures, high pressures,
and exposure to contaminants, such as sand. As further illustrated
in FIG. 2, in an embodiment, the ESP system 10 further includes a
gas separator 26 and a seal 28. In some embodiments, the ESP system
10 may further include additional components such as bellows or
springs (not shown).
[0027] In an embodiment, the present invention provides an electric
submersible pump manufactured via additive manufacturing techniques
that is capable of withstanding high temperatures, high pressures,
and exposure to contaminants. With reference to FIGS. 2-4, the
electric submersible pump 20 according to an embodiment is a
multi-stage unit with the number of stages being determined by the
operating requirements. Each stage consists of a driven impeller
and a diffuser manufactured via additive manufacturing techniques
(described presently) which directs flow to the next stage of the
pump. In an embodiment, the electrical submersible pump 20 is
configured as a centrifugal pump comprising one or more pump stages
30. In the embodiment illustrated in FIG. 3, the electric
submersible pump 20 is comprised of a plurality of pump stages 30.
Each pump stage 30 is comprised of at least one impeller 34 and at
least one diffuser 36, (as best illustrated in FIGS. 3 and 4)
stacked on a common shaft 38 extending at least the length of the
pump 20 and cooperatively engaged one with the other. The one or
more pump stages 30, and more particularly the at least one
impeller 34 and at least one diffuser 36 are disposed within a
housing 40. The shaft 38 extends concentrically through the housing
40 and is rotated by the electric motor 22, thus driving the pump
20. In an embodiment, the electric submersible pump 20 may include
one or more rotating impellers 34 and one or more stationary
diffusers 36 that can be assembled in either floater or compression
configurations to meet performance requirements.
[0028] In a particular configuration, each of the at least one
impellers 34 is configured to rotate within a diffuser 36 during
operation of the pump 20. The diffuser 36 is stationarily mounted
within the housing 40. It has been found that the number of
impellers 34 needed to produce a given flow rate at a given
pressure is inversely proportional to impeller speed. More
particularly, if the impeller speed is increased by a factor of 3,
the number of impellers 34 can be reduced by the same ratio and
produce the desired flow rate and pressure. In an embodiment, the
at least one impeller 34 and the at least one diffuser 36 define an
internal volume 42 within the housing 40, said internal volume 42
configured to receive a fluid 44 as indicated in FIG. 3.
[0029] In an embodiment, the internal volume 42 is configured such
that there is fluid communication between the at least one impeller
34, the at least one diffuser 36 and the fluid 44 that the internal
volume 42 may contain. The term "fluid communication", as used
herein, means that the fluid 44 passing through the electric
submersible pump 20, is in contact with the internal volume 42 of
the electric submersible pump 20, and more particularly is in
contact with the at least one impeller 34 and the at least one
diffuser 36. Furthermore, in an embodiment, the electric
submersible pump 20 and the components of the electric submersible
pump 20 have a geometry and configuration such that the fluid 44
when passing through the internal volume 42 is in fluid
communication with the at least one impeller 34 and the at least
one diffuser 36.
[0030] FIGS. 4 and 5 illustrate embodiments of the at least one
impeller 34 and the at least one diffuser 36 formed via additive
manufacturing techniques. As shown in FIGS. 4 and 5, in an
embodiment, each of the at least one impeller 34 and the at least
one diffuser 36 are configured as a monolithic structure and
comprised of a metal matrix composite 50. As used herein, the term
"metal matrix composite" is comprised of a metal matrix having a
ceramic material dispersed therein (described presently). These
materials are inherently designed to be sand tolerant and highly
resistant to other contaminant materials that may result in
erosion, abrasion, and corrosion to the pump stage components. More
specifically, as illustrated, at least one or both of the
cooperating impeller 34 and diffuser 36 are formed as a monolithic
structure, and having a single solid, uniform material makeup.
During the manufacture process, the monolithic structures may be
manufactured by additive manufacturing processes, such Direct Metal
Laser Melting (DMLM). In general, additive manufacturing techniques
involve applying a source of energy, such as a laser or electron
beam, to deposited powder layers in order to grow a part having a
particular shape and features.
[0031] Referring now to FIG. 6, illustrated is a portion of a
component according to an embodiment, and more particularly a
portion of one of the impeller 34 or the diffuser 36 comprised of a
metal matrix composite 50. The metal matrix composite 50 is
comprised of a metal matrix 52 and a ceramic material 54.
[0032] The term "matrix" as used herein refers to a fine-grained
material in which larger materials or objects are embedded. Further
the term "metal matrix" as used herein refers to a metal material
or a material comprised substantially of a metal material and
capable of having other materials embedded therein. In one
embodiment, the metal matrix 52 includes a metal in combination
with a non-metal. In an embodiment, the metal matrix 52 includes a
material selected from the group consisting cobalt, nickel,
chromium, iron, copper and combinations thereof. In an embodiment,
the metal matrix composite 50 includes the ceramic material 54
dispersed in the metal matrix 52 including chromium.
[0033] The term "ceramic" as used herein refers to an inorganic,
non-metallic material having high hardness, high temperature
strength, good electro-thermal insulation, and high chemical
stability. Further, the term "ceramic" as used herein refers to a
crystalline ceramic material or an amorphous ceramic material. In
one embodiment, the ceramic material 54 includes a metal in
combination with a non-metal. In one embodiment, the ceramic
material 54 includes an oxide, a nitride, a boride, a carbide, a
silicide, a silica, or a sulfide. In one embodiment, the ceramic
material 54 includes a material selected from the group consisting
of alumina, silica, aluminum silicate, zirconium oxide, mica, glass
and combinations thereof. In an embodiment, the ceramic material 54
includes tungsten carbide (WC) dispersed in the metal matrix
52.
[0034] As noted above, additive manufacturing techniques generally
allow for construction of custom parts having complex geometries,
curvatures, and features, such as at least one impeller 34 and the
at least one diffuser 36 discussed herein. Accordingly, additive
manufacturing may be used to construct portions of the submersible
pump having a variety of shapes and features, such as the at least
one impeller 34 and the at least one diffuser 36.
[0035] Additive manufacturing may be particularly useful in the
construction of at least one impeller 34 and the at least one
diffuser 36 for the electric submersible pump, as the at least one
impeller 34 and the at least one diffuser 36 may be constructed as
a monolithic structure from high-strength materials that may be
difficult to machine or tool using traditional methods. In
addition, additive manufacturing techniques provide the capability
to construct complex solid objects from computer models, without
difficult machining steps. In general, additive manufacturing
techniques involve applying a source of heat, such as a laser or
electron beam, to deposited powder layers (e.g., layer after layer)
in order to grow a part having a particular shape.
[0036] In the exemplary embodiment, the at least one impeller 34
and the at least one diffuser 36 are fabricated using an additive
manufacturing process. Specifically, an additive manufacturing
process known as direct metal laser sintering (DMLS) or direct
metal laser melting (DMLM) is used to manufacture the monolithic
components. Although the process is described herein as DMLS, one
having ordinary skill in the art would understand that DMLM could
also be used. Alternatively, the additive manufacturing method is
not limited to the DMLS or DMLM process, but may be any known
additive manufacturing process. This fabrication process eliminates
joints that would typically be defined within the at least one
impeller 34 and the at least one diffuser 36, thus making them
susceptible to contaminants. Rather, DMLS is an additive layer
process that produces a component directly from a CAD model using a
laser and a fine metal/composite powder.
[0037] The CAD model is sliced into thin layers, and the layers are
then reconstructed layer by layer, such that adjacent layers are
laser fused together. The layer thickness is generally chosen based
on a consideration of accuracy vs. speed of manufacture. Initially,
a steel plate is typically fixed inside the DMLS machine to serve
as both a support and a heat sink. A dispenser delivers the powder
to the support plate and a coater arm or blade spreads the powder
on the plate. The machine software controls the laser beam focus
and movement so that wherever the laser beam strikes the powder,
the powder forms into a solid. The process is repeated layer by
layer until the fabrication of the component, and in this
particular instance, the at least one impeller 34 or the at least
one diffuser 36 is completed.
[0038] It will thus be appreciated that using the DMLS method
permits the monolithic design and construction of the at least one
impeller 34 and the at least one diffuser 36 that were previously
not producible in a reliable or economical manner.
[0039] FIG. 7 is a block diagram illustrating an embodiment of a
method 60 for constructing the at least one impeller 34 and the at
least one diffuser 36 using additive manufacturing techniques. The
method 60 may be performed by an additive manufacturing system,
with the acts described herein being performed by a computer. The
method 60 includes defining a particular configuration (block 62).
The configuration may be programmed into an additive manufacturing
system by using a specialized or general purpose computer, for
example. In some embodiments, the model may be for constructing the
at least one impeller 34 or the at least one diffuser 36, wherein
each component has a complex shape. The defined configuration may
include any of the shapes and features described above. In step 64,
a powder (e.g., a metal, ceramic, or composite powder) is deposited
into a chamber, such as a vacuum chamber. Any of a variety of
materials may be used in any suitable combination, including those
described in detail above. In step 66, an energy source, such a
laser or electron beam, for example, is applied to the deposited
metal powder. The laser or electron beam melts or otherwise
consolidates the powder into a layer having a cross-sectional shape
68 corresponding to the configuration defined in step 62. A
computer or operator may determine whether the part is incomplete
or complete, in step 708. If the part is incomplete, then steps 64
and 66 are repeated to produce layers of consolidated powder having
cross-sectional shapes 68 corresponding to the defined confirmation
or model until construction of the part is complete. In other
words, the energy source is applied to melt or otherwise
consolidate each newly deposited powder layer until the final
product is complete and the at least one impeller 34 and/or the at
least one diffuser 36 having the defined configuration is
produced.
[0040] Accordingly, disclosed is a novel electric submersible pump
system, and more particularly, a novel electric submersible pump
configured to provide improved contaminant tolerance and resulting
increase in life span of the pump and pump components. Unlike
contaminant tolerant coatings applied to metal alloy components,
the lifespan made possible through the use of components
manufactured by additive manufacturing techniques and configured as
monolithic structures comprised of a metal matrix composite, as
disclosed herein, is much longer and not limited by thickness of
coating. The resulting system and pump minimize, if not eliminate,
the effects of erosion, abrasion, and corrosion on component
parts.
[0041] In one embodiment, the electric motor 22 is configured to
operate a pump 20 in a borehole, or wellbore 12, as indicated in
FIG. 1. In one embodiment, the electric motor 22 is configured to
operate an electric submersible pump 20 including the impeller 34
and the diffuser 36, as indicated in FIGS. 3-5. In one particular
embodiment, at least one of the impeller 34 and the diffuser 36 is
configured as a monolithic structure, or component, comprised of
the metal matrix composite 50 to allow long term operation of the
at least one of the impeller 34 and the diffuser 36 in the presence
of contaminants, such as sand, in the wellbore 12.
[0042] In one embodiment, an ESP system 10 is provided. Referring
to FIG. 1, in one embodiment, the ESP system 10 is configured to be
installed in a wellbore 12. In one embodiment, the ESP system 10 is
configured to be installed in a geological formation 14, such as an
oilfield. In some embodiments, the ESP system 10 may be capable of
pumping production fluids from a wellbore 12 or an oilfield. The
production fluids may include hydrocarbons (oil) and water, for
example.
[0043] In some embodiments, the ESP system 10 is installed in a
geological formation 14, such as an oilfield, by drilling a hole or
a wellbore 12 in a geological formation 14, for example an
oilfield. The wellbore 12 maybe vertical, and may be drilled in
various directions, for example, upward or horizontal. In one
embodiment, the wellbore 12 is cased with a metal tubular structure
referred to as the casing 16. In some embodiments, cementing
between the casing 16 and the wellbore 12 may also be provided.
Once the casing 16 is provided inside the wellbore 12, the casing
16 may be perforated to connect the geological formation 14 outside
of the casing 16 to the inside of the casing 16. In some
embodiments, an artificial lift device such as the ESP system 10 of
the present disclosure may be provided to drive downhole well
fluids to the surface. The ESP system 10 according to some
disclosed embodiments is used in oil production to provide an
artificial lift to the oil to be pumped.
[0044] An ESP system 10 may include surface components, for
example, an oil platform (not shown) and sub-surface components
(found in the wellbore). In one embodiment, the ESP system 10
further includes surface components such as motor controller
surface cables and transformers (not shown). In one embodiment, the
sub-surface components may include pumps, motor, seals, or
cables.
[0045] Referring again to FIG. 1, in one embodiment, an ESP system
10 includes sub-surface components such as the electric submersible
pump 20 and the electric motor 22 configured to operate the pump
20. In one embodiment, the electric motor 22 is a submersible
two-pole, squirrel cage, induction electric motor. In one
embodiment, the electric motor 22 is a permanent magnet motor. The
motor size may be designed to lift the desired volume of production
fluids. In one embodiment, the pump 22 is a multi-stage unit with
the number of stages being determined by the operating
requirements. In one embodiment, each stage of the electric
submersible pump 20 includes a driven impeller 34 and a diffuser 36
which directs flow to the next stage of the electric submersible
pump 20. On one embodiment, the electric submersible pump 20
includes a first pump stage and a second pump stage.
[0046] In one embodiment, as indicated in FIG. 1, the electric
motor 20 is further coupled to an electrical power cable 24. In one
embodiment, the electrical power cable 24 is coupled to the
electric motor 22 by an electrical connector. In some embodiments,
the electrical power cable 24 provides the power needed to power
the electric motor 22 and may have different configurations and
sizes depending on the application. In some embodiments, the
electrical power cable 24 is designed to withstand the
high-temperature wellbore environment.
[0047] Further, as noted earlier, in one embodiment, the electric
submersible pump 20 includes a housing 40, the impeller 34 and the
diffuser 36, the impeller 34 and the diffuser 36 are disposed
within the housing 40, as indicated in FIG. 3. As noted earlier,
the housing 40, the impeller 34 and the diffuser 36 define the
internal volume 42 within the housing 40, said internal volume 42
containing the fluid 44, as indicated in FIG. 3.
[0048] In the disclosed embodiments, the impeller 34 and the
diffuser 36 are configured as monolithic structures manufactured
utilizing additive manufacturing techniques and comprised of the
metal matrix composite 50, thus enabling operation in the presence
of damaging contaminants, where the system 10 is exposed to these
types of conditions. The metal matrix composite 50 advantageously
allows for the electric submersible pump 20, and more particularly
the impeller 34 and the diffuser 36 to continuously operate in
environments in which contaminants are present.
[0049] This written description uses examples to disclose the
disclosure, including the best mode, and also to enable any person
skilled in the art to practice the disclosure, including making and
using any devices or systems and performing any incorporated
methods. The patentable scope of the disclosure is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they have structural elements that do not differ
from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal language of the claims.
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