Radial Dimensional Stack-Up Analysis: ESP Pump
AME Advisor: Dr. Stalford ISE Advisor: Dr. Raman Company Advisor: Mr. Schoelen
Patrick Detamore, Johnathan McClary, William Powell, Brett Widmer
Problem Background
Current TD Series
Proposed TD Design Features Optimization Model
GE Oil and Gas
Subject to:
đ?‘ĽR : đ??źđ?‘šđ?‘?đ?‘’đ?‘™đ?‘™đ?‘’đ?‘&#x; đ?‘€đ?‘€đ??ś đ??ˇđ?‘’đ?‘Łđ?‘–đ?‘Žđ?‘Ąđ?‘–đ?‘œđ?‘› đ?‘ĽQ : đ??źđ?‘šđ?‘?đ?‘’đ?‘™đ?‘™đ?‘’đ?‘&#x; đ??żđ?‘€đ??ś đ??ˇđ?‘’đ?‘Łđ?‘–đ?‘Žđ?‘Ąđ?‘–đ?‘œđ?‘› đ?‘ĽO : đ??ˇđ?‘–đ?‘“đ?‘“đ?‘˘đ?‘ đ?‘’đ?‘&#x; đ??żđ?‘€đ??ś đ??ˇđ?‘’đ?‘Łđ?‘–đ?‘Žđ?‘Ąđ?‘–đ?‘œđ?‘› Maximize:
§ OKC manufactures electric submersible pumps § ESP pumps produce 150-50,000 barrels/day § Spinning the impellers on the pump shaft creates artificial lift § Head generated by the pump is what lifts fluid to surface
∑O"YR đ?‘Ľ"
Sum of Deviations
đ?‘†đ?‘˜đ?‘–đ?‘&#x;đ?‘Ą đ??źđ?‘šđ?‘?đ?‘’đ?‘™đ?‘™đ?‘’đ?‘&#x; đ?‘‡đ?‘œđ?‘™đ?‘’đ?‘&#x;đ?‘Žđ?‘›đ?‘?đ?‘’: 0.002 ≤ đ?‘§R − đ?‘§Q đ?‘†đ?‘˜đ?‘–đ?‘&#x;đ?‘Ą đ??ˇđ?‘–đ?‘“đ?‘“đ?‘˘đ?‘ đ?‘’đ?‘&#x; đ?‘‡đ?‘œđ?‘™đ?‘’đ?‘&#x;đ?‘Žđ?‘›đ?‘?đ?‘’: 0.002 ≤ đ?‘§O − đ?‘§H đ??ťđ?‘˘đ?‘? đ??źđ?‘šđ?‘?đ?‘’đ?‘™đ?‘™đ?‘’đ?‘&#x; đ?‘‡đ?‘œđ?‘™đ?‘’đ?‘&#x;đ?‘Žđ?‘›đ?‘?đ?‘’: 0.002 ≤ đ?‘§R − đ?‘§Q đ??ťđ?‘˘đ?‘? đ??ˇđ?‘–đ?‘“đ?‘“đ?‘˘đ?‘ đ?‘’đ?‘&#x; đ?‘‡đ?‘œđ?‘™đ?‘’đ?‘&#x;đ?‘Žđ?‘›đ?‘?đ?‘’: 0.002 ≤ đ?‘§O − đ?‘§H
đ?‘§? : đ?‘ đ?‘’đ?‘¤ đ??ˇđ?‘–đ?‘šđ?‘’đ?‘›đ?‘ đ?‘–đ?‘œđ?‘›đ?‘ đ?‘— = (1, 2, 3, 4)
Skirt Clearance
0.018
Redesigned Hub Clearances Hub Clearances
0.012
0.016 0.01
0.012
Clearance Max
0.008
0.01 Clearance Max
0.008 0.006
0.006
0.004
0.004
Current TD Skirt Clearance
Clearance (in.)
Clearance (in.)
0.014
Under-defined ESP running clearances
0.002
0.002 0 TD 1000
TD 675
TD 1750
TD 460
TD 850
TD 3000
Model
TD 3500
TD 4300
TD 6000
0 TD 1000
TD 675
TD 1750
TD 460
TD 850
Model
TD 3000
TD 3500
TD 4300
TD 6000
Redesign Examples TD 1000 Impeller Hub Dimension Current
Current TD Hub Clearance
TD 1750 Impeller Skirt Dimension
New
0.872 0.872 ∅ ∅ 0.870 0.869 Increased Tolerance by 0.001 in.
Current New 1.942 1.939 ∅ ∅ 1.939 1.936 Maintain Tolerance & Standardize Clearance
Proposed Design Impacts • Standardized Running Clearances
Project Process Steps 1) Collect drawings 2) Pull information 3) Calculate clearances 4) Plot clearances 5) Analyze clearances 6) Identify closest running clearance 7) Create a ‘hybrid’ RC standard 8) Adjust tolerances 9) Gather machining shop quotes 10) Cost benefit analysis 11) Design recommendations
đ??ťđ?‘˘đ?‘? đ?‘€đ?‘Žđ?‘Ľ đ??śđ?‘™đ?‘’đ?‘Žđ?‘&#x;đ?‘Žđ?‘›đ?‘?đ?‘’: 0.010 = đ?‘§O − đ?‘§Q đ??ťđ?‘˘đ?‘? đ?‘€đ?‘–đ?‘› đ??śđ?‘™đ?‘’đ?‘Žđ?‘&#x;đ?‘Žđ?‘›đ?‘?đ?‘’: 0.005 = đ?‘§H − đ?‘§R
đ?‘Ś? : đ??śđ?‘˘đ?‘&#x;đ?‘&#x;đ?‘’đ?‘›đ?‘Ą đ??ˇđ?‘–đ?‘šđ?‘’đ?‘›đ?‘ đ?‘–đ?‘œđ?‘›đ?‘ j = (1, 2, 3, 4)
Redesigned Skirt Clearances
6 different series of pump stages ranging 3.38-9.50in OD housing size
§ Excessive Vibration § Flow Recirculation § Self-Machining § Heavy Power Consumption Investigate the radial stack-up of all stages of pumps § Create a hybrid-standard § Loosen tolerances § Standardize the series clearances
đ?‘— = 1: đ??źđ?‘šđ?‘?đ?‘’đ?‘™đ?‘™đ?‘’đ?‘&#x; đ?‘€đ?‘€đ??ś đ??ˇđ?‘–đ?‘šđ?‘’đ?‘›đ?‘ đ?‘–đ?‘œđ?‘› đ?‘— = 2: đ??źđ?‘šđ?‘?đ?‘’đ?‘™đ?‘™đ?‘’đ?‘&#x; đ??żđ?‘€đ??ś đ??ˇđ?‘–đ?‘šđ?‘’đ?‘›đ?‘ đ?‘–đ?‘œđ?‘› đ?‘— = 3: đ??ˇđ?‘–đ?‘“đ?‘“đ?‘˘đ?‘ đ?‘’đ?‘&#x; đ??żđ?‘€đ??ś đ??ˇđ?‘–đ?‘šđ?‘’đ?‘›đ?‘ đ?‘–đ?‘œđ?‘› đ?‘— = 4: đ??ˇđ?‘–đ?‘“đ?‘“đ?‘˘đ?‘ đ?‘’đ?‘&#x; đ?‘€đ?‘€đ??ś đ??ˇđ?‘–đ?‘šđ?‘’đ?‘›đ?‘ đ?‘–đ?‘œđ?‘›
�? = �? + �" � = 1, 2 , 3 � = (1, 2, 3) �H = �H
Problem Definition
Improper running clearances between contacting features can cause
�" ≤ 0 � = 1, 2, 3
Decision Variables:
ESP Pump Diagram
đ?‘†đ?‘˜đ?‘–đ?‘&#x;đ?‘Ą đ?‘€đ?‘Žđ?‘Ľ đ??śđ?‘™đ?‘’đ?‘Žđ?‘&#x;đ?‘Žđ?‘›đ?‘?đ?‘’: 0.017 = đ?‘§O − đ?‘§Q đ?‘†đ?‘˜đ?‘–đ?‘&#x;đ?‘Ą đ?‘€đ?‘–đ?‘› đ??śđ?‘™đ?‘’đ?‘Žđ?‘&#x;đ?‘Žđ?‘›đ?‘?đ?‘’: 0.011 = đ?‘§H − đ?‘§R
•
Standardizing the pump running features will Increase Pump Reliability and decrease Manufacturing Rework
• Maintaining Allowable Tolerances •
Current TD Balance Ring Clearance
Maintaining allowable tolerances will decrease manufacturing cost
• Modification of Current Inventory •
Material is removed in the new designs
• Quote to modify current inventory pending • Cost Impacts Data N/A because TD 460 & TD 850 are Radial Flow Pumps
• •
GE: Consulting Team Savings ($30,000) Manufacturing rework savings: $208,000/yr Customer: Increased pump efficiency/Decreased pump downtime = $8,125/pump/year