Screw type pump or motor

Abstract

A pump assembly comprising a stator and a rotor having vanes of opposite handed thread arrangements is described. A radial gap is located between the stator vanes and the rotor vanes such that rotation of the rotor causes the stator and rotor to co-operate to provide a system for moving fluid longitudinally between them. The operation of the pump results in a fluid seal being is formed across the radial gap. The described apparatus can also be operated as a motor assembly when a fluid is directed to move longitudinally between the stator and rotor. The presence of the fluid seal results in no deterioration of the pump or motor efficiency, even when the radial gap is significantly greater than normal working clearance values. Furthermore, the presence of the radial gap makes the pump/motor assembly ideal for deployment with high viscosity and/or multiphase fluids.

The invention claimed is: 
     
       1. A pump assembly for use with a high viscosity or multiphase hydrocarbon fluid comprising:
 a stator having an internal surface of constant diameter and one or more stator vanes extending from the internal surface to a constant stator vane radial height along a length of the stator; and 
 a rotor having an external surface of constant diameter and one or more rotor vanes extending from the external surface to a constant rotor vane radial height along a length of the rotor, 
 wherein the one or more stator vanes have an opposite handed thread with respect to a thread of the one or more rotor vanes and, wherein the stator and rotor co-operating cooperate to provide, on rotation of the rotor, a system for moving move the high viscosity or multiphase hydrocarbon fluid longitudinally between them the stator and the rotor, 
 wherein a radial gap, having a constant value gap width in the range of 1.28 greater than 0.254 mm to 10 mm, is located between the constant stator vane radial height and the constant rotor vane radial height along a length of the pump assembly, and 
 wherein the constant rotor vane radial height is greater than the constant stator vane radial height, and a ratio of the constant rotor vane radial height to the constant stator vane radial height has a constant value in the range of 1.1 to 20 3.5 to 4.5 along the length of the pump assembly, 
 a helix formed by the one or more rotor vanes has a mean lead angle (α) that is greater than 60° but less than 90°, and a helix formed by the one or more stator vanes has a mean lead angle (β) that is greater than 60° but less than 90°, 
 the one or more stator vanes further comprises a stator vane thickness, and the one or more rotor vane further comprises a rotor vane thickness, and the stator vane thickness is greater than the rotor vane thickness along the length of the pump assembly. 
 
     
     
       2. A pump assembly as claimed in  claim 1  wherein the one or more rotor vanes are arranged on the external surface of the rotor so as to form one or more rotor channels. 
     
     
       3. A pump assembly as claimed in  claim 2  wherein a ratio of the volume to cross sectional area of the rotor channels is equal to, or greater than, 200 mm. 
     
     
       4. A pump assembly as claimed in  claim 1  wherein the one or more stator vanes are arranged on the internal surface of the stator so as to form one or more stator channels. 
     
     
       5. A pump assembly as claimed in  claim 4  wherein a ratio of the volume to cross sectional area of the stator channels is equal to, or greater than, 200 mm. 
     
     
       6. A pump assembly as claimed in  claim 1  wherein a helix formed by the rotor vanes has a mean lead angle (α) that is greater than 60° but less than 90°. 
     
     
       7. A pump assembly as claimed in  claim 6  wherein the mean lead angle (α) is in the range of 70° to 76°. 
     
     
       8. A pump assembly as claimed in  claim 7  wherein the mean lead angle (α) is 73°. 
     
     
       9. A pump assembly as claimed in  claim 1  wherein a helix formed by the stator vanes has a mean lead angle (β) that is greater than 60° but less than 90°. 
     
     
       10. A pump assembly as claimed in  claim 9  wherein the mean lead angle (β) is in the range of 70° to 76°. 
     
     
       11. A pump assembly as claimed in  claim 10  wherein the mean lead angle (β) is 73°. 
     
     
       12. A pump assembly as claimed in  claim 1  wherein the ratio of the constant rotor vane radial height to the constant stator vane radial height is in the range 3.5 to 4.5. 
     
     
       13. A pump assembly as claimed in  claim 1  wherein the ratio of the constant rotor vane radial height to the constant stator vane radial height is 4.2. 
     
     
       14. A pump assembly as claimed in  claim 1  wherein a ratio of a rotor outer diameter to a rotor lead is in the range of 0.5 to 1.5. 
     
     
       15. A pump assembly as claimed in  claim 14  wherein the ratio of the rotor outer diameter to the rotor lead is 1.0. 
     
     
       16. A pump assembly as claimed in  claim 1  wherein a ratio of a stator inner diameter to a stator lead is in the range of 0.5 to infinity. 
     
     
       17. A pump assembly as claimed in  claim 16  wherein the ratio of the stator inner diameter to the stator lead is 1.0. 
     
     
       18. A pump assembly as claimed in  claim 1  wherein one or more anti-rotation tabs are located at each end of the stator. 
     
     
       19. A pump assembly as claimed in  claim 1  wherein the pump assembly further comprises a cylindrical housing within which the rotor and stator are located. 
     
     
       20. A pump assembly as claimed in  claim 1  wherein the rotor is connected to a motor by means of a central shaft such that operation of the motor induces relative rotation between the rotor and the stator. 
     
     
       21. A pump assembly as claimed in any  claim 1  wherein the assembly further comprises a first bearing which defines an inlet for the device. 
     
     
       22. A pump assembly as claimed in claim  21  1wherein the pump assembly further comprises a second bearing, longitudinally spaced from the first bearing, which defines an outlet for the device. 
     
     
       23. A pump assembly as claimed in  claim 1  wherein a stator vane thickness is greater than a rotor vane thickness. 
     
     
       24. A pump assembly as claimed in  claim 1  wherein the rotor is coated with an erosion resistant, corrosion resistant and/ or drag resistant coating. 
     
     
       25. A pump assembly as claimed in  claim 1  wherein the stator is coated with an erosion resistant, corrosion resistant and/ or drag resistant coating. 
     
     
       26. A multistage pump wherein the multistage pump comprises two or more pump assemblies, and wherein at least one of the two or more pump assemblies comprises:
 a stator having an internal surface of constant diameter and one or more stator vanes extending from the internal surface to a constant stator vane radial height along the length of the stator; and   a rotor having an external surface of constant diameter and one or more rotor vanes extending from the external surface to a constant rotor vane radial height along the length of the rotor,   wherein the one or more stator vanes have an opposite handed thread with respect to the thread of the one or more rotor vanes and the stator and rotor cooperating to provide, on rotation of the rotor, a system for moving a high viscosity or multiphase hydrocarbon fluid longitudinally between them;   wherein a radial gap, having a constant value in the range of 1.28 mm to 10 mm, is located between the constant stator vane radial height and the constant rotor vane radial height along a length of the pump assembly, and   a ratio of the constant rotor vane radial height to the constant stator vane radial height has a constant value in the range of 1.1 to 20 along the length of the pump assembly.   
     
     
       27. A multistage pump as claimed in  claim 26  wherein the two or more pump assemblies are deployed on opposite sides of a central inlet aperture. 
     
     
       28. A multistage pump as claimed in  claim 26  wherein the diameter of the two or more pump assemblies differs along the length of the multistage pump. 
     
     
       29. A motor assembly for use with a high viscosity and or multiphase hydrocarbon fluid comprising:
 a stator having an internal surface of constant diameter and one or more stator vanes extending from the internal surface to a constant stator vane radial height along a length of the stator; and   a rotor having an external surface of constant diameter and one or more rotor vanes extending from the external surface to a constant rotor vane radial height along a length of the rotor,   wherein the one or more stator vanes have an opposite handed thread with respect to the thread of the one or more rotor vanes and the stator and rotor cooperating to provide, on the high viscosity or multiphase hydrocarbon fluid moving longitudinally between them, relative rotation of the rotor and stator,   wherein a radial gap, having a constant value in the range of 1.28 mm to 10 mm, is located between the constant stator vane radial height and the constant rotor vane radial height along a length of the motor assembly, and   a ratio of the constant rotor vane radial height to the constant stator vane radial height has a constant value in the range of 1.1 to 20 along the length of the motor assembly.   
     
     
       30. A multistage motor wherein the multistage motor comprises two or more motor assemblies, wherein at least one of the two motor assemblies comprises:
 a stator having an internal surface of constant diameter and one or more stator vanes extending from the internal surface to a constant stator vane radial height along a length of the stator; and   a rotor having an external surface of constant diameter and one or more rotor vanes extending from the external surface to a constant rotor vane radial height along a length of the rotor,   wherein the one or more stator vanes have an opposite handed thread with respect to the thread of the one or more rotor vanes and the stator and rotor co-operating to provide, on a high viscosity or multiphase hydrocarbon fluid moving longitudinally between them, relative rotation of the rotor and stator,   wherein a radial gap, having a constant value in the range of 1.28 mm to 10 mm, is located between the constant stator vane radial height and the constant rotor vane radial height along a length of the motor assembly, and   a ratio of the constant rotor vane radial height to the constant stator vane radial height has a constant value in the range of 1.1 to 20 along the length of the motor assembly.   
     
     
       31. A multistage motor as claimed in  claim 30  wherein the two or more motor assemblies are deployed on opposite sides of a central inlet aperture. 
     
     
       32. A pump assembly for use with a high viscosity or multiphase hydrocarbon fluid comprising a stator and a rotor, each one being provided with one or more vanes having an opposite handed thread with respect to a thread of the one or more vanes on the other, the stator and rotor co-operating to provide, on rotation of the rotor, a system for moving the high viscosity or multiphase hydrocarbon fluid longitudinally between them, wherein: a radial gap, in the range of 1.28 mm to 10 mm, is located between the one or more stator vanes and the one or more rotor vanes along a length of the pump assembly, and a ratio of a radial height of the one or more rotor vanes to a radial height of the one or more stator vanes is in the range of 3.5 to 4.5 along the length of the pump assembly. 
     
     
       33. A method of producing a hydrocarbonaceous fluid, the method comprising:
 deploying a pump assembly to a predetermined depth within a tubular disposed in a wellbore, the pump assembly comprising:
 a stator configured with an at least one helically wound stator vane disposed on a constant diameter inner stator surface, the at least one stator vane further comprising a stator vane length, a constant stator vane height, and a stator vane thickness; 
 a rotor configured with an at least one helically wound rotor vane disposed on a constant diameter outer rotor surface, the at least one rotor vane further comprising a rotor vane length, a constant rotor vane height, and a rotor vane thickness, 
 wherein the at least one stator vane and the at least one rotor vane are separated by a radial gap having a gap width in the range of greater than 0.254 mm to 10 mm along the stator vane length and the rotor vane length, 
 wherein the constant rotor vane height is greater than the constant stator vane height, and a ratio of the constant rotor vane height to the constant stator vane height is a constant value in the range of 3.5 to 4.5 along the rotor vane length and the stator vane length, 
 wherein the at least one helically wound rotor vane comprises a rotor helix having a mean rotor lead angle in the range of 60 degrees and 90 degrees, wherein the at least one helically wound stator vane comprises a stator helix having a mean stator lead angle in a range of 60 degrees to 90 degrees, wherein the stator vane thickness is greater than the rotor vane thickness respectively along the length of the pump assembly; 
   operating the pump assembly in a manner that aids in production of the hydrocarbonaceous fluid from the wellbore to a surface,   wherein the operating speed is in the range of 500 rpm to 20,000 rpm, and wherein the wellbore fluid comprises at least one of:
 (a) a gas phase of up to 95%; 
 (b) a liquid phase of up to 100%; 
 (c) a highly viscous phase up to 100% having the characteristic of a viscosity in the range of 1,000 to 10,000 cP; 
 (d) a steam vapor phase up to 95%; and 
 (e) an entrained solids content of about 1% to about 5% by weight and up to 60% solids; and 
 (f) combinations thereof.