Abstract: An electric submersible pump (ESP) assembly. The ESP assembly comprises an electric motor; a seal section; a fluid intake; a charge pump assembly located downstream of the fluid intake and having an inlet in fluid communication with an outlet of the fluid intake, having a fluid mover coupled to a drive shaft, and having a fluid reservoir located downstream of the fluid mover; a gas separator located downstream of the charge pump assembly and having an inlet in fluid communication with an outlet of the charge pump assembly; an inverted shroud coupled at an upper end to the gas separator or to the charge pump assembly and coupled at a lower end to the ESP assembly below the fluid intake; and a production pump assembly located downstream of the gas separator and having an inlet in fluid communication with a liquid phase discharge port of the gas separator.

Abstract: A manufacturing system includes a tension-wound system having a feedstock system and a shape fixture. The tension-wound system is configured to feed a feedstock from the feedstock system and to wind the feedstock under tension in successive layers around the shape fixture to allow the feedstock to form a component having a shape represented by the shape fixture. The manufacturing system includes a solid-state joining tool configured to additively join the successive layers of the feedstock. In a spiral tension-winding process, with a continuously-fed strip of aluminum feedstock around a piece of tooling, the feedstock can be friction stir welded and additively joined in successive layers to produce a large, near-net structure.

Abstract: A process that uses friction stir welding to connect a tube, for example a thin gauge tube having a wall thickness of about 2.54 mm (0.100 inch) or less, to another element, such as a tube sheet of a heat exchanger. The process employs a tubular anvil that is installed into the end of the tube and which, in one embodiment, can provide material during the friction stir welding process. After the weld is complete, the weld zone between the tubular anvil and the tube is machined away and the anvil tube removed.

Abstract: A process that uses friction stir welding to connect a tube, for example a thin gauge tube having a wall thickness of about 2.54 mm (0.100 inch) or less, to another element, such as a tube sheet of a heat exchanger. The process employs a tubular anvil that is installed into the end of the tube and which, in one embodiment, can provide material during the friction stir welding process. After the weld is complete, the weld zone between the tubular anvil and the tube is machined away and the anvil tube removed.

Abstract: Fluid conveying pipes and processes of forming such pipes using friction stir welding. The fluid conveying pipes are formed from a pipe section that includes a first barrel coaxially and concentrically disposed within a second barrel. The first barrel and the second barrel are each formed from one or more sections or plates where longitudinal extending facing edges of the plates are friction stir welded (FSW) together along a seam(s) that extends longitudinally from the first end to the second end thereof. A plurality of the pipe sections can be connected together end to end using circumferential FSW seams to form a pipe.

Abstract: Fluid conveying pipes and processes of forming such pipes using friction stir welding. The fluid conveying pipes are formed from a pipe section that includes a first barrel coaxially and concentrically disposed within a second barrel. The first barrel and the second barrel are each formed from one or more sections or plates where longitudinal extending facing edges of the plates are friction stir welded (FSW) together along a seam(s) that extends longitudinally from the first end to the second end thereof. A plurality of the pipe sections can be connected together end to end using circumferential FSW seams to form a pipe.

Abstract: A heat exchanger and a method for fabricating the heat exchanger are disclosed. The heat exchanger comprises a heat exchanger core that is formed from a plurality of stacked aluminum panels that are joined together via friction stir welding. Each panel in the core is formed from at least two aluminum extrusions that are joined to one another via friction stir welding.

Abstract: A framing corner joint includes first and second framing rails of fiberglass-reinforced resin construction. The first and second framing rails have hollow mitered ends. A pair of thermoplastic plugs are received in the mitered ends of the respective framing rails. Each of the plugs includes a body inserted into the hollow interior of an associated framing rail and a flat plug flange at an angle of 45° to the body. The plug flanges extend outwardly from the peripheries of the bodies between the rail ends and have flat end faces that are bonded to each other. The bodies of the plugs preferably are hollow, and preferably are received by interference press-fit within the ends of the rails. The plug flanges of the plugs preferably are welded to each other.

Abstract: A method for joining a tube and tube plate for use in a tube-and-shell heat exchanger is disclosed. The method enables a joint between the tube and tube plate that is substantially hermetic and substantially corrosion-resistant. The method comprises providing an anvil inside the tube, wherein the anvil supports the tube wall during a friction-stir welding process used to join the tube and tube plate. The anvil facilitates formation of a reliable weld region and enables faster friction-stir welding.

Abstract: A heat exchanger for exchanging heat between a first fluid and a second fluid is disclosed; wherein the heat exchanger has improved thermal efficiency and low fluid back pressure. The heat exchanger comprises conduits for conveying the first fluid, wherein the conduits include a plurality of flow passages. The flow passages are defined by a plurality of fins that are continuous along the direction of flow of the first fluid. Each fin includes a wave-shaped region, and adjacent fins sub-divide each flow passage into first and second sections that are interposed by a third section. The wave-shape of the fins creates a continuously varying cross-sectional area for each third section. The variation of the cross-sectional area of the third section, coupled with the wave-shape of the fins, induces a swirl flow between the third section and each of the first and second sections. This swirl flow improves the efficiency of the overall convection heat transfer in each conduit.

Abstract: A framing corner joint includes first and second framing rails of fiberglass-reinforced resin construction. The first and second framing rails have hollow mitered ends. A pair of thermoplastic plugs are received in the mitered ends of the respective framing rails. Each of the plugs includes a body inserted into the hollow interior of an associated framing rail and a flat plug flange at an angle of 45° to the body. The plug flanges extend outwardly from the peripheries of the bodies between the rail ends and have flat end faces that are bonded to each other. The bodies of the plugs preferably are hollow, and preferably are received by interference press-fit within the ends of the rails. The plug flanges of the plugs preferably are welded to each other.

Abstract: A method for joining a tube and tube plate for use in a tube-and-shell heat exchanger is disclosed. The method enables a joint between the tube and tube plate that is substantially hermetic and substantially corrosion-resistant. The method comprises providing an anvil inside the tube, wherein the anvil supports the tube wall during a friction-stir welding process used to join the tube and tube plate. The anvil facilitates formation of a reliable weld region and enables faster friction-stir welding.

Abstract: Control systems, methods, and algorithms are provided for controlling the process parameters during FSW in order to repeatedly produce high quality welds for high temperature alloys such as titanium alloys and superalloys. In accordance with exemplary embodiments of the present invention, a desired range of forge load, pinch load, and/or travel load can be reliably maintained in a FSW system by adjusting the rotational speed thereof. In other embodiments, a desired temperature range of the tool or weld can be maintained by adjusting a plunge depth of pin tool for conventional FSW or distances between upper and lower shoulders for self-reacting FSW processes. Other embodiments of the present invention provide methods and/or apparatus suitable for rotational control and/or plunge depth control for FSW of titanium alloys and/or other high temperature alloys such as super alloys.

Abstract: A flush-mounted multi-service floor outlet, to provide electrical power and multiple voice/data access jack outlets has a unitary, longitudinally compartmented cylindrical metal housing for location in penetrating relation through a cement floor. The power, voice and data connections are normally routed through the ceiling space of the underlying room and are sealed within conduits that are threaded into a base portion of the metal housing. The outlet housing is dimensioned to achieve a nominal fit within a standard sized hole drilled through the concrete floor, and to provide a minimal diametrical clearance with the drilled hole as to render the installation effectively fireproof. A threaded retaining nut may be used to secure the outlet housing in place. Internal compartment partitions isolate the respective ones of power, voice and data conductors and terminations, the partitions being withdrawable so as to provide effective access and facilitate installation and servicing of the respective services.