System, method, and apparatus for stackable multi-stage diffuser with anti-rotation lugs

1. An electrical submersible pump assembly, comprising:

a motor coupled to a seal section, which in turn is coupled to a pump, wherein the pump comprises:

a housing having an axis;

a plurality of diffusers mounted in the housing, each diffuser comprising a cylindrical body having at least one lug extending therefrom in an axial direction, a complementary recess formed in the cylindrical body extending in the axial direction opposite the lug, the complementary recess receiving and nesting a respective lug on an axially adjacent diffuser to form an interlocked stack that prevents relative rotation between the diffusers;

a sealing member located on an exterior of each diffuser, and a surface formed on each diffuser that forms a seal with the sealing member on the axially adjacent diffuser; and

a housing adapter mounted and sealed to at least one diffusers, the housing adapter having a housing seal member that seals with the housing.

2. A pump assembly according to claim 1 , wherein the diffusers are mechanically locked to the housing to prevent rotation therebetween.

3. A pump assembly according to claim 2 , wherein the interlocked stack is mechanically locked to the housing with a retaining ring mounted in a recess formed in the housing, and a retaining tube extends from the retaining ring and is coupled to the at least one diffuser.

4. A pump assembly according to claim 3 , wherein the retaining ring and the retaining tube are located above the interlocked stack.

5. A pump assembly according to claim 1 , wherein the at least one lug comprises a plurality of symmetrically arrayed castellations that are adapted to engage and nest in an equal number of complementary recesses on the axially adjacent diffuser.

6. A pump assembly according to claim 1 , wherein the housing adapter vertically supports the interlocked stack in the housing and prevents rotation therebetween.

7. A pump assembly according to claim 1 , wherein a radial clearance of 0.003 to 0.005 inches separates an outer diameter of the at least one diffuser and an inner diameter of the housing such that the diffusers are free of contact with and are unsealed to the housing.

8. An electrical submersible pump assembly, comprising:

a motor coupled to a seal section, which in turn is coupled to a pump, wherein the pump comprises:

a tubular housing having an axis;

a plurality of diffusers coaxially mounted in the tubular housing to prevent relative rotation therebetween, each diffuser comprising a cylindrical body having at least one lug extending therefrom in an axial direction, a complementary recess formed in the cylindrical body extending in the axial direction opposite the lug, the complementary recess receiving and nesting a respective lug on an axially adjacent diffuser to form an interlocked stack that prevents relative rotation between the diffusers;

a sealing member located on an exterior of each diffuser, an inner surface formed on each diffuser that forms a seal with a sealing member on respective axially adjacent diffusers; and

the diffusers are free of contact with and unsealed to the tubular housing.

9. A pump assembly according to claim 8 , wherein:

the diffusers are mechanically locked to the tubular housing with a retaining ring mounted in a recess formed in the tubular housing;

a retaining tube extends from the retaining ring and is coupled to the diffusers; and

the retaining ring and the retaining tube are located above the diffusers.

10. A pump assembly according to claim 8 , wherein the at least one lug comprises a plurality of symmetrically arrayed castellations that engage and nest in an equal number of complementary recesses on respective axially adjacent diffusers.

11. A pump assembly according to claim 8 , wherein the sealing members comprise o-rings, and further comprising a housing adapter mounted and sealed to one of the diffusers, the housing adapter having a housing seal member that seals with the tubular housing, such that the housing adapter vertically supports the diffusers in the tubular housing.

12. A pump assembly according to claim 8 , wherein a radial clearance of 0.003 to 0.005 inches separates an outer diameters of the diffusers and an inner diameter of the tubular housing.

13. An electrical submersible pump assembly, comprising:

a motor coupled to a seal section, which in turn is coupled to a pump, wherein the pump comprises:

a housing having an axis and a recess;

a plurality of diffusers coaxially mounted in the housing to prevent relative rotation therebetween, each diffuser comprising a cylindrical body having at least one lug extending therefrom in an axial direction, a complementary recess formed in the cylindrical body extending in the axial direction opposite the lug, the complementary recess receiving and nesting a respective lug on an axially adjacent diffuser to form an interlocked stack that prevents relative rotation between the diffusers;

a sealing member located on an exterior of each diffuser, and an inner surface formed on each diffuser that forms a seal with a sealing member on respective axially adjacent diffusers;

a retaining ring mounted in the recess in the housing for mechanically locking the diffusers to the housing to prevent rotation therebetween; and

a retaining tube extending from the retaining ring and coupled to the diffusers; and

a housing adapter mounted and sealed to one of the diffusers, the housing adapter having a housing seal member that seals with the housing, such that the housing adapter vertically supports the diffusers in the housing.

14. A pump assembly according to claim 13 , wherein the at least one lug comprises a plurality of symmetrically arrayed castellations that engage and nest in an equal number of complementary recesses on respective axially adjacent diffusers.