Hydrodynamic bearing runner for use in tilting pad thrust bearing assemblies for electric submersible pumps

A runner for use in a pad-type hydrodynamic bearing/runner assembly, the runner comprising:

• a core layer;
• and
• a polymer layer affixed to the core layer,
• wherein the polymer layer forms a plurality of spaced bearing pads to provide a bearing that rotates with the runner.

A submersible pump system comprising:

• a multi-stage centrifugal pump;
• and
• a motor coupled to the multi-stage centrifugal pump, the motor comprising:
• a shaft coupled to the multi-stage centrifugal pump,
• a rotor having a thrust bearing, and
• a first runner affixed to the shaft, the runner comprising a first core layer and a first wear layer affixed to the first core layer, wherein the first wear layer faces the thrust bearing;
• further comprising a rotary gas separator and a seal section, wherein the shaft extends through the seal section, and
• wherein the seal section comprises:
• an up-thrust plate,
• a down-thrust bearing, and
• a second runner affixed to the shaft and disposed between the up-thrust plate and the down-thrust bearing, wherein the second runner comprises:
• a second core layer,
• a second wear layer affixed to a first side of the second runner facing the up-thrust plate, and
• a third wear layer affixed to a second side of the second runner facing the down-thrust bearing.

A submersible pump system comprising:

• a multi-stage centrifugal pump;
• and
• a motor coupled to the multi-stage centrifugal pump, the motor comprising:
• a shaft coupled to the multi-stage centrifugal pump,
• a rotor having a thrust bearing, and
• a first runner affixed to the shaft, the runner comprising a first core layer and a first wear layer affixed to the first core layer, wherein the first wear layer faces the thrust bearing;
• and
• wherein the first core layer comprises mild steel, the first wear layer comprises a polymer, and the thrust bearing comprises uncoated hardened steel.

A method for overhauling a submersible pump system having a runner removably attached to a shaft, the method comprising:

• removing the runner from the shaft;
• removing a surface layer of the runner to expose a core substrate;
• applying a wear layer to the core substrate;
• and reattaching the runner to the shaft.