Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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HIGH SPEED ELECTRIC SUBMERSIBLE PUMPS
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to US Provisional Application No.
63/141,938
filed January 26, 2021, the disclosure of which is incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] The present inventions are directed to electric submersible pump
assemblies for
wells and in particular to electric submersible pumps wherein certain
components are protected
from erosion from high speed solid particles.
BACKGROUND AND SUMMARY OF THE INVENTION
[0003] Electric Submersible Pumps (ESP) are widely used in the production of
fluid
from oil and gas wells. Traditional ESPs have a centrifugal pump coupled to an
electric motor.
The motor is typically protected from wellbore fluid ingress by a seal (also
referred to as
protector or equalizer). The seal section is located between the motor and the
pump which
serves to reduce any pressure difference between the wellbore fluid exterior
of the motor and
the lubricant on the interior of the motor.
[0004] The rotary pump in many ESPs includes a rotating shaft, impeller, and
stationary diffuser. The impellers are coupled to the shaft and create lift as
they rotate, driving
wellbore fluid up the well. A standard induction type motor may include a
single continuously
wound stator, a single shaft, one or multiple induction type rotors mounted on
the shaft, and
rotor bearings to the centralize the shaft.
[0005] Various disclosed embodiments of the invention may have one or multiple
advantages over standard ESP units. Some disclosed embodiments utilize a wider
range of
operating speeds, utilize an active cooling system to reduce motor temperature
rise, reduce the
amount of time required to assemble or install a unit, and/or improve the
power efficiency of
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the ESP system.
[0006] Disclosed embodiments may also reduce the inventory required through
the use
of standardized components, reduce capital requirements, reduce personnel
requirements,
and/or decrease rig exposure to an open well bore during installation, thereby
increasing safety.
[0007] Some of the disclosed embodiments incorporate high-speed downhole
components including pumps, seals, gas separators, intakes, motors and/or
downhole sensors.
[0008] Some embodiments comprise a permanent magnet synchronous motor with a
control system for speed regulation. Some embodiments may additionally or
alternative
comprise a high-speed pump, seal section and/or gas separator connected and
aligned along a
common axis. In some embodiments, the motor may be of modular construction
and/or have
an active cooling system that increases heat removal from the system via
lubricant circulation
through a heat exchange module. In certain embodiments, a downhole sensor may
be utilized
to control the operation of the ESP in substantially real time.
BRIEF DESCRIPTION OF THE FIGURES
[0009] Figure 1 depicts a schematic of an exemplary embodiment of a disclosed
system.
[0010] Figure 2 depicts a schematic of an upper portion of an exemplary pump.
[0011] Figure 3 depicts a schematic of a middle portion of an exemplary pump.
[0012] Figure 4 depicts a schematic of a lower portion of an exemplary pump
and
upper portion of a gas separation module.
[0013] Figure 5 depicts a schematic of a lower portion of an exemplary pump
and
upper portion of an exemplary gas separation model.
[0014] Figure 6 depicts a schematic of an lower portion of an exemplary gas
separation module and upper portion of a seal section.
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[0015] Figure 7 depicts a schematic of a portion of an exemplary seal section.
[0016] Figure 8 depicts a schematic of a portion of an exemplary thrust
chamber in
the lower portion of the seal section.
[0017] Figure 9 depicts a schematic of a portion of an exemplary thrust
chamber and
motor head module.
[001g] Figure 1()A depicts an exemplary embodiment of a disclosed motor.
[0019] Figure 10B depicts a schematic of a portion of an exemplary motor head
module.
[0020] Figure 11 depicts a schematic of a portion of an exemplary power
module.
[0021] Figure 12 depicts a schematic of portion of an exemplary base module.
[0022] Figure 13 depicts a schematic of a portion of an exemplary central heat
exchange module.
[0023] Figure 14 depicts a schematic of a portion of an exemplary lower heat
exchange module.
[0024] Figure 15 depicts a schematic of a portion of an exemplary base module
with
lubricant return.
[0025] Figure 16 A, B, and C, depict schematics of an exemplary central heat
exchange module.
[0026] Figure 17 A, B, and C depict schematics of an exemplary lower heat
exchange
module.
[0027] Figure 18 depicts an exemplary flangeless connection.
[0028] Figure 19A depicts an exemplary assembled sleeve assembly.
[0029] Figure 19 B and C depict components of an exemplary sleeve assembly.
[0030] Figure 20A and B depict embodiments of a bushing with a surface
feature.
[0031] Figure 21 depicts an embodiment of a high-speed gas separator with gas
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separation chambers.
DETAILED DESCRIPTION OF THE INVENTION
100321 In the following description, certain details are set forth such as
specific
quantities, sizes, arrangements, configurations, components, etc., so as to
provide a thorough
understanding of the present embodiments disclosed herein. However, it will be
evident to
those of ordinary skill in the art that the present disclosure may be
practiced without such
specific details. In many cases, details concerning such considerations and
the like have been
omitted inasmuch as such details are not necessary to obtain a complete
understanding of the
present disclosure and are within the skills of persons of ordinary skill in
the relevant art.
[0033] For the purposes of clarifying the various embodiments of the disclosed
inventions, the systems and assemblies described below are presented in the
context of an
exemplary electric submersible pump. It will be apparent to those of ordinary
skill that the
disclosed system may be utilized with other equipment, components, and
applications.
[0034] Exemplary Electric Submersible Pump Embodiments
[0035] In a non-limited exemplary embodiment, the disclosed inventions relate
to an
electric submersible pump (EPS) assembly. As shown in Figure 1, the exemplary
ESP
comprises at least one centrifugal pump module (6), a gas separator (7), a
seal section (8), an
electric motor (9) with an active cooling system, and a downhole sensor unit
(10). In operation,
a motor generates torque, which is communicated through a motor shaft into a
seal section
shaft. The seal section shaft transmits torque up to the gas separator shaft,
which transmits
torque to the pump module. The pump module utilizes the motor generated torque
to lift
wellbore fluid up a well bore.
[0036] As shown in Figure 2, a pump module (6) may have a discharge head (14).
The
discharge head (14) may be integral to the pump module (6) or be attached by
any of a variety
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of suitable techniques as known in the art. The discharge head (14) may be
connected via a
flange to the pump head (16) using a flange or flangeless connection. In some
embodiments,
the discharge head (14) will be connected to the pump head (16) using
corrosion resistant
fasteners (15) such as, for example, screws. A pump shaft (18) may use a split
ring to lock into
an axially adjustable assembly (19). The pump shaft (18) may include a keyway
including, for
example, dual keyways, that attach the impellers (23) and hearing sleeves (24)
to the shaft. In
many embodiments, the impellers (23) and/or bearing sleeves (24) are
rotationally fixed to the
shaft (18). It will be understood that the term impeller, as used herein, may
refer to any rotating
component that is used to move a fluid.
[0037] A diffuser or, in some embodiments, a stack of diffusers (22) with
bearing
bushings, and impellers (23) may be placed inside the pump housing (17). A
compression tube
(21), a radial bearing support (20) and/or a pump head (16) may also be
secured at least partially
within the pump housing (17). In some embodiments, the pump head (16) may
contain a high
speed, self-aligning radial bearing system. In some embodiments, a high speed,
self-aligning
radial bearing system may be separate from the pump head or integral to the
pump head.
[0038] As shown in Figure 3, a pump module (6) has at least one radial bearing
support
(25). In preferred embodiments, radial bearing support (25) comprises a radial
bearing system
comprising a bushing housed in a bearing support and a sleeve (25A) mounted on
a shaft. In
preferred embodiments, the radial bearing system comprises a high-speed, self-
aligning
(HS SA) bearing.
[0039] As shown in Figure 4, a pump shaft (18) may have splines which connect
to a
coupling (28). In some embodiment, the splines described here, as well as
throughout the
application, may be involute splines, SAE6 splines, or other variations which
allow a shaft to
connect to a coupling. The coupling (28) may transmit torque from the shaft of
a gas separator
module (7) to the pump shaft. The bottom flange (27) of the pump module (7)
may be secured
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to the top flange (30) of a gas separator module (7) using fasteners (29)
which may include, for
example, high strength corrosion resistant screws. In many embodiments,
impellers (23) and
bearing sleeves (24) form a rigid connection with the pump shaft (18). The
bottom flange (27)
may contain a radial bearing system, preferably comprising a HSSA bearing used
to provide
radial support to the pump shaft (18). It will be appreciated that the terms
bottom flange and
base may be used interchangeably throughout the specification. It will also be
appreciated that
the terms top flange and head may be used interchangeably throughout the
specification.
High Speed Gas Separator ¨ Figures 5, 6, and 21
[0040] As shown in Figure 5, a gas separator module (7) may comprise a top
flange
(30) with a HSSA bearing (31) and phase crossover (32). Phase crossover (32)
directs the gas
phase of the production fluid to the wellbore annulus and the liquid phase
into the pump. A
spiral inducer (34) may be locked to the gas separator shaft (33) via a keyway
or dual keyways.
A gas separator housing (103) may be fitted with sleeves (35), to protect the
inner surface of
the gas separator housing from abrasive wear and corrosion. In some
embodiments, these
sleeves (35) may comprise a metal ceramic such as, for example, tungsten
carbide, silicon
carbide, or zirconium carbide, and/or other materials that provide wear
resistance, abrasion
resistance, corrosion resistance, or other desirable properties.
[0041] As shown in Figure 6, the bottom flange (38) of the gas separator
module (7)
may comprise a HSSA radial bearing and have at least one port for the inflow
of wellbore fluid.
Wellbore fluid may refer to single and/or multi-phase wellbore or formation
fluid. In some
embodiments, the bottom flange (38) of the gas separator module may be fitted
with a screen
(104) for removing debris from the wellbore fluid. Torque may be transmitted
to the gas
separator shaft (33) from the seal section (8) through a splined coupling
(105). The bottom
flange (38) of the gas separator (7) may be connected to a flange (41) of the
seal section (8) via
high strength corrosion resistant screws (39).
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[0042] When operating an electric submersible pump (ESP) at high speeds the
velocity
of the solids particles may be higher than when operating at a standard speed
of from about
2500-3000rpm depending upon the operating frequency, location, and other
potential factors.
As used herein, a high speed may be greater than about 3500 RPM, or greater
than about 5,000
RPM, or greater than about 6,000 RPM, or greater than about 7,000 RPM, or
greater than about
9,000 RPM, or greater than about 10,000 RPM. In some embodiments, the
disclosed pump
may operate at less than about 3,000 RPM, or less than about 5,000 RPM, or
less than about
6,000 RPM, or less than about 7,000 RPM, or less than about 9,000 RPM, or less
than about
10,000 RPM.
[0043] The gas separators that may be employed herein have added protection to
guard
against, for example, erosion from high speed solid particles. Figure 21
depicts an embodiment
of a high-speed gas separator with lined gas separation chambers shown. The
high speed gas
separators used herein may comprise a lining in the gas separation chamber
which may
comprise, for example, stainless steel, steel alloy, or mixtures thereof Such
stainless steel or
steel alloy may be hardened, heat treated, and/or coated. Additionally or
alternatively, the
lining may be coated with, for example, tungsten carbide, silicon carbide, or
zirconium carbide,
and/or other materials that provide wear resistance, abrasion resistance,
corrosion resistance,
or other desirable properties. Typically, such linings may be at least 6mm, or
at least 7mm, or
at least 8mm up to about 12 mm, or up to about lOmm.
[0044] In some embodiments, parts on the rotating assembly such as number 34
and 35
on Figure 5 may also comprise a lining. The lining may be the same or
different as that used
for the gas separation chamber. That is, the lining for one or more parts on
the gas separator's
rotating asembly may comprise, for example, stainless steel, steel alloy, or
mixtures thereof
Such stainless steel or steel alloy may be hardened, heat treated, and/or
coated. Additionally
or alternatively, the lining may be coated with, for example, tungsten
carbide, silicon carbide,
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or zirconium carbide, and/or other materials that provide wear resistance,
abrasion resistance,
corrosion resistance, or other desirable properties. Typically, such linings
may be at least 6mm,
or at least 7mm, or at least 8mm up to about 12 mm, or up to about lOmm.
[0045] In sum, the erosion or wear protection may be added where needed on the
gas
separator through material selection as well as hardening, coating or other
treatment of the
selected material .
[0046] The seal section (8) may be a multi-chamber assembly which serves at
least one
of four main functions: (1) transmitting torque from the motor module to the
pump module; (2)
absorbing thrust from the pump module; (3) protecting an internal chamber of
the motor
module from wellbore fluid; and/or (4) reducing a pressure differential
between the interior
and exterior of the motor. It will be appreciated that the terms seal section,
equalizer, and/or
protector may be used synonymously within the industry to refer to a seal
section
[0047] In some exemplary embodiments, a seal section (8) may have a top flange
or
head (41) with a HSSA bearing, a dual key shaft and/or seal section shaft
(40), and a mechanical
seal (42). In some embodiments, the seal section shaft (40) comprises splines
on both ends. In
some embodiments, the mechanical seal (42) is a high-speed mechanical seal
configured to
protect the seal section (8) from wellbore fluid ingress around the shaft
(40). In preferred
embodiments, the seal section shaft (40) is fitted with a HSSA bearing sleeve
(43), which
interact with a HSSA bearing bushing. Top flange (41) of the seal section may
have a vent
port (106) for removal of air or other gases when the internal chamber of the
electric motor is
filled with lubricant. In some embodiments, the lubricant serves as a coolant
and/or is a
dielectric or substantially dielectric fluid. Top flange (41) may also have a
tangential port (107)
for removal of sediment, particulate, or other solids, around the mechanical
seal (42). The
body of the top flange may have a port with a tube (109) inserted in it which
facilitates the
transmission of an external hydraulic pressure from the wellbore fluid to the
filling fluid and/or
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lubricant of the seal section and/or electric motor. In some embodiments, the
tube (109)
follows a labyrinth scheme. In some embodiments, the labyrinth transmission of
hydrostatic
pressure between the external wellbore fluid and internal lubricant may be
carried using tube
(109) and tube (110). The seal section head (41) may be connected to the upper
seal section
housing (44).
[00481 As shown in Figure 7, the bottom of the upper seal section housing (44)
may be
connected to the upper seal section body (46) where a second mechanical seal
(45) may be
installed. In such embodiments, the second mechanical seal (45) separates the
labyrinth
chamber from a bag chamber, additional labyrinth chambers, or combinations
thereof. The
seal section body may also contain a HSSA bearing, (111), a vent port (112)
and/or a
connecting channel (113) between an upper labyrinth chamber and a central
chamber of the
bag chamber section and/or additional labyrinth chambers. The specific
configuration of
labyrinth chamber and/or bag chamber may depend on the conditions of the well,
other
components of the ESP, and/or other factors.
[0049] The upper seal section body (46) may be connected to the central seal
section
housing (114). The bottom portion of the upper seal section body (46) may be
fitted with a
tube (115) of the second labyrinth to transmit hydrodynamic and/or hydrostatic
pressure from
the top chamber to the central chamber. The central seal section housing (114)
may be fitted
with an upper bag support (47) and the bag may be secured with a clamp (116)
to the upper
bag support (47). In some embodiments, the upper bag support (47) may be
connected to a
lower bag support (118) via a support tube (117). Support tube (117)
facilitates a rigid
connection between the upper bag support (47) and lower bag support (118). In
some
embodiments a single bag may be used. In other embodiments a plurality of bags
may be
arranged in succession using a similar mounting technique.
[0050] As shown in Figure 8, a lower bag support (118) may be connected to a
lower
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seal body (49) between the central seal section housing (114) and the thrust
chamber housing
(50). The lower seal section body (49) may be fitted with a HSSA bearing (119)
and/or a vent
port (120). The lower seal section body (49) may contain a high-speed
mechanical seal and a
HSSA bearing and may be threaded into the thrust chamber housing (50). In some
embodiments, the thrust chamber housing (50) contains single, dual, or
multiple thrust bearings
(51) and (52).
[0051] In some embodiments, each of the thrust bearings (51 and 52) may be
fitted with
a spring damper (121 and 122). The spring dampers may facilitate a more even
or substantially
uniform distribution of the operational thrust load between the thrust
bearings (51 and 52). In
some embodiments, the spring dampers may comprise a Belleville washer stack.
In some
embodiments, the washer stack is run in a parallel configuration to promote
even thrust load
transfer across the two thrust bearings.
[0052] The top thrust runner (51A) may be dual-sided and engage against a
static face
(123) to absorb potential up-thrust. Up-thrust may be encountered during start-
up. A down-
thrust face on the top thrust runner (51A) may engage against the upper thrust
bearing assembly
(51) if down-thrust is encountered. In some embodiments, a single sided runner
(52A) may
engage against a lower thrust bearing assembly (52) in the event of down
thrust.
[0053] A thrust chamber heat exchanger may comprise an inner wall (124). In
some
embodiments, the exterior of this inner wall may be spiraled or otherwise
comprise a helical or
other tortuous pathway used to move motor oil or other lubricant from the top
of the thrust
chamber to the bottom of the thrust chamber in close proximity to the thrust
chamber housing
50. The lubricant pathway between the inner wall of the thrust chamber heat
exchanger and
the thrust chamber housing (50) may be helical or otherwise tortuous path in
order to increase
the residence time of the lubricant in the heat exchanger pathway, thereby
increasing the
amount of heat dissipated through the thrust chamber housing (50) to the
wellbore fluid. Once
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the circulated lubricant reaches the bottom of the thrust chamber it may
passes through a filter
(126) before being circulated through the thrust chamber again.
[0054] In some embodiments, the lubricant has a high dielectric strength
and/or a high
viscosity. In some embodiments, the lubricant has a dielectric of greater than
20 KV, or greater
than 25 KV, or greater than 30 KV, or greater than 35 Ky. In some embodiments,
the lubricant
has a dielectric of at most 20 KV, or at most 25 KV, or at most 30 KV, or at
most 35 KV
[0055] In some embodiments, the lubricant has a viscosity at 40 C of at least
60 CST,
or at least 70 CST, or at least 80 CST, or at least 100 CST, or at least 120
CST, or at least 140
CST. In some embodiments, the lubricant has a viscosity at 40 'V of at most 70
CST, or at
most 80 CST, or at most 100 CST, or at most 120 CST, or at most 140 CST, or at
most 160
CST.
[0056] In some embodiments, the lubricant has a viscosity at 100 C of at
least 5 CST,
or at least 7 CST, or at least 10 CST, or at least 12 CST, or at least 14 CST,
or at least 16 CST.
In some embodiments, the lubricant has a viscosity at 100 C of at most 7 CST,
or at most 10
CST, or at most 12 CST, or at most 14 CST, or at most 16 CST, or at most 18
CST.
[0057] As shown in Figure 9, the lower part of the thrust chamber housing (50)
may be
designed with a threaded connection. This threaded connection may be used to
connect the
thrust chamber housing (50) to the seal section base (56) which may be fitted
with a HSSA
bearing (127) and/or a relief valve (128) for factory filling of the seal
section with coolant,
lubricant, dielectric fluid, or a fluid with more than one of these
properties.
[0058] The seal section base (56) may be fitted with a screw (129) which
actuates the
valve (128) and allows for the flow of the lubricant fluid into the free
cavity between the bottom
flange of the seal section and the top flange of the motor module. Bottom
splines on the seal
section shaft (40) may be mated to a coupling (131), which may be used to
transmit torque
from the motor head module shaft (59) to the seal section shaft (40).
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[0059] As shown in Figure 10A, in some exemplary embodiments, the motor module
(9) may be a permanent magnet synchronous motor of modular construction. The
combined
motor module (9) may comprise, a head module (310), Power modules (320), and
base module
(330).
[0060] As shown in Figure 10B, in some embodiments, the head module (310)
comprises a HSS A bearing as well as a head (7), a hollow head module shaft
(9) which may
have splines, a head module housing (134), a terminal block (60), and/or a
flangeless
connection (64) that may be used to mate the head module to the top of a power
module.
[0061] The terminal block (60) may hold three terminals that mate to the motor
lead
cable and seal the connection against the ingress of wellbore fluids. These
terminals may be
connected internally via lead wire (132) to the female terminals in the
insulation block (68).
The bottom part of the head (57) may be fitted with a protective insert (61)
which may be used
to protect the lead wire from the rotating head module shaft (59)
[0062] The head module (310) may also be also fitted with a filling valve
(133) which
may be used to fill the internal chamber of the electric motor and/or lower
chamber of the seal
section with lubricant when the unit is run in combination with a seal section
(9).
[0063] The head module housing (134) may be threaded on to the head (57)
and/or a
bearing support (71). In some embodiments, the bearing support is integral to
the head (57).
A HSSA Bearing (62) may be installed in the head module housing and held in
place by a
retaining nut. In certain embodiments, the bearings support, whether integral
to the head or a
separate component, may also comprise mounting holes for any female terminals
that connect
to the male terminals on a power module.
[0064] The lower part of the head module housing (134) may have a flangeless
connection (64). In an exemplary flangeless connection (64), the threads on
either end may be
in opposite directions from one another to enable a threaded connection to a
power module
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(320) without an external upset along the exterior of the motor. For example,
the flangeless
connection (64) may make up to the head module housing (134) via right hand
threads, while
the opposite end may make up to the power module housing (136) which contains
left-hand
threads. It will be appreciated that right-hand threads turn in an opposing
direction as compared
to left-hand threads. This connection may then be secured by locking a
retaining nut (65)
against the housing of the power module. The connection may also be secured
using a set
screw or other similar retaining method. As the connection is made, special
alignment tools
may be used to ensure that the power terminals (63) and (68) and shaft
coupling are mated
properly. The lower splines of the head module shaft (59) may connect to a
coupling (135)
designed to transmit torque from the shaft of the rotor (66) in the power
module to the head
module shaft (59). A bearing support (136) may be located in the upper end of
a power module
(320) where an upper HSSA bearing bushing (137) may be located and/or where a
power
module rotor (66) may be positioned.
[0065] As shown in Figure 11, a wound stator core (72) may be positioned
within the
power module housing (67). The winding coils may be located inside the stator
core (72). A
lower bearing support (75) may be positioned inside the power module housing
(67) below the
winding end coils (73). The lower bearing support (75) may be fitted with a
HSSA Bearing
bushing (76) and a corresponding HSSA Bearing sleeve (74). HSSA bearing sleeve
(74) may
be connected to a rotor (66).
[0066] In some embodiments, both the upper and lower end of the rotor (66) are
associated with axial thrust pads (79) which allow the rotor (66) to self-
align within the
magnetic field of the wound stator core (72).
[0067] A lower bearing support (75) may have mounting slots for the lower
terminals
(138) from the wound stator core (72) above. In some embodiments, a lower
portion of the
power module housing (67) may utilize a flangeless connection system similar
to or
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substantially the same as the flangeless connection previously mentioned.
[0068] As shown in Figure 12, a motor base module (330) may comprise a base
module housing (88), a hollow shaft (80) with a HSSA bearings sleeve, a
bearing support (83)
with a HSSA bearing bushing, an impeller (84) and/or an adjustable axial
thrust pad (85). In
some embodiments, the bearing support (83) of the base module (320) may
contain mounting
points for the male terminals (82) that connect to the female terminals of a
lower power module.
In some embodiments, terminals (82) may be connected with a copper bus to
create a wye point
that connects all three phases of the motor. A lower power module housing (86)
may be mated
to the base module housing (88) via a split ring (87) or flangeless connection
system.
[0069] In some embodiments, the lower end of the rotor shaft (66) may be mated
to a
base module shaft (80) via a splined coupling (90).
[0070] In some embodiments, a centrifugal pump impeller (84) may be mounted on
the
base module shaft (80). The impeller (84) may be fitted with an abrasive-
resistant runner which
may be configured to contact a thrust bearing (85). The thrust bearing (85)
may have swiveling
support (91) with a spring insert (92), which facilitates more uniform contact
of the friction
surfaces of an axial bearing (93). The body of the axial bearing (93) may rest
on a connecting
coupling (94) and be fitted with an adjusting support (95) which may be used
to adjust the axial
clearance of the rotors throughout the motor system.
[0071] In some embodiments, the elements of the base module (320) may have
holes
which form a channel for a sensor wire and/or a thermocouple to be passed
through. These
wires may go through the central channel of a heat-exchanger module to a
flange for a
downhole sensor (10).
[0072] Connecting coupling body (97) may include an upper and/or lower thread
which
may be used to secure the base module housing (88) to a central heat exchange
module (410)
exterior housing (98). Connecting coupling (97) may have tangential channels
which may be
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used to direct the flow of lubricant into a pathway between the exterior
housing (98) and the
interior housing (100) of the central heat exchange module (410). In some
embodiments, the
flow in this pathway is in a spiral or helical motion due to the outer wall of
the interior housing
(100) having a guide vane connected in a helical path to direct the flow of
lubricant. This
helical pathway may be used to increase the residency time of the lubricant
and increase the
amount of h eat transferred from the lubricant to the wel I bore fluid. In
some embodiments, the
internal chamber of the interior housing (100) may be comprise displacement
rings (101) which
reduces the volume of the filling lubricant in the internal chamber of the
exchanger. In some
embodiments, the displacement rings (101) may comprise a low coefficient of
thermal
expansion (CTE) material.
[0073] As shown in Figure 13, once the lubricant reaches the bottom of the
central heat
exchange module (410) it may enter a connecting coupling via a port (146) and
crossover the
connection through channels (147) which direct the flow into the outer channel
of the lower
heat exchange module (450) defined in part by lower heat exchange module
exterior housing
(148).
[0074] As shown in Figure 14, the lower portion of the exterior housing (148)
of the
lower heat exchange module (450) may have a threaded connection with a bottom
flange (149).
The bottom flange may be used to connect a downhole sensor and may be fitted
with a filling
valve (150) which may be used to fill the internal chamber of the heat
exchanger with lubricant.
[0075] The lubricant may flow through the outer pathway (453) of the lower
heat
exchanger in order to dissipate heat from the lubricant to the exterior
housing and into the well
bore fluid. Then lubricant may flow from an outer pathway (453) of the lower
heat exchange
module (450) into the interior of the lower heat exchange module via ports
(151) and may be
passed by and/or through a magnet trap (152) to capture any particulate, such
as, for example,
ferrous wear debris. A lubricant return tube (153) may connect the base and
head of the lower
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heat exchange module (450). In some embodiments, the lubricant return tube
(153) may
provide rigidity and/or a mounting frame for displacement rings (154). The
lubricant return
tube (153) may have several openings from the exterior to the interior that
may be covered with
a fine mesh filter to reduce the number of impurities and/or non-ferrous
materials that are
introduced into the motor. In some embodiments, this mesh filter may be a
screen with
substantially uniform pore size. In some embodiments, the pores are at least
about 10 pm, or
at least about 20 gm, or at least about 25 gm, or at least about 30 gm, or at
least about 40 gm
wide. In some embodiments, the pores are at most about 10 p.m, or at most
about 20 gm, or at
most about 25 gm, or at most about 30 gm, or at most about 40 gm wide.
[0076] As shown in Figure 15, once the lubricant enters the return tube (153)
it may
travel up through the return tubes of one or a plurality of central heat
exchange modules (410)
through connecting tubes (155) and/or through a return path until it reaches
the motor base
module (330). The cooled and filtered lubricant may then be returned through
base module
shaft (80) to the rotor (66) and then circulated up through the various motor
modules and/or
seal section before circulating back through the central (410) and lower (450)
heat exchange
modules.
[0077] It will be apparent to one of ordinary skill that elements of the
exemplary
embodiments described above may be utilized in alternate configurations, in
alternate
applications, with and/or without any of the other various elements described
herein and
otherwise known in the art. It will also be apparent that the various elements
associated with
any embodiment may be utilized with any other embodiment to achieve
substantially the same
or an analogous result.
[0078] High Speed Electric Submersible Pump
[0079] Some embodiments of the disclosed inventions belong to the category of
equipment related to wellbore fluid production via artificial lift with a
downhole submersible
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pumping unit. Some embodiments include a permanent magnet motor, which may be
filled
with a coolant and/or lubricant. In some embodiments, the disclosed pump may
operate at
greater than about 3,000 RPM, or greater than about 5,000 RPM, or greater than
about 6,000
RPM, or greater than about 7,000 RPM, or greater than about 9,000 RPM, or
greater than about
10,000 RPM. In some embodiments, the disclosed pump may operate at less than
about 3,000
RPM, or less than about 5,000 RPM, or less than about 6,000 RPM, or less than
about 7,000
RPM, or less than about 9,000 RPM, or less than about 10,000 RPM.
[0080] Some embodiments of the disclosed inventions relate to an ESP assembly
which
is shorter than a standard ESP for a given flow rate and/or head pressure. In
some
embodiments, the length of a disclosed ESP is less than about 80 feet, or less
than about 60
feet, or less than about 50 feet, or less than about 45 feet, or less than
about 42 feet, or less than
about 35 feet, or less than about 30 feet, or less than about 25 feet, or less
than about 20 feet.
In some embodiments, the length of a disclosed ESP is more than about 80 feet,
or more than
about 60 feet, or more than about 50 feet, or more than about 45 feet, or more
than about 42
feet, or more than about 35 feet, or more than about 30 feet, or more than
about 25 feet, or more
than about 20 feet. In some embodiments, the length of a disclosed ESP is
greater than about
80 feet, or greater than about 60 feet, or greater than about 50 feet, or
greater than about 45
feet, or greater than about 42 feet.
[0081] Certain embodiments relate to an ESP assembly comprising a pump module,
wherein the pump module comprises a pump shaft and an impeller or impellers,
wherein the
pump shaft is operably connected to a motor shaft and wherein the impeller is
rotationally fixed
to the pump shaft by a keyway. In some embodiments, the ESP further comprises
a gas
separator module and/or an intake module wherein the gas separator comprises a
gas separator
shaft and an inducer, wherein the gas separator shaft is operably connected to
the motor shaft
and the inducer is rotationally fixed to the gas separator shaft by a keyway.
In some
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embodiments, the inducer is a variable pitched inducer. In some embodiments,
the ESP further
comprises a seal section located between a motor module and the pump module,
wherein the
seal section is configured to transmit torque from the motor shaft to the pump
shaft and absorb
thrust from the pump module. In some embodiments, the ESP further comprises a
motor
module, wherein the motor module comprises an AC electric permanent magnet
motor
configured to operate at a desired rpm, the motor configured to rotate a motor
shaft and/or a
motor cooling system, wherein the motor cooling system comprises a motor
cooling impeller,
the motor cooling impeller configured to circulate lubricant through a motor
module heat
exchanger wherein the motor module heat exchanger comprises a motor module
lubricant
pathway, the motor module lubricant pathway configured to increase a residence
time of the
lubricant in the motor module heat exchanger.
[0082] In some embodiments, the ESP assembly can be installed in a well with a
casing
having a drift ID of less than about 8 inches, less than about 7 inches, less
than about 6 inches,
less than about 5 inches, or less than about 4.6 inches, or less than about
4.1 inches. In some
embodiments, the ESP assembly can be installed in a well with a casing having
a drift ID of
more than about 8 inches, more than about 7 inches, more than about 6 inches,
more than about
inches, or more than about 4.6 inches, or more than about 4.1 inches. In some
embodiments,
the ESP assembly can be installed in a well with a casing having a drift ID of
about 4.6 inches.
[0083] In some embodiments, the ESP assembly has a total dynamic head (TDH) in
feet to length in feet ratio of at least about 80, or at least about 100, or
at least 150, or at least
about 200, or at least about 220, or at least about 230, or at least about
250, or at least about
300. In some embodiments, the ESP assembly has a TDH to length ratio of at
most about 80,
or at most about 100, or at most 150, or at most about 200, or at most about
220, or at most
about 230, or at most about 250, or at most about 300.
[0084] In some embodiments, the ESP assembly has a break horse power (BHP) to
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length in feet ratio of at least about 4, or at or at least about 5, or at
least about 7, or at least
about 9, or at least about 10, or at least about 10.5, or at least about 12.
In some embodiments,
the ESP assembly has a BHP to length ratio of at most about 4, or at or at
most about 5, or at
most about 7, or at most about 9, or at most about 10, or at most about 10.5,
or at most about
12.
[00g5] In some embodiments, the ESP produces at least about 400 barrels per
day
(bpd), or at least about 1,000 bpd, or at least about 2,000 bpd, or at least
about 2,500 bpd, or at
least about 3,000 bpd, or at least about 3,500 bpd, or at least about 4,000
bpd, or at least about
5,000 bpd, or at least about 6,000 bpd, or at least about 7,000 bpd, or at
least about 7,500 bpd.
In some embodiments, the ESP produces at most about 400 barrels per day (bpd),
or at most
about 1,000 bpd, or at most about 2,000 bpd, or at most about 2,500 bpd, or at
most about 3,000
bpd, or at most about 3,500 bpd, or at most about 4,000 bpd or at most about
5,000 bpd, or at
most about 6,000 bpd, or at most about 7,000 bpd, or at most about 7,500 bpd.
Some
embodiments are configured to produce between about 1,000 and about 3,000 bpd
without
changing the downhole equipment. Preferred embodiments are configured to
produce between
about 400 and about 4,000 bpd without changing the downhole equipment. As
disclosed
embodiments are configured to operate over a wide range of production volumes,
the same
ESP may be used as well production varies. Over the life of an oil and gas
well, production
may slow. Traditionally, this has required removing one ESP, configured to
produce greater
volumes of fluid and replacing it with a different ESP configured to produce
lower volumes of
fluid. This process may be repeated multiple times as the well produces
smaller volumes. Each
time an ESP or other down hole component is changed or replaced, the
corresponding surface
equipment may also need to be replaced. Each of these steps can lead to down
time, lost or
deferred production, and increased inventory requirements. Additionally, there
is a risk of
losing the well each time it is sealed so that equipment may be removed and/or
reinstalled.
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These downsides can be reduced and/or avoided by utilizing disclosed
embodiments which
operate over a wide range of production volumes, thereby reducing or
eliminating the need to
change downhole equipment and/or corresponding surface equipment.
[0086] In certain preferred embodiments, the disclosed ESP can be installed in
wells
where the casing has a drift ID of about 4.6 inches, produces greater than
3,000 barrels per day
(bpd), has a TDH in feet to length in feet ratio of at least about 100 and a
RHP to length in feet
ratio of at least about 5.
[0087] In some embodiments of the disclosed ESP assembly, the seal section
comprises
a port in fluid communication with the exterior environment surrounding the
seal section and
in fluid communication with an interior chamber or multiple chambers, the
interior chamber
configured to reduce a pressure differential between the exterior of the
assembly to the interior
of the assembly.
[0088] In some embodiments of the disclosed ESP assembly the seal section
comprises
a seal section cooling system wherein the seal section cooling system
comprises a seal section
heat exchanger wherein the seal section heat exchanger comprises a seal
section lubricant
pathway, the seal section lubricant pathway configured to increase a residence
time of the
lubricant in the seal section heat exchanger. In such embodiments the seal
section may further
comprise a seal section lubricant return path.
[0089] In some embodiments of the disclosed ESP assembly the seal section and
motor
lubricant pathways are linked and a single heat exchanger system is utilized
to cool both the
seal section and the motor module. In such embodiments, the motor lubricant
return path may
also be linked to the seal section lubricant return path in order to create a
continuous and/or
linked heat exchange assembly for both the seal section and motor module.
[0090] Some embodiments of the disclosed ESP assembly comprising at least one
or
more than one high-speed self-aligning bearing.
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[0091] In some embodiments of the disclosed ESP assembly, the motor module
heat
exchanger comprises an upper heat exchange module and a lower heat exchanger
module, the
lower heat exchange module comprising a screen configured to trap non-ferrous
particles and
a magnetic trap configured to trap ferrous particles.
[0092] In some embodiments of the disclosed ESP assembly, the seal section
comprises
a thrust chamber wherein the thrust chamber comprises at least two thrust
bearings and wherein
each thrust bearing is fitted with a spring damper designed to distribute a
thrust load across two
thrust bearings. In some embodiments, the spring damper may be designed to
distribute the
thrust load of the pump across two thrust bearings substantially evenly.
[0093] In some embodiments of the disclosed ESP assembly, the motor module
comprises a head module, power module, and base module. In some embodiments,
the motor
module comprises more than one power module. The number of power modules may
be
adjusted depending on the power requirements of the ESP for a given
application.
[0094] In some embodiments of the disclosed ESP assembly, at least two power
modules are disposed between the head module and base module and a flangeless
connection
is used to connect the two power modules to each other. In some embodiments, a
flangeless
connection is used to connect the head module to a power module and/or to
connect the base
module to a power module.
[0095] In some embodiments of the disclosed ESP assembly, the motor module
further
comprises a stator with a magnetic field wherein the motor rotor is configured
to self-align
within the magnetic field of the stator.
[0096] Some embodiments of the disclosed ESP further comprise an axial seating
system, configured to seat a motor rotor. In some embodiments, the axial
seating of the rotor
within the magnetic field of the stator may vary throughout the operating
range of the system.
The axial load faces may have slightly different microhardness in order for
material to be
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removed from the lower microhardness face, if and as needed, for the rotor to
seat at a given
operating point. In axial thrust assemblies, the dynamic face preferably has a
higher
microhardness than the static face and the static face is preferably of higher
compressive
strength than that of the dynamic face. The methods and techniques described
in ASTM
C1424-15, Standard Test Method for Monotonic Compressive Strength of Advanced
Ceramics
at Ambient Temperature, may be used to determine the compressive strength of a
material.
[0097] In some embodiments, the dynamic face of an axial thrust assembly
comprises
materials with a compressive strength of at least about 3,500 Mpa, or at least
about 3,700 Mpa,
or at least about 4,000 Mpa, or at least about 4,200 Mpa, or at least about
4,500 Mpa. In some
embodiments, the dynamic face of an axial thrust assembly comprises materials
with a
compressive strength of at most about 3,500 Mpa, or at most about 3,700 Mpa,
or at most about
4,000 Mpa, or at most about 4,200 Mpa, or at most about 4,500 Mpa.
[0098] In some embodiments, the static face of an axial thrust assembly
comprises
materials with a compressive strength of at least about 7,200 Mpa, or at least
about 7,500 Mpa,
or at least about 7,800 Mpa, or at least about 8,000 Mpa, or at least about
8,200 Mpa. In some
embodiments, the static face of an axial thrust assembly comprises materials
with a
compressive strength of at most about 7,200 Mpa, or at most about 7,500 Mpa,
or at most about
7,800 Mpa, or at most about 8,000 Mpa, or at most about 8,200 Mpa.
[0099] In some embodiments, a rotor may be equipped with an axial load face on
both
the upper and lower ends of the rotor body. The con-esponding stator may be
equipped with a
complementary upper and lower load face configured to absorb and distribute
the load to the
stator housing when interacting with the rotor surfaces. This arrangement
allows the rotor to
be preferentially aligned within the magnetic field of the stator throughout
its operating range.
[00100] Active Cooling System
[00101] In some embodiments, an active cooling system is
utilized to reduce or
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maintain the motor temperature and/or lubricant temperature. Disclosed active
cooling systems
may be utilized with a variety of motors, including, for example, permanent
magnet motors
and/or induction motors and/or may be utilized with a seal section or other
non-motor
machinery. It will be appreciated that features and elements of the disclosed
active cooling
system may be used with other disclosed embodiments as well as other equipment
and/or
ma chi n ery.
[00102]
In some embodiments, a motor with the disclosed active cooling system
comprises an electric motor, an impeller, at least one central heat exchanger
module, and a
lower heat exchanger module. Each heat exchanger module typically comprises a
head and a
base. In disclosed embodiments, the impeller may be arranged to drive
lubricant into a central
heat exchanger. As shown in Figures 16 A-C, in some embodiments the central
heat exchanger
module (410) comprises an exterior housing (412), an interior housing (415),
and a lubricant
return tube (417) connected to the head and base of each central heat
exchanger module. The
interior housing (415) is positioned within the exterior housing (412) and
arranged to create a
central heat exchanger lubricant pathway (418) between the interior and
exterior housing. The
lubricant pathway (418) allows a thin layer of lubricant to pass between the
interior and exterior
housings. This creates a thermal pathway allowing heat to be transferred from
the lubricant to
the exterior housing and then to the wellbore fluid. In many embodiments, the
lubricant
pathway (418) is arranged in a helical pattern, which causes the lubricant to
flow around the
helical pathway, thereby increasing the residence time that the lubricant
spends in the heat
exchanger and allowing more heat to be transferred from the lubricant to the
exterior housing
and wellbore fluid. In some embodiments, this helical pathway is created using
a wire or
similar material wrapped around the exterior of the interior housing (415).
Additionally or
alternatively, a wire may be wrapped around the interior of the exterior
housing, thereby
creating a helical lubricant pathway between the interior housing and exterior
housing. In
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preferred embodiments, the helical pathway is created by machining a pathway
into the exterior
of the interior housing (415).
[00103]
In some embodiments, the lubricant pathway (418) defined by the space
between the interior and exterior housing is at least about 0.04 inches, or at
least about 0.06
inches wide, or at least about 0.065 inches wide, or at least about 0.07
inches wide, or at least
about 0.1 inches wide, or at least about 0.25 inches wide or at least about O.
inches wide. In
some embodiments, the lubricant pathway (418) defined by the space between the
interior and
exterior housing is at most about 0.04 inches, or at most about 0.06 inches
wide, or at most
about 0.065 inches wide, or at most about 0.07 inches wide, or at most about
0.1 inches wide,
or at most about 0.25 inches wide or at most about 0.5 inches wide. In
preferred embodiments,
lubricant pathway (418) is about 0.0675 inches wide.
[00104]
As shown in Figures 17 A, B, and C, in some embodiments, a lower heat
exchanger (450) comprises a lower exterior housing (452), a lower interior
housing (455), and
a lower lubricant return tube (457). The lower interior housing (455) may be
disposed within
the lower exterior housing (452). This arrangement creates a lower heat
exchanger lubricant
pathway (458) between the interior and exterior housings. The lower lubricant
return tube
(457) may be disposed within the lower interior housing (455) and be in fluid
communication
with the lower heat exchanger lubricant pathway (458). As cooling lubricant
circulates through
the lower heat exchanger (450), it flows into the lower lubricant return tube
(457), which may
be fluidly connected to a central lubricant return tube (417) which circulates
lubricant to the
top of the central heat exchanger (410) and back through the motor. The
central heat exchanger
(410) may be connected to the lower heat exchanger (450) such that the central
heat exchanger
lubricant pathway (418) is fluidly connected to the lower heat exchanger
lubricant pathway
(458) and the central lubricant return tube (417) is in fluid communication
with the lower
lubricant return tube (457). This arrangement allows lubricant to be
circulated through the
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motor and heat exchangers in order to cool the motor and transfer heat from
the motor
components to the wellbore fluid via the circulating lubricant and heat
exchange modules.
[00105]
In some embodiments, multiple central heat exchanger modules may be
arranged in a series. The central heat exchanger modules may be configured
such that the
lubricant return tube within the interior housing of each central heat
exchanger is connectable
to the lubricant return tube of a central heat exchanger module above and/or
below The heat
exchanger lubricant pathways of each central heat exchanger module may also be
configured
such that it is connectable with the heat exchanger lubricant pathways of the
central heat
exchanger modules above and/or below as well. This modular arrangement allows
the
disclosed active cooling system to be customized based on the needs of a given
application.
When a greater degree of cooling is needed, additional central heat exchanger
modules may be
incorporated into the total motor system. This increases the length of the
combined lubricant
pathway, thereby increasing residence time and allowing a greater amount of
heat to be
transferred from the lubricant to the wellbore fluid. In applications where
total length is a
significant concern, a single lower heat exchanger module may be utilized
without any central
heat exchanger modules. In such embodiments, the lower heat exchanger may be
connected
to the motor base module. It will be appreciated that the lower heat exchanger
module includes
a lubricant pathway between the interior housing and exterior housing which
dissipates heat
from the lubricant to the well bore fluid and also serves to direct lubricant
flowing through the
lubricant pathway into the lubricant return tubes. This allows lubricant to be
circulated
throughout either one or a series of heat exchanger modules before being
directed back through
the motor and/or seal section. In particularly hot wells, additional heat
exchanger modules may
be added to maintain the motor temperature within a desired range.
[00106]
In an exemplary embodiment, the disclosed active cooling system may
be used in an ESP comprising a motor housing, a stator, and a rotor shaft. In
this exemplary
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embodiment, the rotor shaft comprising an interior and an exterior and the
interior of the rotor
shaft is in fluid communication with the lubricant return tube of the lower
and/or central heat
exchange module. The rotor shaft may be arranged such that lubricant flows
from the lubricant
return tube through the interior of the rotor shaft into the interior of the
motor housing between
the motor housing and the stator. In some embodiments, the stator may comprise
channels
which are designed to accommodate the flow of lubricant between the stator and
the motor
housing.
[00107]
Some embodiments of the disclosed active cooling system comprise a
filter and/or magnetic trap configured to remove particles from the
circulating lubricant. In
some embodiments, the lower heat exchanger module comprises a screen designed
to remove
particles including non-ferrous wear products from the circulating lubricant.
In some
embodiments, the lower heat exchanger module comprises a magnetic trap
designed to remove
ferrous particles, including wear products from the circulating lubricant. By
removing
particles, including ferrous and non-ferrous wear product from the circulating
lubricant, the
active cooling system helps to maintain the quality of the circulating
lubricant. This leads to a
longer service life of the overall system incorporating the active cooling
embodiments
disclosed. ESPs which comprise the disclosed active cooling system with screen
filter and
magnet trap may have a longer service life than traditional ESPs, resulting in
improved run life
and service time.
[00108]
In exemplary embodiments, the disclosed active cooling system is used
in an ESP. In such embodiments, when the circulating lubricant reaches the top
of the upper
central heat exchanger module lubricant return tube, it then enters the
interior of a motor base
shaft and rotor shaft. In some embodiments, the motor base shaft and rotor
shaft as part of the
lubricant return pathway. The circulating lubricant flows up the rotor shaft
to the top of the
motor. In some embodiments, the rotor shaft includes holes from the interior
of the shaft to
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the exterior where bushings or other components which may benefit from cooling
and/or
lubrication are located. These holes allow circulating lubricant to contact
bushings, bearings,
or other components in order to cool and/or lubricate the components. The
lubricant then
continues to be circulated through the active cooling system.
[00109]
In some embodiments, lubricant flows up the rotor shaft of the motor
and into the shaft of the seal section. At that point, the lubricant may be
directed out of the seal
section shaft through holes leading from the interior of the shaft to the
exterior where bushings
or other components which may benefit from cooling and/or lubrication may be
located. In
some embodiments, lubricant may be directed out of the seal section shaft by
an impeller
located on or near the top of the lubricant flow path. The impeller may drive
the circulating
lubricant through holes leading from the interior of the shaft to the exterior
of the shaft. In
some embodiments, the lubricant may then flow through the motor module and/or
enter the
linked lubricant pathway between the interior and exterior housings of the
seal section and
motor module to dissipate heat before being recirculated through the motor
module and seal
section.
[00110]
In some embodiments, once circulating lubricant reaches the top of the
motor module, prior to reaching the seal section, the lubricant may be
directed out of the rotor
shaft by an impeller located on the top of the rotor. The impeller drives the
circulating lubricant
through exit holes leading from the interior of the rotor shaft to the
exterior of the rotor shaft.
[00111]
In some embodiments, lubricant channels located between the stator and
the motor housing direct circulating lubricant between the stator and the
housing and may, in
some embodiments, direct lubricant through slots of the wound stator core.
This path allows
lubricant to pick up heat from the interior of the rotor shaft as well as the
stator and motor
housing. Once the lubricant has flown down the motor, between the stator and
housing, the
circulating lubricant enters the lubricant pathway of the upper central heat
exchanger module
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where heat may be dissipated to the exterior housing of the head exchanger
module and the
wellbore fluid in contact with the outside of the exterior housing.
[00112] Modular Motor System and Flangeless Connection
[00113] As can be seen in Figure 10A, in some
embodiments, the motor system
is built in modules that consist of a head module, a power module and a base
module. In some
embodiments, multiple power modules may be connected via a flangeless
connection system
in order to reach the desired application power requirements. It will be
appreciated that the
disclosed module systems and connections may be utilized with any other
disclosed element
or embodiment as well as with other equipment and/or machinery.
[00114] In some embodiments, two modules may be connected
to each other
using a flangeless connection (510). As shown in Figure 18, in some
embodiments, the
flangeless connection (510) comprises a single piece housing coupling (512), a
lock nut (515),
and a spacer ring (518). In some embodiments using the flangeless connection,
the two
components or modules being joined will have opposite handed threads which
turn in different
directions. For example, if the lower end of a first power module is to be
joined to the upper
end of a second power module, the lower end of the first power module may
comprise left-
handed threads while upper end of the second power module may comprise right
handed
threads. In some embodiments, the single piece housing coupling comprises
opposite handed
threads on its upper and lower ends.
[00115] In some embodiments, the lock nut and spacer may
be installed on the
housing coupling. The upper and lower modules to be joined may be engaged with
the threads
on the single piece housing coupling and simultaneously madeup as the single
piece housing
coupling is rotated. Once completely madeup the lock nut may be tightened
against the spacer
ring. Depending on the application, once the modules and/or components are
threadedly
attached, the components may be secured by welding or another method known to
prevent
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unthreading known in the art.
[00116]
Some disclosed embodiments relate to a motor for an electric
submersible pump assembly, the motor comprising a head module; a base module;
and at least
two power modules disposed between the head module and base module. In some
embodiments, each power module comprises a power module housing having an
upper and
lower portion; and at least two power modules are connected to each other
using a flangeless
connection, the flangeless connection comprising a housing coupling, a lock
nut, and a spacer
ring. In some embodiments, a power module may be connected to a base module
and/or a head
module using the disclosed flangeless connection regardless of the number of
power modules
in the ESP assembly.
[00117]
In some embodiments, the upper portion of the power module housings
comprise threads rotating in a certain direction, for example, right handed
threads, and the
lower portion of the power module housings comprise threads rotating in the
opposite direction,
for example, left handed threads. In some embodiments, the housing coupling
comprises an
upper portion and a lower portion, the upper portion of the housing coupling
having right or
left handed threads to connect to the lower portion of a power module housing
and the lower
portion of the housing coupling having opposite handed threads to connect to
the upper portion
of a power module housing.
[00118]
Disclosed embodiments of the flangeless connection may help to
maximize the available motor diameter. The disclosed flangeless connection
also reduces
and/or eliminates choke points that may inhibit the flow of motor oil,
lubricant, and/or
dielectric fluid. Embodiments of the disclosed flangeless connection increase
the available
heat exchanger surface area, thereby allowing greater amounts of heat to be
transferred from
the motor or other components to the wellbore fluids. Disclosed embodiments
also allow the
various modules to be coupled in a manufacturing facility rather that at the
well site
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environment. This allows the operator to save time installing an ESP utilizing
the disclosed
features and leads to increased reliability of the assembled ESP and/or other
components.
[00119] HSSA Bearing Details
[00120] In some embodiments, the disclosed ESP components,
as well as other
equipment, motors, and/or machinery may comprise high-speed self-aligning
(HSSA)
hearings. It will be appreciated that the disclosed hearing design may he
utilized with any of
the disclosed elements or embodiments as well as with other equipment or
machinery.
[00121] In some embodiments, a module may be equipped with
a radial bearing
with the dynamic portion of the bearing (the bearing sleeve) being
rotationally fixed to a
rotating shaft. In such embodiments, the stator may be equipped with a
complementary static
portion (the bushing) which absorbs and distributes a radial load to the
stator housing. The
sleeve comprises material which may have a lower microhardness than the
bushing. This
arrangement allows for the sleeve (the dynamic face) to "wear-in" if necessary
in order to reach
an improved and/or optimum operating point. In some embodiments, the sleeve
will be
attached to a rotor which is contained in the magnetic field of the stator.
The disclosed
arrangement allows the rotor to reach an improved or optimum position within
the magnetic
field of the stator.
[00122] In some embodiments, the sleeve or a sleeve
portion of a sleeve
assembly may comprise carbide. In certain embodiments, the sleeve comprises
tungsten
carbide with at least about 4% nickel, or at least about 5% nickel, or at
least about 6% nickel,
or at least about 7% nickel. In certain embodiments, the sleeve comprises
tungsten carbide
with at most about 4% nickel, or at most about 5% nickel, or at most about 6%
nickel, or at
most about 7% nickel.
[00123] In some embodiments, the bushing may be mounted on
a fixed support
using one or multiple elastomeric bands. In some embodiments, the elastomeric
bands
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comprise materials that, when in contact with a coolant, lubricant, and/or
dielectric fluid, they
will expand and lock the bushing to the support. In some embodiments, the
elastomeric bands
do not allow any axial or rotational movement of the bushing. In some
embodiments, the
anchoring strength on the bushing may be increased by adding a groove or
helical groove on
the outside of the bushing, thereby allowing the bands to -grip" the bushing.
The elastomeric
band may also help to center the bushing in the bushing support and/or provide
a dampening
effect in the event of any vibration.
[00124]
In some embodiments, the bushing may have grooves which allow
lubricant to flow between the static and dynamic bearing faces. In radial
bearings, the static
face is the bushing and the dynamic face is the sleeve. These grooves allow
lubricant to flow
between the bushing and the sleeve and clear any particulate or debris, such
as, for example,
debris caused by wearing of the bearing faces. In some embodiments, the
lubricant cooling
and/or circulation system may comprise a screen and/or magnetic trap to remove
such debris
as the lubricant is circulated.
[00125]
In some embodiments, the bushing may comprise an outer bushing body
and a bushing insert. The outer body may comprise a low CTE material. The
bushing insert
comprises a material of a higher microhardness than the associated sleeve.
[00126]
In some embodiments, a multi-piece bushing may allow for thinner
materials to be used. One advantage of thinner materials is that a higher
proportion of any
thermal growth will be in the axial plane rather than the radial plane. This
arrangement allows
tight tolerances to be maintained at high speeds and high temperatures.
[00127]
As shown in Figure 19, in some embodiments, a sleeve assembly (530)
comprises a sleeve body (533) and at least two sleeves (535). In such
embodiments, the sleeve
body (533) and each sleeve (535) comprises a keyway. In some embodiments, the
two sleeves
(535) may be mounted onto the sleeve body (533) and the sleeve assembly (530)
may be
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mounted onto a rotating shaft using the keyways and associated keys. In some
embodiments,
the sleeve assembly further comprises an inside limiting nut which may be
threaded onto a
rotating shaft and limit axial movement of the sleeve assembly. In some
embodiments, the
limiting nut may hold the keys, for example "L" keys, in the keyway while the
sleeve assembly
is mounted onto a shaft.
[0012fil
In some embodiments, a tapered centralizing ring may be mounted with
a set of keys to provide centralization of the sleeve assembly on the shaft.
In some
embodiments, an outside limiting nut may be threaded into place but may be
stopped prior to
contacting the tapered centralizing ring. This arrangement allows for the
sleeve assembly to
have a small amount of axial movement between the inside and outside limiting
nuts in order
to assist in the bearing finding an improved or optimum operating point. Once
the outside
limiting nut is in place the edges of the tapered centralizing ring may be
peened into a machined
groove on the outside limiting nut.
[00129]
In some embodiments, a rotor shaft may have elastomeric bands which
a sleeve assembly fits around. These elastomeric bands may help to direct
lubricant from the
interior of the shaft to the exterior of the sleeve body and onto the face of
the sleeves. This
arrangement allows lubricant circulating within the rotor shaft to lubricate
and cool the bearing
faces. The elastomeric bands may also help to center the sleeve assembly and
dampen any
vibration.
[00130]
In some embodiments, a pump and/or gas separator may comprise
HSSA bearings. An HSSA bearing for a pump may be comprise of a bushing and a
sleeve.
The bushing may be held onto a bushing support by an interference fit or any
other technique
known in the art. In some embodiments, elastomeric bands maybe used to prevent
rotation of
the bushing, the help center a shaft, and/or to dampen vibration.
[00131]
In some embodiments a two-piece sleeve may be used. A two-piece
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sleeve may comprise an outer sleeve and an inner sleeve. The outer sleeve may
be keyed to
the inner sleeve in order to rotationally fix the inner and outer sleeves of
the two-piece sleeve.
In some embodiments, the outer sleeve may be fluted and/or comprise a helical
groove on the
exterior to allow for the removal of particulate or other contaminants and/or
to promote the
flow of lubricant. In some embodiments, the inner sleeve may be keyed to a
shaft via a dual
keyway. The inner sleeve may comprise low CTE materials designed to help
reduce thermal
growth in the radial direction. This arrangement may allow the outer sleeve to
be thinner which
further reduces radial thermal growth.
[00132]
In some embodiments, the design of the high-speed self-aligning
(HSSA) radial bearings may be based on the concept that at high rotational
speed the dynamic
face (the rotating sleeve) performs better after finding its optimal or
improved running position
within the static face (the non-rotating bushing).
[00133]
To facilitate this process, the materials of the sleeve and bushing should
have slightly different microhardness in order for material to be removed from
the lower
microhardness face, if or as needed, for the bearing to self-align. The sleeve
material may
additionally be of a higher flexural strength than the bushing material in
order to allow it to
overcome any bending stresses encountered during the process of self-
alignment. To further
facilitate the process of self-alignment, in some embodiments, the sleeve
assembly may be
allowed to move, at least to a degree, in the axial direction. In some
embodiments, the sleeve
assembly may be allowed to move at least about 20 mils, or at least about 25
mils, or at least
about 30 mils, or at least about 40 mils, or at least about 50 mils, or at
least about 60 mils, or
at least about 70 mils, or at least about 75 mils. In some embodiments, the
sleeve assembly
may be allowed to move at most about 20 mils, or at most about 25 mils, or at
le most ast about
30 mils, or at most about 40 mils, or at most about 50 mils, or at most about
60 mils, or at most
about 70 mils, or at most about 75 mils.
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[00134]
Some embodiments of the disclosed inventions relate to a radial bearing
assembly suitable for mounting on a rotatable shaft, the radial bearing
assembly comprising
one or more radial bearings, each bearing comprising a bushing and a sleeve,
the bushing and
sleeve each comprising an interior and an exterior. The interior of the
bushing being in
lubricated, engagement with the exterior of the sleeve, wherein the bushing is
affixable to a
non-rotatable bushing support and comprises a material having a higher
microhardness than
the sleeve and wherein the sleeve is configured to mount to a rotating shaft
and comprises a
material having a higher flexural strength than the bushing. In some
embodiments, the bushing
comprises a material having a microhardness of at least about 2,000 MPa, or at
least about
2,500 MPa, or at least about 2,800 MPa, or at least about 3,000 MPa, or at
least about 3,200
MPa on the Knoop microhardness scale. In some embodiments, the bushing
comprises a
material having a microhardness of at most about 2,000 MPa, or at most about
2,500 MPa, or
at most about 2,800 MPa, or at most about 3,000 MPa, or at most about 3,200
MPa on the
Knoop microhardness scale. In some embodiments, the sleeve comprises a
material having a
microhardness of at least about 1,000 MPa, or at least about 1,500 MPa, or at
least about 1,800
MPa, or at least about 2,000 MPa, or at least about 2,200 MPa on the Knoop
microhardness
scale. In some embodiments, the sleeve comprises a material having a
microhardness of at most
about 1,000 MPa, or at most about 1,500 MPa, or at most about 1,800 MPa, or at
most about
2,000 MPa, or at most about 2,200 MPa on the Knoop microhardness scale.
[00135]
The methods and techniques described in ASTM C1326-13, Standard
Test Method for Knoop Indentation Hardness of Advanced Ceramics, may be used
to
determine the microhardness of a material.
[00136]
In some embodiments, the sleeve comprises a material having a flexural
strength of at least about 1,000 Mpa, or at least about 1,300 Mpa, or at least
about 1,500 Mpa,
or at least about 1,800 Mpa, or at least about 2,000 Mpa. In some embodiments,
the sleeve
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comprises a material having a flexural strength of at most about 1,000 Mpa, or
at most about
1,300 Mpa, or at most about 1,500 Mpa, or at most about 1,800 Mpa, or at most
about 2,000
Mpa. In some embodiments, the bushing comprises a material having a flexural
strength of at
least about 300 Mpa, or at least about 300 Mpa, or at least about 400 Mpa, or
at least about 450
Mpa, or at least about 500 Mpa. In some embodiments, the bushing comprises a
material
having a flexural strength of at most about 300 Mpa, or at most about 300 Mpa,
or at most
about 400 Mpa, or at most about 450 Mpa, or at most about 500 Mpa.
[00137]
The methods and techniques described in ASTM C1161-02c(2008)el,
Standard Test Method for Flexural Strength of Advanced Ceramics at Ambient
Temperature,
may be used to determine the flexural strength of a material.
[00138[
In some embodiments, the bushing interior comprises a plurality of
grooves configured to allow lubricant to flow between the bushing and the
sleeve and wherein
the grooves are configured to discharge debris. In some embodiments, the
grooves are at least
about 3.0 mm wide, or at least about 4.0 mm wide, or at least about 4.5 mm
wide, or at least
about 5.0 mm wide. In some embodiments, the grooves are at most about 3.0 mm
wide, or at
most about 4.0 mm wide, or at most about 4.5 mm wide, or at most about 5.0 mm
wide. In
certain embodiments, the grooves are about 4.73 mm wide.
[00139]
In some embodiments, as shown in Figures 20A and 20B, the bushing
(550) has a surface feature (553) configured to distribute lubricant as the
sleeve rotates. The
bushing (550) may have an groove, configured to facilitate and/or maintain the
build-up of
lubricant to be distributed onto the interface of the bushing (550) and
sleeve. This surface
feature (553) may facilitate removal of particulate. In some embodiments, this
surface feature
(553) has a larger radius on the leading edge than the trailing edge.
[00140]
In some embodiments, the radial bearing assembly further comprises an
elastomeric band disposed between the bushing exterior and bushing support,
the elastomeric
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band configured to expand when in contact with a lubricant and prevent
substantial deleterious
movement of the bushing relative to the bushing support. In some embodiments,
deleterious
movement comprises radial and axial movement. In some embodiments, as shown in
Figure
20A, the radial bearing assembly may further comprise a groove (555) in the
bushing exterior
wherein the groove is configured to increase binding between the bushing and
the elastomeric
band In some embodiments, the groove is helical and the elastorneric band is
configured to
dampen vibration.
[00141]
In some embodiments of the radial bearing assembly, the sleeve is
axially movable between about 1.5 mm and about 3.0 mm relative to the rotating
shaft. In
some embodiments, the sleeve may be axially movable relative to the rotating
shaft by at least
about 0.5 mm, or at least about 0.8 mm, or at least about 1.0 mm, or at least
about 1.5 mm, or
at least about 2.0 mm, or at least about 2.5 mm, or at least about 3.0 mm, or
at least about 3.5
mm, or at least about 4.0 mm. In some embodiments, the sleeve may be axially
movable
relative to the rotating shaft by at most about 0.5 mm, or at most about 0.8
mm, or at most
about 1.0mm, or at most about 1.5 mm, or at most about 2.0 mm, or at most
about 2.5 mm, or
at most about 3.0mm, or at most about 3.5 mm, or at most about 4.0 mm. The
allowed axial
movement of the sleeve relative to the shaft may allow a rotor shaft to find
an improved or
optimum position within the magnetic field of a stator.
[00142]
In some embodiments of the radial bearing assembly, the sleeve
comprises two outer sleeves and an inner sleeve body, wherein the two outer
sleeves and inner
sleeve body each comprise a keyway. In some embodiments, the sleeve body and
the rotating
shaft each comprise an interior and an exterior. The sleeve body may comprise
an opening
allowing lubricant to pass from the interior of the sleeve body to the
exterior of the sleeve body
and the shaft may comprise an opening allowing lubricant to pass from the
interior of the shaft
to the exterior of the shaft. One or more elastomeric bands may be disposed
between the
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exterior of the shaft and the interior of the sleeve body creating a gap for
the flow of lubricant
from the interior of the shaft to the exterior of the sleeve body. In some
embodiments, the
assembly further comprises a screen configured to be in fluid communication
with a lubricant,
the screen designed to remove wear products from the lubricant. In some
embodiments, the
assembly further comprises a magnetic trap configured to be in fluid
communication with a
lubricant, the magnetic trap designed to remove ferrous wear products from the
lubricant.
[00143] In some embodiments of the radial bearing assembly
the bushing
comprises a bushing body and a bushing insert, wherein the bushing insert
comprises a material
having a higher microhardness than the sleeve and wherein the bushing body
comprises a low
CTE material. hi some embodiments of the radial bearing assembly the sleeve
comprises an
outer sleeve and an inner sleeve, wherein the inner sleeve comprises a low CTE
material. In
some embodiments, the low CTE material has a CTE of at least about 3.5, or at
least about 4.0,
or at least about 4.5, or at least about 5.0, or at least about 5.5 p.m/m- C.
In some embodiments,
the low CTE material has a CTE of at most about 3.5, or at most about 4.0, or
at most about
4.5, or at most about 5.0, or at most about 5.5 p.m/m- C. In certain
embodiments, the low CTE
material has a CTE of about 4.9 . Low cte materials may include, but are not
limited to, for
example, InvarTM, InovcoTM, KovarTM, RodarTM, TelcosealTm, SealvarTM,
SelvarTM, Alloy 29-
171m, Nib o Kim, DilverTm, Pernifer 29-181m, Alloy 29-181m, NicoselTm,
NicoseaPTM, and/or
Therlo TM.
[00144] It will be appreciated that the disclosed bearings
may be incorporated
into any of the components and/or modules described herein including, but not
limited to the
pump modules, motor modules, gas separator, and/or seal section.
[00145] Symmetrical Rotor
[00146] Disclosed embodiments relate to or comprise a
rotating rotor. In some
embodiments, a symmetrical rotor may allow for a higher grade of balancing to
reduce and/or
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minimize any mechanical vibration when the rotor rotates at operating speeds.
It will be
appreciated that the disclosed ESP embodiments may comprise a symmetrical
rotor and that
the features and elements disclosed herein may be used with any other
equipment or machinery
which utilizes rotating parts, pumps, motors, rotors, and/or stators. The
alignment of various
components, including for example, shaft splines, keyways, impellers,
lubricant holes and/or
bearing seats may all impact operation, particularly high-speed operation. A
symmetrical rotor
may have designated bronze end rings for removal of material to achieve a
balance grade of
G1 per ISO specification 21940-11:2016. These end rings may be covered with
sleeves made
of titanium or other materials and sealed with an anaerobic gasket in order to
ensure that no
material fills the area where material was removed which could lead to future
imbalances. It
will be appreciated that in some embodiments, the symmetrical rotor is
vertically symmetrical
in addition to axially and/or radially symmetrical. In some embodiments, a
vertically
symmetrical rotor does not include an impeller at either end in order to
ensure vertical
symmetry. In such embodiments, any necessary impellers may be relocated to
other areas of
the disclosed ESP assembly including, for example, the seal section and/or the
top of the
lubricant flow path.
[00147] Motor Base Thrust Module
[00148] Some disclosed embodiments comprise a motor base
thrust module. It
will be appreciated that elements and feature of the disclosed thrust module
may be applied to
other embodiments as well as other equipment and/or machinery. A thrust runner
may be
connected to an impeller in the motor base. In some embodiments, a thrust
runner is connected
to the bottom of an impeller that drives the motor active cooling system. In
such embodiments,
the static face may be built into a body and/or assembly that may be axially
adjusted to
compensate for any variation it the position of the shafts of the power
modules.
[00149] The static face of the motor base thrust module
may be centrally
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mounted on a pivot head. In some embodiments, the static face may be tensioned
using springs
that facilitate evenly spreading the load across the bearing. In some
embodiments, between 2
and 8 springs may be used. In preferred embodiments, six springs may be used.
[00150] In some embodiments of the motor module base
thrust module, the
dynamic face of the thrust runner may comprise a material with a higher
microhardness than
the material of the static face. In such embodiments of the thrust module, the
static face may
comprise a material with a lower microhardness than the dynamic face. The
static face may
also comprise a material compression of a higher compression strength than the
material of the
dynamic face.
[00151] One of many potential materials known to have a
high compression
strength is carbon graphite. Carbon graphite is beneficially known to have
high compression
strength, low coefficient of friction and self-lubricating properties. Carbon
graphite materials
are known to have a high operational temperature limit which may be beneficial
in some
embodiments due to the increased friction heat generated by some embodiments
of the
disclosed pump assembly at higher speeds. Thrust washers may additionally or
alternatively
comprise, for example, polymeric materials or other materials depending on the
application
conditions.
[00152] In some embodiments, the static and/or dynamic
face of the motor base
thrust module may comprise grooves. The grooves may be configured to
facilitate maintaining
a lubricant film or layer between the static and dynamic faces of the motor
base thrust module.
[00153] Motor Filter and Magnet Trap
[00154] Some disclosed embodiments comprise a filter
and/or magnet trap for
removing non-ferrous and/or ferrous particulate. It will be appreciated that
elements and
feature of the disclosed filter and magnetic trap may be applied to other
embodiments as well
as other equipment and/or machinery.
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[00155] Some embodiments of the disclosed motor system
comprise a lower heat
exchange module. The lower heat exchange module may comprise a shaft with
holes from the
outer diameter to the inner diameter. The lower heat exchange module may
comprise a filter
medium to filter lubricant which passes through the holes. The filter medium
may include, but
is not limited to screen mesh, fibrous mesh, or any other material capable of
filtering non-
ferrous contaminants from the circulating lubricant. Some embodiments may
comprise a
magnet trap configured to catch ferrous debris or other particles that may be
produced during
the operation of the motor. In some embodiments, the magnet trap may be
positioned near the
bottom of the lubricant return tube in order to capture any ferrous particles
which may settle
during circulation.
[00156[ Dual Bearing Thrust Chamber and Integrated Heat
Exchanger
[00157] Some disclosed embodiments comprise a dual bearing
thrust chamber
and/or an integrated heat exchanger. It will be appreciated that elements and
feature of the
disclosed thrust chamber and heat exchanger may be applied to other
embodiments as well as
other equipment and/or machinery.
[00158] In some embodiments of the disclosed pump
assembly, the seal section
comprises a dual bearing thrust chamber configured to absorb thrust from the
pumps and
transmit rotation from the motor to the pumps. In some embodiments, the dual
bearing thrust
chamber allows axial load to be evenly distributed across two thrust bearings,
thereby
substantially doubling the amount of thrust the seal chamber can absorb. In
some embodiments
of the disclosed pump assembly, the axial thrust generated by the pumps is
transferred entirely
to the thrust bearings in the seal section thrust chamber. In some
embodiments, no axial thrust
is transferred to any bearing which provides radial support.
[00159] In some embodiments, a thrust chamber arranged to
transfer thrust from
a shaft to a thrust bearing comprises a shaft that is operably connected to at
least one impeller.
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The impeller may be configured to generate downward thrust when it is in
operation. The
thrust chamber also comprises a thrust chamber outer housing, a first thrust
runner, that is
coupled to the shaft and comprises an upward facing thrust transferring
surface and a
downward facing thrust transfer surface. The thrust chamber may also comprise
a first thrust
bearing assembly coupled to the outer housing; wherein the first thrust
bearing assembly
comprises an upward facing thrust receiving surface and wherein the first
thrust runner is
configured to transfer downward thrust from the shaft to the first thrust
bearing assembly. In
some embodiments, an up-thrust bearing assembly may be coupled to the outer
housing,
wherein the up-thrust bearing assembly comprises a downward facing thrust
receiving surface
and wherein the first runner is configured to transfer upward thrust from the
shaft to the up-
thrust bearing assembly. In some embodiments, a second thrust runner may be
coupled to the
shaft and comprise a downward facing thrust transfer surface and a second
thrust bearing
assembly may be coupled to the outer housing, wherein the second thrust
bearing assembly
comprises an upward facing thrust receiving surface and wherein the second
thrust runner is
configured to transfer downward thrust from the shaft to the second thrust
bearing assembly.
Some embodiments may also comprise a first and a second damper, wherein the
first damper
is configured to absorb downward thrust from the first thrust runner and
transfer the downward
thrust to the first thrust bearing assembly and the second damper is
configured to absorb
downward thrust from the second thrust runner and transfer the downward thrust
to the second
thrust bearing assembly. In such embodiments, the dampers may be configured to
spread axial
load substantially evenly across at least two thrust bearings.
[00160]
Preferred embodiments of the disclosed thrust chamber may comprise a
thrust chamber heat exchanger, wherein the thrust chamber heat exchanger
comprises a thrust
chamber interior housing and thrust chamber lubricant return path, wherein the
thrust chamber
interior housing is disposed within the thrust chamber outer housing and
defines a thrust
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chamber heat exchanger lubricant pathway therebetween. In such embodiments the
thrust
chamber lubricant return path may be in fluid communication with the thrust
chamber lubricant
pathway and may be disposed within the interior housing.
[00161]
In some embodiments, the shaft comprises an interior and an exterior,
and the interior of the shaft may be in fluid communication with the lubricant
return path. In
some embodiments, the up-thrust bearing assembly comprises a static downward
facing thrust
receiving surface. In some embodiments, the upward facing thrust receiving
surfaces of the
first and second thrust bearing assemblies have a higher microhardness than
the downward
facing thrust transfer surfaces of the first and second thrust runners.
[00162]
In some embodiments, the dampers are configured to distribute
substantially even thrust load across the first and second thrust bearing
assemblies. In some
embodiments, the dampers may comprise Belleville washers and/or stacks of
Belleville
washers configured in parallel.
[00163[
In some embodiments, the thrust chamber lubricant pathway is
substantially helical.
[00164]
In some embodiments, the thrust chamber heat exchanger further
comprises a filter screen and/or a magnetic trap in fluid communication with
the thrust chamber
lubricant pathway
[00165]
In some embodiments, the outer thrust housing is threadedly connected
to a seal section, and the seal section is disposed between a motor module and
a pump module.
In some embodiments, the pump module comprises an impeller that generates
downward thrust
when in operation, and the downward thrust generated by the impeller is
communicated to the
thrust chamber shaft and transferred by the first and second thrust runners to
the first and second
thrust bearing assemblies which are axially fixed to the thrust chamber outer
housing.
[00166[
In certain embodiments, the lubricant pathway of the seal section thrust
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chamber may be in fluid communication with the lubricant pathway of the motor
module heat
exchangers, thereby creating a unified active cooling system for the motor
assembly and seal
section. In embodiments which utilize at least one active cooling system, the
cooler lubricant
may allow for a more viscous lubricant film to be maintained between an axial
thrust
transferring and thrust receiving surface. This viscous lubricant layer may
help extend the life
of the seal section thrust chamber as well as the other thrust transferring
and/or lubricated
components.
[00167]
In addition to being utilized to cool motors, the disclosed active cooling
system may be utilized with a seal section. The disclosed seal section may
comprise an
impeller, interior housing, exterior housing, and lubricant return path. The
housings may be
arranged to create a seal section lubricant pathway between the interior and
exterior seal
housings. Lubricant may be driven by the impeller to flow through the
lubricant pathway,
thereby dissipating heat from the lubricant to the exterior seal housing and
wellbore fluid. The
lubricant may then be circulated through the lubricant return path to the
interior of the seal
section before circulating back through the lubricant pathway. In preferred
embodiments, the
disclosed seal section cooling systems comprise a screen and magnetic trap to
remove ferrous
and non-ferrous particles from the circulating lubricant.
[00168]
In some embodiments, the disclosed active cooling system may be
utilized with both a motor and seal section. In such embodiments, the seal
section lubricant
pathway may be fluidly connected to the central heat exchangers of the motor
section. The
lubricant return tube of the lower heat exchanger module may be fluidly
connected to the
lubricant return tubes of the central heat exchanger modules and also to the
lubricant return
path of the seal section heat exchanger modules. This arrangement allows
circulating lubricant
to cool and lubricate the components of the associated motor and seal section.
This
arrangement further allows lubricant in the seal section to be cooled by as
many heat exchange
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modules as are required to maintain the desired operating temperature relative
to the wellbore
fluid. In some embodiments, the heat exchanger modules may be configured to
maintain the
temperature of the circulating lubricant to less than about 15 C above the
temperature of the
wellbore fluid, or less than about 10 C above the temperature of the wellbore
fluid, or less
than about 7 C above the temperature of the wellbore fluid, or less than
about 5 C above the
temperature of the wellbore fluid In some embodiments, the heat exchanger
modules may be
configured to maintain the temperature of the circulating lubricant to more
than about 15 C
above the temperature of the wellbore fluid, or more than about 10 C above
the temperature
of the wellbore fluid, or more than about 7 'V above the temperature of the
wellbore fluid, or
more than about 5 'V above the temperature of the wellbore fluid.
[00169[ In some alternative embodiments of the disclosed
pump assembly may
be arranged to pump more wellbore fluid, and thereby generate more downward
thrust than
some embodiments of the seal section thrust chamber is designed to absorb. In
such
embodiments, pump modules may be configured to comprise a thrust runner and
thrust
absorbing assembly. In some embodiments, the pump module thrust absorbing
assembly may
be self-leveling. The pump module thrust absorbing assembly may comprise
bushings and
sleeves for radial support in addition to thrust runners and thrust absorbing
surfaces for
absorbing axial support.
[00170] Gas Separator Inducer and Carbide Lined Separation
Chamber
[00171] Some disclosed embodiments comprise a gas
separator inducer and/or a
carbide lined separation chamber. It will be appreciated that elements and
feature of the
disclosed gas separator and separation chamber may be applied to other
embodiments as well
as other equipment and/or machinery.
[00172] In some embodiments, the disclosed ESP assembly
comprises a gas
separator configured to separate gas phase and liquid phase. In some
embodiments, the gas
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separator comprises an inducer, for example a variable pitch and/or helical
inducer. In some
embodiments, the inducer may comprise vanes inclined towards the liquid flow
path. In some
embodiments, a separation chamber may be lined with carbide inserts and/or
comprise abrasion
resistant materials configured to prevent erosional wear from abrasive solids.
Some
embodiments of the disclosed gas separator may further comprise elastomeric
bands connected
to the carbide inserts, the el astomeri c bands configured to dampen and/or
mitigate vibration.
[00173] It will be understood that the various disclosed
embodiments may
incorporate some or all of the components described herein. The particular
components and the
properties thereof may be adjusted based on the properties of each particular
embodiment and
application conditions. From the foregoing description, one of ordinary skill
in the art can
easily ascertain the essential characteristics of this disclosure, and without
departing from the
spirit and scope thereof and can make various changes and modifications to
adapt the disclosure
to various usages and conditions. The embodiments described hereinabove are
meant to be
illustrative only and should not be taken as limiting of the scope of the
disclosure.
[00174] Representative Embodiments
[00175] ESP Embodiments
[00176] 1. An electric submersible pump assembly,
comprising;
[00177] a pump module, wherein the pump module comprises a
pump shaft and
an impeller, wherein the pump shaft is operably connected to a motor shaft and
wherein the
impeller is rotationally fixed to the pump shaft by a keyway;
[00178] a seal section, wherein the seal section is
configured to transmit torque
from the motor shaft and absorb thrust from the pump module;
[00179] a motor module, wherein the motor module comprises
a motor
configured to operate at greater than 4,000 rpm, the motor configured to
rotate a motor shaft;
and
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[00180]
a motor cooling system, wherein the motor cooling system comprises a
motor cooling impeller, the motor cooling impeller configured to circulate
lubricant through a
motor module heat exchanger wherein the motor module heat exchanger comprises
a motor
module lubricant pathway, the motor module lubricant pathway configured to
increase a
residence time of the lubricant in the motor module heat exchanger.
[00181] 2.
The assembly of embodiment 1, further comprising a gas
separator module wherein the gas separator comprises a gas separator shaft and
an inducer,
wherein the gas separator shaft is operably connected to the motor shaft and
the inducer is
rotationally fixed to the gas separator shaft by a keyway.
[00182] 3.
The assembly of embodiment 1, further comprising a fluid in-
take.
[00183] 4.
The assembly of embodiment 1, wherein the seal section
comprises a port in fluid communication with the exterior environment
surrounding the seal
section and in fluid communication with an interior chamber, the interior
chamber configured
to reduce a pressure differential between the pressure from the exterior of
the assembly to the
interior of the assembly.
[00184] 5.
The assembly of embodiment 1, wherein the seal section
comprises a seal section cooling system wherein the seal section cooling
system comprises a
seal section heat exchanger wherein the seal section heat exchanger comprises
a seal section
lubricant pathway, the seal section lubricant pathway configured to increase a
residence time
of the lubricant in the seal section heat exchanger.
[00185] 6.
The assembly of embodiment 5, wherein the seal section
lubricant pathway is in fluid communication with the motor module lubricant
pathway.
[00186] 7.
The assembly of embodiment 1, further comprising a high-speed
self-aligning bearing, the high-speed self-aligning bearing comprising a
bushing and a sleeve,
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the bushing having a microhardness of at least about 2,500 MPa and the sleeve
having a
microhardness of at most about 2,000 MPa.
[00187] 8.
The assembly of embodiment 1 wherein the motor module heat
exchanger comprises a central heat exchanger module and lower heat exchanger
module, and
wherein the lower heat exchanger module comprises a screen configured to trap
non-ferrous
particles and a magnetic trap configured to trap ferrous particles .
[00188] 9.
The assembly of embodiment 1, wherein the seal section
comprises a thrust chamber wherein the thrust chamber comprises at least two
thrust bearings
and wherein each thrust bearing is fitted with a spring damper.
[00189] 10.
The assembly of embodiment 1, wherein the motor module
comprises a head module, power module, and base module.
[00190] 11.
The assembly of embodiment 10, further comprising at least two
power modules disposed between the head module and base module, wherein a
flangeless
connection is used to connect the two power modules to each other.
[00191] 12.
The assembly of embodiment 10, wherein a flangeless
connection is used to connect the head module to a power module and wherein a
flangeless
connection is used to connect the base module to a power module.
[00192] 13.
The assembly of embodiment 1, wherein the motor module
further comprises a stator with a magnetic field and wherein the motor rotor
is configured to
self-align within the magnetic field of the stator.
[00193] 14.
The assembly of embodiment 13, further comprising an axial
seating system comprising a static thrust receiving face and a dynamic thrust
transferring face,
wherein the dynamic face has a higher microhardness than the static face and
the static face
has a higher compressive strength than the dynamic face.
[00194_1 15.
The assembly of embodiment 14, wherein the dynamic thrust
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transferring face has a compressive strength of at most about 4,500 Mpa and
the static thrust
receiving face has a compressive strength of at least about 7,200 Mpa.
[00195] 16. The electric submersible pump assembly of
embodiment 1,
wherein the assembly has a total dynamic head in feet to length in feet ratio
of between about
80 and about 300.
[00196] 17 The electric submersible pump assembly of
embodiment 1,
wherein the assembly has a break horse power to length in feet ratio of
between about 4 and
about 12.
[00197] 18. The electric submersible pump assembly of
embodiment 1,
wherein the assembly is configured to produce between about 400 barrels per
day and about
4,000 barrels per day without changing the electric submersible pump.
[00198] 19. A process for producing well bore fluid
comprising:
[00199] deploying an electric submersible pump within a
wellbore, wherein the
electric submersible pump comprises:
[00200] a pump module comprising a pump shaft and an
impeller, wherein the
pump shaft is operably connected to a motor shaft;
[00201] a seal section wherein the seal section is
configured to transmit torque
from the motor shaft to the gas separator shaft and absorb thrust;
[00202] a motor module comprising an electric motor
configured to rotate a
motor shaft; and
[00203] a motor cooling system comprising a motor cooling
impeller configured
to circulate lubricant through a motor module heat exchanger, the motor module
heat exchanger
comprising a motor module lubricant pathway, the motor module lubricant
pathway configured
to increase a residence time of the lubricant in the motor module heat
exchanger,
11002041 operating the electric submersible pump; and
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[00205] producing well bore fluid.
[00206] 20.
The process of embodiment 19, wherein the seal section
comprises a seal section heat exchanger comprising a seal section lubricant
pathway.
[00207] Active Cooling System Embodiments
[00208] 1.
An actively cooled motor assembly for driving an electric
submersible pump, the assembly comprising:
[00209] an electric motor, wherein the motor comprises an
impeller, a central
heat exchanger, and a lower heat exchanger, the impeller arranged to drive
lubricant into the
central heat exchanger;
[00210] the central heat exchanger comprising a central
exterior housing, a
central interior housing, and a central lubricant return tube, wherein the
central interior housing
is disposed within the central exterior housing and defines a central heat
exchanger lubricant
pathway therebetween, and wherein the central lubricant return tube is
disposed within central
interior housing;
[00211] the lower heat exchanger comprising a lower
exterior housing, a lower
interior housing, and a lower lubricant return tube, wherein the lower
interior housing is
disposed within the lower exterior housing and defines a lower heat exchanger
lubricant
pathway therebetween, and wherein the lower lubricant return tube is disposed
within the lower
interior housing and is in fluid communication with the lower heat exchanger
lubricant
pathway;
[00212] wherein the central heat exchanger is connected to
the lower heat
exchanger such that the central heat exchanger lubricant pathway is in fluid
communication
with the lower heat exchanger lubricant pathway and the central lubricant
return tube is in fluid
communication with the lower lubricant return tube.
[00213] 2.
The assembly of embodiment 1, further comprising a motor
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housing, a stator, and a rotor shaft wherein the rotor shaft is disposed
within the stator and the
stator is disposed within the motor housing;
[00214]
the rotor shaft comprising an interior and an exterior, the interior of
the
rotor shaft in fluid communication with the central lubricant return tube and
the interior of the
motor housing;
[00215]
the rotor shaft arranged such that lubricant may flow from the central
lubricant return tube through the interior of the rotor shaft into the
interior of the motor housing
and between the motor housing and the stator.
[00216] 3.
The assembly of embodiment 2, wherein the stator has channels,
designed to accommodate lubricant between the stator and the motor housing.
[002171 4.
The assembly of embodiment 2, further comprising an electric
submersible pump, wherein the motor is operably connected to the pump.
[00218] 5.
The assembly of embodiment 1, further comprising a first central
heat exchanger and a second central heat exchanger, wherein central heat
exchanger lubricant
pathway of the first central heat exchanger is in fluid communication with the
central heat
exchanger lubricant pathway of the second central heat exchanger and the
central heat
exchanger lubricant pathway of the second central heat exchanger is in fluid
communication
with the lower heat exchanger lubricant pathway of the lower heat exchanger.
[00219] 6.
The assembly of embodiment 1, further comprising a screen
designed to remove non-fen-ous wear products from circulating lubricant and a
magnetic trap
designed to remove ferrous wear products from circulating lubricant.
[00220] 7.
The assembly of embodiment 4, further comprising a seal section
located between the motor and the pump, the seal section comprising a thrust
chamber, an
impeller, an interior seal housing, an exterior seal housing, and a seal
lubricant return path,
wherein the interior seal housing is disposed within the exterior seal housing
and defines a seal
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lubricant pathway therebetween, the seal lubricant pathway in fluid
communication with the
seal lubricant return path and the seal lubricant return path in fluid
communication with the
thrust chamber; the impeller configured to drive lubricant into the seal
lubricant pathway.
[00221] 8.
The assembly of embodiment 6, wherein the screen and
magnetic trap are located within the lower heat exchanger lubricant pathway.
[00222] 9.
The assembly of embodiment 6, wherein the screen and
magnetic trap are located within the seal lubricant pathway.
[00223] 10.
The assembly of embodiment 1, wherein the central heat
exchanger lubricant pathway and lower heat exchanger lubricant pathway are
substantially
helical.
[00224] 11.
The assembly of embodiment 7, wherein the seal lubricant
pathway is substantially helical.
[00225] 12.
The assembly of embodiment 7, wherein the seal lubricant
pathway is in fluid communication with the central heat exchanger lubricant
pathway and lower
heat exchanger lubricant pathway.
[00226] 13.
An actively cooled motor assembly for driving a pump, the
assembly comprising:
[00227] an electric submersible pump;
[00228] an electric motor operably connected to the pump,
wherein the motor
comprises an impeller and a heat exchanger, the impeller arranged to drive
lubricant into the
heat exchanger; and the heat exchanger comprising an exterior housing, an
interior housing,
and a lubricant return tube, wherein the interior housing is disposed within
the exterior housing
and defines a heat exchanger lubricant pathway therebetween, and wherein the
lubricant return
tube is disposed within the interior housing and is in fluid communication
with the heat
exchanger lubricant pathway.
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[00229] 14.
The assembly of embodiment 13, further comprising a motor
housing, a stator, and a rotor shaft wherein the rotor shaft is disposed
within the stator and the
stator is disposed within the motor housing;
[00230] the rotor shaft comprising an interior and an
exterior, the interior of the
rotor shaft in fluid communication with the lubricant return tube and the
interior of the motor
housing;
[00231] the rotor shaft arranged such that lubricant may
flow from the lubricant
return tube through the interior of the rotor shaft into the interior of the
motor housing and
between the motor housing and the stator.
[00232] 15.
The assembly of embodiment 14, further comprising a seal
section located between the motor and the pump, the seal section comprising a
thrust chamber,
an impeller, an interior seal housing, an exterior seal housing, and a seal
lubricant return path,
wherein the interior seal housing is disposed within the exterior seal housing
and defines a seal
lubricant pathway therebetween, the seal lubricant pathway in fluid
communication with the
seal lubricant return path and the seal lubricant return path in fluid
communication with the
thrust chamber; the impeller configured to drive lubricant into the seal
lubricant pathway.
[00233] Flangeless Connection Embodiments
[00234] 1.
A motor for an electrical submersible pump assembly, the motor
comprising:
[00235] a head module:
[00236] a base module;
[00237] at least two power modules disposed between the
head module and base
module wherein each power module comprises an electric motor and a power
module housing
having an upper and lower portion; and wherein at least two power modules are
connected to
each other using a flangeless connection, the flangeless connection comprising
a housing
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coupling, a lock nut, and a spacer ring.
[00238] 2.
The motor of embodiment 1, wherein the upper portion of the
power module housings comprise threads and the lower portion of the power
module housings
comprise threads which turn in the opposite direction as the threads of the
upper portion, and
[00239]
wherein the housing coupling comprises an upper portion and a lower
portion, the upper portion of the housing coupling having threads configured
to connect to the
lower portion of a power module housing and the lower portion of the housing
coupling having
threads configured to connect to the upper portion of a power module housing.
[00240] 3.
The motor of embodiment 1, wherein the head module is
connected to a first power module using a flangeless connection and wherein
the base module
is connected to a second power module using a flangeless connection.
[00241] 4.
The motor of embodiment 1, further comprising a heat
exchanger.
[00242[ 5.
The motor of embodiment 1, further comprising an impeller, a
central heat exchanger, and a lower heat exchanger, the impeller arranged to
drive lubricant
into the central heat exchanger;
[00243]
the central heat exchanger comprising a central exterior housing, a
central interior housing, and a central lubricant return tube, wherein the
central interior housing
is disposed within the central exterior housing and defines a central heat
exchanger lubricant
pathway therebetween, and wherein the central lubricant return tube is
disposed within the
central interior housing;
[00244]
the lower heat exchanger comprising a lower exterior housing, a lower
interior housing, and a lower lubricant return tube, wherein the lower
interior housing is
disposed within the lower exterior housing and defines a lower heat exchanger
lubricant
pathway therebetween, and wherein the lower lubricant return tube is disposed
within the lower
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interior housing and is in fluid communication with the lower heat exchanger
lubricant
pathway;
[00245] wherein the central heat exchanger is connected to
the lower heat
exchanger such that the central heat exchanger lubricant pathway is in fluid
communication
with the lower heat exchanger lubricant pathway and the central lubricant
return tube is in fluid
corn mun cati on with the lower luhri cant return tube
[00246] 6.
The motor of embodiment 1, wherein a power module further
comprises a radial bearing sleeve affixed to a rotor and a radial bushing
coupled to the power
module housing, wherein the radial bushing is configured to provide radial
support to the
bearing sleeve and rotor.
[00247_1 7.
The motor of embodiment 6, wherein the bearing sleeve
comprises a material with a higher microhardness than material of the radial
bushings.
[00248] 8.
A motor for an electrical submersible pump assembly, the motor
comprising:
[00249] a head module;
[00250] a power module;
[00251] abase module; and
[00252] a single-piece housing coupling comprising a first
end and a second end,
the first end of the single-piece housing coupling comprising threads which
turn in a first
direction, the second end of the single-piece housing coupling comprising
threads which turn
in a second direction, wherein the head module is joined to the power module
using a single-
piece housing coupling.
[00253] 9.
The assembly of embodiment 8, wherein the base module is
joined to the power module using a single-piece housing coupling.
[00254_1 10.
The assembly of embodiment 8, further comprising a lock nut,
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and a spacer ring.
[00255] 11. An electric submersible pump assembly,
comprising:
[00256] a pump module, wherein the pump module comprises a
pump shaft and
an impeller;
[00257] a gas separator module wherein the gas separator
comprises a gas
separator shaft and an inducer;
[00258] a seal section configured to transmit torque from
the motor shaft to the
gas separator shaft and absorb thrust from the pump module; and
[00259] a motor module, wherein the motor module comprises
electric motor
configured to rotate a motor shaft;
[00260] wherein the pump module is joined to the gas
separator module using a
flangeless connection, the gas separator is joined to the seal section using a
flangeless
connection, and the seal section is joined to the motor module using a
flangeless connection.
[00261] 12. The assembly of embodiment 11, further
comprising a motor
cooling system, wherein the motor cooling system comprises a motor cooling
impeller, the
motor cooling impeller configured to circulate lubricant through a motor
module heat
exchanger wherein the motor module each exchange is joined to the motor module
using a
flangeless connection.
[00262] 13. An electric submersible pump assembly,
comprising:
[00263] a pump module, wherein the pump module comprises a
pump shaft and
an impeller;
[00264] a fluid intake wherein the fluid intake comprises
an intake shaft;
[00265] a seal section configured to transmit torque from
the motor shaft to the
intake shaft and absorb thrust from the pump module; and
[00266] a motor module, wherein the motor module comprises
electric motor
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configured to rotate a motor shaft;
[00267] wherein the pump module is joined to the fluid
intake using a flangeless
connection, the fluid intake is joined to the seal section using a flangeless
connection, and the
seal section is joined to the motor module using a flangeless connection.
[00268] Thrust Chamber Embodiments
[00269] 1.
A thrust chamber arranged to transfer thrust from a shaft to a.
thrust bearing, the thrust chamber comprising:
[00270] a shaft, wherein the shaft is operably connected
to at least one impeller
wherein the impeller generates downward thrust when in operation;
[00271] a thrust chamber outer housing;
[00272] a first thrust runner, wherein the first thrust
runner is coupled to the shaft
and comprises an upward facing thrust transferring surface and a downward
facing thrust
transfer surface;
[00273] a first thrust bearing assembly coupled to the
outer housing; wherein the
first thrust bearing assembly comprises an upward facing thrust receiving
surface and wherein
the first thrust runner is configured to transfer downward thrust from the
shaft to the first thrust
bearing assembly;
[00274] an up-thrust bearing assembly coupled to the outer
housing, wherein the
up-thrust bearing assembly comprises a downward facing thrust receiving
surface and wherein
the first runner is configured to transfer upward thrust from the shaft to the
up-thrust bearing
assembly;
[00275] a second thrust runner, wherein the second thrust
runner is coupled to
the shaft and comprises a downward facing thrust transfer surface;
[00276] a second thrust bearing assembly coupled to the
outer housing, wherein
the second thrust bearing assembly comprises an upward facing thrust receiving
surface and
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wherein the second thrust runner is configured to transfer downward thrust
from the shaft to
the second thrust bearing assembly;
[00277]
a first and a second damper, wherein the first damper is configured to
absorb downward thrust from the first thrust runner and transfer the downward
thrust to the
first thrust bearing assembly and the second damper is configured to absorb
downward thrust
from the second thrust runner and transfer the downward thrust to the second
thrust bearing
assembly; and
[00278]
a thrust chamber heat exchanger, wherein the thrust chamber heat
exchanger comprises a thrust chamber interior housing and thrust chamber
lubricant return
path, wherein the thrust chamber interior housing is disposed within the
thrust chamber outer
housing and defines a thrust chamber heat exchanger lubricant pathway
therebetween, and
wherein the thrust chamber lubricant return path is in fluid communication
with the thrust
chamber lubricant pathway and is disposed within the interior housing.
[00279[ 2.
The thrust chamber of embodiment 1, wherein the shaft
comprises an interior and an exterior, and wherein the interior of the shaft
is in fluid
communication with the lubricant return path.
[00280] J.
The thrust chamber of embodiment 1, wherein the up-thrust
bearing assembly comprises a static downward facing thrust receiving surface.
[00281] 4.
The thrust chamber of embodiment 1, wherein the upward facing
thrust receiving surfaces of the first and second thrust bearing assemblies
have a lower
microhardness than the downward facing thrust transfer surfaces of the first
and second thrust
runners.
[00282] 5.
The thrust chamber of embodiment 1, wherein the dampers are
configured to distribute substantially even thrust load across the first and
second thrust bearing
assemblies.
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[00283] 6.
The thrust chamber of embodiment 1, wherein the dampers
comprise Belleville washers.
[00284] 7.
The thrust chamber of embodiment 1, wherein the dampers
comprise stacks of Belleville washers configured in parallel.
[00285] 8.
The thrust chamber of embodiment 1, wherein the thrust
eh amber 1 libri cant pathway is substantially helical.
[00286] 9.
The thrust chamber of embodiment 1, wherein the thrust
chamber heat exchanger further comprises a filter screen in fluid
communication with the thrust
chamber lubricant pathway.
[00287] 10.
The thrust chamber of embodiment 1, wherein the thrust
chamber heat exchanger further comprises a magnetic trap in fluid
communication with the
thrust chamber lubricant pathway.
[00288] 11.
The thrust chamber of embodiment 1, wherein the outer thrust
housing is threadedly connected to a seal module, and wherein the seal module
is disposed
between a motor module and a pump module.
[00289] 12.
The thrust chamber of embodiment 11, wherein the pump
module comprises an impeller that generates downward thrust when in operation,
and wherein
the downward thrust generated by the impeller is communicated to the thrust
chamber shaft
and transferred by the first and second thrust runners to the first and second
thrust bearing
assemblies which are axially fixed to the thrust chamber outer housing.
[00290] 13.
The thrust chamber of embodiment 11, the seal module further
comprising an interior seal housing, an exterior seal housing, and a seal
lubricant return path,
wherein the interior seal housing is disposed within the exterior seal housing
and defines a seal
lubricant pathway therebetween, the seal lubricant pathway in fluid
communication with the
seal lubricant return path and the seal lubricant return path in fluid
communication with the
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thrust chamber; the impeller configured to drive lubricant into the seal
lubricant pathway.
[00291] High Speed Self Aligning Bearing Embodiments
[00292] 1.
A radial bearing assembly suitable for mounting on a rotatable
shaft, comprising:
[00293] one or more radial bearings, each bearing
comprising a bushing and a
sleeve, the hushing and sleeve each comprising an interior and an exterior,
the interior of the
bushing being in lubricated engagement with the exterior of the sleeve,
wherein the bushing is
affixable to a non-rotatable bushing support and comprises a material having a
higher micro-
hardness than the sleeve and wherein the sleeve is configured to mount to a
rotating shaft and
comprises a material having a higher flexural strength than the bushing.
[00294[ 2.
The assembly of embodiment 1, wherein the bushing interior
comprises a plurality of grooves configured to allow lubricant to flow between
the bushing and
the sleeve and wherein the grooves are configured to discharge debris.
[00295[ 0.
The assembly of embodiment 1, further comprising an
elastomeric band disposed between the bushing exterior and bushing support,
the elastomeric
band configured to expand when in contact with lubricant and prevent
substantial deleterious
movement of the bushing relative to the bushing support.
[00296] 4.
The assembly of embodiment 3, further comprising a groove in
the bushing exterior wherein the groove is configured to increase binding
between the bushing
and the elastomeric band.
[00297] 5.
The assembly of embodiment 4, wherein the groove is helical
and wherein the elastomeric band is configured to dampen vibration.
[00298] 6.
The assembly of embodiment 1, wherein the sleeve is axially
movable between about 1 mm and about 3 mm relative to the rotating shaft.
[00299[ 7.
The assembly of embodiment 1, wherein the sleeve comprises
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two outer sleeves and an inner sleeve body and wherein the two outer sleeves
and inner sleeve
body each comprise a keyway.
[00300] 8.
The assembly of embodiment 7, wherein the sleeve body and the
rotating shaft each comprise an interior and an exterior and wherein the
sleeve body comprises
an opening allowing lubricant to pass from the interior of the sleeve body to
the exterior of the
sleeve body and wherein the shaft comprises an opening allowing lubricant to
pass from the
interior of the shaft to the exterior of the shaft, and wherein one or more
elastomeric bands are
disposed between the exterior of the shaft and the interior of the sleeve body
creating a gap for
the flow of lubricant from the interior of the shaft to the exterior of the
sleeve body.
[00301] 9.
The assembly of embodiment 8, wherein the assembly further
comprises a screen configured to be in fluid communication with a lubricant,
the screen
designed to filter wear products from the lubricant.
[00302] 10.
The assembly of embodiment 8, wherein the assembly further
comprises a magnetic trap configured to be in fluid communication with a
lubricant, the
magnetic trap designed to remove ferrous wear products from the lubricant.
[00303] 11.
The assembly of embodiment 1, wherein the bushing comprises
a bushing body and a bushing insert, wherein the bushing insert comprises a
material having a
higher micro-hardness than the sleeve and wherein the bushing body comprises a
low CTE
material.
[00304] 12.
The assembly of embodiment 2, wherein the grooves are
configured to discharge debris caused by interaction of the bushing and
sleeve.
[00305] 13.
The assembly of embodiment 2, wherein the grooves are at least
about 4 mm wide.
[00306] 14.
The assembly of embodiment 3, wherein the substantial
deleterious movement comprises axial and rotational movement.
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[00307] 15. The radial bearing assembly of embodiment
1, wherein the
bushing has a microhardness of at least 500 MPa greater than the microhardness
of the sleeve.
[00308] 16. The radial bearing assembly of embodiment
1, wherein the
sleeve has a flexural strength of at least 500 MPa greater than the bushing.
[00309] 17. The radial bearing assembly of embodiment
11, wherein the
bushing body comprises a material with a coefficient of thermal expansion of
less than about
p.m/m- C.
[00310] 18. The radial bearing assembly of embodiment
1, wherein the
rotatable shaft is part of an electrical submersible pump.
[00311] 19. The radial bearing assembly of embodiment
1, wherein the
rotatable shaft is part of an electric motor.
[00312] 20. A radial bearing assembly suitable for
mounting on a rotatable
shaft, comprising:
11003131 one or more radial bearings, each bearing
comprising a bushing and a
sleeve, the bushing and sleeve each comprising an interior and an exterior,
the interior of the
bushing being in lubricated engagement with the exterior of the sleeve,
wherein the bushing is
affixable to a non-rotatable bushing support and comprises a material having a
lower micro-
hardness than the sleeve and wherein the sleeve is configured to mount to a
rotating shaft and
comprises a material having a lower flexural strength than the bushing.
[00314] Additional Embodiments
[00315] 1. An electric submersible pump assembly,
comprising:
[00316] a pump module, wherein the pump module comprises a
pump shaft and
an impeller, wherein the pump shaft is operably connected to a motor shaft and
wherein the
impeller is rotationally fixed to the pump shaft by a keyway:
11003171 a seal section, wherein the seal section is
configured to transmit torque
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from the motor shaft and absorb thrust from the pump module:
[00318]
a motor module, wherein the motor module comprises a motor
configured to operate at greater than 4,000 rpm, the motor configured to
rotate a motor shaft;
and
[00319]
a motor cooling system, wherein the motor cooling system comprises a
motor cooling impeller, the motor cooling impeller configured to circulate
lubricant through a
motor module heat exchanger wherein the motor module heat exchanger comprises
a motor
module lubricant pathway, the motor module lubricant pathway configured to
increase a
residence time of the lubricant in the motor module heat exchanger.
[00320] 2.
The assembly of embodiment 1, wherein the seal section
comprises a seal section cooling system wherein the seal section cooling
system comprises a
seal section heat exchanger wherein the seal section heat exchanger comprises
a seal section
lubricant pathway, the seal section lubricant pathway configured to increase a
residence time
of the lubricant in the seal section heat exchanger.
[00321] 3.
The assembly of any of the preceding embodiments, further
comprising an axial seating system comprising a static thrust receiving face
and a dynamic
thrust transferring face, wherein the dynamic face has a higher microhandness
than the static
face and the static face has a higher compressive strength than the dynamic
face.
[00322] 4.
The assembly of any of the preceding embodiments, wherein the
assembly is configured to produce well bore fluid at a rate of between about
400 barrels per
day and about 4,000 barrels per day without changing the electric submersible
pump.
[00323] 5.
An actively cooled electric submersible pump assembly
comprising:
[00324]
an electric motor, wherein the motor comprises an impeller, a central
heat exchanger, and a lower heat exchanger, the impeller arranged to drive
lubricant into the
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central heat exchanger;
[00325]
the central heat exchanger comprising a central exterior housing, a
central interior housing, and a central lubricant return tube, wherein the
central interior housing
is disposed within the central exterior housing and defines a central heat
exchanger lubricant
pathway therebetween, and wherein the central lubricant return tube is
disposed within central
interior housing;
[00326]
the lower heat exchanger comprising a lower exterior housing, a lower
interior housing, and a lower lubricant return tube, wherein the lower
interior housing is
disposed within the lower exterior housing and defines a lower heat exchanger
lubricant
pathway therebetween, and wherein the lower lubricant return tube is disposed
within the lower
interior housing and is in fluid communication with the lower heat exchanger
lubricant
pathway;
[00327]
wherein the central heat exchanger is connected to the lower heat
exchanger such that the central heat exchanger lubricant pathway is in fluid
communication
with the lower heat exchanger lubricant pathway and the central lubricant
return tube is in fluid
communication with the lower lubricant return tube.
[00328] 6.
The assembly of embodiment 5, further comprising a motor
housing, a stator, and a rotor shaft wherein the rotor shaft is disposed
within the stator and the
stator is disposed within the motor housing;
[00329]
the rotor shaft comprising an interior and an exterior, the interior of
the
rotor shaft in fluid communication with the central lubricant return tube and
the interior of the
motor housing;
[00330]
the rotor shaft arranged such that lubricant may flow from the central
lubricant return tube through the interior of the rotor shaft into the
interior of the motor housing
and between the motor housing and the stator.
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[00331] 7.
The assembly of embodiments 5 or 6, further comprising a first
central heat exchanger and a second central heat exchanger, wherein central
heat exchanger
lubricant pathway of the first central heat exchanger is in fluid
communication with the central
heat exchanger lubricant pathway of the second central heat exchanger and the
central heat
exchanger lubricant pathway of the second central heat exchanger is in fluid
communication
with the lower heat exchanger lubricant pathway of the lower heat exchanger.
[00332] 8.
The assembly of embodiments 5, 6, or 7, further comprising a
seal section, the seal section comprising a thrust chamber, an impeller, an
interior seal housing,
an exterior seal housing, and a seal lubricant return path, wherein the
interior seal housing is
disposed within the exterior seal housing and defines a seal lubricant pathway
therebetween,
the seal lubricant pathway in fluid communication with the seal lubricant
return path and the
seal lubricant return path in fluid communication with the thrust chamber; the
impeller
configured to drive lubricant into the seal lubricant pathway.
11003331 9.
The electric submersible pump assembly of embodiments 1 or 5
further comprising a thrust chamber arranged to transfer thrust from a shaft
to a thrust bearing,
the thrust chamber comprising:
[00334] a shaft, wherein the shaft is operably connected
to at least one impeller
wherein the impeller generates downward thrust when in operation;
[00335] a thrust chamber outer housing;
[00336] a first thrust runner, wherein the first thrust
runner is coupled to the shaft
and comprises an upward facing thrust transferring surface and a downward
facing thrust
transfer surface;
[00337] a first thrust bearing assembly coupled to the
outer housing; wherein the
first thrust bearing assembly comprises an upward facing thrust receiving
surface and wherein
the first thrust runner is configured to transfer downward thrust from the
shaft to the first thrust
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bearing assembly;
[00338]
an up-thrust bearing assembly coupled to the outer housing, wherein the
up-thrust bearing assembly comprises a downward facing thrust receiving
surface and wherein
the first runner is configured to transfer upward thrust from the shaft to the
up-thrust bearing
assembly;
[00339]
a second thrust ninner, wherein the second thrust ninner is coupled to
the shaft and comprises a downward facing thrust transfer surface;
[00340]
a second thrust bearing assembly coupled to the outer housing, wherein
the second thrust bearing assembly comprises an upward facing thrust receiving
surface and
wherein the second thrust runner is configured to transfer downward thrust
from the shaft to
the second thrust bearing assembly;
[00341]
a first and a second damper, wherein the first damper is configured to
absorb downward thrust from the first thrust runner and transfer the downward
thrust to the
first thrust bearing assembly and the second damper is configured to absorb
downward thrust
from the second thrust runner and transfer the downward thrust to the second
thrust bearing
assembly; and
[00342]
a thrust chamber heat exchanger, wherein the thrust chamber heat
exchanger comprises a thrust chamber interior housing and thrust chamber
lubricant return
path, wherein the thrust chamber interior housing is disposed within the
thrust chamber outer
housing and defines a thrust chamber heat exchanger lubricant pathway
therebetween, and
wherein the thrust chamber lubricant return path is in fluid communication
with the thrust
chamber lubricant pathway and is disposed within the interior housing.
[00343] 10.
The assembly of embodiment 9, wherein the outer thrust housing
is threadedly connected to a seal section, and wherein the seal section is
disposed between a
motor module and a pump module.
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[00344] 11.
The assembly of embodiments 9 or 10, wherein the pump
module comprises an impeller that generates downward thrust when in operation,
and wherein
the downward thrust generated by the impeller is communicated to the thrust
chamber shaft
and transferred by the first and second thrust runners to the first and second
thrust bearing
assemblies which are axially fixed to the thrust chamber outer housing.
[00345] 12.
The assembly of embodiments 10 or 11, the seal section further
comprising an interior seal housing, an exterior seal housing, and a seal
lubricant return path,
wherein the interior seal housing is disposed within the exterior seal housing
and defines a seal
lubricant pathway therebetween, the seal lubricant pathway in fluid
communication with the
seal lubricant return path and the seal lubricant return path in fluid
communication with the
thrust chamber; the impeller configured to drive lubricant into the seal
lubricant pathway.
[00346] 13.
The assembly of any of the preceding embodiments, further
comprising a single-piece housing coupling comprising a first end and a second
end, the first
end of the single-piece housing coupling comprising threads which turn in a
first direction, the
second end of the single-piece housing coupling comprising threads which turn
in a second
direction.
[00347] 14.
The assembly of any of the preceding embodiments, further
comprising a radial bearing assembly suitable for mounting on a rotatable
shaft, the radial
bearing assembly comprising:
[00348]
one or more radial bearings, each bearing comprising a bushing and a
sleeve, the bushing and sleeve each comprising an interior and an exterior,
the interior of the
bushing being in lubricated engagement with the exterior of the sleeve,
wherein the bushing is
affixable to a non-rotatable bushing support and comprises a material having a
higher micro-
hardness than the sleeve and wherein the sleeve is configured to mount to a
rotating shaft and
comprises a material having a higher flexural strength than the bushing.
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[00349] 15.
The assembly of embodiment 14, wherein the bushing has a
microhardness of at least 500 MPa greater than the microhardness of the
sleeve.
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