US20170321711A1 - Isolated thrust chamber for esp seal section - Google Patents
Isolated thrust chamber for esp seal section Download PDFInfo
- Publication number
- US20170321711A1 US20170321711A1 US15/531,096 US201415531096A US2017321711A1 US 20170321711 A1 US20170321711 A1 US 20170321711A1 US 201415531096 A US201415531096 A US 201415531096A US 2017321711 A1 US2017321711 A1 US 2017321711A1
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- US
- United States
- Prior art keywords
- motor
- seal section
- pumping system
- thrust chamber
- electric submersible
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
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- 239000000314 lubricant Substances 0.000 claims abstract description 58
- 238000005086 pumping Methods 0.000 claims abstract description 57
- 238000002955 isolation Methods 0.000 claims abstract description 9
- 238000004891 communication Methods 0.000 claims description 15
- 230000007246 mechanism Effects 0.000 claims description 14
- 239000007787 solid Substances 0.000 claims description 8
- 210000003027 ear inner Anatomy 0.000 claims description 4
- 238000007789 sealing Methods 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 description 9
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- 229920000642 polymer Polymers 0.000 description 4
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 4
- 239000004810 polytetrafluoroethylene Substances 0.000 description 4
- 230000008602 contraction Effects 0.000 description 3
- 238000006073 displacement reaction Methods 0.000 description 3
- 229920001971 elastomer Polymers 0.000 description 3
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- -1 polytetrafluoroethylene Polymers 0.000 description 2
- 229920006169 Perfluoroelastomer Polymers 0.000 description 1
- 239000004696 Poly ether ether ketone Substances 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 239000010779 crude oil Substances 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 210000003128 head Anatomy 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 150000002576 ketones Chemical class 0.000 description 1
- 239000010687 lubricating oil Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
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- 238000011144 upstream manufacturing Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D29/00—Details, component parts, or accessories
- F04D29/04—Shafts or bearings, or assemblies thereof
- F04D29/041—Axial thrust balancing
- F04D29/0413—Axial thrust balancing hydrostatic; hydrodynamic thrust bearings
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/12—Methods or apparatus for controlling the flow of the obtained fluid to or in wells
- E21B43/121—Lifting well fluids
- E21B43/128—Adaptation of pump systems with down-hole electric drives
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D13/00—Pumping installations or systems
- F04D13/02—Units comprising pumps and their driving means
- F04D13/06—Units comprising pumps and their driving means the pump being electrically driven
- F04D13/08—Units comprising pumps and their driving means the pump being electrically driven for submerged use
- F04D13/10—Units comprising pumps and their driving means the pump being electrically driven for submerged use adapted for use in mining bore holes
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D29/00—Details, component parts, or accessories
- F04D29/06—Lubrication
- F04D29/061—Lubrication especially adapted for liquid pumps
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D29/00—Details, component parts, or accessories
- F04D29/08—Sealings
- F04D29/10—Shaft sealings
- F04D29/106—Shaft sealings especially adapted for liquid pumps
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D29/00—Details, component parts, or accessories
- F04D29/08—Sealings
- F04D29/10—Shaft sealings
- F04D29/106—Shaft sealings especially adapted for liquid pumps
- F04D29/108—Shaft sealings especially adapted for liquid pumps the sealing fluid being other than the working liquid or being the working liquid treated
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D29/00—Details, component parts, or accessories
- F04D29/08—Sealings
- F04D29/10—Shaft sealings
- F04D29/12—Shaft sealings using sealing-rings
- F04D29/126—Shaft sealings using sealing-rings especially adapted for liquid pumps
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D29/00—Details, component parts, or accessories
- F04D29/70—Suction grids; Strainers; Dust separation; Cleaning
- F04D29/708—Suction grids; Strainers; Dust separation; Cleaning specially for liquid pumps
Definitions
- This invention relates generally to the field of submersible pumping systems, and more particularly, but not by way of limitation, to a system in which the thrust chamber is isolated from other chambers in the seal section and also to a system in which different lubricants are used in the motor and seal section portions of the pumping system.
- Submersible pumping systems are often deployed into wells to recover petroleum fluids from subterranean reservoirs.
- the submersible pumping system includes a number of components, including one or more fluid filled electric motors coupled to one or more high performance pumps located above the motor. When energized, the motor provides torque to the pump, which pushes wellbore fluids to the surface through production tubing.
- Each of the components in a submersible pumping system must be engineered to withstand the inhospitable downhole environment.
- seal sections protect the electric motors and are typically positioned between the motor and the pump. In this position, the seal section provides several functions, including transmitting torque between the motor and pump, restricting the flow of wellbore fluids into the motor, protecting the motor from axial thrust imparted by the pump, and accommodating the expansion and contraction of motor lubricant as the motor moves through thermal cycles during operation.
- Prior art seal sections typically include a “clean side” in fluid communication with the electric motor and a “contaminated side” in fluid communication with the wellbore. Bellows or bags have been used to separate the clean side of the seal section from the contaminated side. Although generally effective, prior art designs allow fluid communication between the motor and the seal section through the thrust chamber and rely on the communication of fluid between the motor and the seal section. Because the lubricant is common to both the motor and the seal section, the same fluid must be used. It is to this and other restrictions in the prior art that the preferred embodiments are directed.
- the present invention includes an electric submersible pumping system that is configured to pump fluids from a wellbore.
- the electric submersible pumping system includes a motor that is filled with a motor lubricant, a pump driven by the motor, a thrust chamber connected between the motor and the pump and a seal section.
- the thrust chamber is filled with a thrust chamber lubricant and the seal section and motor are in fluid isolation from the thrust chamber.
- the preferred embodiments include an electric submersible pumping system that includes a motor that is filled with a first lubricant, a pump driven by the motor, an upper seal section connected to the pump and a thrust chamber connected between the motor and the upper seal section.
- the thrust chamber is filled with a second lubricant that is different than the first lubricant.
- the electric submersible pumping system preferably includes a motor that is filled with motor lubricant.
- the electric submersible pumping system further includes a pump driven by the motor and a lower seal section connected to a lower side of the motor. The lower seal section is in fluid communication with the motor.
- the electric submersible pumping system also includes a thrust chamber connected between the motor and the pump. The thrust chamber is filled with thrust chamber lubricant and the thrust chamber is in fluid isolation from the motor. The isolation of the thrust chamber from the motor prevents mixing of the thrust chamber lubricant and motor lubricant.
- FIG. 1 depicts a submersible pumping system constructed in accordance with a preferred embodiment of the present invention.
- FIG. 2 provides a cross-sectional view of the motor, thrust chamber, and upper seal section constructed in accordance with a presently preferred embodiment.
- FIG. 3 depicts a submersible pumping system constructed in accordance with an alternate preferred embodiment of the present invention.
- FIG. 4 provides a cross-sectional view of the thrust chamber, motor and lower seal section constructed in accordance with a presently preferred embodiment.
- FIG. 5 provides a cross-sectional view of a mechanical seal from the seal section of FIGS. 2 and 4 .
- FIG. 1 shows an elevational view of a pumping system 100 attached to production tubing 102 .
- the pumping system 100 and production tubing 102 are disposed in a wellbore 104 , which is drilled for the production of a fluid such as water or petroleum.
- a fluid such as water or petroleum.
- the term “petroleum” refers broadly to all mineral hydrocarbons, such as crude oil, gas and combinations of oil and gas.
- the pumping system 100 preferably includes a pump 108 , a motor 110 , an upper seal section 112 and a thrust chamber 114 .
- the production tubing 102 connects the pumping system 100 to a wellhead 106 located on the surface.
- the pumping system 100 is primarily designed to pump petroleum products, it will be understood that the present invention can also be used to move other fluids. It will also be understood that, although each of the components of the pumping system are primarily disclosed in a submersible application, some or all of these components can also be used in surface pumping operations.
- the motor 110 receives power from a surface-based facility through power cable 116 .
- the motor 110 is configured to drive the pump 108 .
- the pump 108 is a turbomachine that uses one or more impellers and diffusers to convert mechanical energy into pressure head.
- the pump 108 is configured as a positive displacement pump.
- the pump 108 includes a pump intake 118 that allows fluids from the wellbore 104 to be drawn into the pump 108 .
- the pump 108 forces the wellbore fluids to the surface through the production tubing 102 .
- the upper seal section 112 is positioned above the motor 110 and below the pump 108 .
- the thrust chamber 114 is positioned between the motor 110 and the seal section 112 .
- the pumping system 100 is depicted in a vertical deployment in FIG. 1 , the pumping system 100 can also be used in non-vertical applications, including in horizontal and non-vertical wellbores 104 . Accordingly, references to “upper” and “lower” within this disclosure are merely used to describe the relative positions of components within the pumping system 100 and should not be construed as an indication that the pumping system 100 must be deployed in a vertical orientation.
- the motor 110 preferably includes a motor housing 120 , stator assembly 122 , rotor assembly 124 , rotor bearings 126 and a motor shaft 128 a .
- the stator assembly 122 includes a series of stator coils (not separately designated) that correspond to the various phases of electricity supplied to the motor 110 .
- the rotor assembly 124 is keyed to the motor shaft 128 a and configured for rotation in close proximity to the stationary stator assembly 122 .
- the size and configuration of the stator assembly 122 and rotor assembly 124 can be adjusted to accommodate application-specific performance requirements of the motor 110 .
- Sequentially energizing the various series of coils within the stator assembly 122 causes the rotor assembly 124 and motor shaft 128 a to rotate in accordance with well-known electromotive principles.
- the motor bearings 126 maintain the central position of the rotor assembly 124 within the stator assembly 122 and oppose radial and axial forces generated by the motor 110 on the motor shaft 128 a.
- the motor 110 is filled with motor lubricant 200 during manufacture that reduces frictional wear on the rotating components within the motor 110 .
- the motor lubricant 200 is a dielectric fluid.
- the dielectric motor lubricant 200 expands and contracts. It is desirable to prevent the dielectric motor lubricant 200 from becoming contaminated with wellbore fluids 204 and solids in the wellbore 104 .
- the motor shaft 128 a is preferably connected to a seal section shaft 128 b that extends through the thrust chamber 114 and upper seal section 112 .
- the seal section shaft 128 b transfers torque from the motor 110 to the pump 108 .
- the seal section shaft 128 b preferably includes an internal passage 130 that extends at least along the portion of the seal section shaft 128 b that extends through the thrust chamber 114 .
- the thrust chamber 114 includes a thrust chamber housing 132 , a thrust bearing assembly 134 , a plurality of mechanical seals 136 and a piston expansion assembly 138 .
- the thrust bearing assembly 134 includes a pair of stationary bearings 140 and a thrust runner 142 attached to the seal section shaft 128 b .
- the thrust runner 142 is captured between the stationary bearings 140 , which limit the axial displacement of the thrust runner 142 and the seal section shaft 128 b.
- the mechanical seals 136 each include bellows 144 , a coiled spring 146 , a runner 148 and a stationary ring 150 . These components cooperate to prevent the migration of fluid along the shaft 128 and isolate the motor lubricant 200 from the thrust chamber 114 .
- the stationary ring 150 has an internal diameter sized to permit the free rotation of the shaft 128 .
- the bellows 144 , coiled spring 146 and runner 148 rotate with the shaft 128 .
- the rotating runner 148 is held in place against the stationary ring 150 by the spring-loaded bellows 144 .
- the bellows 144 preferably includes a series of folds that allow its length to adjust to keep the runner 148 in contact with the stationary ring 150 if the shaft 128 should experience axial displacement.
- the bellows 144 may be manufactured from thin corrugated metal or from elastomers and polymers, including AFLAS, perfluoroelastomer, polytetrafluoroethylene (PTFE), perfluoroalkoxy (PFA) and polyethether ketone (PEEK).
- the piston expansion assembly 138 preferably includes one or more cylinders 152 , a piston 154 in each of the cylinders 152 and spring stops 156 .
- the upstream section of each cylinder 152 includes an opening that places the cylinder 152 in fluid communication with the interior of the thrust chamber 114 .
- Each piston 154 rides in a corresponding cylinder 152 and acts as an expansion system to permit the movement of fluid within the thrust chamber 114 .
- the spring stops 156 are positioned at opposite ends of each cylinder 152 and prevent the pistons 154 from crashing into the ends of the cylinders 152 .
- the thrust chamber 114 is filled with clean thrust chamber lubricant 202 .
- the thrust chamber lubricant 202 is different than the dielectric motor lubricant 200 .
- the thrust chamber lubricant 202 preferably has a higher viscosity than the motor lubricant 200 that is beneficial in creating hydrodynamic bearing surfaces within the upper seal section 112 .
- the expansion of the thrust chamber lubricant 202 is accommodated with movement of the pistons 154 within the piston expansion assembly 138 .
- the thrust chamber lubricant 202 is contained within the thrust chamber 114 and is not mixed or exchanged with other fluids within the pumping system 100 .
- the isolation of the thrust chamber 114 reduces the movement of shavings, particles or other material from the thrust bearing assembly 134 into the motor 110 .
- the upper seal section 112 is attached to the upper end of the thrust chamber 114 . To permit the expansion and contraction of the dielectric motor lubricant 200 under elevated wellbore temperatures, the upper seal section 112 is connected to the motor 110 and placed in fluid communication with the dielectric motor lubricant lubricating oil 200 through the passage 130 in the seal section shaft 128 b . Ports 164 extending through the seal section shaft 128 b allow motor lubricant to enter and exit the passage 130 on opposite sides of the thrust chamber 114 .
- the upper seal section 112 preferably includes a bag seal assembly 158 .
- the bag seal assembly 158 in the upper seal section 112 includes a bag support 160 , a bladder 162 , inlet ports 164 and discharge valves 166 .
- the bag support 160 is rigidly attached to the inside surface of the upper seal section 112 .
- the bladder 162 is secured to the bag support 160 .
- the inlet ports 164 extend through the bag support tube 160 and shaft 128 to place the passage 130 in fluid communication with the interior of the bladder 162 .
- the discharge valves 166 are configured to vent fluid from the interior of the bladder 162 in the event the fluid exceeds a predetermined threshold pressure.
- the outside of the bladder 162 is in fluid communication with the pump 108 and wellbore 104 .
- the bag seal assembly 158 in the upper seal section 112 isolates wellbore fluids 204 in the pump 108 from the motor lubricant 200 in the upper seal section 112 and motor 110 .
- the upper seal section 112 is depicted as including a bag seal assembly 158 , it will be appreciated that other seal mechanisms may be incorporated into the upper seal section as additional or alternative seal mechanism to the bag seal assembly 158 .
- additional seal mechanisms include bellows, pistons, labyrinths and combinations of these mechanisms.
- the preferred embodiment in FIG. 2 provides a mechanism for transferring motor lubricant 200 from the motor 110 to the upper seal section 112 , while maintaining fluid isolation with the thrust chamber 114 .
- Thrust chamber lubricant 202 is contained within the thrust chamber 114 and prevented by mechanical seals 136 from entering the motor 110 and upper seal section 112 .
- FIG. 3 shown therein is an elevational view of the pumping system 100 constructed in accordance with a second preferred embodiment. Unless otherwise specified, the elements identified above in connection with the first preferred embodiment are also present in the second preferred embodiment.
- the pumping system 100 of the second preferred embodiment includes a lower seal section 168 .
- the lower seal section 168 is used in place of the upper seal section 112 and is positioned below the motor 110 .
- the lower seal section 168 is used in combination with the upper seal section 112 .
- the thrust chamber 114 is constructed in accordance with the first preferred embodiment and prevents the mixing of motor lubricant 200 with thrust chamber lubricant 202 .
- FIG. 4 shown therein is a cross-sectional view of the lower seal section 168 , motor 110 , and thrust chamber 114 .
- the pump 108 (not shown in FIG. 4 ) is connected to the upper end of the thrust chamber 114 .
- the lower seal section 168 includes a bag seal assembly 158 that in turn includes a bag support 160 , a bladder 162 and discharge valves 166 .
- the lower seal section 168 is depicted as including a bag seal assembly 158 , it will be appreciated that other seal mechanisms may be incorporated into the upper seal section as additional or alternative seal mechanism to the bag seal assembly 158 .
- Such additional seal mechanisms include bellows, pistons, labyrinths and combinations of these mechanisms.
- the lower seal section includes clean fluid ports 170 that place the interior of the bladder 162 directly in fluid communication with the motor lubricant 200 in the motor 110 .
- the discharge valves 166 are preferably one-way relief valves that are configured to open at a predetermined threshold pressure that exceeds the exterior wellbore pressure. In this way, if the fluid pressure inside the bladder 162 exceeds the set-point pressure, the discharge valves 166 open and relieve the pressure inside the bladder 162 by discharging a small volume of motor lubricant 200 into the wellbore 104 .
- the bladder 162 is manufactured from a high-temperature polymer or elastomer. Suitable polymers and elastomers include AFLAS, polytetrafluoroethylene (PTFE), perfluoroalkoxy (PFA), and polyetherether ketone (PEEK). Alternatively, the bladder 162 can be manufactured from a metal expansible bellows.
- the lower seal section 168 also includes a fluid exchange assembly 172 .
- the fluid exchange assembly 172 includes a solids screen 174 and a plurality of exchange ports 176 .
- the exchange ports 176 allow fluids to pass from the wellbore 104 through the solids screen 174 into the lower seal section 168 around the exterior of the bladder 162 .
- the solids screen 174 reduces the presence of particulates in the lower seal section 168 .
- the solids screen 174 is preferably manufactured from a metal or polymer fabric mesh.
- the lower seal section 168 is filled with the dielectric motor lubricant 200 .
- the fluid in the motor 110 expands during operation, it moves downward into the lower seal section 168 , through the clean fluid ports 170 and into the bladder 162 .
- the bladder 162 expands to accommodate introduction of fluid from the motor 110 .
- fluid external to the bladder 162 is expelled through the exchange ports 176 and solids screen 174 . If the pressure inside the bladder 162 exceeds the threshold pressure limit of the discharge valves 166 , the discharge valves 166 open and vent a portion of the motor lubricant 200 into the wellbore 104 .
- the fluid in the motor 110 contracts and fluid is drawn upward out of the bladder 162 .
- fluid from the wellbore 104 is pulled into the lower seal section 168 through the solids screen 174 and exchange ports 176 .
- the lower seal section 168 provides a robust mechanism for allowing expansion and contraction of lubricants from the motor 110 while maintaining an isolation barrier between the clean motor lubricants 200 and the contaminated wellbore fluids 204 from the wellbore 104 .
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- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Mining & Mineral Resources (AREA)
- Life Sciences & Earth Sciences (AREA)
- Fluid Mechanics (AREA)
- Physics & Mathematics (AREA)
- Geology (AREA)
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Abstract
An electric submersible pumping system for use in pumping fluids from a wellbore includes a motor that is filled with a motor lubricant, a pump driven by the motor, a thrust chamber connected between the motor and the pump, and a seal section. The thrust chamber is filled with thrust chamber lubricant and the motor and seal section are filled with motor lubricant. To prevent the mixing of the thrust chamber lubricant with the motor lubricant, the thrust chamber is in fluid isolation from the motor and the seal section. The electric submersible pumping system may include an upper seal section, a lower seal section or both upper and lower seal sections.
Description
- This invention relates generally to the field of submersible pumping systems, and more particularly, but not by way of limitation, to a system in which the thrust chamber is isolated from other chambers in the seal section and also to a system in which different lubricants are used in the motor and seal section portions of the pumping system.
- Submersible pumping systems are often deployed into wells to recover petroleum fluids from subterranean reservoirs. Typically, the submersible pumping system includes a number of components, including one or more fluid filled electric motors coupled to one or more high performance pumps located above the motor. When energized, the motor provides torque to the pump, which pushes wellbore fluids to the surface through production tubing. Each of the components in a submersible pumping system must be engineered to withstand the inhospitable downhole environment.
- Components commonly referred to as “seal sections” protect the electric motors and are typically positioned between the motor and the pump. In this position, the seal section provides several functions, including transmitting torque between the motor and pump, restricting the flow of wellbore fluids into the motor, protecting the motor from axial thrust imparted by the pump, and accommodating the expansion and contraction of motor lubricant as the motor moves through thermal cycles during operation.
- Prior art seal sections typically include a “clean side” in fluid communication with the electric motor and a “contaminated side” in fluid communication with the wellbore. Bellows or bags have been used to separate the clean side of the seal section from the contaminated side. Although generally effective, prior art designs allow fluid communication between the motor and the seal section through the thrust chamber and rely on the communication of fluid between the motor and the seal section. Because the lubricant is common to both the motor and the seal section, the same fluid must be used. It is to this and other restrictions in the prior art that the preferred embodiments are directed.
- In preferred embodiments, the present invention includes an electric submersible pumping system that is configured to pump fluids from a wellbore. The electric submersible pumping system includes a motor that is filled with a motor lubricant, a pump driven by the motor, a thrust chamber connected between the motor and the pump and a seal section. The thrust chamber is filled with a thrust chamber lubricant and the seal section and motor are in fluid isolation from the thrust chamber.
- In another aspect, the preferred embodiments include an electric submersible pumping system that includes a motor that is filled with a first lubricant, a pump driven by the motor, an upper seal section connected to the pump and a thrust chamber connected between the motor and the upper seal section. The thrust chamber is filled with a second lubricant that is different than the first lubricant.
- In yet another aspect, the electric submersible pumping system preferably includes a motor that is filled with motor lubricant. The electric submersible pumping system further includes a pump driven by the motor and a lower seal section connected to a lower side of the motor. The lower seal section is in fluid communication with the motor. The electric submersible pumping system also includes a thrust chamber connected between the motor and the pump. The thrust chamber is filled with thrust chamber lubricant and the thrust chamber is in fluid isolation from the motor. The isolation of the thrust chamber from the motor prevents mixing of the thrust chamber lubricant and motor lubricant.
-
FIG. 1 depicts a submersible pumping system constructed in accordance with a preferred embodiment of the present invention. -
FIG. 2 provides a cross-sectional view of the motor, thrust chamber, and upper seal section constructed in accordance with a presently preferred embodiment. -
FIG. 3 depicts a submersible pumping system constructed in accordance with an alternate preferred embodiment of the present invention. -
FIG. 4 provides a cross-sectional view of the thrust chamber, motor and lower seal section constructed in accordance with a presently preferred embodiment. -
FIG. 5 provides a cross-sectional view of a mechanical seal from the seal section ofFIGS. 2 and 4 . - In accordance with a first preferred embodiment of the present invention,
FIG. 1 shows an elevational view of apumping system 100 attached toproduction tubing 102. Thepumping system 100 andproduction tubing 102 are disposed in awellbore 104, which is drilled for the production of a fluid such as water or petroleum. As used herein, the term “petroleum” refers broadly to all mineral hydrocarbons, such as crude oil, gas and combinations of oil and gas. - The
pumping system 100 preferably includes apump 108, amotor 110, anupper seal section 112 and athrust chamber 114. Theproduction tubing 102 connects thepumping system 100 to awellhead 106 located on the surface. Although thepumping system 100 is primarily designed to pump petroleum products, it will be understood that the present invention can also be used to move other fluids. It will also be understood that, although each of the components of the pumping system are primarily disclosed in a submersible application, some or all of these components can also be used in surface pumping operations. - The
motor 110 receives power from a surface-based facility throughpower cable 116. Generally, themotor 110 is configured to drive thepump 108. In a particularly preferred embodiment, thepump 108 is a turbomachine that uses one or more impellers and diffusers to convert mechanical energy into pressure head. In alternate embodiments, thepump 108 is configured as a positive displacement pump. Thepump 108 includes apump intake 118 that allows fluids from thewellbore 104 to be drawn into thepump 108. Thepump 108 forces the wellbore fluids to the surface through theproduction tubing 102. - In the preferred embodiments, the
upper seal section 112 is positioned above themotor 110 and below thepump 108. Thethrust chamber 114 is positioned between themotor 110 and theseal section 112. Although only one of each component is shown, it will be understood that more can be connected when appropriate, that other arrangements of the components are desirable and that these additional configurations are encompassed within the scope of preferred embodiments. For example, in many applications, it is desirable to use tandem-motor combinations, gas separators, multiple seal sections, multiple pumps, sensor modules and other downhole components. - It will be noted that although the
pumping system 100 is depicted in a vertical deployment inFIG. 1 , thepumping system 100 can also be used in non-vertical applications, including in horizontal andnon-vertical wellbores 104. Accordingly, references to “upper” and “lower” within this disclosure are merely used to describe the relative positions of components within thepumping system 100 and should not be construed as an indication that thepumping system 100 must be deployed in a vertical orientation. - Turning to
FIG. 2 , shown therein is a cross-sectional view of theupper seal section 112,motor 110 andthrust chamber 114. As depicted in the close-up view of themotor 110 inFIG. 2 , themotor 110 preferably includes amotor housing 120,stator assembly 122,rotor assembly 124,rotor bearings 126 and amotor shaft 128 a. Thestator assembly 122 includes a series of stator coils (not separately designated) that correspond to the various phases of electricity supplied to themotor 110. Therotor assembly 124 is keyed to themotor shaft 128 a and configured for rotation in close proximity to thestationary stator assembly 122. The size and configuration of thestator assembly 122 androtor assembly 124 can be adjusted to accommodate application-specific performance requirements of themotor 110. - Sequentially energizing the various series of coils within the
stator assembly 122 causes therotor assembly 124 andmotor shaft 128 a to rotate in accordance with well-known electromotive principles. Themotor bearings 126 maintain the central position of therotor assembly 124 within thestator assembly 122 and oppose radial and axial forces generated by themotor 110 on themotor shaft 128 a. - The
motor 110 is filled withmotor lubricant 200 during manufacture that reduces frictional wear on the rotating components within themotor 110. In particularly preferred embodiments, themotor lubricant 200 is a dielectric fluid. As themotor 110 cycles during use and as themotor 110 is exposed to the elevated temperatures in thewellbore 104, thedielectric motor lubricant 200 expands and contracts. It is desirable to prevent thedielectric motor lubricant 200 from becoming contaminated withwellbore fluids 204 and solids in thewellbore 104. - The
motor shaft 128 a is preferably connected to aseal section shaft 128 b that extends through thethrust chamber 114 andupper seal section 112. Theseal section shaft 128 b transfers torque from themotor 110 to thepump 108. Theseal section shaft 128 b preferably includes aninternal passage 130 that extends at least along the portion of theseal section shaft 128 b that extends through thethrust chamber 114. - The
thrust chamber 114 includes athrust chamber housing 132, athrust bearing assembly 134, a plurality ofmechanical seals 136 and apiston expansion assembly 138. Thethrust bearing assembly 134 includes a pair of stationary bearings 140 and a thrust runner 142 attached to theseal section shaft 128 b. The thrust runner 142 is captured between the stationary bearings 140, which limit the axial displacement of the thrust runner 142 and theseal section shaft 128 b. - As best illustrated in the close-up view of the
mechanical seal 136FIG. 5 , themechanical seals 136 each include bellows 144, acoiled spring 146, arunner 148 and astationary ring 150. These components cooperate to prevent the migration of fluid along theshaft 128 and isolate themotor lubricant 200 from thethrust chamber 114. Thestationary ring 150 has an internal diameter sized to permit the free rotation of theshaft 128. In contrast, thebellows 144, coiledspring 146 andrunner 148 rotate with theshaft 128. Therotating runner 148 is held in place against thestationary ring 150 by the spring-loaded bellows 144. Thebellows 144 preferably includes a series of folds that allow its length to adjust to keep therunner 148 in contact with thestationary ring 150 if theshaft 128 should experience axial displacement. Thebellows 144 may be manufactured from thin corrugated metal or from elastomers and polymers, including AFLAS, perfluoroelastomer, polytetrafluoroethylene (PTFE), perfluoroalkoxy (PFA) and polyethether ketone (PEEK). - Turning back to
FIG. 2 , thepiston expansion assembly 138 preferably includes one ormore cylinders 152, apiston 154 in each of thecylinders 152 and spring stops 156. The upstream section of eachcylinder 152 includes an opening that places thecylinder 152 in fluid communication with the interior of thethrust chamber 114. Eachpiston 154 rides in acorresponding cylinder 152 and acts as an expansion system to permit the movement of fluid within thethrust chamber 114. The spring stops 156 are positioned at opposite ends of eachcylinder 152 and prevent thepistons 154 from crashing into the ends of thecylinders 152. - During manufacture, the
thrust chamber 114 is filled with cleanthrust chamber lubricant 202. In preferred embodiments, thethrust chamber lubricant 202 is different than thedielectric motor lubricant 200. Thethrust chamber lubricant 202 preferably has a higher viscosity than themotor lubricant 200 that is beneficial in creating hydrodynamic bearing surfaces within theupper seal section 112. As heat builds in thethrust chamber 114, the expansion of thethrust chamber lubricant 202 is accommodated with movement of thepistons 154 within thepiston expansion assembly 138. In this way, thethrust chamber lubricant 202 is contained within thethrust chamber 114 and is not mixed or exchanged with other fluids within thepumping system 100. The isolation of thethrust chamber 114 reduces the movement of shavings, particles or other material from thethrust bearing assembly 134 into themotor 110. - The
upper seal section 112 is attached to the upper end of thethrust chamber 114. To permit the expansion and contraction of thedielectric motor lubricant 200 under elevated wellbore temperatures, theupper seal section 112 is connected to themotor 110 and placed in fluid communication with the dielectric motorlubricant lubricating oil 200 through thepassage 130 in theseal section shaft 128 b.Ports 164 extending through theseal section shaft 128 b allow motor lubricant to enter and exit thepassage 130 on opposite sides of thethrust chamber 114. - The
upper seal section 112 preferably includes abag seal assembly 158. Thebag seal assembly 158 in theupper seal section 112 includes abag support 160, abladder 162,inlet ports 164 and dischargevalves 166. Thebag support 160 is rigidly attached to the inside surface of theupper seal section 112. Thebladder 162 is secured to thebag support 160. Theinlet ports 164 extend through thebag support tube 160 andshaft 128 to place thepassage 130 in fluid communication with the interior of thebladder 162. Thedischarge valves 166 are configured to vent fluid from the interior of thebladder 162 in the event the fluid exceeds a predetermined threshold pressure. The outside of thebladder 162 is in fluid communication with thepump 108 andwellbore 104. Thus, thebag seal assembly 158 in theupper seal section 112 isolates wellborefluids 204 in thepump 108 from themotor lubricant 200 in theupper seal section 112 andmotor 110. - Although the
upper seal section 112 is depicted as including abag seal assembly 158, it will be appreciated that other seal mechanisms may be incorporated into the upper seal section as additional or alternative seal mechanism to thebag seal assembly 158. Such additional seal mechanisms include bellows, pistons, labyrinths and combinations of these mechanisms. - Thus, the preferred embodiment in
FIG. 2 provides a mechanism for transferringmotor lubricant 200 from themotor 110 to theupper seal section 112, while maintaining fluid isolation with thethrust chamber 114.Thrust chamber lubricant 202 is contained within thethrust chamber 114 and prevented bymechanical seals 136 from entering themotor 110 andupper seal section 112. - Turning to
FIG. 3 , shown therein is an elevational view of thepumping system 100 constructed in accordance with a second preferred embodiment. Unless otherwise specified, the elements identified above in connection with the first preferred embodiment are also present in the second preferred embodiment. - Unlike the first preferred embodiment, the
pumping system 100 of the second preferred embodiment includes alower seal section 168. Thelower seal section 168 is used in place of theupper seal section 112 and is positioned below themotor 110. Alternatively, thelower seal section 168 is used in combination with theupper seal section 112. Thethrust chamber 114 is constructed in accordance with the first preferred embodiment and prevents the mixing ofmotor lubricant 200 withthrust chamber lubricant 202. - Turning to
FIG. 4 , shown therein is a cross-sectional view of thelower seal section 168,motor 110, and thrustchamber 114. The pump 108 (not shown inFIG. 4 ) is connected to the upper end of thethrust chamber 114. Like theupper seal section 112, thelower seal section 168 includes abag seal assembly 158 that in turn includes abag support 160, abladder 162 and dischargevalves 166. Although thelower seal section 168 is depicted as including abag seal assembly 158, it will be appreciated that other seal mechanisms may be incorporated into the upper seal section as additional or alternative seal mechanism to thebag seal assembly 158. Such additional seal mechanisms include bellows, pistons, labyrinths and combinations of these mechanisms. - Because the
motor shaft 128 does not extend into thelower seal section 168,motor lubricant 200 is not carried into thelower seal section 168 through theshaft 128. Instead, the lower seal section includesclean fluid ports 170 that place the interior of thebladder 162 directly in fluid communication with themotor lubricant 200 in themotor 110. Thedischarge valves 166 are preferably one-way relief valves that are configured to open at a predetermined threshold pressure that exceeds the exterior wellbore pressure. In this way, if the fluid pressure inside thebladder 162 exceeds the set-point pressure, thedischarge valves 166 open and relieve the pressure inside thebladder 162 by discharging a small volume ofmotor lubricant 200 into thewellbore 104. In a particularly preferred embodiment, thebladder 162 is manufactured from a high-temperature polymer or elastomer. Suitable polymers and elastomers include AFLAS, polytetrafluoroethylene (PTFE), perfluoroalkoxy (PFA), and polyetherether ketone (PEEK). Alternatively, thebladder 162 can be manufactured from a metal expansible bellows. - The
lower seal section 168 also includes afluid exchange assembly 172. Thefluid exchange assembly 172 includes asolids screen 174 and a plurality ofexchange ports 176. Theexchange ports 176 allow fluids to pass from thewellbore 104 through the solids screen 174 into thelower seal section 168 around the exterior of thebladder 162. The solids screen 174 reduces the presence of particulates in thelower seal section 168. The solids screen 174 is preferably manufactured from a metal or polymer fabric mesh. - During manufacture, the
lower seal section 168 is filled with thedielectric motor lubricant 200. As the fluid in themotor 110 expands during operation, it moves downward into thelower seal section 168, through theclean fluid ports 170 and into thebladder 162. Thebladder 162 expands to accommodate introduction of fluid from themotor 110. As thebladder 162 expands, fluid external to thebladder 162 is expelled through theexchange ports 176 and solids screen 174. If the pressure inside thebladder 162 exceeds the threshold pressure limit of thedischarge valves 166, thedischarge valves 166 open and vent a portion of themotor lubricant 200 into thewellbore 104. - Conversely, during a cooling cycle, the fluid in the
motor 110 contracts and fluid is drawn upward out of thebladder 162. As the volume and pressure inside thebladder 162 decreases, fluid from thewellbore 104 is pulled into thelower seal section 168 through thesolids screen 174 andexchange ports 176. Thelower seal section 168 provides a robust mechanism for allowing expansion and contraction of lubricants from themotor 110 while maintaining an isolation barrier between theclean motor lubricants 200 and the contaminatedwellbore fluids 204 from thewellbore 104. - It is to be understood that even though numerous characteristics and advantages of various embodiments of the present invention have been set forth in the foregoing description, together with details of the structure and functions of various embodiments of the invention, this disclosure is illustrative only, and changes may be made in detail, especially in matters of structure and arrangement of parts within the principles of the present invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. It will be appreciated by those skilled in the art that the teachings of the present invention can be applied to other systems without departing from the scope and spirit of the present invention.
Claims (20)
1. An electric submersible pumping system for use in pumping fluids from a wellbore, the electric submersible pumping system comprising:
a motor, wherein the motor is filled with a motor lubricant;
a pump driven by the motor;
a thrust chamber connected between the motor and the pump, wherein the thrust chamber is filled with a thrust chamber lubricant; and
a seal section, wherein the seal section is in fluid isolation from the thrust chamber and wherein the seal section is in fluid communication with the motor.
2. The electric submersible pumping system of claim 1 , wherein the seal section is an upper seal section that is connected between the thrust chamber and the pump.
3. The electric submersible pumping system of claim 2 , wherein the seal section further comprises a seal section shaft that extends from the motor to the upper seal section through the thrust chamber.
4. The electric submersible pumping system of claim 3 , wherein the seal section shaft comprises an internal passage that permits the movement of motor lubricant from the motor to the upper seal section.
5. The electric submersible pumping system of claim 1 , wherein the seal section is a lower seal section that is connected to the motor.
6. The electric submersible pumping system of claim 5 , wherein the lower seal section comprises a sealing mechanism selected from the group consisting of bag seals, bellows, pistons, labyrinths and combinations thereof.
7. The electric submersible pumping system of claim 6 , wherein the seal mechanism further comprises one or more discharge ports and wherein each of the one or more discharge ports is configured as a one-way check valve that places the interior of the seal mechanism in fluid communication with the wellbore when opened.
8. The electric submersible pumping system of claim 1 , wherein the lower seal section further comprises a fluid exchange assembly and wherein the fluid exchange assembly comprises:
a solids screen;
exchange ports; and
wherein the fluid exchange assembly is configured to place the exterior of the bladder in fluid communication with the wellbore.
9. The electric submersible pumping system of claim 1 , wherein the thrust chamber comprises:
a piston expansion assembly; and
a thrust bearing assembly.
10. The electric submersible pumping system of claim 9 , wherein the piston expansion assembly comprises:
one or more cylinders;
a piston in each of the one or more cylinders; and
one or more piston stops in each of the one or more cylinders.
11. The electric submersible pumping system of claim 1 , wherein the thrust chamber comprises a thrust chamber seal mechanism selected from the group consisting of pistons, bellows, seal bags, labyrinths and combinations thereof.
12. The electric submersible pumping system of claim 1 , wherein the motor lubricant is different than the thrust chamber lubricant.
13. The electric submersible pumping system of claim 1 , wherein the seal section is an upper seal section connected between the pump and the thrust chamber and wherein the electric submersible pumping system further comprises a lower seal section connected to the motor.
14. An electric submersible pumping system for use in pumping fluids from a wellbore, the electric submersible pumping system comprising:
a motor, wherein the motor is filled with a first lubricant;
a pump driven by the motor;
an upper seal section connected to the pump; and
a thrust chamber connected between the motor and the upper seal section, wherein the thrust chamber is filled with a second lubricant that is different than the first lubricant.
15. The electric submersible pumping system of claim 14 , wherein the first lubricant is dielectric motor lubricant.
16. The electric submersible pumping system of claim 14 , wherein the second lubricant is seal section oil that has a viscosity that is higher than the viscosity of the dielectric motor lubricant.
17. The electric submersible pumping system of claim 14 , further comprising a lower seal section connected to the motor, wherein the lower seal section is in fluid communication with the motor.
18. An electric submersible pumping system for use in pumping fluids from a wellbore, the electric submersible pumping system comprising:
a motor, wherein the motor is filled with motor lubricant;
a pump driven by the motor;
a lower seal section connected to a lower side of the motor, wherein the lower seal section is in fluid communication with the motor; and
a thrust chamber connected between the motor and the pump, wherein the thrust chamber is filled with thrust chamber lubricant and wherein the thrust chamber is in fluid isolation from the motor.
19. The electric submersible pumping system of claim 18 , wherein the thrust chamber comprises:
a piston expansion assembly; and
a thrust bearing assembly.
20. The electric submersible pumping system of claim 19 , wherein the piston expansion assembly comprises:
one or more cylinders;
a piston in each of the one or more cylinders; and
one or more piston stops in each of the one or more cylinders.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/US2014/068432 WO2016089399A1 (en) | 2014-12-03 | 2014-12-03 | Isolated thrust chamber for esp seal section |
Publications (1)
Publication Number | Publication Date |
---|---|
US20170321711A1 true US20170321711A1 (en) | 2017-11-09 |
Family
ID=56092158
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US15/531,096 Abandoned US20170321711A1 (en) | 2014-12-03 | 2014-12-03 | Isolated thrust chamber for esp seal section |
Country Status (3)
Country | Link |
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US (1) | US20170321711A1 (en) |
CA (1) | CA2968941A1 (en) |
WO (1) | WO2016089399A1 (en) |
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US10487844B2 (en) * | 2015-02-05 | 2019-11-26 | Eagle Industry Co., Ltd. | Mechanical seal for rotating shaft |
US11326607B2 (en) | 2019-02-05 | 2022-05-10 | Saudi Arabian Oil Company | Balancing axial thrust in submersible well pumps |
US11359472B2 (en) * | 2019-02-05 | 2022-06-14 | Saudi Arabian Oil Company | Balancing axial thrust in submersible well pumps |
EP4081696A4 (en) * | 2019-12-27 | 2024-01-24 | Baker Hughes Oilfield Operations Llc | Apparatus and method of rotational alignment of permanent magnet tandem motors for electrical submersible pump |
US11994016B2 (en) | 2021-12-09 | 2024-05-28 | Saudi Arabian Oil Company | Downhole phase separation in deviated wells |
US12012550B2 (en) | 2021-12-13 | 2024-06-18 | Saudi Arabian Oil Company | Attenuated acid formulations for acid stimulation |
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US10598221B2 (en) * | 2016-10-11 | 2020-03-24 | Baker Hughes Oilfield Operations, Llc | Permanent magnet thrust bearing |
EP3551888B1 (en) | 2017-02-03 | 2023-07-05 | Halliburton Energy Services, Inc. | Bellows motor expansion chamber for an electric submersible pump |
US20190089221A1 (en) | 2017-09-20 | 2019-03-21 | Upwing Energy, LLC | Magnetic thrust load support for downhole-type system |
CN109723681B (en) * | 2018-11-21 | 2020-06-05 | 台州市日达泵业有限公司 | Self-cleaning type deep-well pump |
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Also Published As
Publication number | Publication date |
---|---|
CA2968941A1 (en) | 2016-06-09 |
WO2016089399A1 (en) | 2016-06-09 |
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