WO2025213166A1 - High speed protector design - Google Patents
High speed protector designInfo
- Publication number
- WO2025213166A1 WO2025213166A1 PCT/US2025/023440 US2025023440W WO2025213166A1 WO 2025213166 A1 WO2025213166 A1 WO 2025213166A1 US 2025023440 W US2025023440 W US 2025023440W WO 2025213166 A1 WO2025213166 A1 WO 2025213166A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- head
- bearing
- esp
- axial grooves
- protector
- 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.)
- Pending
Links
Classifications
-
- 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
-
- 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
- E21B43/34—Arrangements for separating materials produced by the well
- E21B43/38—Arrangements for separating materials produced by the well in the well
-
- 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
- F04D15/00—Control, e.g. regulation, of pumps, pumping installations or systems
-
- 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
- F04D29/046—Bearings
-
- 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
-
- 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
- F04D29/40—Casings; Connections of working fluid
-
- 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
-
- 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
- E21B36/00—Heating, cooling or insulating arrangements for boreholes or wells, e.g. for use in permafrost zones
- E21B36/001—Cooling arrangements
-
- 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
- E21B4/00—Drives for drilling, used in the borehole
- E21B4/003—Bearing, sealing, lubricating details
Definitions
- the present disclosure generally relates to high-speed protectors for operation at given speeds (e.g., 10,000 rpm or more).
- An electric submersible pump comprising: a head comprising one or more top bearings and one or more sand filters; a long bearing with axial grooves configured to be used with two short sleeves; raised and intermediate seal bodies with long-bearings; an internal relief valve mounted internally inside a seal body; a body positioned above a thrust bearing chamber comprising dual bushings with axial grooves in different bores; and a base with long-bearings.
- the present application relates to an electric submersible pump (ESP) comprising a head with one top bearing and one annular sand filter configured to allow for fluid flow.
- the ESP may include an intermediate seal body that is raised, wherein the intermediate seal body comprises a bearing with two axial grooves configured to be used with two sleeves. Additionally, the ESP may feature an internal relief valve mounted inside the intermediate seal body and a body positioned above a thrust bearing chamber, the thrust bearing chamber comprising two bushings each with axial grooves.
- the head may further comprise an elastomer shedder or a metal shedder configured to protect the one or more top bearings from sand.
- the head may also include one or more holes configured to allow well fluid to enter and expand out.
- the ESP may comprise a disk filter for allowing oil flow from a protector to a compensating shipping cap, the disk filter being configured to prevent sand ingress when well fluid enters from a pump during operation.
- the raised seal body of the ESP may include a high-speed seal, and the two axial grooves may be located on an inner diameter.
- the two sleeves may be configured to engage with the two bushings to form two bearing connections for radial stability of the shaft.
- a pin valve arrangement may be configured to allow oil from the motor to enter the protector.
- the two bushings may be mounted on two different bores, respectively, and the thrust bearing chamber may comprise an inducer configured to circulate oil.
- the application also includes a head for a protector, comprising a top bearing, an annular sand filter configured to allow for fluid flow, and a shedder configured to protect the top bearing.
- the head may further include one or more holes configured to allow well fluid to enter and for oil to expand out, a seal mounted on top of the protector, and a bushing comprising two axial grooves on an inner diameter. Two sleeves may engage with the bushing to form two bearing connections for radial stability, and an internal relief valve may be mounted inside a raised seal body.
- the head may further comprise a shedder configured to protect the top bearing from sand.
- the head may also include multiple holes configured to allow well fluid to enter and oil to expand out.
- the raised seal body may comprise a bushing with axial grooves, and the axial grooves may be located on an inner diameter.
- the bushing may comprise two sleeves, and the two sleeves may be configured to engage with the bushing to form two bearing connections for radial stability of the shaft.
- the seal body may comprise two bushings mounted on two bores, and the two bushings may comprise axial grooves, with the axial grooves located on an inner diameter.
- Figure 1 shows a protector head design with bearing at the top according to some embodiments.
- Figures 2 shows hotline shaft seal module design with sand filter at the top according to some embodiments.
- Figure 3 A shows an extract protector using a special port for removing sand and solids from the head seal region according to some embodiments.
- Figure 3B shows a dual thrust bearing design according to some embodiments.
- Figure 4 shows a thrust bearing with cooling arrangement according to some embodiments.
- Figure 5 shows a high-speed protector head according to some embodiments.
- Figure 6 shows a protector modified bag frame design according to some embodiments.
- Figure 7A shows a protector bag chamber according to some embodiments.
- Figure 7B shows a high-speed protector bag chamber according to some embodiments.
- Figure 8B shows an intermediate seal body design for the high-speed protector according to some embodiments.
- Figure 9 shows a body above the thrust bearing chamber for use with bag chamber above according to some embodiments.
- Figure 10 shows a thrust bearing chamber according to some embodiments.
- Figure 11 shows a protector base design with longer bushings according to some embodiments.
- FIG. 1 shows a design of protector head 100 with a bearing 102 at the top.
- This bearing 102 provides extra radial stability to the mechanical seal at the top of the protector 100.
- the design may not use any sand filter and may breathe fluid through an extended pipe at the top.
- a shedder may protect the top bearing from falling sand.
- the shedder may comprise elastomer and/or metal.
- a shedder may protect bearings and other critical parts from sand and debris.
- the shedder may be positioned near the top bearing to prevent sand and other particulates from causing wear or damage to the bearing and other nearby components.
- the hotline shaft seal module 200 uses a sand filter 202 at the top to prevent sand ingress into the chamber.
- a sand filter 202 at the top to prevent sand ingress into the chamber.
- the bearing at the pump base may provide additional protection from sand ingress from the top.
- the sand filter 202 may be of annular design and may have adequate area to allow for the expected fluid flow.
- protectors may be implemented.
- the different concepts for the protector may include a dual thrust bearing design, thrust bearing cooling using an internal flow arrangement, high speed self-aligning bearings, and/or dual keyway shafts (e.g., using single-keyway shaft with balancing grooves on the sleeves).
- Some embodiments may comprise a head filter and/or a separate bearing after the top seal in the protector.
- the bottom flange 38 of the gas separator module 7 may comprise a high-speed, self-aligning (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.
- 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.
- 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.
- 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.
- the seal section shaft 40 comprises splines on both ends.
- 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.
- 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.
- a lower bag support 118 may be connected to a lower 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.
- the thrust chamber housing 50 contains single, dual, or multiple thrust bearings 51 and 52.
- the high-speed protector head may also comprise a bushing ID 504 reduced to have 0.004-0.006-inch diametral clearance, for instance, a bushing bore bushing outer diameter (OD) clearance of 0.003-0.007-inch diametrical with O-rings creating a squeeze film effect, a sleeve with or without a key, and/or a bushing lock ring.
- the highspeed protector head design 500 may comprise a long bushing 514 with axial grooves using two sleeves and/or sleeve drivers.
- the raised body design may be adapted from Maximus protectors with the top end of the body, where the seal is mounted, raised by a given amount (e.g., about 1.0 inch) to prevent any sand that does enter from falling next to the seal surfaces.
- the relief valve is a modified design based on the type used in Hotline protectors. It is mounted internally inside the seal body unlike the legacy protector where the relief valves protrude outside.
- FIG. 8A a particular seal body design 800 is shown. This design may be modified in the intermediate seal body design 802 for the high-speed protector of FIG. 8B.
- Intermediate seal body 802 may refer to the body located in the middle of the protector, between the raised body at the top and thrust chamber at the bottom.
- the intermediate seal body design body 800 may use a longer bushing (e.g., about 3 inches long) with two sleeves (e.g., about 1 inch long) 804 just like the raised body for increased radial stability of the shaft near the one or more mechanical seals 806.
- the difference in length between the bushing and the two sleeves may be 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 inches.
- the one or more relief valves 808 may be again located internally, and the body accommodates the one or more high-speed mechanical seal 806.
- FIG. 9 a thrust bearing chamber and bag chamber 900 are shown.
- the body above the thrust bearing chamber 904 may be designed with 1, 2, 3, 4, 5, 6, 7, or 8 short bushings 902 mounted on 1, 2, 3, 4, 5, 6, 7, or 8 bores, respectively (e.g., 2 short bushings and 2 bores).
- the bushings may have axial grooves in the inner diameter for better lubrication of the bearings.
- the body is designed specifically for use with bag chamber on the top for the high-speed protectors.
- Thrust bearing chamber 1000 may comprise a collar 1002, runner, 1004, inducer body 1006, base 1008, top thrust bearing 1010, bottom thrust bearing 1012, inducer 1014.
- Inducer 1014 may circulate oil inside the thrust bearing chamber 1000 to ensure proper lubrication and cooling.
- Inducer 1014 may enhance fluid flow and ensure proper lubrication and cooling.
- the inducer may consist of a small, axial-flow impeller with angled blades or vanes designed to create a low-pressure zone. This low-pressure zone may help draw fluid into the pump more efficiently, reducing the Net Positive Suction Head Required (NPSHR) and preventing cavitation.
- NPSHR Net Positive Suction Head Required
- the inducer which may be positioned at the inlet of the pump stage, may increase the fluid pressure slightly before it reaches the main impeller, ensuring a smooth and continuous flow of fluid. This continuous flow is helpful for maintaining proper lubrication of the pump's bearings and other moving parts, as well as for dissipating heat generated during operation, thereby preventing overheating and ensuring optimal pump performance.
- the inducer 1014 may be typically made from materials such as stainless steel or high-performance alloys to withstand the operating conditions of the pump.
- the base of the protector 1100 may uses a long axially grooved bearing with 2 short sleeves 1102 similar to the bearings in the raised body and intermediate seal body.
- the pin valve arrangement 1104 may allow oil from the motor to enter the protector.
- connection As used herein, the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via one or more elements”; and the term “set” is used to mean “one element” or “more than one element”. Further, the terms “couple”, “coupling”, “coupled”, “coupled together”, and “coupled with” are used to mean “directly coupled together” or “coupled together via one or more elements”. As used herein, the terms “up” and “down”; “upper” and “lower”; “top” and “bottom”; and other like terms indicating relative positions to a given point or element are utilized to more clearly describe some elements.
- these terms relate to a reference point at the surface from which drilling operations are initiated as being the top point and the total depth being the lowest point, wherein the well (e.g., wellbore, borehole) is vertical, horizontal or slanted relative to the surface.
- the well e.g., wellbore, borehole
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Mining & Mineral Resources (AREA)
- Life Sciences & Earth Sciences (AREA)
- Geology (AREA)
- Physics & Mathematics (AREA)
- Environmental & Geological Engineering (AREA)
- Fluid Mechanics (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Sliding-Contact Bearings (AREA)
Abstract
An electric submersible pump (ESP) comprising: a head comprising one or more top bearings and one or more sand filters; a long bearing with axial grooves configured to be used with two short sleeves; raised and intermediate seal bodies with long-bearings; an internal relief valve mounted internally inside a seal body; a body positioned above a thrust bearing chamber comprising dual bushings with axial grooves in different bores; and a base with long-bearings.
Description
HIGH SPEED PROTECTOR DESIGN
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority benefit of Singapore Provisional Application No. 10202401015T filed April 5, 2024, the entire contents of which are incorporated by reference in their entirety.
BACKGROUND
Field
[0002] The present disclosure generally relates to high-speed protectors for operation at given speeds (e.g., 10,000 rpm or more).
SUMMARY
[0003] An electric submersible pump (ESP) comprising: a head comprising one or more top bearings and one or more sand filters; a long bearing with axial grooves configured to be used with two short sleeves; raised and intermediate seal bodies with long-bearings; an internal relief valve mounted internally inside a seal body; a body positioned above a thrust bearing chamber comprising dual bushings with axial grooves in different bores; and a base with long-bearings.
[0004] The present application relates to an electric submersible pump (ESP) comprising a head with one top bearing and one annular sand filter configured to allow for fluid flow. The ESP may include an intermediate seal body that is raised, wherein the intermediate seal body comprises a bearing with two axial grooves configured to be used with two sleeves. Additionally, the ESP may feature an internal relief valve mounted inside the intermediate seal body and a body positioned above a thrust bearing chamber, the thrust bearing chamber comprising two bushings each with axial grooves.
[0005] In one embodiment, the head may further comprise an elastomer shedder or a metal shedder configured to protect the one or more top bearings from sand. The head may also include one or more holes configured to allow well fluid to enter and expand out. Furthermore, the ESP may comprise a disk filter for allowing oil flow from a protector to a compensating shipping cap, the disk filter being configured to prevent sand ingress when well fluid enters from a pump during operation. The raised seal body of the ESP may include a high-speed seal, and the two axial
grooves may be located on an inner diameter. The two sleeves may be configured to engage with the two bushings to form two bearing connections for radial stability of the shaft. A pin valve arrangement may be configured to allow oil from the motor to enter the protector. The two bushings may be mounted on two different bores, respectively, and the thrust bearing chamber may comprise an inducer configured to circulate oil.
[0006] The application also includes a head for a protector, comprising a top bearing, an annular sand filter configured to allow for fluid flow, and a shedder configured to protect the top bearing. The head may further include one or more holes configured to allow well fluid to enter and for oil to expand out, a seal mounted on top of the protector, and a bushing comprising two axial grooves on an inner diameter. Two sleeves may engage with the bushing to form two bearing connections for radial stability, and an internal relief valve may be mounted inside a raised seal body.
[0007] In another embodiment, the head may further comprise a shedder configured to protect the top bearing from sand. The head may also include multiple holes configured to allow well fluid to enter and oil to expand out. The raised seal body may comprise a bushing with axial grooves, and the axial grooves may be located on an inner diameter. The bushing may comprise two sleeves, and the two sleeves may be configured to engage with the bushing to form two bearing connections for radial stability of the shaft. The seal body may comprise two bushings mounted on two bores, and the two bushings may comprise axial grooves, with the axial grooves located on an inner diameter.
BRIEF DESCRIPTION OF THE FIGURES
[0008] Certain embodiments, features, aspects, and advantages of the disclosure will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It should be understood that the accompanying figures illustrate the various implementations described herein and are not meant to limit the scope of various technologies described herein.
[0009] Figure 1 shows a protector head design with bearing at the top according to some embodiments.
[0010] Figures 2 shows hotline shaft seal module design with sand filter at the top according to some embodiments.
[0011] Figure 3 A shows an extract protector using a special port for removing sand and solids from the head seal region according to some embodiments.
[0012] Figure 3B shows a dual thrust bearing design according to some embodiments.
[0013] Figure 4 shows a thrust bearing with cooling arrangement according to some embodiments.
[0014] Figure 5 shows a high-speed protector head according to some embodiments.
[0015] Figure 6 shows a protector modified bag frame design according to some embodiments.
[0016] Figure 7A shows a protector bag chamber according to some embodiments.
[0017] Figure 7B shows a high-speed protector bag chamber according to some embodiments.
[0018] Figure 8A shows a seal body design according to some embodiments.
[0019] Figure 8B shows an intermediate seal body design for the high-speed protector according to some embodiments.
[0020] Figure 9 shows a body above the thrust bearing chamber for use with bag chamber above according to some embodiments.
[0021] Figure 10 shows a thrust bearing chamber according to some embodiments.
[0022] Figure 11 shows a protector base design with longer bushings according to some embodiments.
DETAILED DESCRIPTION
[0023] In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the disclosure. These are, of course, merely examples and are not intended to be limiting. However, it will be understood by those of ordinary skill in the art that the system and/or methodology may be practiced without these details and that numerous variations or modifications from the described embodiments are possible. This description is not to be taken in a limiting sense, but rather made merely for the purpose of describing general
principles of the implementations. The scope of the described implementations should be ascertained with reference to the issued claims.
[0024] FIG. 1 shows a design of protector head 100 with a bearing 102 at the top. This bearing 102 provides extra radial stability to the mechanical seal at the top of the protector 100. However, the design may not use any sand filter and may breathe fluid through an extended pipe at the top. A shedder may protect the top bearing from falling sand. The shedder may comprise elastomer and/or metal. A shedder may protect bearings and other critical parts from sand and debris. The shedder may be positioned near the top bearing to prevent sand and other particulates from causing wear or damage to the bearing and other nearby components.
[0025] Turning to FIG. 2, the hotline shaft seal module 200 uses a sand filter 202 at the top to prevent sand ingress into the chamber. However, there may be no bearing at the top in this design. The bearing at the pump base may provide additional protection from sand ingress from the top. There may be multiple holes on the head to allow for well fluid to enter and for oil to expand out. The sand filter 202 may be of annular design and may have adequate area to allow for the expected fluid flow.
[0026] Various embodiments, including protectors, may be implemented. The different concepts for the protector may include a dual thrust bearing design, thrust bearing cooling using an internal flow arrangement, high speed self-aligning bearings, and/or dual keyway shafts (e.g., using single-keyway shaft with balancing grooves on the sleeves). Some embodiments may comprise a head filter and/or a separate bearing after the top seal in the protector.
[0027] As shown in FIG. 3A, the bottom flange 38 of the gas separator module 7 may comprise a high-speed, self-aligning (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.
[0028] 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.
[0029] 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 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.
[0030] As shown in FIG. 3B, a lower bag support 118 may be connected to a lower 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.
[0031] 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.
[0032] 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 51 A may engage against the upper thrust bearing assembly 51 if downthrust 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.
[0033] 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 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.
[0034] 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 KV. 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.
[0035] 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° C. 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.
[0036] 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.
[0037] Turning to FIG. 4, a thrust bearing may comprise a cooling arrangement. In operation of cooling chamber assembly 17, cooling chamber shaft 31 rotates in response to rotation
of an ESP pump motor (not shown). Rotation of cooling chamber shaft 31 causes a pump to rotate. As the pump rotates it will draw fluid from a fluid passageway through a pump chamber and then through thrust bearing assembly 13 as illustrated by flow path F in FIG. 4.
[0038] In the following, we describe some features of a high-speed protector. This is indicated in the relevant section below.
[0039] Turning to FIG. 5, a high-speed protector head design 500 used for a protector is shown. It consists of an extra bearing 516 after the top seal, an annular sand fdter 506 to remove sand and solids from the well fluid or oil to flowing into the protector for pressure equalization. The sand filter 506 may take other shapes such as rectangular, square, oval, hyperbolic, triangular, trapezoidal, and/or circular. The annular sand filter 506 may remove sand and solids from fluid entering the protector 500. The sand filter 506 may by locked with one or more square O-rings and one or more snap rings. There may be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 holes on the head for allowing well fluid to flow and may be plugged with plugs (e.g., threaded, national pipe taper-NPT) during oil filing. A second disk filter 508 is used at the top, primarily for allowing oil to flow from the protector to the compensating shipping cap and to prevent sand ingress when well fluid enters from the pump during operation.
[0040] A special high-speed seal 510 is mounted on top of the protectortop body 512 (also known as the raised body). A high-speed seal may operate efficiently at high rotational speeds, providing enhanced stability and protection. High-speed seals may be characterized by their advanced material selection, optimized structural design, tight precision requirements, and ability to perform under high-speed conditions. The high-speed protector head may comprise a shedder 502 to prevent sand from entering the bearing region. The high-speed protector head may also comprise a bushing ID 504 reduced to have 0.004-0.006-inch diametral clearance, for instance, a bushing bore bushing outer diameter (OD) clearance of 0.003-0.007-inch diametrical with O-rings creating a squeeze film effect, a sleeve with or without a key, and/or a bushing lock ring. The highspeed protector head design 500 may comprise a long bushing 514 with axial grooves using two sleeves and/or sleeve drivers.
[0041] High-speed seals may use materials that can withstand high temperatures, friction, and wear. Common materials include silicon carbide, tungsten carbide, carbon graphite, engineered ceramics, and specialized high-performance polymers. Normal seals may use more conventional materials like rubber, standard plastics, or metals that are suitable for lower-speed
applications. High-speed seals may also incorporate materials used in normal seals. High-speed seals have optimized structural designs to minimize heat generation and maintain stability at elevated speeds. Features include balanced seal faces to evenly distribute pressure and reduce friction, precise face geometry to maintain a thin fluid film between the faces, and robust construction to withstand dynamic forces and vibration. Normal seals may not have these specialized design features and are typically simpler in construction. High-speed seals may have tight tolerances and precise manufacturing. Key precision requirements include flatness and parallelism of seal faces, smooth surface finishes to minimize friction and wear, tight clearances between rotating and stationary components, and accurate alignment of seal components. Normal seals may have less stringent precision requirements and can tolerate larger clearances and less precise alignment. High-speed seals are designed to handle increased friction, heat generation, and dynamic forces that occur at high rotational speeds. They may incorporate features like grooves or micro-surface textures to optimize fluid film formation and maintain seal integrity. Normal seals may not perform well under high-speed conditions and can suffer from increased wear, heat buildup, and potential seal failure.
[0042] The raised body may have a new bearing design consisting of a long bushing (e.g., around 3 inches, 2.5-3.5 inches, 2.7-3.3 inches, 2-4 inches long) with axial grooves on the inner diameter. The inner diameter may be that of the raised body, any bearing, any bushing, the shaft tube, or any other element in this protector head. Two short sleeves (around 1 inch, 0.5-1.5 inches, 1.75-2 inches, 2-3 inches long) engage with the bushing to form 2 bearing connections for extra radial stability of the shaft near the seal. The raised body design may be adapted from Maximus protectors with the top end of the body, where the seal is mounted, raised by a given amount (e.g., about 1.0 inch) to prevent any sand that does enter from falling next to the seal surfaces. The relief valve is a modified design based on the type used in Hotline protectors. It is mounted internally inside the seal body unlike the legacy protector where the relief valves protrude outside.
[0043] Turning to FIG. 6, a modified bag frame design 600 may be implemented in the protector. The modified bag frame may comprise a bag frame assembly 602, elastomer bag 604, and a lower ring 606. The modified bag frame design 600 may be shorter (e.g., about 23 inches) than the design used in the conventional protectors (e.g., about 25.7 inches) The modified bag frame design 600 may be about 25, 24, 23, 22, 21, 20, 19, 18, 17, 16, 15, 14, 13, or 12 inches long.
In some embodiments, there is no short tube at the top of the upper ring. In some embodiments, no NPT tubes are used in the bag chamber.
[0044] In FIG. 7A, a particular protector bag chamber design 700 is shown. In FIG. 7B, a modified high-speed protector design 702 is shown, wherein the bag chamber housing for the new protector is shorter than the protector bag chamber housing in FIG. 7A by a given amount (e.g., 1 in, 2 in, 2.5 in, 2.7 in, 3 in, 4, in, 5, in, 6 in, 7, in, 8 in, 9 in, 10 in, 11 in, 12 in, etc.) or ratio (e.g., 95%, 90%, 89.49%, 89.5%, 89%, 88%, 87%, 86%, 85%, 84-80%, 80-75%, 75-70%, 70-65%, 65- 60%, 60-55%, 55-50%, 50-45%, 45-40% etc.)
[0045] Turning to FIG. 8A, a particular seal body design 800 is shown. This design may be modified in the intermediate seal body design 802 for the high-speed protector of FIG. 8B. Intermediate seal body 802 may refer to the body located in the middle of the protector, between the raised body at the top and thrust chamber at the bottom. The intermediate seal body design body 800 may use a longer bushing (e.g., about 3 inches long) with two sleeves (e.g., about 1 inch long) 804 just like the raised body for increased radial stability of the shaft near the one or more mechanical seals 806. The difference in length between the bushing and the two sleeves may be 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 inches. The one or more relief valves 808 may be again located internally, and the body accommodates the one or more high-speed mechanical seal 806.
[0046] Turning to FIG. 9, a thrust bearing chamber and bag chamber 900 are shown. The body above the thrust bearing chamber 904 may be designed with 1, 2, 3, 4, 5, 6, 7, or 8 short bushings 902 mounted on 1, 2, 3, 4, 5, 6, 7, or 8 bores, respectively (e.g., 2 short bushings and 2 bores). The bushings may have axial grooves in the inner diameter for better lubrication of the bearings. The body is designed specifically for use with bag chamber on the top for the high-speed protectors.
[0047] Turning to FIG. 10, a thrust bearing chamber 1000 is shown. Thrust bearing chamber 1000 may comprise a collar 1002, runner, 1004, inducer body 1006, base 1008, top thrust bearing 1010, bottom thrust bearing 1012, inducer 1014. Inducer 1014 may circulate oil inside the thrust bearing chamber 1000 to ensure proper lubrication and cooling. Inducer 1014 may enhance fluid flow and ensure proper lubrication and cooling. Structurally, the inducer may consist of a small, axial-flow impeller with angled blades or vanes designed to create a low-pressure zone. This low-pressure zone may help draw fluid into the pump more efficiently, reducing the Net Positive Suction Head Required (NPSHR) and preventing cavitation. The inducer, which may be positioned
at the inlet of the pump stage, may increase the fluid pressure slightly before it reaches the main impeller, ensuring a smooth and continuous flow of fluid. This continuous flow is helpful for maintaining proper lubrication of the pump's bearings and other moving parts, as well as for dissipating heat generated during operation, thereby preventing overheating and ensuring optimal pump performance. The inducer 1014 may be typically made from materials such as stainless steel or high-performance alloys to withstand the operating conditions of the pump.
[0048] Turning to FIG. 11, the base of the protector 1100 may uses a long axially grooved bearing with 2 short sleeves 1102 similar to the bearings in the raised body and intermediate seal body. The pin valve arrangement 1104 may allow oil from the motor to enter the protector.
[0049] This application discloses one or more embodiments with a new head design with top bearing and sand filters, a new long-bearing design with axial grooves and used with 2 short sleeves, a new design of the raised and intermediate seal bodies with long-bearings and internal relief valve mounting arrangement, a new design of the body above thrust bearing chamber with dual bushings with axial grooves in different bores, and a new design of the base with long- bearings.
[0050] In the context of this application, the terms "long" and "short" may refer to the relative axial lengths of various components, such as bushings and sleeves. A "short" component typically may, in some cases, have a smaller axial length than traditionally used. These shorter components may be used in areas where space is limited or for design improvements. Conversely, a "long" component has a greater axial length, providing enhanced stability and support. These longer components may be utilized in areas where greater radial stability is desired to support the shaft and other moving parts, or for performance improvements. The specific dimensions of "long" and "short" components are determined based on their function and the spatial constraints within the ESP system, ensuring optimal performance and durability.
[0051] As used herein, the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via one or more elements”; and the term “set” is used to mean “one element” or “more than one element”. Further, the terms “couple”, “coupling”, “coupled”, “coupled together”, and “coupled with” are used to mean “directly coupled together” or “coupled together via one or more elements”. As used herein, the terms "up" and "down"; "upper" and "lower"; "top" and "bottom"; and other like terms indicating relative positions to a given point or element are utilized to more clearly
describe some elements. Commonly, these terms relate to a reference point at the surface from which drilling operations are initiated as being the top point and the total depth being the lowest point, wherein the well (e.g., wellbore, borehole) is vertical, horizontal or slanted relative to the surface.
[0052] Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and/or within less than 0.01% of the stated amount. As another example, in certain embodiments, the terms “generally parallel” and “substantially parallel” or “generally perpendicular” and “substantially perpendicular” refer to a value, amount, or characteristic that departs from exactly parallel or perpendicular, respectively, by less than or equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, or 0.1 degree.
[0053] Although a few embodiments of the disclosure have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments described may be made and still fall within the scope of the disclosure. It should be understood that various features and aspects of the disclosed embodiments can be combined with, or substituted for, one another in order to form varying modes of the embodiments of the disclosure. Thus, it is intended that the scope of the disclosure herein should not be limited by the particular embodiments described above.
Claims
1. An electric submersible pump (ESP) comprising: a head comprising one top bearing and one annular sand filter configured to allow for fluid flow; an intermediate seal body that is raised, wherein the intermediate seal body comprises a bearing, the bearing comprising two axial grooves configured to be used with two sleeves; an internal relief valve mounted inside the intermediate seal body; and a body positioned above a thrust bearing chamber, the thrust bearing chamber comprising two bushings each with axial grooves.
2. The ESP of claim 1, wherein the head further comprises an elastomer shedder or a metal shedder configured to protect the one or more top bearings from sand.
3. The ESP of claim 1, wherein the head further comprises one or more holes configured to allow well fluid to enter and expand out.
4. The ESP of claim 1, further comprising a disk filter for allowing oil flow from a protector to a compensating shipping cap, the disk filter being configured to prevent sand ingress when well fluid enters from a pump during operation.
5. The ESP of claim 1 , wherein the raised seal body comprises a high-speed seal.
6. The ESP of claim 1, wherein the two axial grooves are on an inner diameter.
7. The ESP of claim 1, wherein the two sleeves are configured to engage with the two bushings to form two bearing connections for radial stability of the shaft.
8. The ESP of claim 1, wherein a pin valve arrangement is configured to allow oil from the motor to enter the protector.
9. The ESP of claim 1 , wherein the two bushings are mounted on two different bores, respectively.
10. The ESP of claim 1, wherein the thrust bearing chamber comprises an inducer configured to circulate oil.
11. A head for a protector, comprising: a top bearing; an annular sand filter configured to allow for fluid flow; a shedder configured to protect the top bearing; one or more holes configured to allow well fluid to enter and for oil to expand out; a seal mounted on top of the protector; a bushing comprising two axial grooves on an inner diameter; two sleeves engaging with the bushing to form two bearing connections for radial stability; an internal relief valve mounted inside a raised seal body;
12. The head of claim 11, further comprising a shedder configured to protect the top bearing from sand.
13. The head of claim 11, further comprising multiple holes configured to allow well fluid to enter and oil to expand out.
14. The head of claim 11, wherein the raised seal body comprises a bushing with axial grooves.
15. The head of claim 14, wherein the axial grooves are on an inner diameter.
16. The head of claim 14, wherein the bushing comprises two sleeves.
17. The head of claim 16, wherein the two sleeves are configured to engage with the bushing to form two bearing connections for radial stability of the shaft.
18. The head of claim 11, wherein the seal body comprises two bushings mounted on two bores.
19. The head of claim 18, wherein the two bushings comprise axial grooves.
20. The head of claim 19, wherein the axial grooves are on an inner diameter.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| SG10202401015T | 2024-04-05 | ||
| SG10202401015T | 2024-04-05 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2025213166A1 true WO2025213166A1 (en) | 2025-10-09 |
Family
ID=97268203
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/US2025/023440 Pending WO2025213166A1 (en) | 2024-04-05 | 2025-04-07 | High speed protector design |
Country Status (1)
| Country | Link |
|---|---|
| WO (1) | WO2025213166A1 (en) |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN200952466Y (en) * | 2005-11-03 | 2007-09-26 | 天津市油田采油成套设备有限公司 | Three-stage protection upper settling chamber bottom discrete capsule oil-submersible electric pump protector |
| US20110014071A1 (en) * | 2001-06-18 | 2011-01-20 | Schlumberger Technology Corporation | Protector for electrical submersible pumps |
| US20180149173A1 (en) * | 2015-04-28 | 2018-05-31 | COREteQ Systems Ltd. | Electrical submersible motor |
| US20190264707A1 (en) * | 2018-02-23 | 2019-08-29 | Extract Production Services, LLC | Electric submersible pumping unit |
| US11365809B2 (en) * | 2014-12-05 | 2022-06-21 | Baker Hughes Esp, Inc. | Mechanical seal protector for ESP seal sections |
-
2025
- 2025-04-07 WO PCT/US2025/023440 patent/WO2025213166A1/en active Pending
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20110014071A1 (en) * | 2001-06-18 | 2011-01-20 | Schlumberger Technology Corporation | Protector for electrical submersible pumps |
| CN200952466Y (en) * | 2005-11-03 | 2007-09-26 | 天津市油田采油成套设备有限公司 | Three-stage protection upper settling chamber bottom discrete capsule oil-submersible electric pump protector |
| US11365809B2 (en) * | 2014-12-05 | 2022-06-21 | Baker Hughes Esp, Inc. | Mechanical seal protector for ESP seal sections |
| US20180149173A1 (en) * | 2015-04-28 | 2018-05-31 | COREteQ Systems Ltd. | Electrical submersible motor |
| US20190264707A1 (en) * | 2018-02-23 | 2019-08-29 | Extract Production Services, LLC | Electric submersible pumping unit |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CA2851452C (en) | Apparatus, system and method for sealing submersible pump assemblies | |
| US10822933B2 (en) | Electric submersible pumping unit | |
| US9677560B1 (en) | Centrifugal pump impeller support system and apparatus | |
| US10473106B2 (en) | Apparatus and system for sealing submersible pump assemblies | |
| US20020125777A1 (en) | Vibration damping system for ESP motor | |
| US7909090B2 (en) | System, method and apparatus for scale resistant radial bearing for downhole rotating tool components and assemblies | |
| US3468259A (en) | Axial relieving arrangement for impeller-type pumps | |
| GB2411670A (en) | Submersible motor protector having means for reducing wear from abrasives | |
| CA3114800C (en) | Spring biased pump stage stack for submersible well pump assembly | |
| WO2025213166A1 (en) | High speed protector design | |
| US11459869B2 (en) | Shaft seal protector for electrical submersible pumps | |
| US11624368B2 (en) | High speed electric submersible pumps | |
| WO2015098896A1 (en) | Bearing device and pump | |
| WO2022164880A1 (en) | High speed electric submersible pumps | |
| RU2787446C1 (en) | Downhole vane pump | |
| US11624270B2 (en) | Upthrust protection in electric submersible pumps | |
| JP2017009043A (en) | Bearing device and pump | |
| CA3187413C (en) | Upthrust protection in electric submersible pumps | |
| EA049192B1 (en) | WELL VANE PUMP | |
| WO2024010487A1 (en) | Downhole rotary vane pump |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| 121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 25783473 Country of ref document: EP Kind code of ref document: A1 |