Abstract: A bellows motor expansion chamber for electric submersible pumps (ESP). An ESP assembly includes an electric submersible motor between a thrust chamber and a motor expansion chamber, the motor expansion chamber including a bellows coupled to a releasable bellows anti-movement system including a heat-activated release and alterable between an immobilizing position, wherein the releasable anti-movement system prevents concertinaed movement of the bellows in the immobilizing position, and a released position, wherein the bellows is concertinaedly moveable in the released position, and wherein the releasable bellows anti-movement system is in the immobilizing position below a release temperature and in the released position above the release temperature. A filter section within a well fluid inlet of the bellows motor expansion chamber includes a least two concentric filters of varying porosity, and a housing surrounding the filters including angled ribs and flow holes.

Abstract: A downhole tool includes an electric submersible pump to pump a well fluid to a surface of a borehole. The downhole tool includes a motor to power the electric submersible pump and a seal section to protect the motor from the well fluid. The seal section includes an elastomeric bag and a clamp at each end of the elastomeric bag to secure the elastomeric bag. The seal section includes an elastomeric bag protector secured around each clamp, wherein the elastomeric bag protector extends axially beyond a respective clamp to surround a tapered portion of the elastomeric bag above and below the clamp, and wherein the elastomeric bag protector has a sloped inner diameter that matches a profile of the tapered portion.

Abstract: A centrifugal electric submersible pump (ESP). The centrifugal ESP comprises a rotatable shaft, a series of impellers stacked on the rotatable shaft, each impeller comprising a hub secured to the rotatable shaft by a key, the series of impellers comprising an uppermost impeller and a lowermost impeller, a flanged sleeve keyed to the rotatable shaft below the lowermost impeller, and a seal disposed between the lowermost impeller and the flanged sleeve.

Abstract: A centrifugal electric submersible pump (ESP). The centrifugal ESP comprises a rotatable shaft, a series of impellers stacked on the rotatable shaft, each impeller comprising a hub secured to the rotatable shaft by a key, the series of impellers comprising an uppermost impeller and a lowermost impeller, a flanged sleeve keyed to the rotatable shaft below the lowermost impeller, and a seal disposed between the lowermost impeller and the flanged sleeve.

Abstract: A gas resistant pothead system and method for electric submersible motors. A gas resistant pothead system includes a lead foil wrapped motor lead cable (MLE) extending through a pothead, a sleeve of an insulator block inside the pothead, the sleeve including gold plating and lead-foil wrapping over the gold plating, and a lead-to-gold seal formed between the gold plating of the sleeve and the lead foil wrapping over the gold plating. A method of creating a seal to gas around a power cable connection to a downhole electric submersible motor includes wrapping lead foil around a MLE extending through a pothead, continuing the lead foil wrapping around a gold-plated sleeve of an insulating block inside the pothead, mechanically reinforcing the lead foil with an encapsulant, and bonding the lead foil to the gold plating of the insulating block.

Abstract: A pothead retaining sleeve apparatus, system and method. An electric submersible (ESP) motor pothead includes pivotable retaining sleeves, each pivotable retaining sleeve including a ball that seats within a socket inside the pothead, the ball rotatable in the socket such that each pivotable retaining sleeve is independently moveable around a spheroidal joint formed by the ball and socket. An ESP motor pothead system includes a pothead for electrically connecting a power cable to an electric submersible motor, each phase of the power cable extending through a retaining sleeve, the retaining sleeve extending through a conduit formed through an insulating block inside the pothead, the conduit including a spherical socket, the retaining sleeve including a tubular portion terminating at a ball seated within the spherical socket to form a ball and socket joint, and the tubular portion rotatable around the ball and socket joint during tying off of the phases.

Abstract: A downhole tool includes an electric submersible pump to pump a well fluid to a surface of a borehole. The downhole tool includes a motor to power the electric submersible pump and a seal section to protect the motor from the well fluid. The seal section includes an elastomeric bag and a clamp at each end of the elastomeric bag to secure the elastomeric bag. The seal section includes an elastomeric bag protector secured around each clamp, wherein the elastomeric bag protector extends axially beyond a respective clamp to surround a tapered portion of the elastomeric bag above and below the clamp, and wherein the elastomeric bag protector has a sloped inner diameter that matches a profile of the tapered portion.

Abstract: A pothead retaining sleeve apparatus, system and method. An electric submersible (ESP) motor pothead includes pivotable retaining sleeves, each pivotable retaining sleeve including a ball that seats within a socket inside the pothead, the ball rotatable in the socket such that each pivotable retaining sleeve is independently moveable around a spheroidal joint formed by the ball and socket. An ESP motor pothead system includes a pothead for electrically connecting a power cable to an electric submersible motor, each phase of the power cable extending through a retaining sleeve, the retaining sleeve extending through a conduit formed through an insulating block inside the pothead, the conduit including a spherical socket, the retaining sleeve including a tubular portion terminating at a ball seated within the spherical socket to form a ball and socket joint, and the tubular portion rotatable around the ball and socket joint during tying off of the phases.

Abstract: A bellows motor expansion chamber for electric submersible pumps (ESP). An ESP assembly includes an electric submersible motor between a thrust chamber and a motor expansion chamber, the motor expansion chamber including a bellows coupled to a releasable bellows anti-movement system including a heat-activated release and alterable between an immobilizing position, wherein the releasable anti-movement system prevents concertinaed movement of the bellows in the immobilizing position, and a released position, wherein the bellows is concertinaedly moveable in the released position, and wherein the releasable bellows anti-movement system is in the immobilizing position below a release temperature and in the released position above the release temperature. A filter GO section within a well fluid inlet of the bellows motor expansion chamber includes a least two concentric filters of varying porosity, and a housing surrounding the filters including angled ribs and flow holes.

Abstract: A gas resistant pothead system and method for electric submersible motors. A gas resistant pothead system includes a lead foil wrapped motor lead cable (MLE) extending through a pothead, a sleeve of an insulator block inside the pothead, the sleeve including gold plating and lead-foil wrapping over the gold plating, and a lead-to-gold seal formed between the gold plating of the sleeve and the lead foil wrapping over the gold plating. A method of creating a seal to gas around a power cable connection to a downhole electric submersible motor includes wrapping lead foil around a MLE extending through a pothead, continuing the lead foil wrapping around a gold-plated sleeve of an insulating block inside the pothead, mechanically reinforcing the lead foil with an encapsulant, and bonding the lead foil to the gold plating of the insulating block.

Abstract: A gas resistant pothead system and method for electric submersible motors. A gas resistant pothead system includes a lead foil wrapped motor lead cable (MLE) extending through a pothead, a sleeve of an insulator block inside the pothead, the sleeve including gold plating and lead-foil wrapping over the gold plating, and a lead-to-gold seal formed between the gold plating of the sleeve and the lead foil wrapping over the gold plating. A method of creating a seal to gas around a power cable connection to a downhole electric submersible motor includes wrapping lead foil around a MLE extending through a pothead, continuing the lead foil wrapping around a gold-plated sleeve of an insulating block inside the pothead, mechanically reinforcing the lead foil with an encapsulant, and bonding the lead foil to the gold plating of the insulating block.

Abstract: A pothead cable seal for electric submersible motors. An electric submersible motor pothead system including a pothead that couples a power cable to an electric submersible motor operable in well fluid, the pothead including a finger seal including a finger around each phase of the power cable and a radial flange, a compression plate that exerts a radial force on each phase from an axial load provided by the compression plate against the radial flange, a seal seat including sockets that receive each finger; a space extending between a portion of an outer diameter of each finger and a flared inner diameter of the socket of the seal seat, and a seal ring extending circumferentially around an outer diameter of each finger and tangent to the flange, the seal ring contacting the flared inner diameter of the seal seat and closing the space to the ingress of well fluid.

Abstract: An electric submersible motor thrust bearing system is described. An electric submersible motor thrust bearing system includes a thrust bearing assembly carrying a thrust of an electric submersible motor, the thrust bearing assembly including a split ring secured around a shaft of the electric submersible motor inward of a rotatable thrust runner, the rotatable thrust runner coupled around an outer diameter of the split ring and mated above a non-rotatable thrust bearing, the rotatable thrust runner serving as a barrier to radial expansion of the split ring, a lock ring secured to the thrust runner by a threaded connection, at least a portion of the lock ring above the split ring and at least a portion of the thrust runner below the split ring, and the threaded connection securing the split ring axially between the lock ring and the thrust runner.

Abstract: Systems and methods for protecting motor lead from debris and fluid contamination. In one embodiment, detachable, flexible lead wires within an ESP motor are covered by protective sleeves that are sealed against the end connectors of the leads. The end connectors are coupled to corresponding terminals in an epoxy fixture of the motor and a motor head in a manner that provides a seal between them. The sealed sleeve and end connectors prevent debris and contaminants in the fluid within the motor from reaching the conductive elements of the motor leads, thereby preventing accumulations of debris and contaminants that could otherwise cause electrical faults.

Abstract: An electric submersible motor radial support bearing is described. An electric submersible motor includes a motor shaft extending longitudinally through a stator bore, the motor shaft bendable out of alignment with a longitudinal axis of the stator bore, a carrier keyed the stator bore, each rotor section of the motor separated from an adjacent rotor section by a roller bearing including a rounded roller cage between a rotatable inner race and a non-rotatable outer race, the inner race inward of the roller cage and rotatably secured to the motor shaft, the outer race having a curved inner diameter (ID) forming a roller cage socket, an outer diameter (OD) of the outer race non-rotatably secured to an ID of the carrier, the roller cage and outer race forming a spheroidal joint as the roller cage pivots off the longitudinal axis of the stator bore as the motor shaft bends.

Abstract: A pothead cable seal for electric submersible motors. An electric submersible motor pothead system including a pothead that couples a power cable to an electric submersible motor operable in well fluid, the pothead including a finger seal including a finger around each phase of the power cable and a radial flange, a compression plate that exerts a radial force on each phase from an axial load provided by the compression plate against the radial flange, a seal seat including sockets that receive each finger; a space extending between a portion of an outer diameter of each finger and a flared inner diameter of the socket of the seal seat, and a seal ring extending circumferentially around an outer diameter of each finger and tangent to the flange, the seal ring contacting the flared inner diameter of the seal seat and closing the space to the ingress of well fluid.

Abstract: A torque transmitting coupling for an electric submersible pump equipment string. A torque transmitting coupling system includes a first adapter including a first inner diameter mated to a first shaft rotatable about a first axis of rotation, and a first splined outer diameter mated to a splined coupling inner surface, a second adapter including a second inner diameter mated to a second shaft rotatable about a second axis of rotation, and a second splined outer diameter mated to the splined coupling inner surface, the first and second splined outer diameter at least partially spherical such that when the first axis of rotation moves with respect to the second axis of rotation, at least one of the splined outer diameters rock along the coupling inner surface.

Abstract: An electric submersible motor radial support bearing is described. An electric submersible motor includes a motor shaft extending longitudinally through a stator bore, the motor shaft bendable out of alignment with a longitudinal axis of the stator bore, a carrier keyed the stator bore, each rotor section of the motor separated from an adjacent rotor section by a roller bearing including a rounded roller cage between a rotatable inner race and a non-rotatable outer race, the inner race inward of the roller cage and rotatably secured to the motor shaft, the outer race having a curved inner diameter (ID) forming a roller cage socket, an outer diameter (OD) of the outer race non-rotatably secured to an ID of the carrier, the roller cage and outer race forming a spheroidal joint as the roller cage pivots off the longitudinal axis of the stator bore as the motor shaft bends.

Abstract: A gas resistant pothead system and method for electric submersible motors. A gas resistant pothead system includes a lead foil wrapped motor lead cable (MLE) extending through a pothead, a sleeve of an insulator block inside the pothead, the sleeve including gold plating and lead-foil wrapping over the gold plating, and a lead-to-gold seal formed between the gold plating of the sleeve and the lead foil wrapping over the gold plating. A method of creating a seal to gas around a power cable connection to a downhole electric submersible motor includes wrapping lead foil around a MLE extending through a pothead, continuing the lead foil wrapping around a gold-plated sleeve of an insulating block inside the pothead, mechanically reinforcing the lead foil with an encapsulant, and bonding the lead foil to the gold plating of the insulating block.

Abstract: Systems and methods for providing seals around the motor leads and other conductors in ESP's. In one embodiment, elastomeric boot seals are positioned within annular spaces around motor leads in an ESP motor. When the motor is filled with dielectric oil, the elastomeric material of the boot seals absorbs some of the oil and swells. High temperatures may also cause the material of the seals to expand. Retainers which are not subject to swelling are positioned around the boot seals, thereby preventing the boot seals from expanding away from the leads. The retainers thereby maintain the seal of the boot seals against the motor leads.