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.

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 submersible well pump assembly has a pump and an electrical motor for driving the pump. The motor has an electrical receptacle with a base and a central bore containing a plurality of motor electrical terminals. An annular groove in the base encircles the central bore and has a closed bottom. A motor lead extends to the motor for supplying power to the motor. An electrical connector on an end of the motor lead has a rim that inserts into the groove. Either the forward edge of the rim or the bottom of the groove is conical, defining an annular void within the groove that is triangular in cross section when the rim is fully inserted into the groove. A seal ring is located in the void of the groove and is deformed by the forward edge of the rim into sealing engagement.

Abstract: Systems and methods for maintaining a desired compressive force on seals in an electrical junction such as a pothead connector for an ESP motor. In one embodiment, insulated conductors of a power cable extend into a housing of a connector. The insulated conductors pass through an upper insulator, a set of elastomeric boot seals, and a lower insulator. O-rings are positioned between the upper insulator and the housing of the pothead connector. The lower insulator is secured to the upper insulator by a set of bolts and springs that urge the lower insulator toward the upper insulator, compressing the boot seals. The bolts are threaded into the upper insulator and are tightened to compress the springs against the lower insulator. The compression of the boot seals between the insulators maintains a desired range of contact pressure against the seals despite changes in the seal dimensions.

Abstract: Systems and methods for electrically connecting conductors of a downhole electric system using connector bodies that includes an outer housing, one or more inner conductors and an inorganic insulating material such as a glass-ceramic material which forms a fluid-tight seal between the outer housing and the inner conductor. The insulating material may be bonded to the outer housing and to the inner conductor. The insulating material may alternatively have an interference fit with the outer housing and the inner conductor. The connector bodies may have standardized connector interfaces to facilitate connection to complementary standardized connector interfaces on cable-end connectors, etc. Connector bodies may be formed as motor heads, mandrels for cable splices, penetrators, etc.

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: A submersible well pump assembly has a pump and an electrical motor for driving the pump. The motor has an electrical receptacle with a base and a central bore containing a plurality of motor electrical terminals. An annular groove in the base encircles the central bore and has a closed bottom. A motor lead extends to the motor for supplying power to the motor. An electrical connector on an end of the motor lead has a rim that inserts into the groove. Either the forward edge of the rim or the bottom of the groove is conical, defining an annular void within the groove that is triangular in cross section when the rim is fully inserted into the groove. A seal ring is located in the void of the groove and is deformed by the forward edge of the rim into sealing engagement.

Abstract: Systems and methods for maintaining a desired compressive force on seals in an electrical junction such as a pothead connector for an ESP motor. In one embodiment, insulated conductors of a power cable extend into a housing of a connector. The insulated conductors pass through an upper insulator, a set of elastomeric boot seals, and a lower insulator. O-rings are positioned between the upper insulator and the housing of the pothead connector. The lower insulator is secured to the upper insulator by a set of bolts and springs that urge the lower insulator toward the upper insulator, compressing the boot seals. The bolts are threaded into the upper insulator and are tightened to compress the springs against the lower insulator. The compression of the boot seals between the insulators maintains a desired range of contact pressure against the seals despite changes in the seal dimensions.

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.

Abstract: Isolated pressure compensating electrical motor connections and related methods are provided. According to an example of a sealed motor electrical connection, the connection incorporates a sealed female motor connection positioned to receive a male motor connector. The female motor connector has one or more independent dielectric oil chambers each pressure compensated by a bellow or similar device interfaced with the motorhead oil and/or well annulus fluid to thereby pressure compensate the chamber pressure of the female motor connection with that of the internal motor and/or well annulus. This configuration locates the electrical connection point of the motor lead extension with the motor lead wires to a separate area outside the motor to thereby prevent the occurrence of phase to phase or phase to ground shorts occurring in this critical area due to conductive element contamination that may reside in the motor oil or the well bore fluids.

Abstract: Systems and methods for electrically connecting conductors of a downhole electric system using connector bodies that includes an outer housing, one or more inner conductors and an inorganic insulating material such as a glass-ceramic material which forms a fluid-tight seal between the outer housing and the inner conductor. The insulating material may be bonded to the outer housing and to the inner conductor. The insulating material may alternatively have an interference fit with the outer housing and the inner conductor. The connector bodies may have standardized connector interfaces to facilitate connection to complementary standardized connector interfaces on cable-end connectors, etc. Connector bodies may be formed as motor heads, mandrels for cable splices, penetrators, etc.

Abstract: Electric submersible well pumping systems operable in well temperatures of above about 180° C. (356° F.) utilize high temperature electrical insulation. The electrical insulation includes E-base polyimide films or perfluoropolymer TE films on various components. The insulation films are employed around magnet wires that are threaded through slots in the stator. Slot insulation of E-base polyimide or perfluoropolymer TE film surrounds the magnet wires in the stator slots. Sheets of E-base polyimide or perfluoropolymer TE film extend around and between phase loops of the magnet wire at the lower end of the stator. The motor contains a PAO oil having additives to dissipate acid generated by epoxy used in the motor.

Abstract: Systems and methods for providing power to downhole equipment, where an electrical penetrator is installed through the housing of the equipment to provide a high pressure seal between the interior and exterior of the equipment's housing. In one embodiment, the body of the electrical penetrator includes a substantially rigid outer body, an electrically insulating inner body positioned within the outer body, and a set of electrical conductors that extend through the electrically insulating (e.g., glass or ceramic) inner body. Each of the conductors extends through the penetrator body. The inner body is sealed against both the conductors and the outer body by bonding them together, for example. The ends of the conductors which extend into the housing are connected to the motor or other equipment, while the ends of the conductors which to the exterior of the housing are connected to a power cable.

Abstract: Electric submersible well pumping systems operable in well temperatures of above about 180° C. (356° F.) utilize high temperature electrical insulation. The electrical insulation includes E-base polyimide films or perfluoropolymer TE films on various components. The insulation films are employed around magnet wires that are threaded through slots in the stator. Slot insulation of E-base polyimide or perfluoropolymer TE film surrounds the magnet wires in the stator slots. Sheets of E-base polyimide or perfluoropolymer TE film extend around and between phase loops of the magnet wire at the lower end of the stator. The motor contains a PAO oil having additives to dissipate acid generated by epoxy used in the motor.

Abstract: Systems and methods for cooling a pothead connector that couples a power cable to the motor of an ESP system, wherein a heat dissipation structure is provided on the connector to increase the transfer of heat from the connector to the surrounding well fluid. In one embodiment, the connector has a housing through which conductors from the power cable extend to a set of terminals which are configured to mate with complementary terminals of the motor. Heat dissipation structures such as fins are provided on the connector housing to facilitate the transfer of heat from the connector to the surrounding well fluid. Baffles or flow diverters may be positioned near the fins to cause turbulence or increased fluid flow near the fins, thereby increasing the heat transfer and improving the cooling of the pothead connector.

Abstract: Apparatus of components and methods for connecting and sealing a pothead to an electrical cable used in an oil well environment, are provided. Electrical leads are anchored in insulating members retained within the pothead. The leads inserted into passages formed through the insulating members each having an elliptically shaped portion. Channels are formed along the surface of the passages and along the circumference of the elliptically shaped portions. Boot seals are provided in the elliptically shaped portions and circumscribe the electrical leads. A hydrocarbon-based liquid is applied to the boot seals to cause them to swell and occupy the space between the leads and the insulators, including the channels.

Abstract: A connector for connecting electrical power to a well pump motor has cable and motor connector portions that mate with each other in a connected position. The connector portions have insulating members, each of which has a number of passages and an end face. Electrical contact members are mounted in each of the passages. Contact members in the cable connector portion protrude past the end face of the insulating member. A debris seal insulates the electrical contact members in the cable connector and includes expansion slots so that when the material of the debris seal thermally expands, the expansion slots contract in response to the expansion without the debris seal impinging against either connector.

Abstract: An electrical power assembly comprises a motor lead with individual metal sheathed conductors, a power cable with individual metal sheathed conductors and a splice connector for connecting each of the conductors. Each splice connector has a tubular metal fastener body with an upward facing shoulder at an upper end and a downward facing shoulder at a lower end. A metal nut assembly is fixed to one of the power cable conductors with a downward facing shoulder in metal-to-metal sealing engagement with the upward facing shoulder of the fastener body. A metal coupler fixed to one of the motor lead conductors with an upward facing shoulder in metal-to-metal sealing engagement with the downward facing shoulder of the fastener body. Contacts electrically connect one of the motor lead conductors to one of the power cable conductors within the fastener body.

Abstract: An electrical power assembly comprises a motor lead with individual metal sheathed conductors, a power cable with individual metal sheathed conductors and a splice connector for connecting each of the conductors. Each splice connector has a tubular metal fastener body with an upward facing shoulder at an upper end and a downward facing shoulder at a lower end. A metal nut assembly is fixed to one of the power cable conductors with a downward facing shoulder in metal-to-metal sealing engagement with the upward facing shoulder of the fastener body. A metal coupler fixed to one of the motor lead conductors with an upward facing shoulder in metal-to-metal sealing engagement with the downward facing shoulder of the fastener body. Contacts electrically connect one of the motor lead conductors to one of the power cable conductors within the fastener body.