Extra Low Profile Cable Protectors

Abstract

A pumping system useful for pumping fluids from a subterranean formation to a surface facility includes a first component and a second component connected to the first component with a neck flange. The pumping system further includes a motor lead cable that provides electrical power from the surface facility to the pumping system and a cable protector connected to the neck flange that secures the motor lead cable to the first and second components. The cable protector includes a first clamp section and a second clamp section. The second clamp section includes a lead cable recess that extends in a longitudinal direction along the exterior of the second clamp section and a band recess that extends in a circumferential direction along the exterior of the second clamp section. A tie or band resides in the band recess and extends around the circumference of the cable protector to secure the motor lead cable within the lead cable recess.

Description

FIELD OF THE INVENTION

This invention relates generally to the field of submersible pumping systems, and more particularly, but not by way of limitation, to a mechanism for securing a motor lead cable to the pumping system.

BACKGROUND

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.

Power is supplied to the electric motor from surface facilities through a power cable. In many applications, a motor lead cable is used to connect the terminal end of the power cable to the electric motor. The motor lead cable typically includes an armored exterior that prevents damage from contact with the wellbore or components within the pumping system. The motor lead cable may include flattened profiled that fits within the limited space between the larger components of pumping system and the wellbore.

In the past, the motor lead cable has been secured to the exterior surface of the pumping system with bands or ties. Placing the motor lead cable in an exposed position along the exterior of the pumping system may cause damage to the motor lead cable in the event the pumping system rubs against the wellbore during installation, removal or during operation. Accordingly, there is a need for an improved mechanism for securing the motor lead cable to the pumping system. It is to this and other deficiencies in the prior art that the preferred embodiments are directed.

SUMMARY OF THE INVENTION

In preferred embodiments, the present invention includes a pumping system useful for pumping fluids from a subterranean formation to a surface facility. The pumping system includes a first component and a second component connected to the first component with a neck flange. The pumping system further includes a motor lead cable that provides electrical power from the surface facility to the pumping system and a cable protector connected to the neck flange that secures the motor lead cable to the first and second components. The cable protector includes a first clamp section and a second clamp section. The second clamp section includes a lead cable recess that extends in a longitudinal direction along the exterior of the second clamp section and a band recess that extends in a circumferential direction along the exterior of the second clamp section. A tie or band resides in the band recess and extends around the circumference of the cable protector to secure the motor lead cable within the lead cable recess.

In another aspect, the preferred embodiments of the present invention provide a cable protector for use in securing a cable to a pumping system. The cable protector includes a first clamp section and a second clamp section. The second clamp section further includes a lead cable recess that extends in a longitudinal direction along the exterior of the second clamp section and a band recess that extends in a circumferential direction along the exterior of the second clamp section.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a submersible pumping system constructed in accordance with a preferred embodiment of the present invention.

FIG. 2 provides a perspective view of the motor lead cable connected to the motor with a cable protector constructed in accordance with a preferred embodiment.

FIG. 3 provides a perspective view of the cable protector of FIG. 2.

FIG. 4 provides an end view of the cable protector of FIG. 2.

FIG. 5 provides a side view of the cable protector of FIG. 2.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In accordance with a first preferred embodiment of the present invention, 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. 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 a series of interconnected components that collectively produce fluids from the wellbore 104. The various components within the pumping system 100 may be connected by a neck flange 106 that has a smaller external diameter than the adjacent components. In preferred embodiments, the components include a pump 108, a motor 110 and a seal section 112. The production tubing 102 connects the pumping system 100 to surface facilities. Although 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.

Generally, the motor 110 is configured to drive the pump 108. In a particularly preferred embodiment, the pump 108 is a turbomachine that uses one or more impellers and diffusers to convert mechanical energy into pressure head. In alternate embodiments, 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 motor 110 receives power from a surface-based facility through power cable 114 and motor lead cable 116. In a particularly preferred embodiment the motor lead cable 116 extends from the motor 110 to a point adjacent the production tubing 102. The pumping system 100 further includes one or more cable protectors 118 that secure the motor lead cable 118 to the pumping system 100. Although not visible in FIG. 1, the pumping system 100 may further include one or more auxiliary lines 120 that provide a basis for telemetry between the pumping system 100 and surface-mounted facilities, for chemical injection near the pumping system 100 or for other purposes.

It will be noted that although 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.

Turning to FIG. 2, shown therein is a perspective view of cable protector 118 holding the motor lead cable 116 and auxiliary lines 120 adjacent to the motor 110 and seal section 112. It will be noted that the motor lead cable 116 and auxiliary lines 120 are depicted in a pre-installation condition in which the leads of the motor lead cable 116 and auxiliary lines 120 have not yet been connected to the appropriate terminals on the motor 110. As noted in FIG. 2, the cable protector 118 is configured to be installed around the neck flange 106 between the motor 110 and seal section 112. In this way, the outer diameter of the cable protector 118 is approximately the same size as the outer diameter of the motor 110 and seal section 112.

Turning to FIGS. 3-5, shown therein are perspective, end and side views, respectively, of a presently preferred embodiment of the cable protector 118. The cable protector 118 generally includes a first clamp section 122 and a second clamp section 124 connected by a hinge 126. The hinge 126 includes a pin 128 (not visible in FIG. 3) that permits the first clamp section 122 and second clamp section 124 to open and close about the hinge 126. In the preferred embodiment depicted in FIGS. 3-5, the closure of the first clamp section 122 and second clamp section 124 creates a substantially cylindrical interior surface 130. The interior surface 130 is sized to be placed around a neck flange 106 between two adjacent components within the pumping system 100. For the purposes of this disclosure, the cable protector 118 will be understood to have a longitudinal axis that extends through the center of the cable protector 118 and along the length of the pumping system 100.

The first clamp section 122 preferably includes a latch projection 132 that includes a bolt hole 134 and bolt recess 136. The second clamp 124 preferably includes a latch recess 138 and threaded bore 140. The latch recess 138 is configured to accept the latch projection 132 in a manner that creates an alignment between the bolt hole 134 and threaded bore 140 when the first and second clamp sections 122, 124 are approximated (as best depicted in FIG. 5). A threaded fastener 142 (shown in FIG. 5) can be used to secure the first clamp section 122 to the second clamp section 124 in the closed position. As noted in FIGS. 3 and 4, the bolt recess 136 allows the threaded fastener 142 to be concealed within the first clamp section 122 when threaded into the second clamp section 124 such that the threaded fastener 142 does not extend to the outer diameter of the cable protector 118.

The second clamp section 124 includes an anti-rotation tab 144 that extends in the direction of the longitudinal axis of the cable protector 118 and is designed to fit between screw heads on adjacent neck flanges 106 to prevent the rotation of the cable protector 118. The second clamp section 124 further includes an upper body 146. The upper body 146 is preferably wider than the lower portions of the first and second clamp sections 122, 124. In a first preferred embodiment, the upper body 146 includes a lead cable recess 148 that extends longitudinally across the exterior of the upper body 146 and is sized and configured to accept a portion of the motor lead cable 116. The upper body 146 may also include auxiliary line recesses 150 that also extend longitudinally along the exterior of the upper body 146. The auxiliary line recess 150 is sized and configured to accept a portion of the auxiliary lines 120. To protect the auxiliary lines 120 and motor lead cable 116, the upper body 146 further includes bumpers 152 that extend above the lead cable recess 148 and auxiliary line recess 150. The bumpers 152 prevent the motor lead cable 116 and auxiliary lines 120 from contacting the wellbore 104 during installation, removal or operation of the pumping system 100.

As best depicted in FIGS. 2, 3 and 5, the cable protector 118 also includes a band recess 154 that extends circumferentially around the exterior of the first and second clamp sections 122, 124 and is configured to accept a tie or band 156 (shown in partial cutaway in FIG. 5). The band 156 secures the motor lead cable 116 and auxiliary lines 120 within the lead cable recess 148 and auxiliary line recess 150, respectively. The band recess 154 conceals the band 156 from contact with external objects. The cable protector 118 may also include a fastener recess 158 (shown in FIG. 4) within the band recess 154 of the first clamp section 122. The fastener recess 158 provides a void in which a band fastener 160 can be concealed. Suitable band fasteners 160 include buckles, worm-gear closures and Oetiker clasps.

Thus, the band recess 154 extends circumferentially around the exterior of the cable protector 118 and intersects the lead cable recess 148 and auxiliary line recess 150 in an orthogonal relationship. The lead cable recess 148 and auxiliary line recess 150 are preferably sized so that the motor lead cable 118 and auxiliary lines 120 are each captured within the corresponding recess below the intersecting band recess 154. Because the band 156 holds the motor lead cable 116 and auxiliary lines 120 in corresponding recesses within the cable protector 118, the extent of compression applied by the band 156 is limited by the band recess 154. The moderation of the compression applied by the band 156 reduces the risk of damaging the motor lead cable 116 and auxiliary lines 120 with too much force applied by the band 156. In this way, the cable protector 118 provides a low profile and durable mechanism for holding the motor lead cable to the pumping system 100 that is easy to install.

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

1. A cable protector comprising:

a first clamp section; and

a second clamp section, wherein the second clamp section further comprises: a lead cable recess that extends in a longitudinal direction along the exterior of the second clamp section; and a band recess that extends in a circumferential direction along the exterior of the second clamp section.

2. The cable protector of claim 1, wherein the second clamp section further comprises an auxiliary line recess that extends in a longitudinal direction along the exterior of the second clamp section.

3. The cable protector of claim 1, wherein the band recess intersects the lead cable recess in an orthogonal manner.

4. The cable protector of claim 1, wherein the cable protector further comprises a hinge and wherein the first clamp section and second clamp section are each attached to the hinge.

5. The cable protector of claim 4, wherein the second clamp section comprises a latch recess and wherein the first clamp section comprises a latch projection that fits within the latch recess.

6. The cable protector of claim 1, further comprising a plurality of bumpers located along the exterior of the second clamp section adjacent the auxiliary line recess.

7. The cable protector of claim 1, further comprising a band that resides within the band recesses and extends around the circumference of the cable protector.

8. A pumping system for use in pumping fluids from a subterranean formation to a surface facility, the pumping system comprising:

a first component;

a second component connected to the first component, wherein the second component is connected to the first component with a neck flange;

a motor lead cable that provides electrical power from the surface facility to the pumping system; and

a cable protector connected to the neck flange, wherein the cable protector comprises: a first clamp section; and a second clamp section, wherein the second clamp section further comprises: a lead cable recess that extends in a longitudinal direction along the exterior of the second clamp section, wherein the motor lead cable is located within the lead cable recess; a band recess that extends in a circumferential direction along the exterior of the second clamp section; and a band that resides in the band recess and extends around the circumference of the cable protector to secure the motor lead cable within the lead cable recess.

9. The pumping system of claim 8, wherein the first component is a motor.

10. The pumping system of claim 9, wherein the second component is selected from the group consisting of motors, pumps and seal sections.

11. The pumping system of claim 8, further comprising auxiliary lines that extends from the surface facility to the pumping system.

12. The pumping system of claim 11, wherein the cable protector further comprises:

an auxiliary line recess that extends in a longitudinal direction along the exterior of the second clamp section; and

wherein the auxiliary lines resides within the auxiliary line recess.

13. The pumping system of claim 8, wherein the band recess intersects the lead cable recess in an orthogonal manner.

14. The pumping system of claim 8, wherein the cable protector further comprises a hinge and wherein the first clamp section and second clamp section are each attached to the hinge.

15. The pumping system of claim 14, wherein the cable protector of claim 4, wherein the second clamp section comprises a latch recess and wherein the first clamp section comprises a latch projection that fits within the latch recess.

16. The pumping system of claim 8, wherein the cable protector further comprises a plurality of bumpers located along the exterior of the second clamp section adjacent the auxiliary line recess.

17. A pumping system for use in pumping fluids from a subterranean formation to a surface facility, the pumping system comprising:

a first component;

a second component connected to the first component, wherein the second component is connected to the first component with a neck flange;

a third component connected to the second component, wherein the third component is connected to the second component with a neck flange;

a motor lead cable that provides electrical power from the surface facility to the pumping system; and

a first cable protector connected to the neck flange between the first and second components, wherein the first cable protector comprises: a first clamp section; and a second clamp section, wherein the second clamp section further comprises: a lead cable recess that extends in a longitudinal direction along the exterior of the second clamp section, wherein the motor lead cable is located within the lead cable recess; a band recess that extends in a circumferential direction along the exterior of the second clamp section; and a band that resides in the band recess and extends around the circumference of the cable protector to secure the motor lead cable within the lead cable recess; and

a second cable protector connected to the neck flange between the second and third components, wherein the second cable protector comprises: a first clamp section; and a second clamp section, wherein the second clamp section further comprises: a lead cable recess that extends in a longitudinal direction along the exterior of the second clamp section, wherein the motor lead cable is located within the lead cable recess; a band recess that extends in a circumferential direction along the exterior of the second clamp section; and a band that resides in the band recess and extends around the circumference of the cable protector to secure the motor lead cable within the lead cable recess.

18. The pumping system of claim 17, wherein the first component is selected from the group consisting of motors, pumps and seal sections.

19. The pumping system of claim 18, wherein the second component is selected from the group consisting of motors, pumps and seal sections.

20. The pumping system of claim 19, wherein the third component is selected from the group consisting of motors, pumps and seal sections.