Abstract: An electric submersible pumping system includes a motor that is filled with motor lubricant fluid and a pump driven by the motor. The electric submersible pumping system further includes a fluid expansion module connected to the motor that is designed to accommodate the expansion and contraction of the motor lubricant fluid in the motor. The fluid expansion module preferably includes a piston seal housing in fluid communication with the motor and a bag seal housing in fluid communication with the piston seal housing. The fluid expansion module further includes at least one axially movable barrier in the piston seal housing and at least one expansible barrier in the bag seal housing. The axially movable barrier and the expansible barrier cooperate to permit the expansion of the motor lubricant fluid without contaminating the motor lubricant fluid with fluids or and solids from the wellbore.

Abstract: A high temperature connector for use in connecting a power cable to an electric motor includes an outer housing, an inner housing inside the outer housing and a cable conductor disposed through the inner housing. To maintain a seal around the cable conductor during thermal expansion and contraction, the connector includes at least one spring-energized seal disposed around the cable conductor. The spring-energized seal permits the expansion and contraction of the cable conductor without deforming the cable conductor or the inner housing.

Abstract: A pump assembly for use within a high pressure pumping system includes housing, a head and a base. The housing contains at least one centrifugal pump stage. The head and base are attached to the housing with corresponding internal threaded connections. The head and base are further retained to the housing with corresponding external flanged connections. The external flanged connections provide redundant connections that reduce the risk of separation between the housing and the head and base.

Abstract: A vent box for venting gases present on a power cable used to provide power to an electric submersible pumping system includes a front, a back, a plurality of sides, a top and a bottom. The vent box includes one or more upper vents positioned along an upper edge of at least one of the front, the back or the plurality of sides. The vent box further includes one or more lower vents that extend through the bottom. The top includes a weather cap that extends downward from the top to partially conceal the one or more upper vents.

Abstract: A system and process for optimizing the performance and evaluating the risks of pumping systems includes the steps of measuring the operation and condition of components within a discrete electric submersible pumping system, accumulating these measurements across a field of electric submersible pumping systems, performing statistical analysis on the accumulated measurements and producing one or more selected outputs from the group statistical analysis. In the preferred embodiments, the statistical analysis and data processing occurs at both the individual pumping system and at one or more centralized locations.

Abstract: A pumping system frame assembly for use in supporting a horizontal pumping system on a platform includes a central body assembly, a motor plate connected to the central body assembly and a plurality of platform support assemblies connected to the central support member. The central body assembly includes a central support member that has an upper face and a pair of side rails connected to the upper face. In particularly preferred embodiments, each of the pair of side rails extends downward from the upper face at approximately a 45 degree angle.

Abstract: A motor assembly for use in a downhole submersible pumping system includes an electric motor and a motor protection bag. The motor protection bag surrounds a portion of the exterior surface of the motor to form an impermeable, corrosion-resistant barrier. The motor protection bag comprises a seamless, elongate cylindrical having a substantially constant inner diameter and open ends. The motor protection bag may be constructed from a suitable polymer, such as perfluoroalkoxy (PFA) fluoropolymer. The motor protection bag is held in place along the exterior surface of the motor with a plurality of clamps that prohibit the migration of fluid between the exterior of the motor and the motor protection bag.

Abstract: A suction chamber for use in a horizontal fluid pumping system is supported by a fixed vertical bracket, which is attached to a platform. The suction chamber is positioned between a motor and a pump in the horizontal pumping system. The pumping system may also include a thrust bearing chamber positioned between the motor and the suction chamber. The pumping system may also include a bearing chamber adapter positioned between the thrust bearing chamber and the suction chamber. The suction chamber has a suction chamber pump end and a suction chamber motor end. The suction chamber enables both motor-end seal removal and pump-end seal removal. In both motor end seal removal and pump end seal removal, the suction chamber of the invention remains connected to the vertical bracket. The pumping system may also include an integrated lifting device connected to the vertical bracket to lift the thrust bearing assembly.

Abstract: An electric submersible pumping system has an electric motor, a pump assembly driven by the electric motor and a sensor module. The sensor module preferably includes a detachable sensor array that can be selectively released from the sensor module. In preferred embodiments, the detachable sensor array includes a self-propelled sensor array vehicle that has a drive motor, a drive mechanism driven by the drive motor and a sensor array. The detachable sensor array provides a wellbore condition signal that can be used to automatically adjust the performance of the electric submersible pumping system.

Abstract: A mechanical seal has a stationary face and rotating assembly adjacent to the stationary face. The rotating assembly includes an upper bellows ring, a lower bellows ring and a runner between the lower bellows ring and the stationary face. A bellows extends between the upper bellows ring and the lower bellows ring. In preferred embodiments, the bellows is constructed from a perfluoroalkoxy polymer and is secured within the upper bellows ring and the lower bellows ring by a selected locking mechanism. The locking mechanism may include the use of crimp rings configured for a press fit engagement within the upper and lower bellows rings. Alternatively, the locking mechanism may employ locking rings configured for threaded engagement with the upper and lower bellows rings.

Abstract: A gas separator is configured to separate gas from a two-phase fluid. The gas separator includes a rotatable shaft and one or more separation stages. At least one of the one or more separation stages includes a rotor connected to the rotatable shaft and a channeled compression tube, wherein the channeled compression tube includes a compression tube hub and a plurality of channels. The channels are configured to isolate abrasive solid particles from the rotary components within the gas separator. The gas separator may optionally include a streamer upstream from the separation stage that reduces rotational currents upstream from the rotor.

Abstract: An independent power system provides electrical power to an electric submersible pumping system positioned in a well that produces petroleum products. The independent power system includes a generator and an engine connected to the generator. The engine is preferably provided with combustible gases from the petroleum products of the well. The independent power system further includes an integrated control system that is connected to the electric submersible pumping system and the generator. The independent power system is configured to balance the loads created by the electric submersible pumping system with the output from the electrical generator.

Abstract: A pumping system includes a hydraulic motor assembly configured to drive a production pump. The hydraulic motor assembly includes a master pump located on the surface and an electric motor configured to controllably power the master pump. When moved by the electric motor, the master pump discharges a working fluid under pressure. The pressurized working fluid is transferred to a hydraulic turbine located in the wellbore. The hydraulic turbine converts the pressure of the working fluid into torque, which is transferred through a driveline to a production pump. The production pump pressurizes production fluids, which are carried under pressure to the surface.

Abstract: A centrifugal pump has a gas accumulation reduction system to reduce the risk of gas locking caused by the accumulation of gas at the inlet of the impeller. The gas accumulation reduction system includes: (i) one or more diffuser ports extending through the hub of a diffuser; and (ii) one or more recirculation passages extending through the hub of an impeller. The recirculation passages are in fluid communication with the one or more diffuser ports to permit the recirculation of a portion of pumped fluid through the stage. Additionally, a centrifugal pump that includes at least one turbomachinery stage. The stage includes a rotatable impeller that has an impeller hub with a centrally disposed eye and a plurality of impeller vanes. The impeller is variously configured to encourage mixing of two-phase fluids at the eye of the impeller hub.

Abstract: A method for identifying the location of a binding zone between a stuck tubular and a borehole includes the steps of passing a demagnetizing stress sensor through the tubular on a baseline magnetization pass to magnetize the tubular. Next, the demagnetizing stress sensor measures a baseline magnetization of the tubular. Once the baseline magnetization has been established, the method continues by applying a stress to the tubular and passing the demagnetizing stress sensor through the tubular on a scanning pass while the tubular is stressed. The demagnetizing stress sensor then measures a stress-induced magnetization of the tubular. The method concludes by comparing the baseline magnetization of the tubular against the stress-induced magnetization of the tubular. Notably, in preferred embodiments, the method includes the magnetization of the tubular in a substantially radial direction and the stresses are applied in vectors perpendicular to the radial magnetization of the tubular.

Abstract: A downhole submersible pumping system includes an adapter for use in connecting a first component to a second component within the downhole pumping system. The adapter preferably includes an upstream section configured for connection to the first component and a downstream section configured for connection to the second component. The adapter further includes an articulating joint that permits the angular movement of the first component with respect to the second component.

Abstract: An electrical submersible pumping system includes a pump assembly and a motor assembly. The motor assembly includes a plurality of stator coils and each of the plurality of stator coils comprises magnet wire. The magnet wire includes an inner insulation layer and an outer protective layer. The inner insulation layer is preferably constructed from a high-temperature, epitaxial co-crystallized perfluoropolymer that exhibits favorable resistance to elevated temperatures. The outer protective layer shields the inner insulation layer from mechanical abrasion and contaminants.

Abstract: An electric motor assembly configured for use in a downhole pumping system includes a number of electrically conductive components that are insulated from fluids, mechanical abrasion, electrical current and electrical grounds using an advanced polyimide film. Preferred polyimide films include poly(4,4?-oxydiphenylene-pyromellitimide) and biphenyl-tetracarboxylic acid dianhydride (BPDA) type polyimide films. Magnet wire, stator laminates, stator coil end turns, motor leads and power cables can all be insulated with the selected polyimide film.

Abstract: A method for applying a metalized polymer film to a seal bag for use in a downhole submersible pumping system includes the steps of applying a metal layer to a polymer layer, applying an adhesive layer to the polymer layer, and rolling the adhesive layer onto a substrate of the seal bag. The method may also include the steps of rotating a first roller, which is located above the polymer layer of the metalized polymer film, and rotating a second roller, which is located on an interior surface of the substrate of the seal bag, in the opposite direction of the first roller. Also disclosed is a downhole pumping system that incorporates a seal bag manufactured from these techniques.

Abstract: A mechanical seal has a stationary face and rotating assembly adjacent to the stationary face. The rotating assembly includes an upper bellows ring, a lower bellows ring and a runner between the lower bellows ring and the stationary face. A bellows extends between the upper bellows ring and the lower bellows ring. In preferred embodiments, the bellows is constructed from a perfluoroalkoxy polymer and is secured within the upper bellows ring and the lower bellows ring by a selected locking mechanism. The locking mechanism may include the use of crimp rings configured for a press fit engagement within the upper and lower bellows rings. Alternatively, the locking mechanism may employ locking rings configured for threaded engagement with the upper and lower bellows rings.