Abstract: A system and method for enhanced magnet wire insulation is described. The method comprises a sequence of operations to create an enhanced magnet wire insulation suitable for use in temperatures of about 550° Fahrenheit. A magnet copper wire is wrapped with a polyimide wrap and subsequently wrapped with an organic polymer thermoplastic (e.g., PEEK). The polyimide wrap is applied while the magnet copper wire is around a spool to create a wrapped magnet wire. The wrapped magnet wire can be heated using an induction coil in a metal tube bolted to an extruder to remove moisture and to enable adding the layer of organic polymer thermoplastic. The metal tube can be held at a partial vacuum to augment moisture removal of the wrapped magnet wire prior to running the wrapped magnet wire through the extruder which adds the organic polymer thermoplastic layer. This method produces an enhanced magnet wire suitable for a wide range of temperatures.

Abstract: An apparatus and system for a thrust-absorbing horizontal surface pump assembly. A thrust-absorbing horizontal surface pump system includes an intake chamber including a stationary thrust bearing paired with a rotatable thrust runner to form a thrust bearing set, wherein a first face of the stationary thrust bearing positioned towards the rotatable thrust runner is at least partially diamond-coated, and wherein a second face of the rotatable thrust runner positioned towards the stationary thrust bearing is at least partially diamond-coated, a fluid entrance that receives fluid into the intake chamber, and a pump inlet that receives the fluid into the multi-stage centrifugal pump, wherein the thrust bearing set is arranged around the intake shaft such that during operation of the electric motor the thrust bearing is in a pathway of the fluid as the fluid flows between the fluid entrance and the pump inlet.

Abstract: A system and method for enhanced magnet wire insulation is described. A method of making an enhanced magnet wire insulation suited for an electric submersible motor application includes drawing copper magnet wire to size, cleaning the copper magnet wire, pulling the copper magnet wire through a polyimide wrap machine to produce wrapped copper magnet wire and placing the wrapped copper magnet wire around a spool, heating the wrapped magnet wire by unspooling the wrapped magnet wire through a tube comprising an induction coil, removing moisture from the heated, wrapped copper magnet wire by creating at least a partial vacuum inside the tube, redrawing the wrapped copper magnet wire through an extrusion mold after moisture is removed, applying molten PEEK to the wrapped copper magnet wire to produce enhanced magnet wire, and winding the enhanced magnet wire into an induction motor to be used to operate an electric submersible pump.

Abstract: A system and method for enhanced magnet wire insulation is described. The system of the invention provides an enhanced insulation for magnet wire that is capable of withstanding high temperatures and provides a seal against water that is needed in electric submersible pump (ESP) applications. The enhanced insulation of the system of the invention provides the dielectric advantages of polyimide tape, such as Kapton tape, while also including the advantages of organic polymer thermoplastic insulation that prevents the delaminating at high temperatures that may occur in pumping applications using a variety of electrical submersible motors.

Abstract: An apparatus and system for a thrust-absorbing horizontal surface pump assembly is described. A thrust-absorbing horizontal surface pump system includes an intake chamber including a stationary thrust bearing paired with a rotatable thrust runner to form a thrust bearing set, wherein a first face of the stationary thrust bearing positioned towards the rotatable thrust runner is at least partially diamond-coated, and wherein a second face of the rotatable thrust runner positioned towards the stationary thrust bearing is at least partially diamond-coated, a fluid entrance that receives a fluid into the intake chamber, and a pump inlet that receives the fluid into the multi-stage centrifugal pump, wherein the thrust bearing set is arranged around the intake shaft such that during operation of the electric motor the thrust bearing is in a pathway of the fluid as the fluid flows between the fluid entrance and the pump inlet.

Abstract: An apparatus and system for a thrust-absorbing horizontal surface pump assembly is described. A thrust-absorbing horizontal surface pump system includes an intake chamber including a stationary thrust bearing paired with a rotatable thrust runner to form a thrust bearing set, wherein a first face of the stationary thrust bearing positioned towards the rotatable thrust runner is at least partially diamond-coated, and wherein a second face of the rotatable thrust runner positioned towards the stationary thrust bearing is at least partially diamond-coated, a fluid entrance that receives a fluid into the intake chamber, and a pump inlet that receives the fluid into the multi-stage centrifugal pump, wherein the thrust bearing set is arranged around the intake shaft such that during operation of the electric motor the thrust bearing is in a pathway of the fluid as the fluid flows between the fluid entrance and the pump inlet.

Abstract: An apparatus, system and method for sealing an electrical submersible pump assembly are described. An electric submersible pump (ESP) system for pumping solid-laden fluid comprises a thrust chamber of an ESP seal section, the thrust chamber sealed from well fluid on a downstream side by a stationary sand barrier and on an upstream side by a mechanical seal, the thrust chamber further comprising, a rotatable shaft extending axially through the thrust chamber, a head tubularly encasing the thrust chamber and threadedly coupled to a centrifugal pump intake, and a diamond-coated hydrodynamic bearing set inside the thrust chamber, wherein well fluid enters and exits the chamber through cross-drilled apertures in the head of the chamber, and wherein the well fluid forms a hydrodynamic film between the bearing set.

Abstract: An apparatus and system for a thrust-absorbing horizontal surface pump assembly is described. A thrust-absorbing horizontal surface pump system includes an intake chamber including a stationary thrust bearing paired with a rotatable thrust runner to form a thrust bearing set, wherein a first face of the stationary thrust bearing positioned towards the rotatable thrust runner is at least partially diamond-coated, and wherein a second face of the rotatable thrust runner positioned towards the stationary thrust bearing is at least partially diamond-coated, a fluid entrance that receives a fluid into the intake chamber, and a pump inlet that receives the fluid into the multi-stage centrifugal pump, wherein the thrust bearing set is arranged around the intake shaft such that during operation of the electric motor the thrust bearing is in a pathway of the fluid as the fluid flows between the fluid entrance and the pump inlet.

Abstract: An apparatus, system and method for sealing an electrical submersible pump assembly are described. An electric submersible pump (ESP) system for pumping solid-laden fluid comprises a thrust chamber of an ESP seal section, the thrust chamber sealed from well fluid on a downstream side by a stationary sand barrier and on an upstream side by a mechanical seal, the thrust chamber further comprising, a rotatable shaft extending axially through the thrust chamber, a head tubularly encasing the thrust chamber and threadedly coupled to a centrifugal pump intake, and a diamond-coated hydrodynamic bearing set inside the thrust chamber, wherein well fluid enters and exits the chamber through cross-drilled apertures in the head of the chamber, and wherein the well fluid forms a hydrodynamic film between the bearing set.

Abstract: An apparatus, system and method for sealing an electrical submersible pump assembly are described. An electric submersible pump (ESP) system for pumping solid-laden fluid comprises a thrust chamber of an ESP seal section, the thrust chamber sealed from well fluid on a downstream side by a stationary sand barrier and on an upstream side by a mechanical seal, the thrust chamber further comprising, a rotatable shaft extending axially through the thrust chamber, a head tubularly encasing the thrust chamber and threadedly coupled to a centrifugal pump intake, and a diamond-coated hydrodynamic bearing set inside the thrust chamber, wherein well fluid enters and exits the chamber through cross-drilled apertures in the head of the chamber, and wherein the well fluid forms a hydrodynamic film between the bearing set.

Abstract: An apparatus, system and method for sealing an electrical submersible pump assembly are described. An electric submersible pump (ESP) system for pumping solid-laden fluid comprises a thrust chamber of an ESP seal section, the thrust chamber sealed from well fluid on a downstream side by a stationary sand barrier and on an upstream side by a mechanical seal, the thrust chamber further comprising, a rotatable shaft extending axially through the thrust chamber, a head tubularly encasing the thrust chamber and threadedly coupled to a centrifugal pump intake, and a diamond-coated hydrodynamic bearing set inside the thrust chamber, wherein well fluid enters and exits the chamber through cross-drilled apertures in the head of the chamber, and wherein the well fluid forms a hydrodynamic film between the bearing set.

Abstract: A system and method for enhanced magnet wire insulation is described. The system of the invention provides an enhanced insulation for magnet wire that is capable of withstanding high temperatures and provides a seal against water that is needed in electric submersible pump (ESP) applications. The enhanced insulation of the system of the invention provides the dielectric advantages of polyimide tape, such as Kapton tape, while also including the advantages of organic polymer thermoplastic insulation that prevents the delaminating at high temperatures that may occur in pumping applications using a variety of electrical submersible motors.

Abstract: Applicants have discovered new composite materials and have developed a variety of new ways of making reactive composite materials (RCMs) and methods of controlling the properties and characteristics of the materials that are pertinent to numerous new or improved applications. This patent application is directed to new and improved ways of making reactive composite materials using mechanical deformation and making such materials with controlled, predictable characteristics. This application is also directed toward useful applications of the resulting materials. In accordance with the invention, RCMs are fabricated by a series of mechanical deformation steps. In the first deformation step, an assembly of reactive layers and/or particles is plastically deformed to reduce its cross sectional area by one-half or more. This severe initial deformation substantially eliminates the tendency of deformed layers to delaminate and eliminates the necessity of using specially cleaned metal layers.

Abstract: Novel reactive composite materials and associated methods for making the same which are pertinent to numerous new or improved applications. The method for making the reactive composite materials utilizes mechanical deformation to manufacture such materials with controlled, predictable characteristics. In the first deformation step, an assembly of reactive layers and/or particles is plastically deformed to reduce its cross sectional area by one-half or more. Portions of the deformed sheets are stacked or bent into a new assembly, and the new assembly is then deformed. The steps of assembly and deformation are repeated a sufficient number of times that the resulting materials are only locally layered but have relatively uniform reaction velocity and heat generating characteristics predictable by stochastic models derived herein.

Abstract: A device and method for emitting electromagnetic radiation utilizing a reactive composite material (RCM) as an emission source. By selective modification of the reactive composite material (RCM), attributes of the emitting device, including the ability to produce specific radiation intensity levels at specific electromagnetic wavelengths, the ability to emit for a specific duration, the avoidance of dangerous reaction products, portability, geometric design flexibility, and simple, safe storage may be selected.

Abstract: A method for bonding components with a reactive multilayer foil, wherein during bonding, the components are held at a temperature or temperature gradient chosen to reduce thermal stress in the resulting bonded product.