Abstract: A gas separator having an improved flowpath for lighter fluids having a higher concentration of gas decreases total pumping head for an ESP assembly. The ESP assembly includes a rotary primary pump, a motor coupled to the primary pump for driving the pump, a seal assembly between the primary pump and the motor, and a gas separator between the seal assembly and the primary pump. An outlet of the gas separator feeds an intake of the primary pump, and a rotating shaft operationally couples the primary pump to the motor and passes through the seal assembly and the gas separator. The gas separator contains a venting portion, and a diverter positioned within the venting portion having diverter guide vanes formed in a flowpath of the lighter fluid for aiding in a directional change of fluid momentum. A slinger is positioned within the diverter for impelling fluid through the venting port.

Abstract: A method to separate a gas phase from a liquid phase in a subterranean formation that includes positioning a downhole tool in a wellbore, operating the downhole tool to form perforations in the subterranean formation in a manner that creates cyclonic motion in fluids that exit the subterranean formation and enter the wellbore through the perforations, the fluid having a gas phase and a liquid phase, and producing the liquid phase to the surface, whereby the liquid phase is substantially devoid of the gas phase as a result of the cyclonic motion.

Abstract: An electrical submersible pump (ESP) having a sleeve coupled to the shaft that rotates as the shaft rotates. The sleeve can be a base portion of a pump impeller, a journal bearing, or a bushing. A drive collar mounts around the shaft and has an end with a portion that projects past an end of the sleeve profiled to correspond with the shape of the projecting portion. As the shaft rotates the drive collar the projecting portion of the drive collar pushes against the profiled end of the sleeve to rotate the sleeve. The projecting portion can be a wedge shaped tab on the drive collar, or an angular segment of the drive collar extending axially past the remaining segments. The profiled end of the sleeve can include a recess formed to receive the tab and can have an angular segment corresponding to that on the drive collar.

Abstract: The present invention relates to a process for cooling an electrical submersible pump. More specifically, the invention relates to blocking a portion of wellbore fluid from entering a sump, thereby causing the pump to draw fluid from below the pump motor past the exterior of the pump motor toward a pump inlet.

Abstract: An electric submersible pump (ESP) torque absorbtion anchor system (TAS) and a method to assemble the same are disclosed. The TAS includes a collar having an uphole end coupled to a production string and a flange formed on an outer diameter of the collar. The TAS also includes a sleeve having a rim extending radially inward from an uphole end of the sleeve. The collar is positioned in a cavity of the sleeve so that oppositely facing shoulders of the collar and the sleeve contact and transfer axial loads between the sleeve and the collar. A spring is positioned in an annulus between the sleeve and the collar and mounts to the collar and the sleeve so that rotational loading of the sleeve relative to the collar transfers to the spring.

Abstract: A two-phase, homogenizing or mixing stage for a centrifugal pump assembly homogenizes the fluids being circulated therethrough. The mixing stage produces high shut-in head pressure and a very high maximum flow rate. The mixing stage has a diffuser with fixed diffuser vanes that extend radially or tangentially at acute angles. The vanes may be curved in both the axial and radial directions to force fluids impinging thereon to have a radially inward component to create turbulence. The turbulence mixes and homogenizes the gas and liquid fluids to improve the overall performance of centrifugal pump assemblies that operate in two-phase fluids. The mixing stage also has an impeller adjacent the diffuser. The impeller vanes likewise extend radially and tangentially therefrom at acute angles and may be curved.

Abstract: Vibration of an electric submersible pump assembly is monitored to produce a vibration spectrum. The vibration spectrum is compared to a known vibration signature for a pump condition that precedes gas lock. The pump condition is at least one of an impeller rotating stall condition, a diffuser stall condition, a pre-surge condition, and percentage of free gas within the wellbore fluid. Operation of the pump is then adjusted in response to the similarity of the vibration spectrum to the vibration signature for the pump condition to prevent impending gas lock.

Abstract: The pump can be utilized in gassy oil wells to prevent gas slugs from locking the electrical submersible pump. A shroud assembly is provided with a bottom that can be fixed to the top of a seal section connected to the top of a motor. Additional lengths of shroud can be added as the shroud assembly is lowered into the well. The electrical submersible pump can then lowered into the shroud and supported from a production tubing string. A hanger can then be attached to the production tubing string to carry the weight of the shroud assembly, motor, and seal section.

Abstract: Systems and methods of cooling a motor of an electrical submersible pump (ESP) assembly employed in an electrical submersible subsea booster pumping system, are provided. A supporting frame structure such as an ESP mounting skid or top end assembly of a caisson having structural members exposed to environmental seawater, is modified or designed to include fluid conduits within the structural members to establish lubricant pathways for lubricant to flow. A heated/hot lubricant line connects between a supporting structure lubricant inlet port and an ESP motor lubricant outlet port. A cooled lubricant line connects between a supporting structure lubricant outlet port and an ESP motor lubricant inlet port. A pump or other fluid moving device circulates lubricant from the ESP motor to the lubricant pathways within the supporting frame structure, whereby the seawater cools the lubricant contained therein, which is then circulated back into the motor to assisting cooling the motor.

Abstract: An electrical submersible pump that regulates pump flow rate based on sensor measurements of the fluid is disclosed. The sensor measures a property of the fluid being processed. The sensor may be located at the intake, discharge or other area of the pump. The sensor measures the relative proportion of gas in the pumped liquid. The pump flow rate is adjusted to maintain a desired level for the gas in a production environment. The pump may be used to operate and control a seabed gas-liquid separation and centrifugal pump system.

Abstract: A seafloor pump assembly is installed within a caisson that has an upper end for receiving a flow of fluid containing gas and liquid. The pump assembly is enclosed within a shroud that has an upper end that seals around the pump assembly and a lower end that is below the motor and is open. An extraction tube has an upper end above the shroud within the upper portion of the caisson and a lower end connected to a jet pump. The extraction tube causes gas that separates from the liquid and collects in the upper portion of the caisson to be drawn into the jet pump and mixed with the liquid as the liquid is being pumped.

Abstract: A gas extraction device for down hole oilfield applications utilizes the flow of the liquid, created by an artificial lift device, to produce conditions by which the gas is drawn into tubing. A venturi creates a low pressure area through a constricted section of the tubing. The pressure within the throat of the venturi drops the pressure in the casing. The device is axially adjusted to allow communication ports to a lower pressure area of the casing annulus. The lower pressure in the venturi draws the gas into the liquid stream and into the production tubing above the device. The gas is then transferred through the well head within the liquid stream.

Abstract: The present invention relates to a process for cooling an electrical submersible pump. More specifically, the invention relates to blocking a portion of wellbore fluid from entering a sump, thereby causing the pump to draw fluid from below the pump motor past the exterior of the pump motor toward a pump inlet.

Abstract: A seafloor pump assembly is installed within a caisson that has an upper end for receiving a flow of fluid containing gas and liquid. The pump assembly is enclosed within a shroud that has an upper end that seals around the pump assembly and a lower end that is below the motor and is open. A separating device is connected to an upper end portion of the discharge pipe within the caisson. The separating device causes separation of gas from the flow containing gas and liquid to be enhanced prior to the flow reaching the operating liquid level in the caisson.

Abstract: A connection between a shaft and a coupling that preferably involves involute shaped splines is designed to reduce stress from torque applied to the shaft by a drive motor. To avoid stress concentration at the mouth of the coupling on startup, the shaft splines are made to taper from the shaft end down to the spline end. As a result, the initial contact with the coupling splines occurs within the coupling and removed from it mouth. The shaft is allowed to elastically twist in response to the applied torque as the contact area increases with shaft twisting and the contact line moves toward the mouth of the coupling. Stress concentration that formerly occurred at the coupling mouth is alleviated as some shaft elastic twist occurs without adding stress to the shaft splines until coupling contact is made.

Abstract: The pump can be utilized in gassy oil wells to prevent gas slugs from locking the electrical submersible pump. A shroud assembly is provided with a bottom that can be fixed to the top of a seal section connected to the top of a motor. Additional lengths of shroud can be added as the shroud assembly is lowered into the well. The electrical submersible pump can then lowered into the shroud and supported from a production tubing string. A hanger can then be attached to the production tubing string to carry the weight of the shroud assembly, motor, and seal section.

Abstract: A submersible pumping system for use downhole that includes a housing, a pump and gas separator within the housing, a motor for driving the pump and separator, and a foaming agent injection system. The foaming agent injection system injects a foaming agent upstream of the pump and optionally upstream of the separator. The foaming agent injection system comprises a foaming agent supply, an injection pump, and foaming agent injection line.

Abstract: An electrical submersible well pump assembly having a progressing cavity pump, a pump motor, a flex shaft connecting the pump motor to the pump, and a gas/liquid separator on the inlet to the pump. An inner and outer housing circumscribe a portion of the flex shaft, each having fluid inlets. The fluid inlets on the outer housing are above the inner housing inlets and an annulus is formed between the inner and outer housing. Wellbore fluid enters the assembly through the outer housing inlets, flows downward through the annulus, and into the inner housing inlets. Gas separates from the liquid as the fluid flows downward from the outer housing inlets to the inner housing inlets.

Abstract: A submersible well pump assembly has a gas separator that separates gas prior to entering into the pump. A shroud encloses a portion of the pump assembly, including the gas separator. The gas separator has gas discharge tubes that extend from it out through the shroud. The gas discharge tubes are tangentially aligned to create a vortex on the exterior of the shroud.

Abstract: A gas extraction device for down hole oilfield applications utilizes the flow of the liquid, created by an artificial lift device, to produce conditions by which the gas is drawn into tubing. A venturi creates a low pressure area through a constricted section of the tubing. The pressure within the throat of the venturi drops the pressure in the casing. The device is axially adjusted to allow communication ports to a lower pressure area of the casing annulus. The lower pressure in the venturi draws the gas into the liquid stream and into the production tubing above the device. The gas is then transferred through the well head within the liquid stream.