Abstract: A gas separator operationally coupled between a submersible pump and a motor for use in downhole reservoirs includes an intake housing and an inner intake assembly. The intake housing includes at least two sets of intake ports along an upper section adjacent to the pump with ports in a set vertically offset and sets horizontally offset. The inner intake assembly includes a separation chamber, a self-orienting intake rotatable around a central axis and having at least one communication port, and a port controller. The port controller functions to position the communications port toward the bottom of the gas separator when the gas separator is positioned horizontally in a downhole wellbore. The intake housing allows reservoir fluid traveling downstream to pass through intake ports and into the separation chamber through the communication ports.

Abstract: A gas separator operationally coupled between a submersible pump and a motor for use in downhole reservoirs includes an intake housing and an inner intake assembly. The intake housing includes at least two sets of intake ports along an upper section adjacent to the pump with ports in a set vertically offset and sets horizontally offset. The inner intake assembly includes a separation chamber, a self-orienting intake rotatable around a central axis and having at least one communication port, and a port controller. The port controller functions to position the communications port toward the bottom of the gas separator when the gas separator is positioned horizontally in a downhole wellbore. The intake housing allows reservoir fluid traveling downstream to pass through intake ports and into the separation chamber through the communication ports.

Abstract: A submersible well pump motor has features to prevent the carrier bearing from sliding axially along the stator due to thermal growth of the rotor. The rotor has a shaft and rotor sections spaced apart from each other. Carrier bearings are located between the rotor sections, each having an anti-rotation member that frictionally engages the inner diameter of the stator to prevent spinning of the carrier bearing. A deflectable thrust washer may be located between ends of the carrier bearing and the rotor sections. The thrust washer reduces in thickness in response to an axial thermal growth force due to axial thermal growth movement of the rotor sections and shaft. The thermal growth force is less than an amount of dislodging force required to cause the anti-rotation member to axially move relative to the stator. Rather than deflectable thrust washers, sacrificial thrust washers that dissolve prior to normal operation may be used.

Abstract: An electrical submersible pump assembly has a motor module coupled to a centrifugal pump module by a seal section module. A shaft assembly extends through each of the modules for causing the motor module to rotate the pump module. At least one of the modules has a sleeve extending around the shaft that is of a harder material than the shaft. A torque transmitting ring is deformed between an inner diameter of the sleeve and an exterior portion of the shaft. The inner diameter of the sleeve is a continuous cylindrical surface free of any torque transmitting shoulders. Friction created by the torque transmitting ring transmits the entire rotational force from the shaft to the sleeve.

Abstract: An electrical submersible pumping system (ESP) having a stator lamination stack that is anchored to prevent the stack from spinning. The ESP includes a motor section having a housing with an axial bore. A groove circumscribes an inner surface of the housing and a snap ring is set in the groove. A portion of the snap ring projects into the bore and exerts an axial compression force onto the lamination stack The snap ring includes a gap that aligns with a bead of material that is set in the groove; engagement between the bead and gap prevents the snap ring from spinning in the groove. The bead, that in an embodiment is a weld, can extend across all or a portion of the groove and can also provide coupling between the lamination stack and the housing.

Abstract: A submersible well pump motor has features to prevent the carrier bearing from sliding axially along the stator due to thermal growth of the rotor. The rotor has a shaft and rotor sections spaced apart from each other. Carrier bearings are located between the rotor sections, each having an anti-rotation member that frictionally engages the inner diameter of the stator to prevent spinning of the carrier bearing. A deflectable thrust washer may be located between ends of the carrier bearing and the rotor sections. The thrust washer reduces in thickness in response to an axial thermal growth force due to axial thermal growth movement of the rotor sections and shaft. The thermal growth force is less than an amount of dislodging force required to cause the anti-rotation member to axially move relative to the stator. Rather than deflectable thrust washers, sacrificial thrust washers that dissolve prior to normal operation may be used.

Abstract: A submersible well pump motor has features to prevent the carrier bearing from sliding axially along the stator due to thermal growth of the rotor. The rotor has a shaft and rotor sections spaced apart from each other. Carrier bearings are located between the rotor sections, each having an anti-rotation member that frictionally engages the inner diameter of the stator to prevent spinning of the carrier bearing. A deflectable thrust washer may be located between ends of the carrier bearing and the rotor sections. The thrust washer reduces in thickness in response to an axial thermal growth force due to axial thermal growth movement of the rotor sections and shaft. The thermal growth force is less than an amount of dislodging force required to cause the anti-rotation member to axially move relative to the stator. Rather than deflectable thrust washers, sacrificial thrust washers that dissolve prior to normal operation may be used.

Abstract: Systems and methods for constructing electric motors in which a stator core includes inner and outer portions that enable slots for magnet windings to be open during construction and closed in the completed motor. One embodiment comprises a method in which an inner stator core having a plurality of slots is formed by stacking a set of laminations. The slots are open radially outward from an axis of the inner stator core and which are configured to accommodate turns of magnet wire. After the magnet wire is positioned in the open slots, an outer stator core comprising stacked laminations is positioned around the inner stator core, enclosing the slots. The inner and outer stator cores are then positioned within a housing and assembled into a downhole motor.

Abstract: An electrical submersible pump assembly has a motor module coupled to a centrifugal pump module by a seal section module. A shaft assembly extends through each of the modules for causing the motor module to rotate the pump module. At least one of the modules has a sleeve extending around the shaft that is of a harder material than the shaft. A torque transmitting ring is deformed between an inner diameter of the sleeve and an exterior portion of the shaft. The inner diameter of the sleeve is a continuous cylindrical surface free of any torque transmitting shoulders. Friction created by the torque transmitting ring transmits the entire rotational force from the shaft to the sleeve.

Abstract: A submersible electric pump motor comprises an unvarnished stator structure having stator windings formed of conductors. The stator windings form end coils at each end of the stator for each phase. The end coils are tied to three arc-shaped, metal segments, each having an opening and positioned circumferentially within a circumferential groove. The metal segments are welded to the interior of the housing to provide a rigid surface. High temperature strings are wound through the openings in each metal segment and around the end coils for each phase to tie each end coil of that phase to that metal segment. This prevents the end coils of each phase from twisting during startup, sliding into the slots, and moving inwards towards a rotating rotor.

Abstract: A submersible pumping system for use downhole, wherein the system includes a pump and a pump motor for driving the pump. The pump motor includes a housing with corresponding stator and rotor lamination stacks disposed within the housing. Also included with the pump motor is an anchoring system for axially securing the stator lamination stack within the motor housing.

Abstract: A rotary pump having thrust bearings includes a system for equalizing the loading on the thrust bearings. The thrust bearings are each supported on pistons that are in fluid communication with a hydraulic circuit. The hydraulic circuit has substantially the same pressure throughout, thereby floating each piston at the same pressure to provide an equal support force to each thrust bearing via each piston.

Abstract: An electrical submersible pump has a pump assembly joined to a seal section. The pump assembly shaft, which may experience upthrust axial forces, may joined to the seal section shaft by a detachable coupling. The detachable coupling may have splines on its inner diameter that engage splines on the outer diameters of the pump assembly shaft and the seal section shaft. The detachable coupling can be bolted to one of the shafts. Locking members, such as plates, can be inserted through slots on the coupling to engage a recess on one of the shafts. A retaining device, such as a sleeve, can be used to hold the locking members in place.

Abstract: A submersible well pump motor has features to prevent the carrier bearing from sliding axially along the stator due to thermal growth of the rotor. The rotor has a shaft and rotor sections spaced apart from each other. Carrier bearings are located between the rotor sections, each having an anti-rotation member that frictionally engages the inner diameter of the stator to prevent spinning of the carrier bearing. A deflectable thrust washer may be located between ends of the carrier bearing and the rotor sections. The thrust washer reduces in thickness in response to an axial thermal growth force due to axial thermal growth movement of the rotor sections and shaft. The thermal growth force is less than an amount of dislodging force required to cause the anti-rotation member to axially move relative to the stator. Rather than deflectable thrust washers, sacrificial thrust washers that dissolve prior to normal operation may be used.

Abstract: A submersible electric pump motor comprises an unvarnished stator structure having stator windings formed of conductors. The stator windings form end coils at each end of the stator for each phase. The end coils are tied to three arc-shaped, metal segments, each having an opening and positioned circumferentially within a circumferential groove. The metal segments are welded to the interior of the housing to provide a rigid surface. High temperature strings are wound through the openings in each metal segment and around the end coils for each phase to tie each end coil of that phase to that metal segment. This prevents the end coils of each phase from twisting during startup, sliding into the slots, and moving inwards towards a rotating rotor.

Abstract: An electrical submersible pumping system (ESP) having a stator lamination stack that is anchored to prevent the stack from spinning. The ESP includes a motor section having a housing with an axial bore. A groove circumscribes an inner surface of the housing and a snap ring is set in the groove. A portion of the snap ring projects into the bore and exerts an axial compression force onto the lamination stack The snap ring includes a gap that aligns with a bead of material that is set in the groove; engagement between the bead and gap prevents the snap ring from spinning in the groove. The bead, that in an embodiment is a weld, can extend across all or a portion of the groove and can also provide coupling between the lamination stack and the housing.

Abstract: A bearing configuration for use in electrical submersible pumps having improved stability. The bearing configuration comprised of a plurality of pads, each able to freely tilt and adjust to the surface of the shaft.

Abstract: A well pump assembly has a rotary pump with an electrical motor that contains a motor lubricant. A thrust chamber is mounted between the motor and the pump, the thrust chamber containing a thrust chamber lubricant. Seals prevent the entry of thrust chamber lubricant into the motor chamber. A pressure equalizing chamber is mounted to the motor for admitting well fluid. A first pressure barrier in the equalizing chamber equalizes the pressure of the thrust chamber lubricant with that of the well fluid. A second pressure barrier contained within the first pressure barrier equalizes the pressure of the motor lubricant with thrust chamber lubricant.

Abstract: A bearing configuration for use in electrical submersible pumps having improved stability. The bearing configuration comprised of a plurality of pads, each able to freely tilt and adjust to the surface of the shaft.

Abstract: A rotary pump having thrust bearings includes a system for equalizing the loading on the thrust bearings. The thrust bearings are each supported on pistons that are in fluid communication with a hydraulic circuit. The hydraulic circuit has substantially the same pressure throughout, thereby floating each piston at the same pressure to provide an equal support force to each thrust bearing via each piston.