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: 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: Induction motor stator windings are described. An electric submersible pump apparatus comprises an induction motor rotatably coupled to a multi-stage centrifugal pump, the induction motor comprising a stator frame, the stator frame comprising a plurality of slots, and a squircle-shaped magnet wire windingly inserted into the plurality of slots, the magnet wire comprising a conductor comprising a squircular-shaped cross-sectional area, and an insulation layer coating an outer surface of the squircular-shaped conductor.

Abstract: In aspects, the present disclosure provides an apparatus for handling axial thrust in rotating equipment. The apparatus may include a thrust bearing and a runner having a contact surface engaging the thrust bearing. The runner may include passages extending between the contact surface and an opposing surface of the runner. The apparatus may further include a lock ring assembly that has channels in communication with the passages of the runner. In certain embodiments, one or more cavities may be formed on the contact surface of the runner. The cavities may be in communication with the internal passages of the runner. In aspects, the present disclosure provides a method for handling axial thrust in a pump assembly. The pump assembly may include a thrust bearing assembly that may include a runner having a contact surface engaging a thrust bearing pad. The method may include flowing a lubricating fluid to the contact surface using at least one internal passage formed in runner.

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: Vibration of a rotor positioned within a stator of an electric motor of an electric submersible pump assembly is attenuated in a first embodiment by adjusting the length of the rotor to position rotor bearings supporting the rotor within the stator at locations of low amplitude vibration. In a second embodiment, hydraulic pressure is applied to a fluid chamber supporting a thrust bearing that supports the rotor. When hydraulic fluid pressure is applied, the thrust bearing and the rotor move axially. Thus, moving the rotor bearings away from areas of high amplitude vibration of the rotor. In a third embodiment, a sliding mass affixed to the motor is moved in response to vibration of the motor. Movement of the sliding mass changes the vibration profile of the motor.

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: Vibration of a rotor positioned within a stator of an electric motor of an electric submersible pump assembly is attenuated in a first embodiment by adjusting the length of the rotor to position rotor bearings supporting the rotor within the stator at locations of low amplitude vibration. In a second embodiment, hydraulic pressure is applied to a fluid chamber supporting a thrust bearing that supports the rotor. When hydraulic fluid pressure is applied, the thrust bearing and the rotor move axially. Thus, moving the rotor bearings away from areas of high amplitude vibration of the rotor. In a third embodiment, a sliding mass affixed to the motor is moved in response to vibration of the motor. Movement of the sliding mass changes the vibration profile of the motor.

Abstract: In aspects, the present disclosure provides an apparatus for handling axial thrust in rotating equipment. The apparatus may include a thrust bearing and a runner having a contact surface engaging the thrust bearing. The runner may include passages extending between the contact surface and an opposing surface of the runner. The apparatus may further include a lock ring assembly that has channels in communication with the passages of the runner. In certain embodiments, one or more cavities may be formed on the contact surface of the runner. The cavities may be in communication with the internal passages of the runner. In aspects, the present disclosure provides a method for handling axial thrust in a pump assembly. The pump assembly may include a thrust bearing assembly that may include a runner having a contact surface engaging a thrust bearing pad. The method may include flowing a lubricating fluid to the contact surface using at least one internal passage formed in runner.

Abstract: An improved seal assembly for a downhole electrical submersible pump assembly.

Abstract: An electrical submersible pumping system having a pump, a motor, a shaft connecting the pump and motor, and a mechanical seal assembly on the shaft. The mechanical seal assembly includes a sleeve circumscribing the shaft that is axially movable with respect to the shaft. The shaft is retained within a guide mount, an inner circumference of the guide mount extends radially outward to define a shoulder. An annular seat is disposed on the shoulder. One end of a resilient retention assembly couples on the outer surface of the sleeve with its other end compressively urged against the seat. A resilient member is compressively mounted on one end to the sleeve and on another end to the shaft at a location past the end of the sleeve distal from the seat.

Abstract: An improved seal assembly for a downhole electrical submersible pump assembly.

Abstract: A seal section for location between a submersible rotary pump and motor has a primary mechanical seal and a secondary oil seal at the pump end of the seal section. The mechanical seal has rigid seal faces that slide in engagement with each other. The secondary seal has an inner portion that seals against the shaft of the seal section and an outer portion that seals against the housing. The seal section has a pressure equalizing device for equalizing pressure of motor lubricant with well bore pressure.

Abstract: A power line for an electrical submersible pump has three metallic impermeable tubes. A single electrical conductor is located within each of the tubes. Each conductor has at least one elastomeric insulation layer surrounding it. An annular portion of the insulation layer of each of the electrical conductors is in tight contact with the tube to form a seal. The annular portions may be annular crimps formed in the tube at intervals. The annular portion could also be a continuous seal caused by swelling of the insulation layer due to contact with a hydrocarbon.