Abstract: A well pump electrical motor has a motor housing filled with a dielectric motor lubricant. A motor head has at least one motor lead passage in fluid communication with the motor lubricant. An outer seal, which is exposed to well fluid, seals around a motor lead in the motor lead passage. An inner seal seals around the motor lead in the motor lead passage inward from the outer seal and has an inner side in contact with the motor lubricant in the motor. A barrier fluid passage extends into an annular space between the inner and outer seals and contains a barrier fluid. A pressure compensating device has an inner side in contact with the barrier fluid in the barrier fluid passage for reducing a pressure differential between the barrier fluid and a hydrostatic fluid pressure of well fluid on the exterior of the motor.

Abstract: An electrical submersible well pump assembly includes an electrical motor for driving a pump. A pressure compensating chamber contains a dielectric lubricant in fluid communication with an interior of the motor. A movable pressure compensating element has a first side in contact with the lubricant in the chamber. Movement of the element relative to the chamber causes a change in volume of the chamber. An electrical drive mechanism is connected with and moves the element. A controller senses a pressure difference between the lubricant pressure and the well fluid pressure and operates the drive mechanism in response. The element may be a piston, a bellows or telescoping tubes.

Abstract: A subsea pump assembly includes a tubular conduit that has an upstream end plate and an inlet for flowing well fluid into an interior of the conduit. A power cable opening extends through the upstream end plate. An electrical submersible pump and motor are in the interior of the conduit. The motor has a motor assembly housing with an upstream end having an electrical insulator opening. An end connection secures the upstream end to an interior side of the upstream end plate with the insulator opening registering with the power cable opening. An insulated electrical connector is mounted in the insulator opening. A motor wire in the motor assembly housing joins to an inner end of the electrical connector. A power conductor extends from exterior of the conduit through the power cable opening and joins to an outer end of the electrical connector.

Abstract: A submersible well pump assembly has a motor that rotates a drive shaft within the pump. The pump has a number of pump stages, each stage having a diffuser and an impeller. A bushing is fixed for non-rotation within the diffuser. A thrust runner sleeve mounted to the drive shaft has an outer diameter surface in sliding rotating engagement with an inner diameter surface of the bushing. At least one seal ring is mounted to the sleeve in sealing engagement with the drive shaft to block the entry of well fluid particulates between the sleeve and the drive shaft.

Abstract: Downhole tools for use in downhole operations and electrical submersible pumping systems having an additively manufactured first part including a first layer having a first predetermined material property and a second layer having a second predetermined material property, wherein the first and second layers are layers of an integral piece and the first predetermined material property is different from the second predetermined material property and a second part configured to rotationally engage with the additively manufactured first part. One of the first part and the second part is rotated relative to the other of the first part and the second part in operation.

Abstract: An electrical submersible pump assembly has a pressure equalizer coupled to a lower end of a motor. The equalizer has a motor lubricant passage through which lubricant in the motor communicates with motor lubricant in the equalizing element. A valve element in the motor lubricant passage has a closed upper position and an open lower position. The valve element has a drive member on an upper end that mates with a shaft drive member on a lower end of the motor shaft while the valve element is in the upper position and disengages from the shaft drive member while the valve element is in the lower position. A locking feature between the valve element and the motor lubricant passage retains the valve element in the upper position and is releasable in response to rotation of the motor shaft in a selected direction.

Abstract: Downhole tools for use in downhole operations and electrical submersible pumping systems having an additively manufactured first part including a first layer having a first predetermined material property and a second layer having a second predetermined material property, wherein the first and second layers are layers of an integral piece and the first predetermined material property is different from the second predetermined material property and a second part configured to rotationally engage with the additively manufactured first part. One of the first part and the second part is rotated relative to the other of the first part and the second part in operation.

Abstract: An electrical submersible pump assembly has a magnetic coupling between the motor shaft and the pump shaft. The coupling includes motor shaft disks mounted to the motor shaft, each having upward and downward facing disk surfaces joined by an outward facing disk cylindrical surface. Motor shaft magnets are mounted in each of the disk cylindrical surfaces and in the upward and downward facing disk surfaces. A pump shaft rotor mounted to the pump shaft has annular bands axially separated from each other by recesses into which the disks extend. Rotor magnets are mounted in each of the recess cylindrical surfaces and in upward and downward facing band surfaces. The magnets in the recesses interact with the magnets on the disks.

Abstract: Downhole tools for use in downhole operations and electrical submersible pumping systems having an additively manufactured first part including a first layer having a first predetermined material property and a second layer having a second predetermined material property, wherein the first and second layers are layers of an integral piece and the first predetermined material property is different from the second predetermined material property and a second part configured to rotationally engage with the additively manufactured first part. One of the first part and the second part is rotated relative to the other of the first part and the second part in operation.

Abstract: Systems and methods for protecting motor lead from debris and fluid contamination. In one embodiment, detachable, flexible lead wires within an ESP motor are covered by protective sleeves that are sealed against the end connectors of the leads. The end connectors are coupled to corresponding terminals in an epoxy fixture of the motor and a motor head in a manner that provides a seal between them. The sealed sleeve and end connectors prevent debris and contaminants in the fluid within the motor from reaching the conductive elements of the motor leads, thereby preventing accumulations of debris and contaminants that could otherwise cause electrical faults.

Abstract: A well pump electrical motor has a motor housing filled with a dielectric motor lubricant. A motor head has at least one motor lead passage in fluid communication with the motor lubricant. An outer seal, which is exposed to well fluid, seals around a motor lead in the motor lead passage. An inner seal seals around the motor lead in the motor lead passage inward from the outer seal and has an inner side in contact with the motor lubricant in the motor. A barrier fluid passage extends into an annular space between the inner and outer seals and contains a barrier fluid. A pressure compensating device has an inner side in contact with the barrier fluid in the barrier fluid passage for reducing a pressure differential between the barrier fluid and a hydrostatic fluid pressure of well fluid on the exterior of the motor.

Abstract: An electrical submersible well pump assembly includes an electrical motor for driving a pump. A pressure compensating chamber contains a dielectric lubricant in fluid communication with an interior of the motor. A movable pressure compensating element has a first side in contact with the lubricant in the chamber. Movement of the element relative to the chamber causes a change in volume of the chamber. An electrical drive mechanism is connected with and moves the element. A controller senses a pressure difference between the lubricant pressure and the well fluid pressure and operates the drive mechanism in response. The element may be a piston, a bellows or telescoping tubes.

Abstract: Upper and lower pressure equalizers couple to a lower end of a motor of an electrical submersible pump assembly. An intermediate connection having a liquid flow passage connects the pressure equalizers. A connection valve located in the liquid flow passage closes the liquid flow passage prior to connecting the pressure equalizers with each other, and opens the liquid flow passage after the connection between the pressure equalizers is made. A sensor lower equalizer wire extends from a sensor unit through the lower pressure equalizer to a lower electrical terminal at the upper end of the lower pressure equalizer. A sensor upper equalizer wire connects to the lower electrical terminal and extends through the upper pressure equalizer to an upper electrical terminal at the upper end of the upper pressure equalizer. A sensor motor wire extends downward from the motor into engagement with the upper electrical terminal.

Abstract: A bellows position monitoring arrangement to determine the axial position of a bellows assembly within the outer housing of a seal section or equalizer. The position can be correlated to an amount of motor oil being retained within the bellows assembly.

Abstract: An electrical submersible pump assembly has a pump driven by a motor. A pressure compensator has first and second bellows units axially separated from each other. Each of the first and second bellows units are movable between an increased volume position and a decreased volume position and have a bias toward the decreased volume position. The bias of the first bellows unit is greater than the bias of the second bellows unit. The greater bias of the first bellows unit over the second bellows unit causes the second bellows unit to be at a full volume position at a lower level of the pressure differential than the level at which the first bellows unit is at the full volume position.

Abstract: Downhole tools for use in downhole operations and electrical submersible pumping systems having an additively manufactured first part including a first layer having a first predetermined material property and a second layer having a second predetermined material property, wherein the first and second layers are layers of an integral piece and the first predetermined material property is different from the second predetermined material property and a second part configured to rotationally engage with the additively manufactured first part. One of the first part and the second part is rotated relative to the other of the first part and the second part in operation.

Abstract: An electrical submersible pump assembly has a seal section coupled to a motor that drives the pump. The seal section has first and second end members spaced axially apart from each other. An outer bellows has a fixed end mourned to the first end member and a floating end that moves axially relative to the fixed end. A rigid, tubular interconnect member has an inner end within the outer bellows and an cuter end fixed to the floating end of the outer bellows. An inner bellows has a floating end secured to the inner end of the interconnect member and a fixed end secured to the second end member. An interconnect evacuation passage extends axially through a side wall of the interconnect member. A first end member evacuation passage extends through the first end member and registers with the interconnect evacuation passage while the outer bellows is contracted.

Abstract: An electrical submersible pump assembly has modules including a pump, a motor, and a pressure equalizer. A first adapter having threads is mounted to one of the modules. A second adapter is mounted to an adjacent one of the modules, the second adapter having a tubular body, a neck, and an external shoulder at a base of the neck. A collar is rotatably carried on the neck and in threaded engagement with the threads of the first adapter. A clamp secures around the neck between the external shoulder and the collar after the collar is fully engaged with the threads on the first adapter. A pair of flanges are mounted to and extend outward from the clamp. A motor lead locates between the flanges.

Abstract: An electrical submersible pump assembly has a thrust bearing mechanism with first and second thrust runners axially and rotationally secured to the shaft and located within a housing. First and second thrust receiving structures are rigidly mounted in the housing to receive thrust from the first and second thrust transferring devices. A deflectable member located in the first thrust transfer thrust device decreases in axial thickness in response to thrust of a selected level. The second thrust transfer thrust device has an axial length less than an axial distance from the second thrust receiving structure to the second thrust runner, defining an initial axial gap. During operation of the pump, the shaft and the first and second thrust runners move axially a limited extent, closing the gap and transferring thrust from the second thrust transfer device to the second thrust receiving structure.

Abstract: A well pump assembly has a number modules, including a pump and a motor, secured together. Each of the modules has a housing, and at least one of the modules has a neck of reduced diameter relative to the housing. A clamp is secured around the neck. The clamp has a dovetail groove extending around and within the outer surface of the clamp. An accessory member protrudes radially outward from the outer surface of the clamp and has an inner portion located in the groove. A threaded fastener secures the accessory member to the clamp. The accessory member is slidable along the groove to a selected orientation prior to tightening the fastener.