Abstract: Systems and methods for preventing rotation of an ESP motor when the motor is not powered on, thereby preventing the motor from acting as a generator when fluid flowing through the pump section of the ESP applies a torque to the motor. In one embodiment, an ESP has a motor section, a pump section. The ESP may include a directional coupling that allows unidirectional rotation between the motor shaft and a pump shaft of the pump section, and a directional lock that allows unidirectional rotation between the motor shaft and a housing of the motor section. The directional coupling and directional lock allow the pump shaft to freewheel in the forward direction without causing the motor shaft to rotate, and prevent the pump shaft and motor from rotating in the reverse direction.

Abstract: Systems and methods for preventing rotation of an ESP motor when the motor is not powered on, thereby preventing the motor from acting as a generator when fluid flowing through the pump section of the ESP applies a torque to the motor. In one embodiment, an ESP has a motor section, a pump section. The ESP may include a directional coupling that allows unidirectional rotation between the motor shaft and a pump shaft of the pump section, and a directional lock that allows unidirectional rotation between the motor shaft and a housing of the motor section. The directional coupling and directional lock allow the pump shaft to freewheel in the forward direction without causing the motor shaft to rotate, and prevent the pump shaft and motor from rotating in the reverse direction.

Abstract: An electrical submersible pump (ESP) isolates its motor lubricant from pumped product without requiring a bellows, diaphragm, bladder, or external lubricant pressurizing system. A pair of nested isolation chambers below the motor housing are filled with a barrier fluid that is non-reactive, non-miscible, and higher in density than the pumped product and the motor lubricant. As the motor lubricant expands and contracts after pump start-up and shut-down, motor lubricant and barrier fluid are exchanged between the motor housing and the isolation chambers via three interconnections, while pumped product is exchanged with the inner barrier chamber, while being isolated from the motor housing. The interconnections extend between the bottom of the motor housing and the bottom of the outer barrier chamber, between the top of the outer barrier chamber and the bottom of the inner barrier chamber, and between the top of the inner barrier chamber and the pumped product.

Abstract: An electrical submersible pump (ESP) isolates its motor lubricant from pumped product without requiring a bellows, diaphragm, bladder, or external lubricant pressurizing system. A pair of nested isolation chambers below the motor housing are filled with a barrier fluid that is non-reactive, non-miscible, and higher in density than the pumped product and the motor lubricant. As the motor lubricant expands and contracts after pump start-up and shut-down, motor lubricant and barrier fluid are exchanged between the motor housing and the isolation chambers via three interconnections, while pumped product is exchanged with the inner barrier chamber, while being isolated from the motor housing. The interconnections extend between the bottom of the motor housing and the bottom of the outer barrier chamber, between the top of the outer barrier chamber and the bottom of the inner barrier chamber, and between the top of the inner barrier chamber and the pumped product.

Abstract: A string of coiled tubing having a power cable therein supports and supplies power to an electrical submersible well pump assembly in a well. The coiled tubing has an upper section and a lower section joining each other, the upper section having a smaller inner diameter than the lower section. The power cable has an upper portion installed in the upper section of the coiled tubing and a lower portion installed in the lower section of the coiled tubing. The power cable has three insulated electrical conductors embedded within an elastomeric jacket. A metal armor strip has turns wrapped helically around the jacket. The armor strip is compressed between the jacket and the coiled tubing both in the upper section and in the lower section of the coiled tubing.

Abstract: Systems and methods for preventing rotation of an ESP motor when the motor is not powered on, thereby preventing the motor from acting as a generator when fluid flowing through the pump section of the ESP applies a torque to the motor. In one embodiment, an ESP has a motor section, a pump section. The ESP may include a directional coupling that allows unidirectional rotation between the motor shaft and a pump shaft of the pump section, and a directional lock that allows unidirectional rotation between the motor shaft and a housing of the motor section. The directional coupling and directional lock allow the pump shaft to freewheel in the forward direction without causing the motor shaft to rotate, and prevent the pump shaft and motor from rotating in the reverse direction.

Abstract: A downhole well pump assembly includes a pump and a motor. The motor has a motor housing with a motor head adapter on one end, the motor head adapter having a threaded connector. A seal section seals around a shaft of the motor, the seal section having a seal section adapter connected to the motor head adapter with the threaded connector. The motor head adapter and the motor housing have cylindrical exterior surfaces and end faces that face each other, defining a joint between the end faces. A first strip of metal foil is welded around the exterior surfaces of the motor head adapter and the motor housing at the joint, sealing the entry of well fluids into the joint.

Abstract: A string of coiled tubing having a power cable therein supports and supplies power to an electrical submersible well pump assembly in a well. The coiled tubing has an upper section and a lower section joining each other, the upper section having a smaller inner diameter than the lower section. The power cable has an upper portion installed in the upper section of the coiled tubing and a lower portion installed in the lower section of the coiled tubing. The power cable has three insulated electrical conductors embedded within an elastomeric jacket. A metal armor strip has turns wrapped helically around the jacket. The armor strip is compressed between the jacket and the coiled tubing both in the upper section and in the lower section of the coiled tubing.

Abstract: A downhole well pump assembly includes a pump and a motor. The motor has a motor housing with a motor head adapter on one end, the motor head adapter having a threaded connector. A seal section seals around a shaft of the motor, the seal section having a seal section adapter connected to the motor head adapter with the threaded connector. The motor head adapter and the motor housing have cylindrical exterior surfaces and end faces that face each other, defining a joint between the end faces. A first strip of metal foil is welded around the exterior surfaces of the motor head adapter and the motor housing at the joint, sealing the entry of well fluids into the joint.

Abstract: An electrical submersible pumping system includes a well fluid pump driven by a three-phase motor. The motor has a stack of motor laminations mounted in a housing. The motor laminations have axially aligned slots spaced circumferentially around a bore. Motor windings are wound through the slots for receiving three-phase power provided to the motor. At least one set of three control lines extend axially through the motor laminations radially outward from the bore and equally spaced around the axis, The control lines may extend through channels on the outer diameter of the motor laminations. The control lines may also extend through the same slots that contain the windings. The control lines extend to a downhole element below the motor for controlling the downhole element.

Abstract: Systems and methods for connecting power cables to downhole equipment such as ESPs using side-exit (radial) connections. In one embodiment, a system includes an electric drive coupled by a power cable to an ESP. The electric drive is positioned at the surface of a well with the power cable coupled to it. The power cable extends into the well bore and is coupled to the downhole equipment which is positioned in the well bore. The power cable has a connector with a first set of radially oriented terminals (the terminals are perpendicular to the conductors of the power cable). These terminals engage a second set of terminals that are installed in the downhole equipment. The radial orientation of the terminals of the connector and downhole equipment allow the power cable to remain axially oriented, thereby facilitating engagement of the terminals and requiring less annular space in the well bore.

Abstract: Systems and methods for constructing electric motors including both permanent magnet elements and inductive elements. In one embodiment, a motor is implemented of an ESP system has multiple rotor sections that are mounted end-to-end within the bore of the stator. The permanent magnet elements and inductive elements may be combined within individual rotor sections, or they may be segregated so that one rotor section has only one type or the other. The inductive elements of the rotor allow the motor to be started without a VFD, and without knowing the position of the rotor within the motor. The permanent magnet elements synchronize the rotor with the rotating stator fields when the rotor approaches the operating frequency of the drive.

Abstract: A well pump includes a plunger reciprocally carried within a barrel between up stroke and down stroke positions. A tubular linear actuator housing located below the barrel has a rotatable rotor. An array of rotor magnets is mounted to the rotor, directing rotor magnetic fields in an outward direction. A cage is fixed against rotation relative to the housing and carried within the housing for axial movement relative to the rotor and the housing. The cage has a cylindrical inner sidewall surrounding the outer sidewall of the rotor. An array of cage magnets is mounted to the inner sidewall of the cage. The cage magnets direct cage magnetic fields in an inward direction relative to the axis. The cage and rotor magnetic fields interact such rotation of the rotor causes axial movement of the cage. A motor rotates the rotor.

Abstract: An electrical submersible pumping system includes a well fluid pump driven by a three-phase motor. The motor has a stack of motor laminations mounted in a housing. The motor laminations have axially aligned slots spaced circumferentially around a bore. Motor windings are wound through the slots for receiving three-phase power provided to the motor. At least one set of three control lines extend axially through the motor laminations radially outward from the bore and equally spaced around the axis, The control lines may extend through channels on the outer diameter of the motor laminations. The control lines may also extend through the same slots that contain the windings. The control lines extend to a downhole element below the motor for controlling the downhole element.

Abstract: A submersible well pump assembly include a rotary pump driven by an electrical motor. A seal section operably connects between the motor and the pump for reducing a pressure differential between motor oil in the motor and well fluid surrounding the pump assembly. The pump assembly contains a sealed fluid. A sensor mounted to the well pump assembly detects contamination of the sealed fluid by well fluid encroaching into contact with the sealed fluid. The sensor may be mounted in the motor or the seal section to detect well fluid contamination of motor oil. The sensor may be mounted in a secondary pump that has that has temporary barriers to block the entry of well fluid into a buffer fluid contained in the secondary pump while the secondary pump is in a storage condition within a well.

Abstract: Systems and methods for preventing rotation of rotor bearings in electric motors which enable retrofitting of conventionally designed bearings to use spring-loaded keys instead of elastomeric T-rings to prevent rotation while allowing axial movement of the bearings within a stator bore. An elongated, curved spring arm is positioned in the nesting groove at the outer periphery of the bearing. One end of the spring may be secured to the bearing by positioning an S-shaped bend in the spring arm through a hole in the floor of the nesting groove. A key at the opposite end of the spring arm is urged radially outward by the spring arm. The key may be positioned in a slot in the outer portion of the bearing, and the spring arm may be retained in the groove by a retaining pin installed in the groove.

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 well pump includes a plunger reciprocally carried within a barrel between up stroke and down stroke positions. A tubular linear actuator housing located below the barrel has a rotatable rotor. An array of rotor magnets is mounted to the rotor, directing rotor magnetic fields in an outward direction. A cage is fixed against rotation relative to the housing and carried within the housing for axial movement relative to the rotor and the housing. The cage has a cylindrical inner sidewall surrounding the outer sidewall of the rotor. An array of cage magnets is mounted to the inner sidewall of the cage. The cage magnets direct cage magnetic fields in an inward direction relative to the axis. The cage and rotor magnetic fields interact such rotation of the rotor causes axial movement of the cage. A motor rotates the rotor.

Abstract: Systems and methods for providing moisture-proof seals around the splices in an ESP motor. Two-layer encapsulation around each splice includes an outer layer of heat-shrink material that shrinks at a first temperature, and an inner layer of insulating material that melts at a temperature below the first temperature. The encapsulation materials are positioned around the electrical junction of the splice and heated. As the temperature reaches the melting temperature of the inner material, this material melts. As the temperature reaches the temperature at which the outer layer begins to shrink, the outer layer presses softened material of the inner layer against the conductors and the wire insulation near the splice, thereby conforming the material of the inner layer to the magnet wires at the splice and forming a moisture-proof barrier. Similarly constructed splices can connect motor lead extensions to the stator windings and form a Y-point of the motor.

Abstract: Systems and methods for connecting power cables to downhole equipment such as ESPs using side-exit (radial) connections. In one embodiment, a system includes an electric drive coupled by a power cable to an ESP. The electric drive is positioned at the surface of a well with the power cable coupled to it. The power cable extends into the well bore and is coupled to the downhole equipment which is positioned in the well bore. The power cable has a connector with a first set of radially oriented terminals (the terminals are perpendicular to the conductors of the power cable). These terminals engage a second set of terminals that are installed in the downhole equipment. The radial orientation of the terminals of the connector and downhole equipment allow the power cable to remain axially oriented, thereby facilitating engagement of the terminals and requiring less annular space in the well bore.