Abstract: A system for producing wellbore fluids. The system includes a pumping system deployable into tubing disposed in a wellbore, the pumping system includes a pump, a pump motor, a reservoir for containing purging fluid, and conductors in electrical communication with the pump motor. Electrical supply contacts are provided in the tubing and are connected to a downhole electrical power supply via a power cable extending along the tubing length from the surface. The conductors are engageable with the electrical supply contacts when the pumping system is landed within the tubing. Purging fluid in the reservoir can be flowed between the conductors and the supply contacts to remove conductive fluid prior to engaging the conductors and supply contacts. The conductors are selectively extended from a retracted position in the pumping system. In an alternative embodiment, the electrical supply contacts are provided at locations along the length of the tubing.

Abstract: An electrical power assembly comprises a motor lead with individual metal sheathed conductors, a power cable with individual metal sheathed conductors and a splice connector for connecting each of the conductors. Each splice connector has a tubular metal fastener body with an upward facing shoulder at an upper end and a downward facing shoulder at a lower end. A metal nut assembly is fixed to one of the power cable conductors with a downward facing shoulder in metal-to-metal sealing engagement with the upward facing shoulder of the fastener body. A metal coupler fixed to one of the motor lead conductors with an upward facing shoulder in metal-to-metal sealing engagement with the downward facing shoulder of the fastener body. Contacts electrically connect one of the motor lead conductors to one of the power cable conductors within the fastener body.

Abstract: An electrical power assembly comprises a motor lead with individual metal sheathed conductors, a power cable with individual metal sheathed conductors and a splice connector for connecting each of the conductors. Each splice connector has a tubular metal fastener body with an upward facing shoulder at an upper end and a downward facing shoulder at a lower end. A metal nut assembly is fixed to one of the power cable conductors with a downward facing shoulder in metal-to-metal sealing engagement with the upward facing shoulder of the fastener body. A metal coupler fixed to one of the motor lead conductors with an upward facing shoulder in metal-to-metal sealing engagement with the downward facing shoulder of the fastener body. Contacts electrically connect one of the motor lead conductors to one of the power cable conductors within the fastener body.

Abstract: A submersible electric motor has feature to enhance thermal conductivity from the motor interior to the exterior. The motor has a cylindrical housing and a stator rigidly mounted within housing. A rotatable rotor is located within the stator. A gap formed between the stator's outer diameter and the inner wall of the housing is filled with a high thermal conductivity material to improve heat transfer from the motor. The remaining portion of the housing may be filled with a dielectric lubricant that has lesser thermal conductivity than the high thermal conductivity material.

Abstract: A thrust module and a seal module for use in an electric submersible pump assembly is provided. The thrust module provides increased lubrication and heat dissipation while increasing sealing redundancies within the module. The thrust module includes a thrust bearing that absorbs thrust from the primary pump. A circulation pump assembly is coupled to the thrust bearing to circulate fluid through the thrust bearing and dissipate heat generated in the thrust bearing through a plurality of fins formed on an exterior surface of the circulation pump assembly. The seal module has labyrinth discs positioned within the seal module that inhibit fluid flow through the seal module. The seal module also includes check valves that release fluid from and allow fluid into the seal module at predetermined pressures. The sealing assembly is interposed between the thrust bearing and a primary pump of the electric submersible pump.

Abstract: An electrical submersible pumping (ESP) system for use in a wellbore that can be assembled in the wellbore. Upper and lower pump tandems are fitted with connectors that align the tandems when coupled in the wellbore. The connectors on the lower tandems have bores with enlarged openings on upward facing surfaces. Downward pointing pins are on lower facing surfaces of the connectors on the upper tandems. The cross sectional area of each bore decreases with distance away from the openings, so that as the pins insert into the bores the pins move along a helical path that in turn rotates the upper tandem into a designated azimuth and into alignment with the lower tandem. Properly aligning the upper and lower tandems couples respective drive and driven shafts in the tandems as the upper tandem lands on the lower tandem.

Abstract: An electric motor of an electric submersible pump is electrically isolated from a power conduit for diagnostic testing of the power conduit and wet connection components in place within a wellbore. The electric motor is electrically connected to the power conduit through a wet connection assembly having motor leads in electrical connection with a transfer contact and a receptacle assembly disposed on a tubing string having a supply contact electrically connected to the power conduit. Electric power flows through the power conduit, through the supply contact, through the transfer contact, and through the motor leads to the motor. The supply contact and the transfer contact are separated by a sliding sleeve that hydraulically inserts between the contacts, insulating the transfer contact and grounding the supply contact for testing. The contacts may also be separated by a relative rotation of the assemblies that grounds the supply contact for testing.

Abstract: A test device for testing the integrity of a seal has a clear t-shaped liquid reservoir with three ends. A guide adapter is connected to the first end of the liquid reservoir and extends axially therefrom along an axis of the reservoir. A shaft adapter is connected to the second end of the body, opposite the first end. A test shaft with first and second ends extends axially through the first and second ends of the body and test and shaft adapters along the axis. The first end of the shaft is adapted to be connected to the rotating shaft of pump assembly.

Abstract: Systems and methods for employing gauge packages for use with a wet-connect ESPs. In one embodiment, a modular gauge package includes a body, a gauge electronics assembly housed within the body, and a pair of electrical connectors at the upper and lower ends of the body, where power is passed through the body from one connector to the other. The electrical connector at the top of the body engages a complementary electrical connector on the bottom of a pump motor. The electrical connector at the bottom of the body engages a complementary electrical connector at the end of a production conduit. The connector at the bottom of the body may be identically configured with the connector at the bottom of the pump motor, and the connector at the top of the body may be identically configured with the connector at the end of the production conduit.

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: An electrical submersible pumping (ESP) system for use in a wellbore having a pressure equalization system that employs modules with a bellows. The bellows axially expands and contracts in response to pressure fluctuations encountered in the wellbore. The modules are attachable in series on a lower end of a motor of the ESP to form the string, where the string can range from a single module to a multiplicity of modules, depending on the application. The bellows has a conduit axially inserted through the bellows that includes an umbilical and has an end in pressure communication with the motor.

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: A downhole pumping system includes a submersible pump assembly having a pump and a motor, and an inlet apparatus operably coupled to the submersible pump assembly. The inlet apparatus includes a tubular housing for connection to an intake of the pump, the housing having an axis and defining a plurality of circumferentially spaced apart apertures, a plurality of valve members, each valve member positioned within a corresponding aperture, and a plurality of spring members coupled to the housing, each spring member coupled to a corresponding valve member. At least a portion of one or more of the spring members and the valve members extend above the outer surfaces of the housing.

Abstract: A latching mechanism for selectively disengaging an upper pump from a motor in an ESP. The latching mechanism comprises barbs formed on an upper end of an upper shaft that are engaged by a tool to lift the upper shaft until a lower end of the upper shaft disengages from an upper end of a motor shaft. When the upper pump is disengaged from the motor shaft, only a lower pump is driven by the motor and flow of well fluid is circulated past the disengaged upper pump via a bypass line. The upper pump shaft may reengage the motor shaft if additional lift is required.

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 system for producing wellbore fluids. The system includes a pumping system deployable into tubing disposed in a wellbore, the pumping system includes a pump, a pump motor, a reservoir for containing purging fluid, and conductors in electrical communication with the pump motor. Electrical supply contacts in the tubing are connected to a downhole electrical power supply via a power cable extending along the tubing length from the surface. The conductors are engageable with the electrical supply contacts when the pumping system is landed within the tubing. Purging fluid in the reservoir can be flowed between the conductors and the supply contacts to remove conductive fluid prior to engaging the conductors and supply contacts. The conductors are selectively extended from a retracted position in the pumping system.

Abstract: A system for producing wellbore fluids. The system includes a pumping system deployable into tubing disposed in a wellbore, the pumping system includes a pump, a pump motor, a reservoir for containing purging fluid, and conductors in electrical communication with the pump motor. Electrical supply contacts are provided in the tubing and are connected to a downhole electrical power supply via a power cable extending along the tubing length from the surface. The conductors are engageable with the electrical supply contacts when the pumping system is landed within the tubing. Purging fluid in the reservoir can be flowed between the conductors and the supply contacts to remove conductive fluid prior to engaging the conductors and supply contacts. The conductors are selectively extended from a retracted position in the pumping system. In an alternative embodiment, the electrical supply contacts are provided at locations along the length of the tubing.

Abstract: A submersible electric motor has feature to enhance thermal conductivity from the motor interior to the exterior. The motor has a cylindrical housing and a stator rigidly mounted within housing. A rotatable rotor is located within the stator. A gap formed between the stator's outer diameter and the inner wall of the housing is filled with a high thermal conductivity material to improve heat transfer from the motor. The remaining portion of the housing may be filled with a dielectric lubricant that has lesser thermal conductivity than the high thermal conductivity material.

Abstract: An inlet apparatus for a submersible well pump.

Abstract: A test device for testing the integrity of a seal has a clear t-shaped liquid reservoir with three ends. A guide adapter is connected to the first end of the liquid reservoir and extends axially therefrom along an axis of the reservoir. A shaft adapter is connected to the second end of the body, opposite the first end. A test shaft with first and second ends extends axially through the first and second ends of the body and test and shaft adapters along the axis. The first end of the shaft is adapted to be connected to the rotating shaft of pump assembly.