Baker Hughes, a Ge Compnay, LLC

Baker Hughes Oilfield Operations LLC

Baker Hughes Corporation

James Christopher Clingman

Sean A Cain

Yong Li

Kenneth O'Grady

Ryan P Semple

John Knapp

John Jay Mack

Michael Forsberg

Chad A Craig

Howard G Thompson

Randal Perisho

Spencer Wilcox

Arslan Amjad

Arturo Luis Poretti

Michael R Rumbaugh

Ignacio Martinez

Mark L Bellmyer

Ameen Muhammed

Kenneth O'grady

John M Knapp

Arturo L Poretti

A motor for an electrical submersible pump includes a stator and rotor, where the rotor is made up of adjacent columns of magnets affixed onto an annular core. End rings on opposite ends of the core provide axial backstops for magnet columns. Thin coaxial sleeves are shrunk fit over the magnets and end rings and that radially compress the magnets. Apertures in a column are formed radially through the core and receive fasteners for securing a guide bar to the core. The guide bar simulates an installed column of magnets to guide placement of adjacent columns of magnets as the guide bar width is substantially the same as a column of magnets, and aperture locations are strategically positioned so that when the guide bar is secured onto the core. After the guide bar is removed the one of the columns of magnets is then adhered to the core.

Permanent magnet motor for electrical submersible pump and method of assembly rotor

A pumping system configured to recover wellbore fluids from a wellbore includes an electric motor that has a motor head, a pothead receiving bore within the motor head, a motor insulator block within the motor head, and a stator lead within the motor insulator block. The pumping system further includes a motor lead cable and a pothead connector connected between the motor head and the motor lead cable. The pumping system includes a hermetically fused pothead-to-motor connection at an interface between the pothead connector and the motor head that obviates the need for conventional elastomeric seals at the interface between the pothead connector and the motor head.

Seam-sealed pothead to motor connection

Systems and methods for reclaiming and remagnetizing permanent magnet motors such as may be used in electric submersible pumps. In one embodiment, a method includes removing a permanent magnet rotor assembly from a motor and heating the rotor to burn off the residual oil and evaporate water in between laminations of the rotor and on the rotor surface. The rotor should be heated to a temperature that is above a flashpoint of oil on the rotor and below a Curie temperature of a material of a set of permanent magnets in the rotor (e.g., at least 600° F. for at least 12 hours). The heating may partially or fully demagnetize the permanent magnets in the rotor. The exposed surfaces of the rotor are then cleaned and the permanent magnets in the rotor are remagnetized using a specialized magnetizing fixture.

Systems and methods for magnetizing permanent magnet rotors

An electrical submersible well pump assembly has first and second permanent magnet motors. The first motor drive shaft is connected to a coupling that has internal splines for receiving an externally splined end of the second motor drive shaft. Alignment devices rotationally align magnetic poles of the first drive shaft with the magnetic poles of the second drive shaft prior to securing the housings of the first and second motors together. The alignment devices may be a coupling irregularity in the internal splines that is at a controlled orientation relative to the magnetic poles of the first shaft and a shaft irregularity in the external splines that prevents the second drive shaft from fully engaging the coupling unless the shaft irregularity is in a specified rotational position relative to the coupling irregularity.

Apparatus and method of rotational alignment of permanent magnet tandem motors for electrical submersible pump

An electrical power connector for an electrical submersible well pump motor has a housing having a bore. A pair of rigid insulators are within the bore of the housing, each of the insulators having a cylindrical outward-facing side that is in contact with an inward-facing side wall of the housing. A resilient elastomer seal is sandwiched between the insulators in sealing engagement with the inward-facing side wall. Passages extend through each of the insulators and the elastomer seal for receiving insulated conductors of a power cable. A spring in abutment with one of the insulators exerts an axial compressive force on the elastomer seal.

Power connector with spring-biased elastomeric conductor seal for submersible pump

Systems and methods for reclaiming and remagnetizing permanent magnet motors such as may be used in electric submersible pumps. In one embodiment, a method includes removing a permanent magnet rotor assembly from a motor and heating the rotor to burn off the residual oil and evaporate water in between laminations of the rotor and on the rotor surface. The rotor should be heated to a temperature that is above a flashpoint of oil on the rotor and below a Curie temperature of a material of a set of permanent magnets in the rotor (e.g., at least 600&#xb0; F. for at least 12 hours). The heating may partially or fully demagnetize the permanent magnets in the rotor. The exposed surfaces of the rotor are then cleaned and the permanent magnets in the rotor are remagnetized using a specialized magnetizing fixture.

A submersible pump electrical motor has a stator with a stator bore, a shaft with rotor sections in the stator bore, and a shaft bearing between rotor sections. The bearing has a bearing body having a hub and centralizing arms circumferentially spaced around the hub. Each of the arms curves and is biased against the stator bore wall. A tab on at least one of the arms engages a slot in the stator bore wall. The bearing body, the hub, and the arms are formed of a single-piece monolithic metal that undergoes elastic deflection of the arms when the bearing body is installed in the stator bore.

Biased centralizing arms bearing in submersible pump motor

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.

Coiled tubing power cable with varying inner diameter

A submersible well pump assembly has a pump driven by an electrical motor. The motor has a number of rotor sections axially separated from each other by radial bearings. Each of the rotor sections has disks stacked together, each of the disks having a central opening and slots circumferentially spaced around the central opening. Metal rods extend through the slots. A center tube extends through the central openings of the disks. The center tube has an outer diameter in an interference fit with the disks. A slot and key arrangement between the inner diameter of the center tube and the motor shaft rotates the motor shaft in unison. The ends of the center tube extend past end rings of the rotor sections and abut with center tubes of adjacent rotor sections.

Rotor section with center tube for submersible pump assembly motor

A submersible pump electrical motor has a bearing sleeve between first and second rotor sections and mounted to the shaft for rotation in unison. An insert sleeve surrounds the bearing sleeve. A carrier body surrounds the insert sleeve. A carrier anti-rotation ring on an outer diameter of the carrier body engages the bore of the stator. First and second seal rings are axially spaced apart from each other between an outer diameter of the insert sleeve and an inner diameter of the carrier body. A hole in the carrier body has an inner end at the inner diameter of the carrier body. An electrically conductive coil spring within the hole has an inner end protruding through the inner end of the hole into contact with the outer diameter of the insert sleeve, creating electrical continuity between the insert sleeve and the carrier body.

Electrical discharge prevention in bearing for submersible pump motor using a conductive spring between a sleeve and a carrier body

A method for installing an electrical submersible pump (ESP) in a well containing a production conduit includes securing an ESP to a lower end of a coiled tubing segment containing an electrical power cable. An operator secures a load transfer device with a gripping member to the coiled tubing segment above the ESP. The operator lowers the coiled tubing segment into the well along with the ESP and the load transfer device. The load transfer device contacts an interior side wall of the production conduit with the gripping member and transfers a load on the coiled tubing segment to the production conduit. When powered, the ESP causes well fluid to flow upward from the ESP through the load transfer device up the production conduit.

Load reduction device and method for reducing load on power cable coiled tubing

Systems and methods for constructing permanent magnet electric motors in which rotors have magnetically permeable end rings that are active for torque production. In one embodiment, a rotor section has a set of flat, generally annular laminations stacked on an inner rotor sleeve, with a pair of end rings positioned at opposing ends of the lamination stack to secure the stack. One or both of the end rings is made of a magnetically permeable and highly resistive material such as a soft magnetic composite, so that the end ring(s) actively produce torque during operation of the motor without significant increase in core loss at end rings. A set of permanent magnets are installed in or on the rotor core formed by the laminations. These magnets or other magnets may be positioned to axially overlap with the end rings and aid active torque production by the end rings.

Systems and methods for constructing permanent magnet motors having increased power density

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.

Electrically powered motor lubricant pressure compensator for submersible pump motor

An electrical submersible well pump motor has metal-to-metal sealing for the power cable electrical connection. A conductor passage in the motor head has a conical seat. A motor contact member electrically connected with the motor is located in the conductor passage below the seat. A metal tube has a lower portion that inserts into an upper portion of the conductor passage. A metal sealing ferrule encircles the tube, and a compression nut deforms the ferrule into sealing engagement with the seat and the tube. An electrical conductor extending from the power cable protrudes downward from the tube and has a conductor contact member on a lower end. The motor contact member and the conductor contact member stab into partial engagement with each other, defining a gap between terminal surfaces of the contact members that can close up during operation due to thermal growth.

Growing community of inventors

Broken Arrow, OK, United States of America

James Christopher Clingman