Baker Hughes, a Ge Compnay, LLC

Baker Hughes Oilfield Operations LLC

Baker Hughes Corporation

Yong Li

John Knapp

James Christopher Clingman

Jackson Reynolds

Howard G Thompson

Randal Perisho

Arslan Amjad

Scott C Strattan

Zheng Ye

Charles Collins

John M Knapp

Jackson E Reynolds

Systems and methods for manufacturing stators for electric submersible pumps, where a stator core having an inner portion and an outer portion is formed. The inner portion has a plurality of teeth and outward-facing slots. Magnet wire coils are formed on the inner portion by holding the inner portion in a stationary position and using a linearly movable robotic arm to position the magnet wire in each slot while preventing the wire from sliding axially with respect to the stator and adjacent turns of the coil. After forming the magnet wire coils on the inner portion of the stator core, the outer portion of the stator core is press-fit onto the inner portion to close the slots. The magnet wire can thereby be positioned to maximize the fill factor of each slot and increase power density for a given temperature rise.

Method for external winding of ESP motor using a split core stator

Systems and methods for monitoring and suppressing a back EMF generated by an ESP motor when the ESP system is moved in a well. Embodiments provide both electrical braking to reduce the rotation of the motor (and corresponding back EMF) and warnings to alert users to hazardous conditions caused by the back EMF. One embodiment includes an ESP system having a permanent magnet motor, a back EMF safety system, and a power cable connected between them. The proximal ends of the cable's conductors are connected terminals of the back EMF safety system, which has switches that are closed to short circuit the conductors so that back EMF currents from rotation of the motor induce electrical braking in the motor. Currents and phase-to-phase voltages on the conductors are monitored to detect overcurrent and overvoltage conditions that may trigger alarms or other actions.

Systems and methods for back-EMF monitoring and suppression during installation or pulling of PMM-driven ESP

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

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.

Systems and methods for electric motor, where the stator core has one or more stator core sections, each of which is a single-piece unit formed of soft magnetic composite (SMC) material, and where the stator core sections are positioned end-to-end with seals at each end to form a plurality of stator slots, where each of the stator slots extends through each of the stator core sections and is in fluid communication with the others to form a sealed stator chamber. The sealed stator chamber may have an expansion chamber to allow expansion and contraction of dielectric fluid in the stator chamber while maintaining separation of the dielectric oil from lubricating oil which is within the motor but external to the stator chamber. The sealed stator chamber can prevent well fluids that leak into the motor from reaching the stator windings and degrading their insulation.

ESP motor with stator core sections sealed to form a stator chamber

Methods for constructing ESP motors with sealed stator windings and stator chamber

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

ESP motor with sealed stator windings and stator chamber

An electrical submersible well pump assembly includes a rotary pump and a motor. An inner rotor is coupled to the motor shaft. The inner rotor has steel discs stacked together with end caps at each end. The discs have apertures that align to define axially extending slots. Each of the slots has a closed outer wall spaced radially inward from an outer diameter surface of the inner rotor. Inner rotor magnets are located within the slots. Continuous open and thin gaps between rotating components act as hydrodynamic bearings. Damper bars extend axially at points between the outer walls of the slots and the outer diameter surface of the inner rotor. An outer rotor has a bore that receives the inner rotor, the outer rotor being operatively coupled to the pump shaft for rotation therewith. Outer rotor magnets are mounted to the bore of outer rotor.

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Owasso, OK, United States of America

Yong Li