This invention relates generally to the field of submersible pumping systems, and more particularly, but not by way of limitation, to an improved volumetric compensator for use in a submersible pumping system.
Submersible pumping systems are often deployed into wells to recover petroleum fluids from subterranean reservoirs. Typically, the submersible pumping system includes a number of components, including one or more fluid filled electric motors coupled to one or more high performance pumps. Each of the components and sub-components in a submersible pumping system must be engineered to withstand the inhospitable downhole environment, which includes wide ranges of temperature, pressure and corrosive well fluids.
During installation and use, the motor undergoes repeated thermal cycles in which the temperature of the motor increases and decreases. As the motor temperature cycles, the lubricating fluid inside the motor expands and contracts. To prevent damage to seals within the motor from excessive pressure, it is important to provide a mechanism for accommodating the expansion of the motor lubricant. It is equally important to provide a mechanism that isolates the motor from contaminated wellbore fluids when the motor cools and the fluid lubricants contract. Pumping systems typically include fluid isolation systems designed to accommodate the volumetric changes of the motor lubricant, while isolating the clean motor lubricants from contaminated fluids from the wellbore.
In many pumping systems, “seal sections” are used to accommodate the expansion and contraction of motor lubricants while transmitting torque between the motor and pump. In other pumping systems, the fluid isolation mechanisms are incorporated within a dedicated volumetric compensator that is placed below the motor to accommodate the expansion and contraction of motor fluids without transferring torque from the motor to the pump. Many fluid isolation mechanisms employ seal bags to accommodate the volumetric changes and movement of fluid in the seal section. Seal bags can also be configured to provide a positive barrier between clean lubricant and contaminated wellbore fluid.
In other cases, bellows are used to accommodate the contraction and expansion of the internal fluid lubricants. The bellows are typically manufactured from a durable, flexible metal to mitigate water permeation under elevated temperatures. In the past, bellows seals have been configured such that the clean lubricant from the motor is directed into the interior of the bellows and wellbore fluid is contained in the variable space between the housing and the outside of the bellows. As the temperature of the lubricant fluid increases, the volumetric expansion of the fluid forces the bellows to expand, thereby displacing wellbore fluids in the housing. As the motor lubricant cools and contracts, the bellows contract and wellbore fluids are drawn into the housing. The bellows may expand and contract many times during the operation of the electric submersible pump.
Although generally effective at preventing wellbore fluid permeation at elevated temperatures, prior art metal bellows are expensive to manufacture and subject to mechanical failure following repeated flexing. In particular, the prolonged exposure to wellbore fluids and solid particles may increase friction at the interface between the metal bellows and the interior of the housing. Repeated rubbing may abrade the metal bellows, thereby compromising the isolating barrier between clean motor lubricant and contaminated wellbore fluids. There is, therefore, a need for an improved volumetric compensator that exhibits fluid impermeability under high temperatures while retaining the durability of conventional bag seals. It is to this and other needs that the present disclosure is directed.
In one aspect, the present invention provides a pumping system deployed in a wellbore has a motor, a pump driven by the motor, and a volumetric compensator connected to the motor to accommodate the expansion and contraction of fluids contained within the motor. The volumetric compensator has a head connected to the motor, a base that includes a fluid exchange port that extends to the wellbore, and a housing extending between the head and the base. The volumetric compensator further includes an inverted bellows assembly contained within the housing. The inverted bellows assembly includes a metal bellows that has an interior, an exterior, a proximal end and a distal end. The interior of the metal bellows is in fluid communication with the wellbore. The inverted bellows assembly may also include one or more guide rings connected to the exterior of the metal bellows. The guide rings are lubricated by the clean motor fluid surrounding the exterior of the metal bellows.
In another aspect, the present invention includes a pumping system deployed in a wellbore. The pumping system includes a motor, a pump driven by the motor, and a volumetric compensator connected to the motor such that the motor is positioned between the pump and the volumetric compensator. The volumetric compensator includes a head connected to the motor, a base that includes a fluid exchange port that extends to the wellbore, a housing extending between the head and the base, and an inverted bellows assembly contained within the housing. The inverted bellows assembly includes a metal bellows that has an interior, an exterior, a proximal end and a distal end. The interior of the metal bellows is in fluid communication with the wellbore.
In another aspect, the present invention includes an inverted bellows assembly configured for use in a pumping system deployed in a wellbore. The pumping system has a motor with motor lubricant and a pump driven by the motor to produce fluids from the wellbore. The inverted bellows assembly has a metal bellows with an interior and an exterior. The interior of the metal bellows is in fluid communication with the wellbore. The inverted bellows assembly also includes a guide ring connected to the exterior of the metal bellows, wherein the guide ring is in contact with the motor lubricant.
In accordance with an exemplary embodiment,
As used herein, the term “petroleum” refers broadly to all mineral hydrocarbons, such as crude oil, gas and combinations of oil and gas. The production tubing 102 connects the pumping system 100 to a wellhead 106 located on the surface. Although the pumping system 100 is primarily designed to pump petroleum products, it will be understood that the present invention can also be used to move other fluids. It will also be understood that, although each of the components of the pumping system 100 are primarily disclosed in a submersible application, some or all of these components can also be used in surface pumping operations. The pumping system 100 can also be deployed in offshore applications in which the surface is a production platform.
The pumping system 100 preferably includes some combination of a pump 108, a motor 110 and a volumetric compensator 112. In some embodiments, the motor 110 is an electrical motor that receives its power from a surface-based supply. The motor 110 converts the electrical energy into mechanical energy, which is transmitted to the pump 108 by one or more interconnected shafts. The pump 108 transfers a portion of this mechanical energy to fluids within the wellbore 104, causing the wellbore fluids to move through the production tubing 102 to the wellhead 106 on the surface. In some embodiments, the pump 108 is a turbomachine that uses one or more impellers and diffusers to convert mechanical energy into pressure head. In an alternative embodiment, the pump 108 is a progressive cavity (PC) or positive displacement pump that moves wellbore fluids with one or more screws or pistons.
The volumetric compensator 112 is configured to accommodate the expansion and contraction of motor lubricants or other fluids within the motor, while preventing the ingress of contaminants from the wellbore 104 into the motor 110. As used herein, the term “motor lubricant” refers to any liquid or fluid placed within the motor 110 during manufacture or repair. Although only one pump 108, volumetric compensator 112 and motor 110 are shown, it will be understood that the downhole pumping system 100 could include additional components, including pumps, seals sections, gas separators, volumetric compensators and motors.
Turning to
The head 116 is connected to the motor 110 and includes an inlet port 122 that places the motor lubricant within the interior of the motor 110 in fluid communication with the interior of the housing 114 in an annular space 124 around the outside of the inverted bellows assembly 120. As best depicted in
Continuing with
The metal bellows 130 includes an interior 138, an exterior 140, a proximal end 142, and a distal end 144. The proximal end 142 of the metal bellows 130 is secured to the base 118. The distal end 144 of the metal bellows 130 includes a top plate 146 and is free to linearly reciprocate within the housing 114 as the metal bellows 130 extends and collapses. The metal bellows 130, base 118 and top plate 146 cooperate to provide a sealed, variable volume chamber that surrounds the standoff post 128 and prevents the migration of wellbore fluids into the annular space 124 surrounding the inverted bellows assembly 120 within the housing 114.
The guide rings 132 are connected to the exterior 140 of the metal bellows 130 at various intervals. The guide rings 132 have an outside diameter that is larger than outside diameter of the convolutions of the metal bellows 130. The guide rings 132 are configured to provide a bearing interface with the interior of the housing 114 to facilitate the linear, reciprocating movement of the guide rings 132 and metal bellows 130 within the housing 114, while protecting the metal bellows 130 from direct contact with the housing 114. In other embodiments, the guide rings 132 are connected between adjacent sections of the metal bellows 130 rather than being connected to the exterior of a continuous section of the metal bellows 130.
As depicted in
Unlike the prior art use of guide rings and metal bellows, the inverted bellows assembly 120 is configured to place the guide rings 132 in contact with clean motor lubricant in the annular space 124 around the exterior 140 of the metal bellows 130. The clean motor lubricant significantly improves the low-friction interface between the housing 114 and the guide rings 132. This, in turn, improves the responsiveness and durability of the metal bellows 130 and reduces the risk of impingement between the guide rings 132 and the housing 114.
Turning back to
Thus, the inverted bellows assembly 120 presents several advantages over similar fluid isolation mechanisms deployed in prior art volumetric compensators and seal sections. By directing the contaminated wellbore fluids into the interior 138 of the metal bellows 130, the clean motor lubricant can be used to improve the functionality of the guide rings 132 that support the metal bellows 130 within the housing 114. Additionally, unlike conventional bellows or bag seals that are configured to expand with an increasing volume of motor fluid, the inverted bellows assembly 120 and volumetric compensator 112 cooperate to safely compress the metal bellows 130 to a minimum position against the standoff post 128. Additionally, as the metal bellows 130 are compressed, the convolutions of the metal bellows 130 will touch and support each other to reduce the risk of buckling failure from an increased pressure gradient across the metal bellows 130.
It is to be understood that even though numerous characteristics and advantages of various embodiments of the present invention have been set forth in the foregoing description, together with details of the structure and functions of various embodiments of the invention, this disclosure is illustrative only, and changes may be made in detail, especially in matters of structure and arrangement of parts within the principles of the present invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
It will be appreciated by those skilled in the art that the teachings of the present invention can be applied to other systems without departing from the scope and spirit of the present invention. For example, it will be appreciated that the inverted bellows assembly 120 may find utility in other applications. Similarly, it may be desirable in certain applications to place the entire volumetric compensator 112 in different locations within the pumping system 100 where the accommodation of expanding and contracting motor lubricants is necessary.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/898,477 filed Sep. 10, 2019 entitled, “Inverted Closed Bellows with Lubricated Guide Ring Support,” the disclosure of which is herein incorporated by reference.
Number | Name | Date | Kind |
---|---|---|---|
2857181 | Myers | Oct 1958 | A |
3475634 | Bogdanov et al. | Oct 1969 | A |
3677665 | Corkill | Jul 1972 | A |
3947709 | Waltman | Mar 1976 | A |
4421999 | Beavers et al. | Dec 1983 | A |
4436488 | Witten | Mar 1984 | A |
4477235 | Gilmer et al. | Oct 1984 | A |
4576404 | Weber | Mar 1986 | A |
4583923 | James | Apr 1986 | A |
4940911 | Wilson | Jul 1990 | A |
4992689 | Bookout | Feb 1991 | A |
5011166 | Watts | Apr 1991 | A |
5087846 | Wright | Feb 1992 | A |
5367214 | Turner | Nov 1994 | A |
5554897 | Martin et al. | Sep 1996 | A |
5622222 | Wilson et al. | Apr 1997 | A |
5796197 | Bookout | Aug 1998 | A |
6100616 | Heinig et al. | Aug 2000 | A |
6242829 | Scarsdale | Jun 2001 | B1 |
6268672 | Straub et al. | Jul 2001 | B1 |
6666664 | Gross | Dec 2003 | B2 |
6851935 | Merrill et al. | Feb 2005 | B2 |
6863124 | Araux et al. | Mar 2005 | B2 |
6971848 | Watson | Dec 2005 | B2 |
6979174 | Watson et al. | Dec 2005 | B2 |
6981853 | Du et al. | Jan 2006 | B2 |
7066248 | Howell | Jun 2006 | B2 |
7326034 | Sheth et al. | Feb 2008 | B2 |
7370697 | Sakamoto et al. | May 2008 | B1 |
7530391 | Hall et al. | May 2009 | B2 |
7654315 | Du et al. | Feb 2010 | B2 |
7708534 | Parmeter et al. | May 2010 | B2 |
7741744 | Watson et al. | Jun 2010 | B2 |
8221092 | Chilcoat et al. | Jul 2012 | B2 |
8328539 | Watson et al. | Dec 2012 | B2 |
8430649 | Albers et al. | Apr 2013 | B2 |
8604740 | D'Amico et al. | Dec 2013 | B2 |
8651837 | Tetzlaff | Feb 2014 | B2 |
8740586 | Martinez et al. | Jun 2014 | B2 |
8807966 | Du et al. | Aug 2014 | B2 |
9593693 | Howell et al. | Mar 2017 | B2 |
9777560 | Tetzlaff et al. | Oct 2017 | B2 |
9869322 | Tanner et al. | Jan 2018 | B2 |
9920774 | Ghasripoor et al. | Mar 2018 | B2 |
9995118 | Tanner et al. | Jun 2018 | B2 |
10094206 | Santos et al. | Oct 2018 | B2 |
10107050 | Williamson et al. | Oct 2018 | B2 |
10125759 | Pyron et al. | Nov 2018 | B2 |
20070142547 | Vaidya et al. | Jun 2007 | A1 |
20110097223 | Verichev et al. | Apr 2011 | A1 |
20140154101 | Gerrard et al. | Jun 2014 | A1 |
20150337843 | Tanner | Nov 2015 | A1 |
20170306733 | Reeves et al. | Oct 2017 | A1 |
Number | Date | Country |
---|---|---|
2004257928 | Dec 2008 | AU |
1080366 | Jan 1994 | CN |
101860108 | Oct 2010 | CN |
201726224 | Jan 2011 | CN |
2002242902 | Aug 2002 | JP |
2012136258 | Oct 2012 | WO |
2014105400 | Jul 2014 | WO |
2015094250 | Jun 2015 | WO |
2015185325 | Dec 2015 | WO |
2016081335 | May 2016 | WO |
WO-2016081335 | May 2016 | WO |
2018136651 | Jul 2018 | WO |
Entry |
---|
Kurokawa et al., JP 2002242902 Mach. Trans.—(“JP_2002242902_A_I_MT.pdf”), Aug. 2008 (Year: 2008). |
ISA/KR; Search Report for PCT/US2020/049880; dated Dec. 9, 2020. |
ISA/KR; Written Opinion for PCT/US2020/049880; dated Dec. 9, 2020. |
Number | Date | Country | |
---|---|---|---|
20210071510 A1 | Mar 2021 | US |
Number | Date | Country | |
---|---|---|---|
62898477 | Sep 2019 | US |