This disclosure relates in general to electrical submersible well pumps and in particular to a seal section for equalizing internal motor lubricant pressure with the hydrostatic well fluid pressure, the seal section having a metal bellows with guide rings to reduce wear.
Electrical submersible pump assemblies (ESP) are commonly employed to pump well fluid from oil producing wells. A typical ESP has a pump driven by an electrical motor filled with a dielectric motor lubricant. A pressure equalizer or seal section cooperatively connects with the motor to reduce a pressure differential between the motor lubricant and well fluid on the exterior.
One type of seal section employs bellows, typically metal. The seal section has an inner axially extending guide tube located within a cylindrical housing. In one arrangement, an outer bellows has one end fixed to an end of the housing and another end free to float or move axially. An inner bellows of smaller outer diameter has a fixed end secured to an opposite end of the housing and a floating end fixed to the floating end of the outer bellows. When the hydrostatic pressure differs from the motor lubricant pressure, one of the bellows extends while the other contracts to equalize the motor lubricant pressure with the hydrostatic pressure. Extension and contraction may occur while running the ESP into the well. Extension and contraction also occurs as the motor lubricant heats and cools. Heating and cooling occurs each time the motor re-starts after being turned off.
The inner diameter of the corrugated flexible wall of the inner bellows will contact and slide along the guide tube during extension and contraction of the inner bellows. Similarly, the outer diameter of the corrugated flexible wall of the outer bellows will contact and slide along the inner surface of the housing during extension and contraction of the outer bellows. The sliding movement of the inner diameter portions of the inner bellows against the guide tube can cause wear of the thin corrugated wall. The sliding movement of the outer diameter portions of the outer bellows against the inner surface of the housing can cause wear of the thin corrugated wall of the outer bellows. As larger volume, longer inner and outer bellows are developed, the extent of the sliding, rubbing contact increases because the axial travel range of the floating ends increases. The wear of the thin metal of the inner and outer bellows can result in a reduced fatigue life.
The well pump assembly disclosed herein has a pump driven by an electrical motor. A seal section is operatively coupled to the motor for reducing a pressure difference between dielectric lubricant in the Motor and hydrostatic well fluid pressure on an exterior of the motor. The seal section has a guide member having a longitudinal axis and a cylindrical guide surface. A bellows is coaxial with the guide member and has a flexible corrugated wall that is closely spaced to the guide surface. The corrugated wall moves axially relative to the guide surface when the bellows contracts and extends. A guide ring is secured to the wall of the bellows between ends of the bellows. The guide ring has a contacting surface protruding slightly from the wall and slidingly engaging the guide surface as the bellows contracts and extends.
A wear resistant element may be on at least one of the surfaces of the guide ring and the guide member to reduce friction and increase wear life. The wear resistant element may comprise a coating on at least one of the surfaces of the guide ring and the guide member. The wear resistant element may comprise an insert member of a hard, wear resistant material bonded to the guide ring.
A plurality of axially extending grooves may be formed in at least one of the surfaces of the guide ring and guide member, the grooves being circumferentially spaced apart from each other.
The bellows comprises at least two separate flexible corrugated wall segments. The guide ring joins and secures mating ends of the two segments together.
In an alternate embodiment, the guide ring has an intermediate portion, a first cylindrical extension protruding axially from the intermediate portion in one direction and a second cylindrical extension protruding axially from the intermediate portion in an opposite direction. The first and second cylindrical extensions have a diameter that differs from a diameter of the intermediate portion. The bellows comprises at least two separate flexible corrugated wall segments, each of the segments having an end that secures to the intermediate portion of the guide ring. Each of the segments has a corrugated portion of the wall extending alongside one of the cylindrical extensions. The contacting surface of the guide ring extends from a free end of one of the cylindrical extensions to a free end of another of the cylindrical extensions, defining a greater axial length for the contacting surface than the axial dimension of the intermediate portion.
The guide surface of the guide member may be located on an outer diameter of the guide member. In that instance, the wall of the bellows surrounds the guide surface, and the contacting surface of the guide ring protrudes inward from the wall of the bellows.
The guide surface may also be located on an inner diameter of the guide member. In that instance, the wall of the bellows is located within the inner diameter of the guide member. The contacting surface of the guide ring protrudes outward from the wall of the bellows.
So that the manner in which the features, advantages and objects of the disclosure, as well as others which will become apparent, are attained and can be understood in more detail, more particular description of the disclosure briefly summarized above may be had by reference to the embodiment thereof which is illustrated in the appended drawings, which drawings form a part of this specification. It is to be noted, however, that the drawings illustrate only a preferred embodiment of the disclosure and is therefore not to be considered limiting of its scope as the disclosure may admit to other equally effective embodiments.
The methods and systems of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The methods and systems of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout. The terms “upper”, “lower” and the like are used only for convenience and not in a limiting manner.
It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation.
Referring to
ESP 11 has a seal section or pressure equalizer 17, a thrust bearing unit 19, and an electrical motor 21. Seal section 17 normally connects to pump intake 15; however, if a gas separator (not shown) is employed, pump intake 15 will be at the upstream end of the gas separator instead of the upstream end of pump 13. Thrust bearing unit 19 may be a separate module secured to seal section 17 or it may be located within an upstream end of seal section 17. Motor 21 usually connects to the lower end of seal section 17 or thrust bearing unit 19. Motor 21 rotates a shaft assembly (not shown in
Motor 21 is typically a three-phase electrical motor supplied with power from a motor lead 23 at the lower end of a power cable extending to the wellhead. Motor 21 is filled with a dielectric motor lubricant for lubricating bearings within motor 21. The motor lubricant is in communication with thrust bearing 19 and part of seal section 17. Seal section 17 seals around the shaft assembly and reduces a pressure difference between the motor lubricant and the hydrostatic pressure of well fluid on the exterior of ESP 11. Pump 13, seal section 17, thrust bearing unit 19, and motor 21 may be connected together with bolted connections, with threaded collars, or other arrangements.
Referring to
Shaft 31 is located within an inner guide tube 34 that extends from motor end adapter 29 to pump end adapter 27. Guide tube 34 does not rotate, rather serves to communicate motor lubricant from motor 21 (
In this embodiment, seal section 17 has an outer bellows 35 located within housing 25 and surrounding guide tube 34. Outer bellows 35 is preferably metal and comprises a cylinder with a flexible corrugated wall. Outer bellows 35 has a fixed end 37 sealingly secured to one of the adapters, which in this embodiment comprises pump end adapter 27. Outer bellows 35 has a floating end 39 that moves axially within housing 25 when outer bellows 35 contracts and extends. Outer bellows 35 is made up of a number of corrugated wall segments 41 that are joined to each other to achieve the desired overall length of outer bellows 35. In this example, outer bellows 35 has four separate segments 41 but it could be more or less. Outer bellows guide rings 43 join the adjacent separate segments 41 to each other in a manner that will be explained in connection with
Seal section 17 has an inner bellows 45 also located within housing 25 and surrounding guide tube 34. Inner bellows 45 is preferably metal and comprises a cylinder with a flexible corrugated wall of smaller outer diameter than an inner diameter of outer bellows 35. Inner bellows 45 has a fixed end 47 sealingly secured to the other adapter, which in this embodiment comprises motor end adapter 29. Inner bellows 45 has a floating end 49 that moves axially within housing 25 when inner bellows 45 contracts and extends.
Inner bellows floating end 49 is cooperatively joined to outer bellows floating end 39 for axial movement therewith. In this embodiment, a sleeve 51 joins floating ends 39 and 49 to each other. Sleeve 51 has an internal flange 53 at a lower end that sealingly secures to inner bellows floating end 49. Sleeve 51 has an external flange 54 at an upper end that sealing secures to outer bellows floating end 39. Sleeve 51 places the interiors of inner and outer bellows 45, 35 in fluid communication with each other for containing motor lubricant.
Inner bellows 45 is also made up of several separate segments 55. Inner bellows guide rings 57 sealingly join the separate segments 55. In this example, inner bellows 45 has four segments 55 joined by three guide rings 57, but the number could differ. The discussion of
Seal section 17 has a well fluid entry port 59 in pump end adapter 27 that admits well fluid into housing 25 on the outer sides of inner and outer bellows 45, 35. The well fluid will be located in a chamber 61 and in contact with the outer sides of inner and outer bellows 45, 35. The combined interior or volume of inner and outer bellows 45, 35 is initially filled with motor lubricant. Extension and contraction of inner and outer bellows 45, 35 reduces or equalizes the motor lubricant pressure with the hydrostatic well fluid pressure on the exterior of seal section 17. Also, over time, the volume of lubricant in inner and outer bellows 45, 35 may deplete.
Referring to
Each inner bellows guide ring 57 has an inner diameter or contacting surface 75 that is smaller than the minimum inner diameter defined by inner bends 65. Thus each guide ring 57 protrudes radially inward past the effective inner diameter of corrugated wall 63, preferably by an amount slightly less than gap 69. The protrusion is sufficient for contacting surface 75 to substantially contact the outer diameter of guide tube 34, preventing the inner bends 65 of inner bellows guide ring 57 from contacting guide tube 34. A small clearance between contacting surface 75 and guide tube 34 will be provided for tolerances in the outer diameter of guide tube 34 and contacting surface 75 of guide ring 57. Guide rings 57 and guide tube 34 do not rotate relative to each other, but guide rings 57 do slide axially relative to guide tube 34 when inner bellows 45 extends and contracts.
Inner bellows guide rings 57 may have upper and lower corners 77 with a large radius to facilitate axial sliding on guide tube 34. Upper and lower corners 77 join inner contacting surface 75 with upper and lower ends of guide rings 57.
Motor lubricant will be located in the interior of inner bellows 45, thus will provide lubrication between contacting surfaces 75 and the outer surface of guide tube 34. However, a wear resistant element may be employed to increase the wear life between guide ring inner contacting surface 75 and guide tube 34. The wear resistant element may comprise a coating 79 on guide ring inner contacting surface 75, a coating 81 on the outer diameter of guide tube 34, or both, as shown. Coatings 79, 81 may be any suitable materials to enhance wear resistance, including hard, wear resistant materials and low friction materials. For example, coatings 79, 81 may comprise layers of tungsten carbide.
Referring to
The protrusion of outer bellows guide rings 43 radially outward from the corrugated wall of outer bellows 35 prevents outer bends 83 from axially sliding against housing inner diameter 84 during expansion and contraction. The engagement of outer bellows guide ring contacting surfaces 91 with housing inner diameter 84 will be lubricated by well fluid. However, wear resistant elements such as coatings 79, 81 of inner bellows guide rings 57 and guide tube 34 may be employed.
Referring to
In operation, referring to
When reaching the desired depth, the operator turns on motor 21 to operate pump 13 (
As outer bellows 35 contracts and inner bellows 45 extends, inner bellows guide rings 57 slide on guide tube 34. Outer bellows guide rings 43 slide on inner guide surface 84 of housing 25 at the same time. Similarly, the extension of outer bellows 35 and contraction of inner bellows 45 causes inner bellows guide rings 57 to slide on guide tube 34 and outer bellows guide rings 43 to slide on housing inner guide surface 84. During the axial sliding movement, inner bellows guide rings 57 prevent sliding contact of the inner diameter or inner bends 65 with guide tube 34, avoiding wear on the thin surfaces of inner bellows 45. Outer bellows guide rings 43 prevent sliding contact of the lower diameter or outer bends 83 with housing inner guide surface 84.
Each extension 105, 109 has a free end 113. The length of guide member 103 measured from the upper free end 113 to the lower free end 113 is longer than the axial length of intermediate portion 107. Coatings 79, 81 optionally may be placed on the inner surfaces of intermediate portion 107 and upper and lower extensions 105, 109. Axial grooves, such as grooves 95 are feasible. Cylindrical extensions could also be employed with outer bellows guide rings 43 (
While shown in only a few of its forms, it should be apparent to those skilled in the art that the disclosure is not limited to the embodiments shown. For example, the outward protrusion of outer bellows guide rings may not be needed in some instances. The wear resistant elements such as the coatings or inserts may not be required in some instances. The arrangement of outer bellows and inner bellows can differ.
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Entry |
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PCT Search Report mailed Feb. 3, 2016—S.N. PCT/US2015/060797, Filed Nov. 16, 2015. |
Number | Date | Country | |
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20160138375 A1 | May 2016 | US |