Patent Application
20180371852
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 the seal section of 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.
Components commonly referred to as “seal sections” protect the electric motors and are typically positioned between the motor and the pump. In this position, the seal section provides several functions, including transmitting torque between the motor and pump, restricting the flow of wellbore fluids into the motor, absorbing axial thrust imparted by the pump, and accommodating the expansion and contraction of the dielectric motor lubricant as the motor moves through thermal cycles during operation and pressure equalization. Many seal sections 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.
At high temperatures, water can permeate through the polymeric barrier materials that are used in modern seal bags. In such high temperature applications, metal barrier materials must be used. Although effective at preventing water permeation at elevated temperatures, metal barrier options are expensive to manufacture and subject to mechanical failure following repeated flexing. There is, therefore, a need for an improved seal bag that exhibits water impermeability under high temperatures while retaining the durability of conventional polymer bags. It is to this and other needs that the present invention is directed.
In one aspect, the present invention provides a volumetric compensator assembly that includes an envelope bladder that in turn includes a flexible top sheet and a bottom sheet connected to the top sheet along one or more seams. The top sheet and bottom sheet together define a bladder interior that has a variable capacity.
In another aspect, the present invention includes a volumetric compensator assembly for use in the seal section of a pumping system. The volumetric compensator assembly has a bladder support tube and an envelope bladder that is coiled around the bag support tube.
In another aspect, the present invention includes a downhole pumping system that has a motor assembly, a pump assembly driven by the motor assembly and a seal section positioned between the pump assembly and the motor assembly. The seal section includes a shaft and a volumetric compensator assembly. The volumetric compensator assembly includes a bladder support tube that surrounds the shaft and has an interior. The volumetric compensator assembly further includes an envelope bladder connected to the bladder support tube.
In accordance with a preferred embodiment of the present invention,
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 preferably includes some combination of a pump assembly 108, a motor assembly 110 and a seal section 112. In some embodiments, the motor assembly 110 is an electrical motor that receives its power from a surface-based supply. The motor assembly 110 converts the electrical energy into mechanical energy, which is transmitted to the pump assembly 108 by one or more shafts. The pump assembly 108 then 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 assembly 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 assembly 108 is a progressive cavity (PC) or positive displacement pump that moves wellbore fluids with one or more screws or pistons.
The seal section 112 shields the motor assembly 110 from mechanical thrust produced by the pump assembly 108. The seal section 112 is also configured to prevent the introduction of contaminants from the wellbore 104 into the motor assembly 110. Although only one pump assembly 108, seal section 112 and motor assembly 110 are shown, it will be understood that the downhole pumping system 100 could include additional pumps assemblies 108, seals sections 112 or motor assemblies 110.
Referring now to
Continuing with
The lower separation module 118b includes a conventional seal bag assembly 126. The seal bag assembly 126 includes a seal bag 128, bag support tube 130 and a seal bag retention mechanism 132. The bag support tube 130 provides support for the seal bag 128 and shields the shaft 122 as its passes through the seal bag 128. In some embodiments, the seal bag 128 is fabricated from a suitable plastic, polymer or elastomer, all of which are commercially available from a number of sources, including E.I. du Pont de Nemours and Company and Daikin Industries. Suitable materials include PFA, AFLAS® and other fluoropolymer plastics that exhibit favorable resistance to corrosive chemicals and elevated temperatures.
In contrast to the seal bag assembly 126 found in the lower separation module 118b, the upper separation module 118a includes a volumetric compensator assembly 134. Generally, the volumetric compensator assembly 134 includes a substantially flat envelope bladder 136 that is secured to a bladder support tube 138. The bladder support tube 138 surrounds the shaft 122 and provides a fluid path from the motor assembly 110, around the shaft 122, through ports 140 to the interior of the envelope bladder 136. The envelope bladder 136 expands and contracts as fluid passes in and out of the envelope bladder 136.
The volumetric compensator assembly 134 is shown in greater detail in
The relatively flat construction of the envelope bladder 136 permits the use of highly impermeable metal materials. In some embodiments, the envelope bladder 136 includes an outer foil layer 156 that is fused or otherwise secured to a support matrix 158. The support matrix 158 can be manufactured from flexible wire mesh to which the outer foil layer 156 is welded, brazed, diffusion bonded, glued or otherwise secured. In other embodiments, the envelope bladder 136 is constructed from a single layer of material. Suitable materials of construction include metal foils and plastic and polymer or elastomers, such as polytetrafluoroethylene (PTFE) and perfluoroalkoxy (PFA).
Turning to
Turning to
Although the volumetric compensator assembly 134 is disclosed within the seal section 112, it will be understood that the volumetric compensator assembly 134 may also be incorporated within a designated fluid expansion module connected directly or indirectly to the motor assembly 110. For example, in some embodiments, the volumetric compensator assembly 134 is incorporated within a designated fluid expansion module connected to the opposite end side of the motor assembly 110 from the seal section 112. In yet other embodiments, two or more volumetric compensator assemblies 134 are incorporated within the pumping system 100. In such embodiments, it may be useful to employ volumetric compensator assemblies 134 above and below the motor assembly 110 to both shield the motor assembly 110 from wellbore fluids and to permit the expansion and contraction of lubricants within the motor assembly 110.
The exemplary embodiments include a method of isolating expanding fluids using the volumetric compensator assembly 134. The method includes the steps of providing the volumetric compensator assembly 134 within a component in the pumping system 100 such that an internal fluid is placed in fluid communication with the bladder interior 154 of the envelope bladder 136. The method further includes the step of containing the interior fluid within the envelope bladder 136 as it expands under increasing pressure. The step of containing the interior fluid within the envelope bladder 136 further comprises containing the interior fluid within the envelope bladder 136 as the envelope bladder 136 uncoils within the component of the pumping system 100.
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.
