High speed electric submersible pumps
An electric submersible pump assembly with integral heat exchanger, high speed gas separator, high-speed self-aligning bearings, and dual bearing thrust chamber is described. The described gas separator may be used for operating an electric submersible pump at high speeds as well as over a wide range of speeds and flowrates without replacing downhole equipment.
1. An electric submersible pump assembly, comprising:
a pump module comprising a pump shaft and an impeller;
a high speed gas separator module comprising a gas separator shaft and an inducer;
a motor module comprising an electric motor configured to rotate a motor shaft;
a seal section configured to transmit torque from the motor shaft to the gas separator shaft and absorb thrust from the pump module; and
a single-piece housing coupling comprising a first end and a second end, the first end of the single-piece housing coupling comprising threads on an outer diameter which turn in a first direction, the second end of the single-piece housing coupling comprising threads on an outer diameter which turn in a second direction,
wherein (1) wherein an inner diameter of the pump module comprises threads which turn in a first direction and an inner diameter of the gas separator module comprises threads which turn in a second direction and wherein the pump module is joined directly to the gas separator module using the single-piece housing coupling, or (2) wherein an inner diameter of the gas separator comprises threads which turn in a first direction and an inner diameter of the seal section comprises threads which turn in a second direction and wherein the gas separator module is joined directly to the seal section using the single-piece housing coupling, or (3) wherein an inner diameter of the seal section comprises threads which turn in a first direction and an inner diameter of the motor module comprises threads which turn in a second direction; wherein the threads which turn in a first direction and wherein the threads which turn in a second direction of (1), (2), and (3) comprise opposite handed threads which turn in different directions; and wherein the seal section is joined directly to the motor module using the single-piece housing coupling;
wherein the gas separator module comprises a lining with a thickness of equal to or greater than 5 millimeter (mm) up to 12 millimeter (mm) and wherein the lining comprises steel, a steel alloy, a carbide, or any combination thereof.
2. The electric submersible pump assembly of claim 1 , further comprising a lock nut, and a spacer ring.
3. The electric submersible pump assembly of claim 1 , wherein the pump module is joined directly to the gas separator module using the single-piece housing coupling and the gas separator module is joined directly to the seal section using a second single-piece housing coupling.
4. The electric submersible pump assembly of claim 1 , wherein the pump module is joined directly to the gas separator module using the single-piece housing coupling and the seal section is joined directly to the motor module using a second single-piece housing coupling.
5. The electric submersible pump assembly of claim 1 , wherein the gas separator module is joined directly to the seal section using the single-piece housing coupling and wherein the seal section is joined directly to the motor module using a second single-piece housing coupling.
6. The electric submersible pump assembly of claim 5 , wherein the pump module is joined directly to the gas separator module using a third single-piece housing coupling.
7. The electric submersible pump assembly of claim 1 , wherein the carbide material comprises a silicon carbide, a tungsten carbide, a zirconium carbide, or any combination thereof.
8. A gas separator for use in an electric submersible pump assembly wherein the gas separator comprises:
a gas separator housing;
a plurality of chambers; and
a rotating assembly;
wherein (1) at least one of the plurality of chambers comprises a lining, and (2) wherein the rotating assembly comprises a lining; and wherein the gas separator comprises a top flange with a first high-speed self-aligning bearing and a bottom flange with a second high-speed self-aligning bearing and wherein the first high-speed self-aligning bearing and the second high-speed self-aligning bearing each comprise a bushing comprised of a first material and a sleeve comprised of a second material and wherein the first material and the second material have a different microhardness from each other.
9. The gas separator of claim 8 , wherein each lining comprises a stainless steel material.
10. The gas separator of claim 8 , wherein each lining comprises steel or a steel alloy that has been hardened, heat treated or coated.
11. The gas separator of claim 8 , wherein each lining comprises a carbide material.
12. The gas separator of claim 11 , wherein the carbide material comprises a silicon carbide, a tungsten carbide, a zirconium carbide, or any combination thereof.
13. The gas separator of claim 8 , wherein the thickness of each lining is equal to or greater than 5 millimeter (mm) up to 12 millimeter (mm).
14. The gas separator of claim 8 wherein the gas separator further comprises an inducer.