Apparatus and system for sealing submersible pump assemblies

Abstract

An apparatus and system for sealing an electrical submersible pump (ESP) assembly are described. An ESP system includes a top portion of a seal section including a sand barrier portion defined by a sand barrier stop secured between the ESP intake and an adapter portion, the sand barrier portion including a sand barrier wedged between the sand barrier stop and the adapter portion, the adapter portion encasing a mechanical seal and secured between the sand barrier portion and a head portion, the head portion secured between the adapter portion and a seal section housing, the head portion including a thrust bearing and a thrust runner, wherein each of the thrust bearing and the thrust runner includes at least one pad having a diamond-like carbon (DLC) layer on an outer surface.

Claims

1. A seal for an electric submersible pump assembly comprising a rotatable shaft extending axially through the seal section; a head tubularly surrounding a top portion of the seal section and coupled to a centrifugal pump intake, wherein the head further comprises: a mechanical seal, a well-fluid exit aperture proximate to the mechanical seal and extending radially through a wall of the head to the mechanical seal, wherein the well-fluid exit aperture flushes debris away from the mechanical seal, and a motor-oil vent port extending radially through the wall of the head and coupled to a communication port, the motor oil vent port located below the mechanical seal.

2. A seal section for an electric submersible pump assembly comprising: a rotatable shaft extending axially through a seal section; a top portion of the seal section comprising: a sand barrier that blocks sand from accumulating on a mechanical seal, the sand barrier substantially sealed from leaks on an inner and outer diameter; an adapter secured between a pump intake and a head of the seal section, the adapter holds the sand barrier in place; the mechanical seal coupled to the rotatable shaft within the adapter and cooled by well fluid flowing through the adapter, and the head tubularly surrounding a bearing set in motor oil and coupled to a seal section housing; wherein the bearing set further comprises: a thrust bearing coupled to the head and a thrust runner keyed to the rotatable shaft.

3. The seal section of claim 2, wherein one of the thrust bearing or the thrust runner comprises a diamond-like carbon layer.

4. The seal section of claim 3, wherein the diamond-like carbon layer is a vapor deposition of diamond-like carbon.

5. The seal section of claim 2, wherein each of the thrust bearing and the thrust runner comprise a diamond-like carbon layer.

6. A seal section for an electric submersible pump assembly comprising: a rotatable shaft extending axially through a seal section; a top portion of the seal section comprising: a sand barrier that blocks sand from accumulating on a mechanical seal, the sand barrier substantially sealed from leaks on an inner and outer diameter; a sand barrier stop extending longitudinally and around the outer diameter of the sand barrier, the sand barrier stop coupled to a centrifugal pump intake, an adapter secured between the sand barrier stop and a head, the sand barrier wedged between the sand barrier stop and the adapter, the mechanical seal coupled to the rotatable shaft within the adapter and cooled by well fluid flowing through the adapter, and; the head tubularly surrounding a bearing set in motor oil and coupled to a seal section body; wherein the bearing set further comprises: a thrust bearing coupled to the head and a thrust runner keyed to the rotatable shaft.

7. The seal section of claim 6, wherein the thrust runner comprises: a base comprising a disc-shaped impression; a runner pad fit within the impression; and a diamond-like carbon layer on an outer surface of the runner pad.

8. The seal section of claim 7, wherein the thrust bearing comprises: a plurality of bearing pads secured circumferentially about a bearing holder with a locking plate; and a diamond-like carbon layer on an outer surface of each of the plurality of bearing pads.

9. The seal section of claim 6, wherein the sand barrier is coupled to the rotatable shaft on an inner diameter and the adapter on an outer diameter.

10. The seal section of claim 6, wherein the outer diameter of the sand barrier is sandwiched between the sand barrier stop and the adapter.

11. The seal section of claim 6, further comprising a motor-oil vent port located upstream of the mechanical seal and extending radially through a wall of the head from a communication port.

12. The seal section of claim 6, wherein the thrust bearing is pressed into a shelf of the head.

13. A electric submersible pump (ESP) system for pumping solid-laden fluid comprising: a top portion of a seal section secured on a downstream side to an ESP intake, the top portion comprising: a sand barrier portion defined by a sand barrier stop, the sand barrier stop secured between the ESP intake and an adapter portion, the sand barrier portion comprising a sand barrier that prevents sand from accumulating on a mechanical seal, the sand barrier sealedly coupled to a rotatable shaft on an inner diameter and sandwiched between the sand barrier stop and the adapter portion on an outer diameter, the adapter portion tubularly encasing the mechanical seal cooled by well fluid flowing through the adapter portion, the adapter portion secured between the sand barrier portion and a head portion, and the head portion secured between the adapter portion and a seal section housing, the head portion comprising a bearing set in motor oil, the bearing set comprising: a thrust bearing and a thrust runner, wherein each of the thrust bearing and the thrust runner comprises at least one pad; and the at least one pad of each of the thrust bearing and the thrust runner comprising a diamond-like carbon (DLC) layer on an outer surface such that the DLC layer on the thrust bearing faces the DLC layer on the thrust runner.

14. The system of claim 13, further comprising a check valve extending radially through a wall of the head, the check valve fluidly coupled to a communication port and configured to vent expanding motor oil.

15. The system of claim 13, wherein the DLC layer is one of a physical vapor deposition or a plasma-assisted chemical vapor deposition.

16. The system of claim 13, wherein the at least one pad of the thrust runner is a single disc-shaped runner pad.

17. The system of claim 16, wherein the at least one pad of the thrust bearing is a plurality of bearing pads dispersed circumferentially about a bearing holder and secured by a locking plate.

18. An apparatus for absorbing a thrust of an electric submersible pump (ESP) comprising: an ESP configured to pump a well fluid; an electric motor operatively coupled to the ESP, the motor operating to rotate a shaft of the ESP; a seal section located between the ESP and the motor, the seal section comprising: a thrust bearing comprising a plurality of bearing pads, wherein each of the plurality of bearing pads has a deposition diamond-like carbon film on an outer surface of the bearing pad, the deposition diamond-like carbon film having a thickness of between one and six microns, and a thrust runner paired with the thrust bearing to form a bearing set, wherein the thrust runner rotates with the shaft, the thrust runner comprising having a single disc shaped runner pad secured within an impression in a thrust runner base, wherein the single pad has a deposition diamond-like carbon film on an outer surface of the single runner pad, the deposition diamond-like carbon film having a thickness of between one and six microns; wherein the bearing set is located in a head in a top portion of the seal section; wherein the head is secured between an adapter and a seal section housing, and wherein the adapter comprises a mechanical seal; wherein the adapter is secured between the head and a sand barrier stop.

19. The apparatus of claim 18, wherein the plurality of bearing pads are arranged around a face of the thrust bearing.

20. The apparatus of claim 18, wherein the deposition diamond-like carbon film on the outer surface of the bearing pads and the runner pad is a physical vapor deposition film.

21. The apparatus of claim 18, wherein the deposition diamond-like carbon film on the outer surface of the bearing pads and the runner pad is a plasma-assisted chemical vapor deposition film.

22. The apparatus of claim 18, wherein the sand barrier stop is secured to an intake of the ESP.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Advantages of the present invention may become apparent to those skilled in the art with the benefit of the following detailed description and upon reference to the accompanying drawings in which:

(2) FIG. 1 is a schematic side view of a conventional electric submersible pump assembly of the prior art.

(3) FIG. 2 is an illustrative embodiment of a sectional view of a seal section of a submersible pump assembly.

(4) FIG. 3A is an illustrative embodiment of a perspective view of a top of a seal section.

(5) FIG. 3B is a cross sectional view taken along line 3B-3B of FIG. 3A of an illustrative embodiment of a top of seal section.

(6) FIG. 4 is a perspective view of an illustrative embodiment of a thrust bearing.

(7) FIG. 5A is a perspective view of a bearing set of an illustrative embodiment.

(8) FIG. 5B is a cross sectional view taken along line 5B-5B of FIG. 5A of a bearing set of an illustrative embodiment.

(9) FIG. 5C is a cross sectional view taken along line 5C-5C of FIG. 5A of a bearing set of an illustrative embodiment.

(10) FIG. 6 is a sectional view of diamond coated pad of an illustrative embodiment.

(11) FIG. 7A is a schematic of a top view of a locking plate of an illustrative embodiment.

(12) FIG. 7B is a cross sectional view taken along line 7B-7B of FIG. 7A of a locking plate of an illustrative embodiment.

(13) FIG. 8A is a top view of a thrust runner of an illustrative embodiment.

(14) FIG. 8B is a cross sectional view taken along line 8B-8B of FIG. 8A of a thrust runner of an illustrative embodiment.

(15) FIG. 9A is a top view of a thrust bearing of an illustrative embodiment.

(16) FIG. 9 B is a cross sectional view taken along line 9B-9B of FIG. 9A of a thrust bearing of an illustrative embodiment.

(17) FIG. 10 is a perspective view of a thrust runner of an illustrative embodiment.

(18) FIG. 11 is a schematic of a conventional seal section of the prior art.

(19) FIG. 12A is a perspective view of a conventional thrust bearing of the prior art.

(20) FIG. 12B is a cross sectional view taken along line 12B-12B of FIG. 12A of a conventional thrust bearing of the prior art.

(21) FIG. 13 is a sectional view of a seal section of an illustrative embodiment of a submersible pump assembly.

(22) FIG. 14A is a top plan view of a thrust bearing of an illustrative embodiment.

(23) FIG. 14B is a cross sectional view across line 14B-14B of FIG. 14A of a thrust bearing of an illustrative embodiment.

(24) FIG. 15A is a top plan view of a thrust runner of an illustrative embodiment.

(25) FIG. 15B is a cross sectional view across line 15B-15B of a thrust runner of an illustrative embodiment.

(26) FIG. 16 is a perspective view of a thrust bearing of an illustrative embodiment.

(27) FIG. 17 is a perspective view of a thrust runner of an illustrative embodiment.

(28) While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and may herein be described in detail. The drawings may not be to scale. It should be understood, however, that the embodiments described herein and shown in the drawings are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the scope of the present invention as defined by the appended claims.

DETAILED DESCRIPTION

(29) An apparatus and system for sealing submersible pump assemblies will now be described. In the following exemplary description, numerous specific details are set forth in order to provide a more thorough understanding of embodiments of the invention. It will be apparent, however, to an artisan of ordinary skill that the present invention may be practiced without incorporating all aspects of the specific details described herein. In other instances, specific features, quantities, or measurements well known to those of ordinary skill in the art have not been described in detail so as not to obscure the invention. Readers should note that although examples of the invention are set forth herein, the claims, and the full scope of any equivalents, are what define the metes and bounds of the invention.

(30) As used in this specification and the appended claims, the singular forms a, an and the include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to an aperture includes one or more apertures.

(31) As used in this specification and the appended claims, the term diamond includes true diamond as well as other natural or manmade diamond-like carbon materials, which may have a crystalline, polycrystalline and/or graphite structure. Diamond coating and diamond coated as used herein is intended to encompass composites of diamond in combination with other materials and having at least 5% pure diamond by weight.

(32) As used herein, the terms sand, debris, dirt, particles, and solids are used interchangeably to refer to solid contamination in pumped well fluid.

(33) As used herein, the term outer or outward means the radial direction away from the shaft of the ESP pump assembly. In the art, outer diameter and outer circumference are sometimes used equivalently. As used herein, the outer diameter is used to describe what might otherwise be called the outer circumference of a pump component such as a thrust bearing, thrust runner or sand barrier.

(34) As used herein, the term inner or inward means the radial direction towards the shaft of the ESP pump assembly. In the art inner diameter and inner circumference are sometimes used equivalently. Herein, the inner diameter is used to describe what might otherwise be called the inner circumference of a pump component such as a thrust bearing, thrust runner or sand barrier.

(35) Coupled refers to either a direct connection or an indirect connection (e.g., at least one intervening connection) between one or more objects or components. The phrase directly attached means a direct connection between objects or components.

(36) Downstream refers to the direction substantially with the principal flow of well fluid when the submersible pump assembly is in operation. The top of a component of an ESP assembly refers to the downstream portion of that component. By way of example but not limitation, in a vertical downhole ESP assembly, the downstream direction may be towards the surface of the well.

(37) Upstream refers to the direction substantially opposite the principal flow of well fluid when the submersible pump assembly is in operation. The bottom of a component of an ESP assembly refers to the upstream portion of that component. By way of example but not limitation, in a vertical downhole ESP assembly, the upstream direction may be opposite the surface of the well.

(38) One or more embodiments of the invention provide an apparatus and system for sealing submersible pump assemblies. While for illustration purposes the invention is described in terms of a submersible pump assembly, nothing herein is intended to limit the invention to that embodiment. The invention may be equally applicable to any pump assembly and/or electric motor which must be sealed from fluids and/or particulate contamination, such as a horizontal surface pump assembly.

(39) The invention disclosed herein includes an apparatus and system for sealing submersible pump assemblies. Illustrative embodiments improve the performance of an ESP seal section, particularly when pumping solid-laden well fluid. Improvements to the seal section of a submersible pump assembly may include a fixed (stationary) sand barrier in the head of the seal section, downstream of a mechanical seal, the sand barrier sealed from leaks to prevent sand from falling down production tubing and accumulating on the mechanical seal. A diamond-coated thrust bearing and thrust runner may be located in a thrust chamber created between the sand barrier and the mechanical seal, in the seal section head away from the motor, to reduce buckling of the assembly. Well fluid flowing through this thrust chamber may serve as a hydrodynamic fluid for the bearing set, which bearing set, unlike conventional hydrodynamic bearings, need not be located in a clean chamber of motor oil. One or more horizontal apertures in the head of the seal section may allow well fluid to lubricate and cool the thrust bearing and/or mechanical seal, act as a hydrodynamic fluid and/or flush away accumulated debris. A vent port for venting expanding motor oil, may be located in the wall of the head of the seal section upstream of the mechanical seal, run substantially perpendicular to the shaft, be fluidly coupled to the communication port and/or prevent sand from plugging the communication port of the seal section. A tungsten carbide bushing set upstream of the mechanical seal may provide radial support in contaminated well fluid conditions.

(40) The invention includes an apparatus for sealing submersible pump assemblies. FIGS. 2, 3A and 3B illustrate a top portion of a seal section of illustrative embodiments. Seal section 200 may be part of an ESP assembly and coupled to an electric motor well known to those of skill in the art on an upstream side, and a centrifugal pump, ESP charge pump and/or pump intake well known to those of skill in the art on a downstream side. For example, the electric motor may be a two-pole, three-phase, squirrel cage induction motor, or a permanent magnet motor. The ESP pump may be a multistage centrifugal pump. The intake for the ESP assembly may be a bolted-on or integral intake.

(41) Seal section 200 may be a seal section of a submersible pump assembly located in a downhole well, such as an oil, water and/or gas well. As shown in FIG. 2, seal section 200 includes shaft 220 running axially through the center of seal section 200. During operation of the ESP assembly, shaft 220 rotates about its vertical axis. The ESP motor and ESP pump of the ESP assembly similarly contain rotating shafts, which are all connected such that the motor turns the pump and the pump lifts fluid to the surface of the well. Head 280 encases the top portion of seal section 200 in a tubular fashion. Head 280 may comprise steel bar stock. In some embodiments the bar stock may have a 4 inch diameter. Head 280 may be machined and its top side and threaded to the ESP pump, ESP charge pump and/or ESP intake. The bottom side of head 280 may be pinned, bolted, threaded or otherwise attached to the first seal chamber of seal section 200. In some embodiments, head 280 is attached, threaded and/or bolted at a downstream side to the pump intake. The base (not shown) of seal section 200 may be threaded and/or bolted to the electric motor the ESP assembly.

(42) Sand Barrier

(43) As shown in FIGS. 2 and 3B, seal section 200 may include sand barrier 210. Sand barrier 210 may be fixed in place and/or may not rotate with shaft 220. Sand barrier 210 may be sealed from leaks, such that well fluid and/or its associated solids may not fall upstream, down the production tubing, and accumulate on mechanical seal 250 and/or mechanical seal faces 255. Instead, sand barrier 210 may catch accumulating debris, keeping the debris away from more vital seal section components, such as thrust bearing 260, thrust runner 205 and mechanical seal 250. The outer circumference (outer diameter) of sand barrier 210 may be pressed against the inner side of the wall of head 280 and sealed with gasket 230, such as an o-ring. Gasket 230 may be inserted into an o-ring groove in head 280. The inner circumference (inner diameter) of sand barrier 210 may be sealed against shaft 220 with radial shaft seal 240 (lip seal) to prevent sand from leaking through the barrier while still allowing shaft 220 to rotate. Sand barrier 210 may prevent sand, well fluid and/or other particulates carried in well fluid from bypassing the barrier and collecting on thrust bearing 260, thrust runner 205 and/or mechanical seal 250. In some embodiments, sand barrier 210 is stainless steel grade 316 and about inch thick. Adapter 325 may be located at, on or near the top of head 280 and assists in holding sand barrier 210 in place, for example by preventing shaking or sliding of sand barrier 210 and/or by wedging or sandwiching sand barrier 210 against head 280.

(44) Seal Section Thrust Chamber

(45) Bearing set 270, including thrust bearing 260 and thrust runner 205, may be located in thrust chamber 212 of seal section 200, the thrust chamber 212 created by and located between sand barrier 210 and mechanical seal 250. Bearing set 270 (thrust bearing 260 and thrust runner 205) may reduce or eliminate incipient buckling of shaft 220, even in the instances where there are multiple seal chambers in the pump assembly. Thrust bearing 260 and thrust runner 205 may be located in thrust chamber 212 substantially adjacent and/or downstream of mechanical seal 250 within head 280, and/or between mechanical seal 250 and sand barrier 230. Locating thrust bearing 260 and thrust runner 205 near and/or in the top (downstream) portion of seal 200 and/or in head 280, rather than in the bottom-most seal section chamber (adjacent to the base) next to the motor, eliminates buckling concerns and removes thrust bearing 260 and thrust runner 205 from the heat generated by the pump's motor. In some embodiments, placing bearing set 270 in thrust chamber 212 keeps bearing set 270 in excess of about 100 degrees Fahrenheit cooler as compared to conventional locations in the base of the seal section and/or close to the motor of the pump assembly. Instead of conventional bearings, low cost spacers may be included in the bottom-most seal chamber by the motor, to momentarily absorb upthrust and keep the shaft in the correct position during start-up. Thrust bearing 260 and thrust runner 205 may be hydrodynamic thrust bearings making use of well fluid as the hydrodynamic film. In such embodiments, thrust bearing 260 and/or thrust runner 205 may be diamond coated and/or solid tungsten carbide for increased strength. In some embodiments, only a single thrust bearing 260 and a single thrust runner 205 are necessary, rather than conventional arrangements requiring separate upthrust and downthrust bearings.

(46) Thrust Chamber Apertures

(47) Entry aperture 330 and exit aperture 335 may be cross-drilled into head 280 of seal section 200 to allow well fluid, otherwise sealed off by sand barrier 230, to cool and lubricate thrust bearing 260, thrust runner 205 and/or mechanical seal 250. Entry aperture 330 may be located proximate and/or radially outwards from bearing set 270. Exit aperture 335 may be located proximate and/or radially outwards from mechanical seal 250. In some embodiments, apertures 330, 335 may extend in a radial direction, as judged from shaft 220, through the wall of head 280. Apertures 330, 335 may be cross-drilled substantially perpendicular to shaft 220, extending entirely through the wall of head 280. Entry aperture 330 may allow well fluid to lubricate and cool thrust bearing 260, thrust runner 205 and/or mechanical seal 250 without allowing the well fluid to contaminate the electrical motor and/or without allowing sand to accumulate on mechanical seal 250. Exit aperture 335 may allow accumulated debris to be flushed away from mechanical seal 250 and/or mechanical seal faces 255 with well fluid when the pump assembly is stopped. In such instances, well fluid may back flow through the bottom end of the pump due to gravity and flush any debris (solids) around mechanical seal 250 and/or mechanical seal faces 255.

(48) Bearings

(49) FIG. 10 is an exemplary thrust runner of an illustrative embodiment. As shown in FIG. 10, thrust runner 205 includes runner base 305, which may be keyed to shaft 220 (shown in FIG. 2). Runner locking plate 1025 is secured to base 305. In some embodiments, runner locking plate 1025 may be secured to runner base 305 with a series of screws 1015. Screws 1015 may additionally secure runner pads 1020 into place. A plurality of runner pads 1020 may be arranged circumferentially about runner locking plate 1025, for example as illustrated in FIG. 10. In some embodiments nine runner pads 1020 are arranged about runner locking plate 1025. In other embodiments, at least three runner pads 1020 are arranged about runner locking plate 1025. The size and number of runner pads 1020 may depend upon the size of the surface area of runner face 1035 and/or runner locking plate 1025. In some embodiments, runner pads 1020 include a circular surface area and are distributed uniformly around central opening 1030 of base 305, through which shaft 220 will run. Runner pads 1020 may be circular in surface area and be 9 mm, 16 mm, inch, inch, and/or inch in diameter. The number of runner pads 1020 may vary depending on the diameter of the overall bearing. In some embodiments runner pads 1020 may be made with different profiles other than round, for example a sector of a circle or a modified ellipse.

(50) An illustrative embodiment of thrust bearing 260 is shown in FIG. 4. Thrust bearing 260 may remain stationary during operation of the pump assembly. Thrust bearing 260 includes bearing holder 405, to which bearing locking plate 410 is secured. As with thrust runner 205, in some embodiments, bearing locking plate 410 may be secured to bearing holder 405 with a series of screws 1015. Screws 1015 may additionally secure bearing pads 415 into place. A plurality of bearing pads 415 may be arranged circumferentially about bearing locking plate 410, for example as illustrated in FIG. 4. In some embodiments nine bearing pads 415 are arranged about bearing locking plate 410. In other embodiments, at least three bearing pads 415 are arranged about bearing locking plate 410. The size and number of bearing pads 415 may depend upon the size and/or cross-sectional area of bearing face 423 and/or bearing locking plate 410. In some embodiments, bearing pads 415 include a circular surface area and are distributed uniformly around opening 420 of bearing holder 405. Bearing pads 415 may be circular in surface area and be 9 mm, 16 mm, inch, inch, and/or inch in diameter. The number of bearing pads 415 may vary depending on the diameter and/or circumference of the overall bearing. In some embodiments bearing pad 415 may be made with different profiles other than round, for example a sector of a circle or a modified ellipse.

(51) FIGS. 5A, 5B and 5C are illustrative embodiments of thrust runner 205 paired with thrust bearing 260 to form bearing set 270. Faces 1035, 425 face towards each other, with space 500 in between them, space 500 sufficient to accommodate a hydrodynamic film. Space 500 may be between about 0.00001 to 0.005 inches separation due to temperature and fluid viscosity. Water and oil are considered incompressible fluids. As the velocity of thrust runner 205 increases, a fluid wedge may be created in space 500, which separates faces 1035, 425 from one another. The wedge may increase in height with the speed of rotating shaft 220 and thrust runner 205, providing greater load capacity. Thus, these illustrative embodiments reduce heat and friction in order to increase load capacity.

(52) FIG. 6 is an illustration of an exemplary pad of illustrative embodiments. Bearing pad 415 is illustrated in FIG. 6, but runner pad 1020 may similarly be as illustrated. Bearing and/or runner pad(s) 415, 1020 may be diamond coated, made of diamond, include leached diamond and/or comprise diamond. In some embodiments, bearing and runner pads 415, 1020 may comprise a polycrystalline matrix of inter-bonded, hard carbon-based crystals. For example, bearing and/or runner pads 415, 1020 may comprise a facing table of polycrystalline diamond integrally bonded to a substrate of less hard material, such as tungsten carbide and/or pad base 605, which pad base may be tungsten carbide. In embodiments including leached diamond, the leached diamond may include a polycrystalline matrix whereby the cobalt or other binder-catalyzing material in the polycrystalline diamond is leached out from the continuous interstitial matrix after formation.

(53) As shown in FIGS. 4, 7A and 10, bearing pad 415 and/or runner pad 1020 may have a circular cross-sectional area, or alternatively may have an elliptical or sector profile. Pad base 605 may be made of tungsten carbide and comprises a diamond coating 600. In certain embodiments, the diamond coating may be between about 0.070 and 0.080 inches thick, or may be between a few thousandths of an inch thick and 0.5 inch thick or more. In some embodiments, diamond coating 600 may be a diamond wafer that is silver brazed to pad base 605. In some embodiments, diamond coating 600 may be a diamond table.

(54) FIGS. 7A and 7B illustrate an exemplary embodiment of a locking plate. Bearing locking plate 410 is illustrated in FIGS. 7A and 7B, but runner locking plate 1025 may also be as illustrated. As shown in FIG. 7A, nine bearing pads 415 are evenly and circumferentially placed about locking plate 410. FIGS. 8A and 8B are an illustrative embodiment of runner base 305 of thrust runner 205. FIGS. 9A and 9B are an illustrative embodiment of bearing holder 405.

(55) Operation of the Pump

(56) Once the pump assembly has been positioned at the desired location, operation of the pump may be initiated. In instances where pumped fluid is employed as the hydrodynamic fluid, unlike motor oil, the water and/or pumped fluid may not provide boundary layer separation between faces 425 and 1035 when the ESP pump is first started. This is predominantly due to well fluid's relatively lower viscosity of about 1, the lack of additives in pumped fluid that would otherwise provide boundary layer lubrication and/or due to contaminants in the water or pumped fluid. Thus, water and/or pumped fluid would not typically be used as a hydrodynamic film in pump assemblies. As a result of the lack of lubrication, thrust runner 205 and thrust bearing 260 must endure contact of faces 425 and 1035 during pump start-up. Illustrative embodiments of thrust runner 205 and thrust bearing 260 are uniquely suited to solve this problem. Diamond coat 600 may endure face to face contact and prevent damage to thrust runner 205 and thrust bearing 260 prior to formation of the hydrodynamic film, due to the extreme hardness of diamond as employed in illustrative embodiments. Upon continued operation of the ESP pump, a hydrodynamic film may form in space 500 between faces 425, 1035 from the pumped fluid. In embodiments in which well fluid forms the hydrodynamic film, thrust runner 205 and thrust bearing 225 may handle increased axial loads due to the well fluid's improved heat transfer rate over motor oil which is used in traditional seals. In some embodiments, thrust runner 205 and thrust bearing 260, configured as described herein, may handle loads of about 5,000-10,000 pounds.

(57) Motor Oil Vent Port

(58) Returning to FIG. 2, vent port 290 may be located in the wall of head 280. This is in contrast to the conventional location at the bottom of the well bore as illustrated with conventional vent port 1105 in prior art FIG. 11. Moving vent port 290 from the well bore and connecting vent port 290 to communication port 295 radially through head 280 may prevent sand from plugging communication port 295 and/or decrease the amount of sand that accumulates on communication port 295. In addition, moving vent port 290 to the side of head 280, upstream of mechanical seal 250, eliminates or significantly reduces the risk that vent port 290 will clog with sand or other contaminants, which may reduce the risk of disturbing the pressure equalization of the seal and/or motor failure. As illustrated in FIGS. 2 and 3B, vent port 290 of illustrative embodiments may extend radially outward from communication port 295, and not extend substantially parallel to shaft 220, up through mechanical seal 250 as with conventional vent ports. As is well known to those of skill in the art, vent port 290 may include a check valve to allow expanding motor oil to exit seal section 200, but does not allow fluid to enter seal section 200.

(59) Abrasion Resistant Trim

(60) As shown in FIG. 3B, bushing set 310 may be comprised of sleeve 320 and bushing 315 located upstream of mechanical seal 250, in place of what would conventionally be a bronze shaft bushing. In some embodiments bushing set 310 comprises tungsten carbide. Sleeve 320 may be located on shaft 220 adjacent to bushing 315. In some embodiments, sleeve 320 rotates with shaft 220 by keying sleeve 320 to shaft 220. Sleeve 320 may be attached to the shaft using snap-rings at the top and/or bottom of sleeve 320. Sleeve 320 and bushing 315 may operate unimpeded in contaminated well fluid conditions in the present invention, whereas a bronze bushing of the prior art would fail under similar contamination. Bushing 315 may also provide radial shaft support. Even if mechanical seal 250 fails, bushing 315 may continue to provide radial shaft support, which might then prevent a failure of the pump assembly.

(61) Seal Section Illustrative Embodiment

(62) In some well applications, for example in tar sands, it may be desirable to place bearing set 270 in motor oil rather than well fluid, yet still keep bearing set 270 at the top of seal section 200 in head 280, which positioning may improve protection against shaft buckling and cooling characteristics. In one tar sand example, steam may be injected into a hole parallel to the well bore. Melted tar may seep into the well bore where the pump equipment is located. If bearing set 270 were exposed to well fluid in such a tar sand example, direct contact between bearing set 270 and melted tar may undesirably clog the area around bearing pad 415 openings and prevent cooling.

(63) As shown in the embodiment of FIG. 13, bearing set 270 may be located in head 280 below mechanical seal 250 and in motor oil, rather than between sand barrier 210 and mechanical seal 250 in working fluid as shown in FIG. 2. To implement positioning of bearing set 270 below mechanical seal 250 in head 280, additional modifications to seal section 200 may be employed. Mechanical seal 250 may be removed from a conventional location in the head, and relocated within adapter 325. Mechanical seal 250 may be sealed to shaft 220 within adapter 325 as shown in FIG. 13, rather than within head 280 as shown in FIG. 2 or in a conventional mechanical seal location. In some embodiments, the diameter of adapter 325 may decrease around mechanical seal 250 in order to accommodate differences in diameter between seal section 200 and intake 1320. Adapter 325 and/or sand barrier stop 1305 of illustrative embodiments may increase the length of seal section 200 by a few inches, for example two to six inches longer than conventional seal sections. As a result the length of shaft 220 may also be increased by a few inches correspondingly.

(64) Bearing set 270 may be secured within head 280 in the location reserved for mechanical seal 250 in the embodiment of FIG. 2. Specifically, bearing set 270 may be placed within head 280 at the top of seal section 200, just below adapter 325. Thrust bearing 260 may be pressed and/or secured to support 1325 of head 280 with an anti-roll pin, such that thrust bearing 260 does not rotate with shaft 220. The surface area of support 1325 may be increased as compared to the embodiment of FIG. 2, since there is no need to bore out the cavity to accommodate mechanical seal 250 at that location, which increased support 1325 may improve the stability of thrust bearing 260. The surface area of support 1325 in contact with thrust bearing 260 may be increased as compared to that of the embodiment of FIG. 2 to provide a most secure attachment for thrust bearing 260. Thrust runner 205 may be keyed by way of a machined keyway 1700 (shown in FIG. 17), pressure fit, or otherwise attached to shaft 220 such that thrust runner 205 rotates with shaft 220.

(65) Sand barrier 210 may include axially oriented sand barrier stop 1305, which sand barrier stop 1305 may extend longitudinally downstream from sand barrier 210 at the outer diameter of sand barrier 210. Sand barrier stop 1305 may be attached on a downstream side to pump intake 1320, and on an upstream side to adapter 325. In sand barrier stop 1305 embodiments, sand barrier stop 1305 may wedge and/or sandwich sand barrier 210 in place rather than, or in addition to, adapter 325. As shown in FIG. 13, sand barrier 210 is wedged between sand barrier stop 1305 and adapter 325 at the outer diameter of sand barrier 210. Sand barrier stop 1305 may be attached to sand barrier 210 and/or adapter 325 with fasteners 1310 which may be bolts, threading, screws or another fastening means known to those of skill in the art. The outer circumference (outer diameter) of sand barrier 210 may be pressed against the inner side of adapter 325 and sealed with gasket 230, such as circular steel ring and/or an o-ring. Gasket 230 may be inserted into an o-ring groove in adapter 325, rather than head 280. The inner circumference (inner diameter) of sand barrier 210 may be sealed against shaft 220 with radial shaft seal 240 (lip seal) to prevent sand from leaking through the barrier while still allowing shaft 220 to rotate while sand barrier remains stationary. Sand barrier 210 may prevent sand, well fluid and/or other particulates carried in well fluid from bypassing the barrier and collecting on thrust bearing 260, thrust runner 205 and/or mechanical seal 250.

(66) As opposed to the embodiment of FIG. 2, where adapter 325 is between intake 1320 and head 280, adapter 325 may instead be between sand barrier stop 1305 and head 280. Head 280 may be attached upstream of adapter 325secured to adapter 325 on a downstream side, and seal section body 1315 on an upstream side. Bolts 1300, screws, threading or anther attachment means known to those of skill in the art may be employed to secure head 280 between adapter 325 and body 1315.

(67) The design of thrust runner 205 and thrust bearing 260 may be as described previously herein. In certain embodiments, thrust runner 205 may be as shown in FIGS. 15A, 15B and FIG. 17. As shown in FIG. 15A, thrust runner 205 may include steel runner base 305. Runner base 305 may be undercut and/or milled out in face to form impression 1505 in the shape of a disc and/or donut. In one example, impression may be about .sup.th an inch in depth. A single tungsten carbide runner pad 1020 that interlocks with, fits within and/or is a mirror image of impression 1505 may be secured within the impression in base 305. Runner pad 1020 may held in place with screws 1015, pressure fit, brazed or another attachment mechanism known to those of skill in the art.

(68) The outer surface of runner pad 1020 and/or bearing pad 415 may be layered with a diamond vapor deposition layer 1400. In some embodiments, diamond deposition layer may be diamond coating 615 as described herein. In certain embodiments, diamond vapor deposition layer 1400 maybe between about three microns and six microns thick. FIGS. 14B and 15B illustrate an exemplary layer 1400 of illustrative embodiments. Layer 1400 may be a thin infusion, coating and/or film of diamond-like carbon (DLC) between about one and six microns in thickness. DLC coating may be a carbon compound having a combination of SP.sup.2 (graphite) and SP.sup.3 (diamond) carbon bonding and varying hydrogen content. Films with a higher SP.sup.3 bonding content may be harder with a high level of abrasion resistance, but may be less ductile than films with higher SP.sup.2 bonding content. DLC coating of illustrative embodiments may have a hardness of about 2500 on the Vickers scale, and a friction coefficient of DLC against DLC of about 0.15.

(69) Layer 1400 may be applied using physical vapor deposition, plasma-assisted chemical vapor deposition, or a similar process. In one example, layer 1400, may be applied to runner pad 1020 and/or bearing pad 415 using physical vapor deposition in a vacuum at 350 C. In another example, layer 1400 may be applied to runner pad 1020 and/or bearing pad 415 using plasma-assisted chemical vapor deposition at 180 C. with a plasma nitride surface layer that is then overlaid with physical vapor deposition of DLC.

(70) As illustrated in FIG. 14B, layer 1400 may be employed on bearing pads 415 in addition to, or instead of, runner pads 1020. In the example of FIG. 16 and FIGS. 14A and 14B, bearing pads 415 may be arranged about bearing holder 405 and secured by locking plate 410. Layer 1400 may coat the surface of bearing pads 415 as described herein.

(71) The inventions described herein may be suitable for a variety of types of seal sections 200. For ease of description, the embodiments described herein are in terms of an electrical submersible pump assembly, but those of skill in the art will recognize that the apparatus, system and method of the invention may be used to seal any type of electrical motor that may be exposed to fluid, sand and/or other contaminants. The inventions described herein prevent or reduce sand, well fluid and/or other contaminants from accumulating on mechanical seal 250 and/or bearing set 270, plugging vent port 290 and/or entering the electrical motor of a pump assembly. The risk of incipient buckling of the assembly may also be reduced or eliminated despite contaminated well fluid conditions (i.e., well fluid contaminated with sand). Illustrative embodiments described herein improve the thrust handling (thrust absorbing) capabilities of ESP pumps. The bearing pad(s) 415, runner pad(s) 1020, layer 1400 and/or diamond coating 605 on plate faces allow the thrust bearings of illustrative embodiments to be placed closer to the pump, away from the motor and/or eliminate the need for the bearings to be placed in a cavity of clean oil. Use of pumped fluid to act as a hydrodynamic film in space 500 between the bearings improves the heat and thrust absorbing capabilities of the bearings, improving the function of the pump assembly and increasing its lifespan. Other types of pump assemblies, such as horizontal surface pumps or other pumps requiring improved thrust handling capabilities may benefit from the apparatus, system and method of the invention. Those of ordinary skill in the art will recognize that the bearing set of illustrative embodiments may be implemented in other locations of a submersible pump assembly where bearings may be used, for example, the thrust chamber of a horizontal surface pump. Using the apparatus, systems and methods of the invention, well fluid may assist in cooling components of the seal section without contaminating the electrical motor or disturbing the pressure equalization function of the seal section.

(72) Further modifications and alternative embodiments of various aspects of the invention may be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the invention. It is to be understood that the forms of the invention shown and described herein are to be taken as the presently preferred embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features of the invention may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description of the invention. Changes may be made in the elements described herein without departing from the scope and range of equivalents as described in the following claims. In addition, it is to be understood that features described herein independently may, in certain embodiments, be combined.