U.S. patent application number 11/796623 was filed with the patent office on 2008-10-30 for drill rig apparatuses with directly driven shaft & drilling fluid pump systems.
Invention is credited to Gregory Paul Cervenka, Richard Urquhart.
Application Number | 20080267785 11/796623 |
Document ID | / |
Family ID | 39521998 |
Filed Date | 2008-10-30 |
United States Patent
Application |
20080267785 |
Kind Code |
A1 |
Cervenka; Gregory Paul ; et
al. |
October 30, 2008 |
Drill rig apparatuses with directly driven shaft & drilling
fluid pump systems
Abstract
A drilling rig system with a main shaft or shaft-like structure
driven directly by an AC motor; the system in one aspect for
pumping fluid (e.g., but not limited to, drilling fluid), the
system having, in certain aspects, pump apparatus with a pumping
section and a motor section, the pumping section having an inlet
and an outlet, the motor section having a drive shaft for
connection to a pump pinion shaft for reciprocating in and out of
the pumping section to alternately suck fluid into the inlet and
pump fluid out the outlet, and the motor being directly connected
to the pump pinion shaft, and methods for using such a system.
Inventors: |
Cervenka; Gregory Paul;
(Houston, TX) ; Urquhart; Richard; (Katy,
TX) |
Correspondence
Address: |
Guy McClung;# 114
5315-B F. M. 1960 Rd. West
Houston
TX
77069-4410
US
|
Family ID: |
39521998 |
Appl. No.: |
11/796623 |
Filed: |
April 27, 2007 |
Current U.S.
Class: |
417/50 |
Current CPC
Class: |
H02K 7/14 20130101; H02K
21/24 20130101; F04B 9/02 20130101; F04B 17/03 20130101; F04B 15/02
20130101 |
Class at
Publication: |
417/50 |
International
Class: |
F01B 21/00 20060101
F01B021/00 |
Claims
1. A system for pumping fluid, the system comprising a pump
apparatus including a pumping section and a motor section, the
pumping section having at least one pump, at least one inlet, and
at least one outlet, and a main pinion shaft for operating the at
least one pump, motor apparatus comprising at least one AC motor,
and the at least one AC motor directly connected to the main pinion
shaft.
2. The system of claim 1 wherein the fluid is drilling fluid and
the system is for pumping the drilling fluid with respect to a
wellbore in earth.
3. The system of claim 1 wherein the pump apparatus includes a
plurality of pump apparatuses each with a pumping section.
4. The system of claim 1 wherein the at least one AC motor is a
plurality of motors, each motor of the plurality of motors directly
connected to the main pinion shaft of the pumping section.
5. The system of claim 1 wherein the at least one AC motor is a
permanent magnet motor.
6. The system of claim 5 wherein the permanent magnet motor is an
axial field permanent magnet motor.
7. The system of claim 6 wherein the permanent magnet motor is a
printed circuit board motor.
8. The system of claim 1 wherein the at least one AC motor is
connected to the main pinion shaft with a mechanical
connection.
9. The system of claim 8 wherein the at least one AC motor has a
motor shaft secured to a motor hub and wherein the mechanical
connection comprises a friction fit between the motor hub and the
main pinion shaft.
10. The system of claim 1 wherein the at least one AC motor is
water cooled.
11. The system of claim 1 further comprising a control system for
controlling the system for pumping fluid.
12. A system for pumping fluid, the system comprising motor
apparatus comprising at least one AC motor, a pump apparatus
including a pumping section and a motor section, the pumping
section having at least one pump, at least one inlet, and at least
one outlet, and a main pinion shaft for transferring powered motion
to the at least one pump from the motor apparatus, the at least one
AC motor directly connected to the main pinion shaft, wherein the
pump apparatus includes a plurality of pump apparatuses each with a
pumping section, wherein the at least one AC motor is a plurality
of motors, each motor of the plurality of motors directly connected
to the main pinion shaft of the pumping section, wherein the motors
are axial field permanent magnet AC motors, and wherein each motor
is connected to the main pinion shaft with a mechanical
connection.
13. A method for pumping fluid, the method comprising sucking fluid
into an inlet of a pumping section of a pump system, the pump
system comprising a pump apparatus including a pumping section and
a motor section, the pumping section having at least one pump, at
least one inlet, and at least one outlet, and a main pinion shaft
for the at least one pump, motor apparatus comprising at least one
AC motor, and the at least one AC motor directly connected to the
main pinion shaft, and with the pump apparatus, pumping fluid out
the outlet.
14. The method of claim 13 wherein the fluid is drilling fluid and
the method further comprising pumping drilling fluid with respect
to a wellbore in the earth.
15. The method of claim 14 further comprising pumping the drilling
fluid into the wellbore to run a fluid motor located in the
wellbore.
16. The method of claim 14 further comprising transporting material
from the wellbore with pumped fluid.
17. The method of claim 13 wherein the pump apparatus includes a
plurality of pump apparatuses each with a pumping section, and the
at least one AC motor is a plurality of motors, each motor of the
plurality of motors directly connected to the main pinion shaft of
the pumping section.
18. The method of claim 13 further comprising controlling the pump
system with a control system.
19. A drilling rig apparatus comprising a main shaft for providing
rotative motion for operation of the drilling rig apparatus, motor
apparatus comprising at least one AC motor, and the at least one AC
motor directly connected to the main shaft.
20. The drilling rig apparatus of claim 19 wherein the motor
apparatus is from the group including AC permanent magnet motor, AC
axial field permanent magnet motor, and AC printed circuit board
axial field permanent magnet motor; and the drilling rig apparatus
is from the group including top drive, centrifugal pump,
centrifuge, pump, shale shaker, rig thruster, drawworks, cuttings
conveyance system, auger system, rotary table, power swivel,
jacking system, multiplex pump, blower motor, hydrocyclone, lube
pump, pipe handler, iron roughneck, cherry picker, generator, brake
system, frequency conversion apparatus, and crane, winch, utility
winch, cable handling winch, manrider winch, coil tubing unit,
wireline unit, and cathead.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention is directed to: drill rig apparatuses
(machines, devices, apparatuses, systems) with a driven shaft
driven by an AC motor directly connected to the driven shaft
without the use of intermediate gear reductions or torque
multipliers; drilling fluid pump systems used in drilling wellbores
in the earth; and to methods of the use of such apparatuses and
systems.
[0003] 2. Description of Related Art
[0004] A wide variety of drilling systems, apparatuses, and methods
are disclosed in prior developments including, but not limited to,
the disclosures in U.S. Pat. Nos. 6,944,547; 6,918,453; 6,802,378;
6,050,348; 5,465,799; 4,995,465; 4,854,397; and 3,658,138, all
incorporated fully herein for all purposes. Prior developments
include a wide variety of drilling systems, apparatuses, machines
and devices which use a powered shaft driven by a motor with an
intermediate apparatus between the motor and the powered shaft such
as a gear system, a speed reduction system, or a torque multiplier.
A wide variety of drilling fluid pumps ("mud pumps") are used in
drilling operations and in pump systems, for example, and not by
way of limitation, those pumps and systems disclosed in U.S. Pat.
Nos. 6,257,354; 4,295,366; 4,527,959; 5,616,009; 4,242,057;
4,676,724; 5,823,093; 5,960,700; 5,059,101; 5,253,987; and in U.S.
application Ser. No. 10/833,921 filed Apr. 28, 2004 (all said U.S.
references incorporated fully herein for all purposes).
[0005] A drill bit carried at an end of a drillstring is rotated to
drill a wellbore in the earth. Certain drillstrings include
tubulars which may be drill pipe made of jointed sections or a
continuous coiled tubing and a drilling assembly that has a drill
bit at its bottom end. The drilling assembly is attached to the
bottom end of the tubing or drillstring. In certain systems, the
drill bit is rotated by a downhole mud motor carried by the
drilling assembly and/or by rotating the drill pipe (e.g. with a
rotary system, power swivel, or with a top drive system). A
drilling fluid, also referred to as "mud," is pumped by a pump or
pumps ("mud pumps") into the drillstring under pressure from a pit
or container at the surface by a pumping system at the surface.
[0006] Certain prior, known mud pumps and mud pump systems have
relatively complex, relatively large, and relatively heavy drive
systems with typical connecting rods, eccentric shafts, belts,
pulleys, chains and sprockets, gears and/or other speed reduction
apparatus.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention discloses, in certain aspects, an
apparatus for use on a drilling rig which has a driven shaft driven
by an AC motor which is directly connected to the driven shaft for
operation of the apparatus. The AC motor is directly connected to
the driven shaft without the use of intermediate apparatus such as
a gear system, a speed reduction system, or a torque multiplier.
The motor (or motors) used for this direct drive is an AC motor; in
certain particular aspects a permanent magnet motor; in certain
particular aspects an axial field permanent magnet motor; in
certain more particular aspects a printed circuit board motor; in
certain aspects, an AC axial field printed circuit board permanent
magnet motor from Core Motion, Inc. and, in certain aspects, a
Model 6100 or Model 7500 AC axial field printed circuit board
permanent magnet motor from Core Motion, Inc. The AC motor (or
motors) can be fluid cooled, e.g. with air, nitrogen, liquid,
water, or another heat exchange liquid.
[0008] The present invention, in certain aspects, discloses systems
for pumping fluid, the systems including: a pump apparatus
including a pumping section and a motor section; the pumping
section having at least one pump, at least one inlet, and at least
one outlet, and a main pinion shaft for operating the at least one
pump; motor apparatus which is at least one AC motor; and the at
least one AC motor directly connected to the main pinion shaft. In
particular aspects the fluid is drilling fluid and the system is
for pumping the drilling fluid with respect to a wellbore in earth,
e.g. to remove cuttings and/or to power a downhole motor.
[0009] The present invention discloses, in certain aspects, a fluid
pumping system, also known as a mud pump system (in certain
particular aspects a drilling fluid pumping system), for pumping
fluid (e.g., but not limited to, drilling fluid or mud used in
wellbore operations). In certain aspects an AC motor (or motors)
operates a pump apparatus to pump the fluid. In certain aspects of
systems according to the present invention in which one or more AC
(alternating current) motors applies power directly, increased
efficiencies are possible, inefficiencies associated with
non-direct drive systems are eliminated, overall size and space
requirements are reduced, and/or overall system weight is
reduced.
[0010] In certain aspects the motor (or motors) used for direct
drive is an AC motor; in certain particular aspects a permanent
magnet motor; in certain particular aspects an axial field
permanent magnet motor; in certain more particular aspects a
printed circuit board motor; and, in one aspect, a Model 6100 axial
field printed circuit board permanent magnet motor from Core
Motion, Inc. The AC motor (or motors) can be fluid cooled, e.g.
with air, nitrogen, liquid, water, or another heat exchange
liquid.
[0011] A mud pump system according to the present invention may
have one, two to ten, or more mud pump apparatuses, each with an AC
motor directly connected to a mud pump system shaft according to
the present invention. In one aspect, the present invention
discloses a system for pumping fluid (e.g., but not limited to,
drilling fluid), the system having pump apparatus with a pumping
section and a motor section with one or more AC motors, the pumping
section having a main shaft and an inlet and an outlet, the motor
directly connected to the mainshaft of the pumping section to
alternately suck fluid into the inlet and pump fluid out the
outlet, the shaft in a reciprocating motion, e.g., but not limited
to, vertically or horizontally; and methods for using such a
system.
[0012] Optionally, in any system according to the present
invention, a mechanical speed reduction apparatus or device can be
used between a motor output (e.g. a motor shaft) and a pump system
power input (e.g. a pinion shaft of a pump apparatus), i.e. without
directly connecting the motor shaft to the pump system pinion
shaft.
[0013] Accordingly, the present invention includes features and
advantages which are believed to enable it to advance fluid pumping
technology. Characteristics and advantages of the present invention
described above and additional features and benefits will be
readily apparent to those skilled in the art upon consideration of
the following detailed description of preferred embodiments and
referring to the accompanying drawings.
[0014] What follows are some of, but not all, the objects of this
invention. In addition to the specific objects stated below for at
least certain preferred embodiments of the invention, there are
other objects and purposes which will be readily apparent to one of
skill in this art who has the benefit of this invention's teachings
and disclosures. It is, therefore, an object of at least certain
preferred embodiments of the present invention to provide:
[0015] New, useful, unique, efficient, nonobvious fluid drilling
rig apparatuses and methods of their use, the drilling apparatuses
having an AC motor directly connected to a driven shaft without the
use of intermediate gear systems, speed reducing systems, or torque
multipliers; and
[0016] New, useful, unique, efficient, nonobvious fluid pumping
systems, methods of their use, drilling systems and methods, and
mud pump systems for use in drilling operations; and
[0017] Such systems and methods which employ an AC motor directly
connected to a pumping section shaft.
[0018] Certain embodiments of this invention are not limited to any
particular individual feature disclosed here, but include
combinations of them distinguished from the prior art in their
structures, functions, and/or results achieved. Features of the
invention have been broadly described so that the detailed
descriptions that follow may be better understood, and in order
that the contributions of this invention to the arts may be better
appreciated. There are, of course, additional aspects of the
invention described below and which may be included in the subject
matter of the claims to this invention. Those skilled in the art
who have the benefit of this invention, its teachings, and
suggestions will appreciate that the conceptions of this disclosure
may be used as a creative basis for designing other structures,
methods and systems for carrying out and practicing the present
invention. The claims of this invention are to be read to include
any legally equivalent devices or methods which do not depart from
the spirit and scope of the present invention.
[0019] The present invention recognizes and addresses the problems
and needs in this area and provides a solution to those problems
and a satisfactory meeting of those needs in its various possible
embodiments and equivalents thereof. To one of skill in this art
who has the benefits of this invention's realizations, teachings,
disclosures, and suggestions, other purposes and advantages will be
appreciated from the following description of certain preferred
embodiments, given for the purpose of disclosure, when taken in
conjunction with the accompanying drawings. The detail in these
descriptions is not intended to thwart this patent's object to
claim this invention no matter how others may later attempt to
disguise it by variations in form, changes, or additions of further
improvements.
[0020] The Abstract that is part hereof is to enable the U.S.
Patent and Trademark Office and the public generally, and
scientists, engineers, researchers, and practitioners in the art
who are not familiar with patent terms or legal terms of
phraseology to determine quickly from a cursory inspection or
review the nature and general area of the disclosure of this
invention. The Abstract is neither intended to define the
invention, which is done by the claims, nor is it intended to be
limiting of the scope of the invention or of the claims in any
way.
[0021] It will be understood that the various embodiments of the
present invention may include one, some, or all of the disclosed,
described, and/or enumerated improvements and/or technical
advantages and/or elements in claims to this invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0022] A more particular description of embodiments of the
invention briefly summarized above may be had by references to the
embodiments which are shown in the drawings which form a part of
this specification. These drawings illustrate certain preferred
embodiments and are not to be used to improperly limit the scope of
the invention which may have other equally effective or legally
equivalent embodiments.
[0023] FIG. 1 is a schematic view, partially cutaway, of a system
according to the present invention.
[0024] FIG. 2A is a perspective view of a pump system according to
the present invention.
[0025] FIG. 2B is a side view of part of the pump system of FIG.
2A.
[0026] FIG. 2C is a side view of part of the pump system of FIG.
2A.
[0027] FIG. 2D is a top view of part of the pump system of FIG.
2A.
[0028] FIG. 3A is a side view partially cutaway away of part of the
system of FIG. 2A.
[0029] FIG. 3B is a cross-sectional view along line A-A of FIG.
3A.
[0030] FIG. 3C is a cross-section view along line B-B of FIG.
3A.
[0031] FIG. 4 is a perspective view, partially cutaway, of part of
the pump system of FIG. 2A.
[0032] FIG. 5 is a perspective view, partially cutaway, partially
schematic, of a system according to the present invention.
[0033] Presently preferred embodiments of the invention are shown
in the above-identified figures and described in detail below.
Various aspects and features of embodiments of the invention are
described below and some are set out in the dependent claims. Any
combination of aspects and/or features described below or shown in
the dependent claims can be used except where such aspects and/or
features are mutually exclusive. It should be understood that the
appended drawings and description herein are of preferred
embodiments and are not intended to limit the invention or the
appended claims. On the contrary, the intention is to cover all
modifications, equivalents and alternatives falling within the
spirit and scope of the invention as defined by the appended
claims. In showing and describing the preferred embodiments, like
or identical reference numerals are used to identify common or
similar elements. The figures are not necessarily to scale and
certain features and certain views of the figures may be shown
exaggerated in scale or in schematic in the interest of clarity and
conciseness.
[0034] As used herein and throughout all the various portions (and
headings) of this patent, the terms "invention", "present
invention" and variations thereof mean one or more embodiment, and
are not intended to mean the claimed invention of any particular
appended claim(s) or all of the appended claims. Accordingly, the
subject or topic of each such reference is not automatically or
necessarily part of, or required by, any particular claim(s) merely
because of such reference.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The system 500 shown in FIG. 1 includes a derrick 502 from
which extends a drillstring 504 into the earth 506. The drillstring
504, as is well known, can include drill pipes and drill collars. A
drill bit 512 is at the end of the drillstring. A rotary system
514, top drive system 526, and/or a downhole motor 532 ("fluid
motor", "mud motor") may be used to rotate the drillstring 504 and
the drill bit 512. A typical drawworks 516 has a cable or rope
apparatus 518 for supporting items in the derrick 502. A mud pump
system 522 with one, two, three-to-ten, or more mud pumps 521
according to the present invention supplies drilling fluid 524 to
the drillstring 504. Drilling forms a wellbore 530 extending down
into the earth 506. Each mud pump system 521 has at least one AC
motor 523 directly connected to a main drive pinion shaft of the
pump system (any disclosed herein for systems according to the
present invention). In certain aspects, the system 522 has two such
motors, one on each end of a system main pinion shaft and directly
connected to the pinion shaft.
[0036] During drilling, the drilling fluid 524 is pumped by pump(s)
521 of the mud pump system 522 into the drillstring 504 (thereby
operating a downhole motor 532 if such an optional motor is used).
Drilling fluid 524 flows to the drill bit 512, and then flows into
the wellbore 530 through passages in the drill bit 512. Circulation
of the drilling fluid 524 transports earth and/or rock cuttings,
debris, etc. from the bottom of the wellbore 530 to the surface
through an annulus 527 between a well wall of the wellbore 530 and
the drillstring 504. The cuttings are removed from the drilling
fluid 524 so that it may be re-circulated from a mud pit or
container 528 by the pump(s) of the mud pump system 522 back to the
drillstring 506. A control system CS (any suitable known mud pump
system control system and/or system with control apparatus for
controlling motors directly connected to a main pinion shaft of a
mud pump system and in certain aspects a control system for
controlling axial field permanent magnet motors and printed circuit
board motors) controls the mud pump system.
[0037] FIGS. 2A-2D and FIGS. 3A-3C show a system 10 (or parts
thereof) according to the present invention for pumping mud
(drilling fluid), e.g. as in a drilling operation as shown in FIG.
1. A pump system 20 has one or a plurality of pumps mounted on a
base 12 driven by motors 30 (any AC motor disclosed herein for
systems according to the present invention). As discussed in detail
below, the pump(s) of the pump system 20 have a main drive pinion
and the motors 30 are each directly connected to a main drive
pinion.
[0038] Each motor 30 is connected to a main drive pinion shaft 32
which is rotated by the motors 30. The shaft 32 moves in bearings
38. The main drive pinion shaft 32 has a gear 34 which meshes with
and drives a bull gear 52 of a pump drive mechanism 50. The gear 52
is connected to a crank shaft 54. The crank shaft 54 projects into
and is connected to reciprocating members 56 (one per pump).
Rotation of the shafts 54 results in reciprocating motion
(left-to-right-to-left as viewed in FIG. 3A) of an end 57 of the
members 56. This motion reciprocates pump shafts 58 which provide
the pumping action of the pumps 20. As shown the system 10 has
three pumps 20; but systems according to the present invention may
have one, two, three, four or more pumps. The shafts 58 are
connected to crossheads 59 which are movable within a housing 61.
The crank shaft 54 moves in bearings 63 covered by caps 65.
[0039] In one particular aspect, the fluid end FE of the system 10
has three pumps (a "triplex pump" system) with six inlets and two
outlets.
[0040] FIG. 4 shows one embodiments of a connection of a motor 30
to a system pinion shaft 32. According to the present invention the
motor or motors may be directly connected to a system main pinion
shaft with any suitable mechanical connection, device or structure,
including, but not limited to: splined connection, keyed
connection, tapered fit connection, friction fit connection, and/or
bolted connection.
[0041] As shown in FIG. 4, an axial field permanent magnet motor
30a has a motor shaft 35 connected to a motor hub 31. The main
pinion shaft 32 and the motor hub 31 have corresponding sizes and
shapes for a friction fit connection. The motor hub 31 is bolted to
the motor shaft 35. Cooling liquid enters the motor 30a through
inlets 37 and exits through outlets 39. In one particular aspect
the motor 30a is a Model 6100 water-cooled axial field printed
circuit board permanent magnet motor from Core Motion, Inc.
[0042] As shown in FIG. 5, an AC axial field permanent magnet motor
30b has a motor shaft MS connected to a motor hub MH. A main driven
shaft DS of a rig apparatus RA and the motor hub MH have
corresponding sizes and shapes for a friction fit connection. The
motor hub MH is bolted to the motor shaft MS. Cooling liquid is
used as with the motor shown in FIG. 4. The motor 30b is mounted to
a mount (or mounts) 30c.
[0043] In one particular aspect the motor 30b is an AC water-cooled
axial field printed circuit board permanent magnet motor from Core
Motion, Inc. In one particular aspect the motor 30b is a Model 6100
water-cooled AC axial field printed circuit board permanent magnet
motor from Core Motion, Inc. In one particular aspect the motor 30a
is a Model 7500 water-cooled AC axial field printed circuit board
permanent magnet motor from Core Motion, Inc. The motor 30b may be
any AC motor referred to herein for systems according to the
present invention. The rig apparatus RA is any drilling rig
apparatus that has a driven shaft driven by a motor or shaft-like
structure driven by a motor, the motor directly connected to the
driven shaft (or shaft-like structure) and may be, but is not
limited to, top drive, centrifugal pump, centrifuge, pump, shale
shaker, rig thruster, drawworks, cuttings conveyance system, auger
system, rotary table, power swivel, jacking system, multiplex pump,
blower motor, hydrocyclone, lube pump, pipe handler, iron
roughneck, generator, brake system, frequency conversion apparatus,
cherry picker, and cathead.
[0044] In systems according to the present invention in which a
motor shaft is directly connected to a pump system pinion shaft,
mechanical speed reduction apparatus and torque multiplier
apparatus (required by certain prior systems without such a direct
drive connection) are eliminated, reducing size and weight of the
overall system and reducing maintenance and repair requirements.
Printed circuit board motors contribute significantly to size and
weight reductions.
[0045] The present invention, therefore, provides in at least some
embodiments, a system for pumping fluid having a pump apparatus
with a pumping section and a motor section, the pumping section
with a body with an inlet and an outlet, the motor section for
pumping fluid into the inlet and out the outlet, and the motor
being a direct drive AC motor which, in certain aspects, is a
permanent magnet motor, an axial field permanent magnet motor,
and/or a printed circuit board motor.
[0046] The present invention, therefore, provides in at least some
embodiments, a system for pumping fluid, the system including: a
pump apparatus including a pumping section and a motor section; the
pumping section having at least one pump, at least one inlet, and
at least one outlet, and a main pinion shaft for operating the at
least one pump; motor apparatus comprising at least one AC motor;
and the at least one AC motor directly connected to the main pinion
shaft. Such a system according to the present invention may have
one or some (in any possible combination) of the following: wherein
the fluid is drilling fluid and the system is for pumping the
drilling fluid with respect to a wellbore in earth; wherein the
pump apparatus includes a plurality of pump apparatuses each with a
pumping section; wherein the at least one AC motor is a plurality
of motors, each motor of the plurality of motors directly connected
to the main pinion shaft of the pumping section; wherein the at
least one AC motor is a permanent magnet motor; wherein the
permanent magnet motor is an axial field permanent magnet motor;
wherein the permanent magnet motor is a printed circuit board
motor; wherein the at least one AC motor is connected to the main
pinion shaft with a mechanical connection; wherein the at least one
AC motor has a motor shaft secured to a motor hub and wherein the
mechanical connection comprises a friction fit between the motor
hub and the main pinion shaft; wherein the at least one AC motor is
water cooled; and/or a control system for controlling the system
for pumping fluid.
[0047] The present invention, therefore, provides in at least some
embodiments, a system for pumping fluid, the system including:
motor apparatus comprising at least one AC motor; a pump apparatus
including a pumping section and a motor section; the pumping
section having at least one pump, at least one inlet, and at least
one outlet, and a main pinion shaft for transferring powered motion
to the at least one pump from the motor apparatus; the at least one
AC motor directly connected to the main pinion shaft; wherein the
pump apparatus includes a plurality of pump apparatuses each with a
pumping section; wherein the at least one AC motor is a plurality
of motors, each motor of the plurality of motors directly connected
to the main pinion shaft of the pumping section; wherein the motors
are axial field permanent magnet AC motors; and wherein each motor
is connected to the main pinion shaft with a mechanical
connection.
[0048] The present invention, therefore, provides in at least some
embodiments, a method for pumping fluid, the method including:
sucking fluid into an inlet of a pumping section of a pump system,
the pump system having a pump apparatus including a pumping section
and a motor section, the pumping section having at least one pump,
at least one inlet, and at least one outlet, and a main pinion
shaft for the at least one pump, motor apparatus which is at least
one AC motor, and the at least one AC motor directly connected to
the main pinion shaft; and with the pump apparatus, pumping fluid
out the outlet. Such a method according to the present invention
may have one or some (in any possible combination) of the
following: wherein the fluid is drilling fluid and the method
includes pumping drilling fluid with respect to a wellbore in the
earth; pumping the drilling fluid into the wellbore to run a fluid
motor located in the wellbore; transporting material from the
wellbore with pumped fluid; the pump apparatus including a
plurality of pump apparatuses each with a pumping section, and the
at least one AC motor is a plurality of motors, each motor of the
plurality of motors directly connected to the main pinion shaft of
the pumping section; wherein the permanent magnet motor is an axial
field permanent magnet motor; cooling the at least one AC motor
with liquid; and/or controlling the pump system with a control
system.
[0049] The present invention, therefore, provides in at least some
embodiments, a drilling rig apparatus with a main shaft (this term
here includes apparatus with shaft-like structure that is rotated)
for providing rotative motion for operation of the drilling rig
apparatus, motor apparatus comprising at least one AC motor, and at
least one AC motor directly connected to the main shaft. In certain
aspects in such a drilling rig apparatus the motor apparatus is
from the group including AC permanent magnet motor, AC axial field
permanent magnet motor, and AC printed circuit board axial field
permanent magnet motor; and the drilling rig apparatus is from the
group including top drive, centrifugal pump, centrifuge, pump,
shale shaker, rig thruster, drawworks, cuttings conveyance system,
auger system, rotary table, power swivel, jacking system, multiplex
pump, blower motor, hydrocyclone, lube pump, pipe handler, brake
system, generator, frequency conversion apparatus, iron roughneck,
cherry picker, crane, winch, utility winch, cable handling winch,
manrider winch, coil tubing unit, and wireline unit, and
cathead.
[0050] In conclusion, therefore, it is seen that the present
invention, embodiments disclosed herein, and those covered by the
appended claims are well adapted to carry out the objectives set
forth. Certain changes can be made in the subject matter without
departing from the spirit and the scope of this invention. Changes
are possible within the scope of this invention and it is further
intended that each element or step recited in any of the following
claims is to be understood as referring to the step literally
and/or to all equivalent elements or steps. The following claims
are intended to cover the invention as broadly as legally possible
in whatever form. The invention claimed herein is new and novel in
accordance with 35 U.S.C. .sctn. 102 and satisfies the conditions
for patentability in .sctn. 102. The invention claimed herein is
not obvious in accordance with 35 U.S.C. .sctn. 103 and satisfies
the conditions for patentability in .sctn. 103. This specification
and the claims that follow are in accordance with all of the
requirements of 35 U.S.C. .sctn. 112. The inventors may rely on the
Doctrine of Equivalents to determine the scope of their invention
and of the claims as they may pertain to apparatus not materially
departing from, but outside of, the literal scope of the invention
as set forth in the claims. Patents and applications identified
herein are incorporated fully herein for all purposes.
* * * * *