U.S. patent application number 12/141514 was filed with the patent office on 2009-12-24 for esp motor windings for high temperature environments.
This patent application is currently assigned to SCHLUMBERGER TECHNOLOGY CORPORATION. Invention is credited to Albert Kyin, Gregory H. Manke, Aider Matarrita, Mark Metzger.
Application Number | 20090317264 12/141514 |
Document ID | / |
Family ID | 41431489 |
Filed Date | 2009-12-24 |
United States Patent
Application |
20090317264 |
Kind Code |
A1 |
Manke; Gregory H. ; et
al. |
December 24, 2009 |
ESP MOTOR WINDINGS FOR HIGH TEMPERATURE ENVIRONMENTS
Abstract
An electric submersible pump device, comprising: an electric
motor having motor windings; a pump coupled with the motor; and
high temperature polymeric insulation surrounding at least a
portion of the motor windings, the high temperature polymeric
insulation comprising HN polyimide film and a high temperature
fluoropolymer adhesive coating at least one side of the HN
polyimide film.
Inventors: |
Manke; Gregory H.; (Overland
Park, KS) ; Metzger; Mark; (Lawrence, KS) ;
Kyin; Albert; (Missouri City, TX) ; Matarrita;
Aider; (Olathe, KS) |
Correspondence
Address: |
SCHLUMBERGER RESERVOIR COMPLETIONS
14910 AIRLINE ROAD
ROSHARON
TX
77583
US
|
Assignee: |
SCHLUMBERGER TECHNOLOGY
CORPORATION
Sugar Land
TX
|
Family ID: |
41431489 |
Appl. No.: |
12/141514 |
Filed: |
June 18, 2008 |
Current U.S.
Class: |
417/53 ;
417/423.3 |
Current CPC
Class: |
H02K 5/132 20130101;
H02K 3/30 20130101; F04B 47/06 20130101 |
Class at
Publication: |
417/53 ;
417/423.3 |
International
Class: |
F04B 45/067 20060101
F04B045/067 |
Claims
1. An electric submersible pump device, comprising: an electric
motor having motor windings, comprising an electrical conductor; a
pump coupled with the motor; and high temperature polymeric
insulation surrounding at least a portion of the motor windings,
the high temperature polymeric insulation comprising polyimide film
and a high temperature fluoropolymer adhesive coating at least one
side of the polyimide film; wherein the polyimide film is adhered
to the conductor with the high temperature fluoropolymer
adhesive.
2. The device of claim 1, comprising multiple layers of the high
temperature polymeric insulation.
3. The device of claim 1, wherein the high temperature insulation
is in tape form.
4. The device of claim 3, wherein the high temperature polymeric
insulation is applied longitudinally.
5. The device of claim 3, wherein the high temperature polymeric
insulation is wrapped onto the conductor in an overlap
configuration.
6. The device of claim 1, wherein the thickness of the polyimide
film is from 0.0005 inch to 0.005 inch.
7. The device of claim 1, wherein the polyimide film is adhered to
itself with the fluoropolymer adhesive coating.
8. The device of claim 1, wherein the fluoropolymer adhesive
coating is coated on the polyimide film and is activated by short
term exposure to extreme heat.
9. The device of claim 1, wherein the fluoropolymer adhesive
coating comprises a material selected from a group consisting of
the following: fluorinated ethylene propylene,
polytetrafluoroethylene, and perfluoroalkoxy.
10. The device of claim 1, wherein the high temperature polymeric
insulation has material capabilities that allow operation of the
electric submersible motor where conductor temperature within in
the motor is at least 500 degrees Fahrenheit.
11. A method of pumping subterranean fluids, comprising: lowering
an electric submersible pump device downhole, the electric
submersible pump device comprising an electric motor having motor
windings, comprising an electrical conductor; a pump coupled with
the motor; and high temperature polymeric insulation surrounding at
least a portion of the motor windings; wherein the high temperature
polymeric insulation comprises polyimide film and a high
temperature fluoropolymer adhesive coating at least one side of the
polyimide film, wherein the polyimide film is adhered to the
conductor with the high temperature fluoropolymer adhesive; and
operating the motor.
12. (canceled)
13. The method of claim 11, wherein the motor windings comprising
multiple layers of the high temperature polymeric insulation.
14. The method of claim 11, wherein the high temperature insulation
is in tape form.
15. The method of claim 11, wherein the high temperature polymeric
insulation is applied longitudinally.
16. The method of claim 11, wherein the high temperature polymeric
insulation is wrapped onto the conductor in an overlap
configuration.
17. The method of claim 11, wherein the thickness of the polyimide
film is from 0.0005 inch to 0.005 inch.
18. The method of claim 11, wherein the polyimide film is adhered
to the conductor and to itself with the fluoropolymer adhesive
coating.
19. The method of claim 18, wherein the fluoropolymer adhesive
coating is coated on the polyimide film and is activated by short
term exposure to extreme heat.
20. The method of claim 18, wherein the fluoropolymer adhesive
coating comprises a material selected from a group consisting of
the following: fluorinated ethylene propylene,
polytetrafluoroethylene, and perfluoroalkoxy.
21. The device of claim 1, wherein the polyimide film is HN
polyimide film.
22. The device of claim 1, wherein the polyimide film is CR
polyimide film.
23. The method of claim 11, wherein the polyimide film is HN
polyimide film.
24. The method of claim 11, wherein the polyimide film is CR
polyimide film.
25. The method of claim 11, further comprising operating the
electric submersible pump while the motor conductor temperature is
at least 500 degrees Fahrenheit continuously for at least one
hour.
26. The device of claim 1, wherein the electric submersible pump is
configured to be capable of operating for at least one
uninterrupted hour when the motor conductor temperature is at least
500 degrees Fahrenheit.
Description
TECHNICAL FIELD
[0001] The present application relates to an electric submersible
motor, and more specifically, to motor windings of an electric
submersible motor.
BACKGROUND
[0002] Fluids are located underground. The fluids can include
hydrocarbons (oil) and water, for example. Extraction of at least
the oil for consumption is desirable. A hole is drilled into the
ground to extract the fluids. The hole is called a wellbore and is
oftentimes cased with a metal tubular structure referred to as a
casing. A number of other features such as cementing between the
casing and the wellbore can be added. The wellbore can be
essentially vertical, and can even be drilled in various
directions, e.g. upward or horizontal.
[0003] Once the wellbore is cased, the casing is perforated.
Perforating involves creating holes in the casing thereby
connecting the wellbore outside of the casing to the inside of the
casing. Perforating involves lowering a perforating gun into the
casing. The perforating gun has charges that detonate and propel
matter thought the casing thereby creating the holes in the casing
and the surrounding formation and helping formation fluids flow
from the formation and wellbore into the casing.
[0004] Sometimes the formation has enough pressure to drive well
fluids uphole to surface. However, that situation is not always
present and cannot necessarily be relied upon. An artificial lift
device can therefore be needed to drive downhole well fluids
uphole, e.g., to surface. The artificial lift device is placed
downhole inside the casing.
SUMMARY
[0005] According to an embodiment an electric submersible pump
device comprises an electric motor having motor windings; a pump
coupled with the motor; and high temperature polymeric insulation
surrounding at least a portion of the motor windings, the high
temperature polymeric insulation comprising HN polyimide film and a
high temperature fluoropolymer adhesive coating at least one side
of the HN polyimide film.
BRIEF DESCRIPTION OF THE FIGURES
[0006] FIG. 1 is a view of an electric submersible pump within a
wellbore according to embodiments.
[0007] FIG. 2 is a cut away longitudinal view of a submergible
electric motor according to embodiments.
[0008] FIG. 3A is an isometric view of the magnet wire with the
conductor and helically wrapped dielectric layers according to
embodiments.
[0009] FIG. 3B is a sectional view of the magnet wire with the
conductor and helically wrapped dielectric layers according to
embodiments.
DETAILED DESCRIPTION
[0010] In the following description, numerous details are set forth
to provide an understanding of the present invention. However, it
will be understood by those skilled in the art that the present
invention may be practiced without many of these details and that
numerous variations or modifications from the described embodiments
are possible.
[0011] As used here, the terms "above" and "below"; "up" and
"down"; "upper" and "lower"; "upwardly" and "downwardly"; and other
like terms indicating relative positions above or below a given
point or element are used in this description to more clearly
describe some embodiments of the invention. However, when applied
to equipment and methods for use in wells that are deviated or
horizontal, such terms may refer to a left to right, right to left,
or diagonal relationship as appropriate.
[0012] Electrical submersible pumping systems (herein referred to
as ESPs) are used in a wide variety of environments, including
wellbore applications for pumping production fluids, such as water
or petroleum. The submersible pumping system includes, among other
components, an induction motor used to power a pump, lifting those
fluids to the surface. At times, it is desirable to operate the ESP
system in high temperature applications, such as steam flood
conditions. Production fluid recovery in such applications can
expose the ESP motor to temperatures of 500.degree. F. or greater.
Temperatures at or exceeding that level may lead to undesirable
levels of degradation of materials used in current ESP motor
designs, in particular, the dielectric insulation layer used on the
motor windings. Incorporating new higher temperature materials for
the dielectric layer of the motor windings can allow improved
resilience and improved levels of degradation that can lead to
continuous operation of the motor in temperature environments at or
exceeding 500.degree. F. for an extended period of time.
[0013] The present application features a submersible pumping
system that is deployed in a wellbore to pump fluids disposed in a
subterranean environment. The system includes a submersible motor
and pump powered by the motor. The submersible electric motor
comprises a motor housing having a plurality of laminations stacked
there within, a drive shaft longitudinally extending through the
motor housing, and a plurality of electrical windings extending
through slots in the laminations. The electrical windings are
formed from magnet wire comprising an electrical conductor and a
polymeric dielectric insulation surrounding the electrical
conductor. The polymeric insulation layer is comprised of single or
multiple layers of thin, high dielectric, high temperature tape
that is continuously helically wrapped around the electrical
conductor and is bonded to the electrical conductor and to itself
through the use of high temperature adhesive. The unique design
permits the use of the motor and the overall ESP system in high
temperature environments or applications where the system is
exposed to high temperature conditions.
[0014] Referring generally to FIG. 1, an exemplary system 10
includes a wellbore environment with an ESP system installed. The
wellbore typically is drilled into a geological formation 20 and is
then lined with casing 24. The casing is then perforated to form
perforations 26 to allow fluid to flow into the casing 24. For this
example an electric submersible pump system 10 is then deployed
into the wellbore 22. The deployment system 28 may be tubing or
coiled tubing 30 connected to the submersible pump by a connector
32.
[0015] For this system 10, an electrical power cable 12 is coupled
to an electrical submersible motor 14 in the wellbore environment
22 by an electrical connector 40. This electrical connector is
commonly referred to as a "pothead". The electrical power cable 12
provides typically the three phase power needed to power the
electrical submersible motor 14 and may have different
configurations and sizes depending on the application. For this
system 10 the electrical power cable 12 and connector 40 are
designed to withstand the high-temperature wellbore environment
22.
[0016] The electrical submersible pump system 10 may have a variety
of configurations depending on the application. The system 10
typically comprises an electrical submersible motor 14, motor
protector 16, pump intake 36, and submersible pump 13. The system
is deployed into the wellbore 22 to extract fluids from within the
wellbore 22 and to pump the fluids to surface. The well fluids 26
are extracted by the system 10 and delivered through the production
tubing 30 from which the electrical submersible pump 13 is
connected.
[0017] Internally, the electric motor 14 includes, as shown in FIG.
2, an elongated cylindrical motor housing 42 with a plurality of
metallic laminations 44 stacked there within. To form the
electrical phases a plurality of magnet wires 46 are wrapped around
the laminations 44 to form what are called "windings" 34 of the
motor 18. A drive shaft 36 extends longitudinally through the
laminations 44 and at least two bearings 38, and extends out from
the housing 42 for interconnection with the pump.
[0018] As shown in FIG. 3A, the magnet wire comprises an electrical
conductor 52 and a polymeric insulation 54. The electrical
conductors 52 are single drawn wires of copper or copper alloys or
a twist of several wires. For typical wellbore applications, the
conductors 52 are single drawn copper wires having a diameter or
gauge thickness of from about 0.162'' (#6 AWG) to about 0.0050''
(#16 AWG).
[0019] FIG. 3B is a sectional view of the magnet wire with the
conductor 52 and the polymeric insulation 54. The polymeric
insulation 54 comprises one layer or multiple layers of a high
temperature polymeric dielectric material selected from the
material group polyimide. The polymeric insulating material 54 is
in tape form and is applied by helically or longitudinally wrapping
the polyimide tape onto the conductor in an overlap configuration.
Multiple layers can be applied to the conductor all in the same
direction or in opposite directions. The thickness of the polyimide
film can vary from 0.0005 inch to 0.005 inch. The polyimide film is
adhered to the conductor and to itself with the use of a
fluoropolymer material that is coated on one or both sides of the
polyimide film and is activated by short term exposure to extreme
heat. These fluoropolymer materials can be FEP (fluorinated
ethylene propylene), PTFE (polytetrafluoroethylene), PFA
(perfluoroalkoxy) or a blend thereof. The use of this high
temperature, high dielectric polyimide along with the high
temperature fluoropolymer adhesive allows the magnet wire, and
hence the ESP motor, to continuously operate in downhole
environments at temperatures at or greater than 500.degree. F.
Continuous operation is considered to be a period longer than one
hour and up to at least multiple years.
[0020] An example of the polymeric insulation 54 referred to herein
is commercially available from DuPont.TM. under the identification
150PRN411. The 150 indicating 1.5 mils thick overall tape
thickness, the PRN indicating an HN polyimide film with the high
temperature fluoropolymer adhesive, the 4 indicating 0.0004 inch
thick high temperature adhesive on the bottom side of the tape, the
first 1 indicating the thickness of the polyimide film and the
second 1 indicating 0.0001 inch thick high temperature adhesive on
the top side of the tape.
[0021] Another polymeric insulation 54 available from DuPont.TM. is
CR polyimide film (Corona Resistant Film), identified as PRCR. The
PRCR is used with the high temperature fluoropolymer adhesive
referred to above.
[0022] The embodiments referred to above are meant to illustrate
features of a number of embodiments of the inventive idea. The
embodiments are in no way meant to limit the scope of the claims
herein.
* * * * *