U.S. patent application number 14/230747 was filed with the patent office on 2015-10-01 for pumping system for a wellbore and methods of assembling the same.
This patent application is currently assigned to General Electric Company. The applicant listed for this patent is General Electric Company. Invention is credited to Kiruba Sivasubramaniam Haran, Manoj Ramprasad Shah, Jeremy Daniel Van Dam.
Application Number | 20150275870 14/230747 |
Document ID | / |
Family ID | 52727418 |
Filed Date | 2015-10-01 |
United States Patent
Application |
20150275870 |
Kind Code |
A1 |
Van Dam; Jeremy Daniel ; et
al. |
October 1, 2015 |
PUMPING SYSTEM FOR A WELLBORE AND METHODS OF ASSEMBLING THE
SAME
Abstract
A pumping system for use in moving a fluid present within a
wellbore is provided. The pumping system includes an electric
linear motor having a motor housing and a stator coupled to the
motor housing. The stator includes a track having a primary magnet
assembly. A motor shaft is electrically coupled to the stator and
includes a body having a secondary magnet assembly. The pumping
system includes a pump coupled to the electric linear motor, which
includes a pump housing coupled to the motor housing and a pump
piston coupled to the motor shaft. The pump piston is configured to
reciprocate within the pump housing between a second position and a
first position. A seal is coupled to the motor housing and the
motor housing and configured to direct the fluid into the pump
housing when the pump piston is in the first position and to direct
the fluid out of the pump housing when the pump piston is in the
second position.
Inventors: |
Van Dam; Jeremy Daniel;
(West Coxsackie, NY) ; Shah; Manoj Ramprasad;
(Latham, NY) ; Haran; Kiruba Sivasubramaniam;
(Clifton Park, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
General Electric Company |
Schenectady |
NY |
US |
|
|
Assignee: |
General Electric Company
Schenectady
NY
|
Family ID: |
52727418 |
Appl. No.: |
14/230747 |
Filed: |
March 31, 2014 |
Current U.S.
Class: |
417/415 ;
29/888.02 |
Current CPC
Class: |
F04B 53/22 20130101;
F04B 47/12 20130101; F04B 47/06 20130101; H02K 41/031 20130101;
F04B 17/03 20130101; F04B 17/04 20130101; E21B 43/128 20130101;
Y10T 29/49236 20150115 |
International
Class: |
F04B 17/03 20060101
F04B017/03; F04B 47/12 20060101 F04B047/12 |
Claims
1. A pumping system for use in moving a fluid present within a
wellbore, said pumping system comprising: an electric linear motor
comprising: a motor housing; a stator coupled to said motor housing
and comprising a track having a primary magnet assembly; and a
motor shaft electrically coupled to said stator and comprising a
body having a secondary magnet assembly and a first diameter; a
first pump coupled to said electric linear motor, said pump
comprising: a pump housing coupled to said motor housing; and a
pump piston coupled to said motor shaft and having a second
diameter which is different than said first diameter, said pump
piston configured to reciprocate within said pump housing between a
first position and a second position; and a seal coupled to said
motor housing and said pump housing and configured to direct the
fluid into said pump housing when said pump piston is in said first
position and to direct the fluid out of said pump housing when said
pump piston is in said second position.
2. The pumping system of claim 1, wherein said primary magnet
assembly comprises at least one of a plurality of magnetic windings
and a permanent magnet.
3. The pumping system of claim 1, wherein said secondary magnet
assembly comprises at least one of a plurality of permanent
magnetic windings and a permanent magnet.
4. The pumping system of claim 1, wherein said motor housing has a
first length and said pump housing has a second length which is
less than said first length.
5. The pumping system of claim 1, wherein said housing comprises an
inner surface coupled to said track.
6. The pumping system of claim 1, wherein said first diameter is
larger than said second diameter.
7. The pumping system of claim 1, wherein said seal comprises a
channel coupled in flow communication to the wellbore and said pump
housing.
8. The pumping system of claim 1, further comprising a motor
channel and a pump channel.
9. The pumping system of claim 1, further comprising a connector
removably coupled to at least one of said motor housing and said
pump housing.
10. The pumping system of claim 1, further comprising another pump
coupled to said motor shaft.
11. A well assembly for pumping a fluid, said well assembly
comprising: a well casing comprising a first zone, a second zone
and a plurality of perforations coupled in flow communication to
said second zone; an electric linear motor coupled to said well
casing in at least one of said first zone and said second zone and
comprising: a motor housing; a stator coupled to said motor housing
and comprising a track having a primary magnet assembly; and a
motor shaft electrically coupled to said stator and comprising a
body having a secondary magnet assembly and a first diameter; a
pump coupled to said electric linear motor and located within said
second zone, said pump comprising: a pump housing coupled to said
motor housing; and a pump piston coupled to said motor shaft and
having a second diameter which is less than said first diameter,
said pump piston configured to reciprocate within said pump housing
between a first position and a second position; and a seal coupled
to said motor housing and said pump housing and configured to
direct the fluid into said pump housing when said pump piston is in
said first position and to direct the fluid out of said pump
housing when said pump piston is in said second position.
12. The well assembly of claim 11, wherein said motor housing has a
housing length and said pump housing has a pump length which is
less than said housing length.
13. The well assembly of claim 11, wherein said primary magnet
assembly comprises a magnetic winding and said secondary magnet
assembly comprises a permanent magnet.
14. The well assembly of claim 11, wherein said primary magnet
assembly comprises a permanent magnetic material and wherein said
secondary magnet assembly comprises a plurality of magnetic
windings.
15. The well assembly of claim 11, further comprising a heat
transfer device coupled to said motor housing.
16. A method of assembling a pumping system, the method comprising:
coupling a stator to a motor housing, the stator comprising a
primary magnet assembly; coupling a motor shaft to the stator, the
motor shaft comprising a secondary magnet assembly and having a
first diameter; coupling a pump housing to the motor housing;
coupling a pump piston to the motor shaft, the pump piston having a
second diameter which less than the first diameter and configured
to reciprocate within the pump housing between a first position and
a second position; and coupling a seal to the motor housing and the
piston housing, the seal configured to direct the fluid into the
pump housing when the pump piston is in the first position and to
direct the fluid out of the pump housing when the pump piston is in
the second position.
17. The method of claim 16, further comprising coupling a plurality
of magnetic windings to a track of the stator.
18. The method of claim 16, further comprising coupling a permanent
magnet to the motor shaft.
19. The method of claim 16, further comprising coupling a permanent
magnet to a track of the stator.
20. The method of claim 16, further comprising coupling a plurality
of magnetic windings to the motor shaft.
Description
BACKGROUND
[0001] The embodiments described herein relate generally to pumping
systems, and more particularly, to methods and systems for
selectively pumping a fluid out of a well casing of a wellbore.
[0002] In producing petroleum and other useful fluids from
production wells, some well assemblies include submergible pumping
systems for raising the fluids collected in the well. Production
fluids enter the well casing via perforations formed in the well
casing adjacent a geological formation. Fluids contained in the
geological formation collect in the well casing and may be raised
by the submergible pumping system to a collection point above the
surface of the earth.
[0003] At least some known conventional pumping systems include a
submergible pump, a submergible electric motor and a motor
protector. The submergible electric motor typically supplies power
to the submergible pump by a drive shaft, and the motor protector
serves to isolate the motor from the well fluids. A deployment
system, such as deployment tubing in the form of tubing strings,
can be used to deploy the submergible pumping system within a
wellbore. Generally, power is supplied to the submergible electric
motor or motors by one or more power cables supported along the
deployment system.
[0004] Conventional production wells may provide a high rate of
fluid production in the early phase of the well life and may
provide a lower rate of fluid production for the remainder of the
well life due to lower levels of available fluid. Producing the
well at an efficient recovery rate may require the installation of
an initial pumping system having a high flow rate in the early
phase of well life and then replacing the initial pumping system
with another pumping system having a lower flow rate one or more
times over the life of the well. However, typical replacement
pumping systems can wear out quickly, and in particular, the pump
piston is especially vulnerable due to the harsh conditions of the
geological formation. Replacing pumping systems over the life of
the well may increase design, operational, and/or maintenance costs
of the well assembly. Moreover, at least some known conventional
pump motors may include seals and encapsulation materials between
the motor shaft and motor stator which may lead to interference and
reduced electromagnetic performance of the pumping system.
BRIEF DESCRIPTION
[0005] In one aspect, a pumping system for use in moving a fluid
present within a wellbore is provided. The pumping system includes
an electric linear motor having a motor housing and a stator
coupled to the motor housing. The stator includes a track having a
primary magnet assembly. A motor shaft is electrically coupled to
the stator and includes a body having a secondary magnet assembly.
The body includes a first diameter. The pumping system includes a
pump coupled to the electric linear motor. The pump includes a pump
housing coupled to the motor housing and a pump piston coupled to
the motor shaft and has a second diameter which is different than
the first diameter. The pump piston is configured to reciprocate
within the pump housing between a second position and a first
position. A seal is coupled to the motor housing and the motor
housing. The seal is configured to direct the fluid into the pump
housing when the pump piston is in the first position and to direct
the fluid out of the pump housing when the pump piston is in the
second position.
[0006] A well assembly for pumping a fluid is provided. The well
assembly includes a well casing having a first zone, a second zone
and a plurality of perforations coupled in flow communication to
the second zone. The well assembly further includes an electric
linear motor having a motor housing and a stator coupled to the
motor housing. The stator includes a track having a primary magnet
assembly. A motor shaft is electrically coupled to the stator and
includes a body having a secondary magnet assembly and a first
diameter. The pumping system includes a pump coupled to the
electric linear motor. The pump includes a pump housing coupled to
the motor housing and a pump piston coupled to the motor shaft and
having a second diameter which is less than the first diameter. The
pump piston is configured to reciprocate within the pump housing
between a second position and a first position. A seal is coupled
to the motor housing and the pump housing. The seal is configured
to direct the fluid into the pump housing when the pump piston is
in the first position and to direct the fluid out of the pump
housing when the pump piston is in the second position.
[0007] A method of assembling a pumping system is provided. The
method includes coupling a stator to a motor housing, wherein the
stator includes a primary magnet assembly. A motor shaft is coupled
to the stator and includes a secondary magnet assembly. The motor
shaft includes a first diameter. The method also includes coupling
a pump housing to the motor housing. A pump piston is coupled to
the motor shaft. The pump piston has a second diameter which less
than the first diameter and is configured to reciprocate within
said pump housing between a second position and first position. The
method further includes coupling a seal to the motor housing and
the piston housing, wherein the seal configured to direct the fluid
into the pump housing when the pump piston is in the first position
and to direct the fluid out of the pump housing when the pump
piston is in the second position.
DRAWINGS
[0008] These and other features, aspects, and advantages will
become better understood when the following detailed description is
read with reference to the accompanying drawings in which like
characters represent like parts throughout the drawings,
wherein:
[0009] FIG. 1 is a cross-sectional side view of a well assembly
having an exemplary pumping system vertically coupled to the
wellbore;
[0010] FIG. 2 is cut-away, perspective view of an electric linear
motor and a pump of the pumping system shown in FIG. 1;
[0011] FIG. 3 is another cross-sectional side view of the electric
linear motor and the pump shown in FIG. 1 and a seal coupled to the
electric linear motor and the pump;
[0012] FIG. 4 is a cross-sectional side view of the electric linear
motor, the pump and the seal in a first position;
[0013] FIG. 5 is a cross-sectional side view of the electric linear
motor, the pump and the seal in a second position;
[0014] FIG. 6 is a cross-sectional side view of an alternative
pumping system in a first position;
[0015] FIG. 7 is a cross-sectional side view of the pumping system
shown in FIG. 6 in a second position;
[0016] FIG. 8 is a cross-sectional side view of an alternative
pumping system in a first position;
[0017] FIG. 9 is a cross-sectional side view of the pumping system
shown in FIG. 8 in a second position;
[0018] FIG. 10 is a cross-sectional side view of yet another
alternative pumping system in a first position;
[0019] FIG. 11 is a cross-sectional side view of the pumping system
shown in FIG. 10 in a second position;
[0020] FIG. 12 is a flowchart illustrating an exemplary method of
assembling a pumping system shown in FIG. 1;
[0021] FIG. 13 is a cross-sectional view of a pump piston and a
valve for use with the pumping system shown in FIG. 1;
[0022] FIG. 14 is a cross-sectional view of a pump piston and a
valve for use with the pumping system shown in FIG. 1;
[0023] FIG. 15 is a cross-sectional view of a pump piston and a
valve for use with the pumping system shown in FIG. 1;
[0024] FIG. 16 is a cross-sectional view of an alternative pumping
system in a first position;
[0025] FIG. 17 is a cross-sectional side view of the pumping system
shown in FIG. 16 in a second position; and
[0026] FIG. 18 is a cross-sectional view of an alternative pumping
system.
[0027] Unless otherwise indicated, the drawings provided herein are
meant to illustrate features of embodiments of the disclosure.
These features are believed to be applicable in a wide variety of
systems comprising one or more embodiments of the disclosure. As
such, the drawings are not meant to include all conventional
features known by those of ordinary skill in the art to be required
for the practice of the embodiments disclosed herein.
DETAILED DESCRIPTION
[0028] In the following specification and the claims, reference
will be made to a number of terms, which shall be defined to have
the following meanings The singular forms "a", "an", and "the"
include plural references unless the context clearly dictates
otherwise. "Optional" or "optionally" means that the subsequently
described event or circumstance may or may not occur, and that the
description includes instances where the event occurs and instances
where it does not.
[0029] Approximating language, as used herein throughout the
specification and claims, may be applied to modify any quantitative
representation that could permissibly vary without resulting in a
change in the basic function to which it is related. Accordingly, a
valve modified by a term or terms, such as "about" and
"substantially", are not to be limited to the precise valve
specified. In at least some instances, the approximating language
may correspond to the precision of an instrument for measuring the
valve. Here and throughout the specification and claims, range
limitations may be combined and/or interchanged, such ranges are
identified and include all the sub-ranges contained therein unless
context or language indicates otherwise.
[0030] The embodiments described herein relate to pumping systems
and methods of pumping a fluid from a well assembly. The
embodiments also relate to methods, systems and/or apparatus for
controlling pumping of production fluid to facilitate improvement
of well production performance. More particularly, the embodiments
described herein reduce electromagnetic interference and enhance
electromagnetic performance of a linear motor and pump assembly by
providing different magnetic assemblies for the linear motor. It
should be understood that the embodiments described herein include
a variety of types of well assemblies, and further understood that
the descriptions and figures that utilize a linear motor are
exemplary only. The exemplary pumping system positively displaces a
production fluid at different production rates to efficiently
operate the well assembly over extended periods of time.
[0031] FIG. 1 is a cross-sectional side view of a well assembly 10
having a pumping system 12 vertically coupled to a wellbore 14 via
a wellhead 16. Pumping system 12 includes an electric linear motor
18 and a pump 20. Pumping system 12 is designed for deployment in
wellbore 14 within a geological formation 22 containing desirable
production fluids 24, such as, but not limited to, petroleum.
Wellbore 14 is drilled into geological formation 22 and lined with
a well casing 26. Well casing 26 includes an inner sidewall 28, an
outer sidewall 30, a casing bore 32 defined by inner sidewall 28,
and a casing end 29. Well casing 26 defines a first zone 34 and a
second zone 36 therein. In the exemplary embodiment, first zone 34
is vertically located above second zone 36. Alternatively, well
casing 26 may be positioned in any orientation within geological
formation 22 and may include any number of zones in any orientation
to enable pumping system 12 to function as described herein. A
plurality of perforations 38 is formed through well casing 26 to
permit fluid 24 to flow into wellbore 14 from geological formation
22 and into second zone 36. Alternatively, perforations 38 can be
formed through well casing 26 to permit fluid 24 to flow into
wellbore 14 from geological formation 22 and into first zone 34.
Pumping system 12 includes a seal assembly 40 coupled to electric
linear motor 18 and pump 20.
[0032] A motor controller 42 is coupled to linear motor 18 by power
cables 50. Motor controller 42 includes a rectifier 44, an inverter
46, a programmable logic controller (PLC) 48, one or more
electrical sensors (not shown), and one or more electrical
indicators (not sown) such as, but not limited to, a voltmeter and
one or more ammeters. Alternatively, any programmable control
device configured to process executable instructions to enable
pumping system 12 to operate as described herein may be used. Motor
controller 42 is configured to receive a three phase alternating
current (AC) power signal from a utility grid or generator (neither
shown). Rectifier 44 is configured to convert the three phase AC
power signal to a direct current (DC) power signal and supply the
converted DC power signal to inverter 46. Inverter 46 includes an
output for each stator phase of motor 18 and may modulate the DC
power signal to drive each phase of motor 18 based on control
signals from PLC 48. Sensors (not shown) may measure voltage and
current of one or more of the inverter outputs and be in data
communication with PLC 48. Well assembly 10 further includes a
production string 52 coupled to wellhead 16 and to pumping system
12. In the exemplary embodiment, pumping system 12 is configured to
pump fluid 24 from geological formation 22 to wellhead 16.
[0033] FIG. 2 is a cross-sectional view of electric linear motor 18
and pump 20. FIG. 3 is another cross-sectional view of linear motor
18, pump 20 and seal assembly 40 coupled to linear motor 18 and
pump 20. FIG. 4 is a cross-sectional view of linear motor 18, pump
20, and seal assembly 40 in a first position 54 such as, but not
limited to, a return position. FIG. 5 is a cross-sectional view of
linear motor 18, pump 20, and seal assembly 40 in a second position
56 such as, but not limited to, a discharge position. In the
exemplary embodiment, linear motor 18 includes a motor housing 58
having a first motor end 60, a second motor end 62, and a motor
body 64 located between first motor end 60 and second motor end 62.
Motor body 64 includes an outer surface 66 coupled to well casing
26 (shown in FIG. 1) and an inner surface 68 defining a motor bore
70. Motor body 64 includes a first length L1 between first motor
end 60 and second motor end 62. In the exemplary embodiment, first
length L1 has a range between about 70 inches and about 90 inches.
More particularly, first length L1 is about 81 inches.
Alternatively, motor body 64 has any length to enable linear motor
18 to function as described herein. A stator 72 is coupled to inner
surface 68 and includes a track 74 having a primary magnet assembly
76. In the exemplary embodiment, primary magnet assembly 76
includes a plurality of magnetic windings 78 coupled to track 74.
Magnetic windings 78 are configured in a 3-phase sequence 80.
[0034] Linear motor 18 includes a motor shaft 82 magnetically
coupled to stator 72. Motor shaft 82 includes a body 84 having a
secondary magnet assembly 86. In the exemplary embodiment,
secondary magnet assembly 86 includes at least one permanent magnet
88. Alternatively, secondary magnet assembly 86 may include at
least one of a plurality of magnetic windings, an induction cage, a
magnetically permanent material having a magnetic flux pathway such
as, but not limited to, a synchronous reluctance configuration and
a switched reluctance configuration. Primary magnet assembly 76 and
secondary magnet assembly 86 facilitate providing stationery
support to magnetic windings 78 to reduce load stresses applied to
magnetic windings 78 during operation of linear motor 18.
Stationery support provided by motor shaft 82 facilitates
enhancement of motor life by reducing mechanical breakdown caused
by load stresses applied to the plurality of windings 78. More
particularly, the mechanical stresses applied to moving motor shaft
82 are compensated or carried by the robust structure of solid
metal components of control windings 78. Moreover, motor shaft 82
includes a first diameter D1 having a range between about 0.5
inches and about 3.5 inches. More particularly, first diameter D1
has a length of about 2.25 inches. In the exemplary embodiment,
first diameter D1 includes a circular cross-sectional area.
Alternatively, first diameter D1 can have any length to enable
meter motor shaft 82 to function as described herein. Moreover, in
an alternative embodiment, first diameter D1 can include other
non-circular cross-sectional areas such as, but not limited to, an
elliptical cross-sectional area.
[0035] Pump 20 includes a pump housing 90 coupled to motor housing
58 and located outboard of motor second motor end 62. Pump housing
90 has a first pump end 92, a second pump end 94, and a pump body
96 located between first pump end 92 and second pump end 94. First
pump end 92 is coupled in flow communication to second motor end 62
and in flow communication with perforations 38 and second pump end
94 is located in second zone 36 (both shown in FIG. 1). Moreover,
second pump end 94 is coupled in flow communication to casing end
29. Pump body 96 includes an outer surface 98 that is orientated
toward well casing 26 (shown in FIG. 1) and an inner surface 100
defining a pump bore 102. Body 96 includes a second length L2
between first pump end 92 and second pump end 94. Second length L2
is different than first length L1. In the exemplary embodiment,
second length L2 is less than first length L1. Second length L2 has
a range between about 15 inches and about 25 inches. More
particularly, second length L2 is about 16 inches. Second length L2
can include any dimension to enable pump 20 to function as
described herein. Pump housing 90 further includes a coupler 104
such as, but not limited to, a flange that is configured to couple
first pump end 92 in flow communication to second motor end 62. In
the exemplary embodiment, flange 104 is removably coupled to at
least one of second motor end 62 and first pump end 92 to
facilitate removal and/or retrieval of pump housing 90 out of well
casing 26 (shown in FIG. 1) without removing linear motor 18 from
well casing 26. Alternatively, coupler 104 may be an integrated
coupler such as, but not limited to, a weld. Coupler 104 may
include any configuration to enable coupling between motor housing
58 and pump housing 90.
[0036] Pump 20 further includes a pump piston 106 coupled to motor
shaft 82. Pump piston 106 includes a second diameter D2 that is
different than first diameter D 1. In the exemplary embodiment,
second diameter D2 is less than first diameter D1. In the exemplary
embodiment, second diameter D2 includes a circular cross-sectional
area. Second diameter D2 has a range between about 0.025 inches and
about 2.5 inches. More particularly, second diameter D2 has a
length of about 1.125 inches. First diameter D1 and second diameter
D2 can include any dimension to enable pump 20 to function as
described herein. Moreover, in an alternative embodiment, first
diameter D1 can include other non-circular cross-sectional areas
such as, but not limited to, an elliptical cross-sectional area.
The arrangement of pump housing 90 outboard of motor housing 58
facilitates second diameter D2 being less than first diameter D1.
Accordingly, motor shaft 82 has a greater cross-sectional area as
compared to pump piston 106 which exposes more surface area of
permanent magnet 88 to magnetic windings 78 which facilitates
reducing first length L1 of linear motor 18. A reduced first length
L1 increases efficiency and decreases operational maintenance and
repair costs. In the exemplary embodiment, pump piston 106 is
configured to reciprocate within motor housing 58 and pump housing
90 between first position 54 and second position 56.
[0037] Seal assembly 40 is coupled to motor housing 58 and pump
housing 90. More particularly, seal assembly 40 includes a first
valve 108 coupled in flow communication to second motor end 62 and
first pump end 92. Seal assembly 40 further includes a second valve
110 coupled in flow communication to second pump end 94 and casing
end 29. First valve 108 includes a first seat 101, a second seat
103, and valve device 105. Valve device 105 includes a one-way flow
valve such as, but not limited to, a ball check valve, a swing
check valve, and a diaphragm check valve. First seat 101 and second
seat 103 are coupled to pump piston 106. In the exemplary
embodiment, first seat 101, second seat 103, and pump piston 106
define a channel 107 therein. Channel 107 includes a first end 99
in flow communication with perforations 38. Channel 107 is
configured to direct fluid 24 from perforations 38, through channel
107, beyond first seat 101 and second seat 103, and into pump bore
102. Second valve 110 includes a first seat 109, a second seat 111,
and a valve device 113. Valve device 113 includes a one-way flow
valve such as, but not limited to, a ball check valve, a swing
check valve, and a diaphragm check valve. In an alternative
embodiment, valve device 105 may be positioned within pump bore 102
and between end 99 and flange 104. Moreover, in an alternative
embodiment, valve device 113 may be positioned within pump bore
102.
[0038] First valve 108 is in flow communication with motor bore 70
and pump bore 102 and can include any configuration to facilitate
fluid 24 to flow from perforations 38 and into pump bore 102 and
prevent flow of fluid 24 from pump bore 102 into motor bore 70.
Second valve 110 is coupled in flow communication to pump bore 102
and casing bore 32 and can include any configuration to facilitate
flow of fluid 24 within casing bore 32 and prevent flow of fluid 24
from casing bore 32 and into pump bore 102.
[0039] In first position 54 (FIG. 4), motor shaft 82 is configured
to move pump piston 106 into motor bore 70. Pump piston 106 is
configured to draw fluid 24, under a first piston pressure P1, from
geological formation 22, through perforations 38, and into channel
107. First piston pressure P1 in channel 107 induces valve device
105 to move to an open position 114, represented by hash lines
within valve 108. More particularly, in open position 114, valve
device 105 is decoupled from first seat 101 and second seat 103 to
facilitate flow of fluid 24 from perforations 38, through channel
107, and into piston bore 102. A seal 121 is configured to seal
motor bore 70 from exposure to fluid 24. In the exemplary
embodiment, motor shaft 82 can be coupled closely to stator 72 with
minimal and/or no seals (not shown) and/or encapsulation materials
(not shown) located between motor shaft 82 and magnetic windings
78. More particularly, minimal space between stator 72 and motor
shaft 82 reduces and/or eliminates interference between magnetic
windings 78 and permanent magnet 88 to facilitate enhancement of
electromagnetic performance between magnetic windings 78 and
permanent magnet 88. Moreover, in first position 54, first piston
pressure P1 in pump bore 102 is less than a casing pressure CP of
fluid 24 located in casing bore 32. Based at least on the pressure
differential between first piston pressure P1 and casing pressure
CP, casing pressure CP induces second valve 110 to move to closed
position 115. More particularly, in closed position 115, valve
device 113 is coupled to first seat 109 and second seat 111 and
configured to seal pump bore 102 from casing bore 32. Moreover, in
closed position 115, valve device 113 prevents fluid 24 in casing
bore 32 from entering pump bore 102 and prevents fluid 24 in pump
bore 102 from entering casing bore 32.
[0040] In second position 56 (FIG. 5), motor shaft 82 is configured
to move pump piston 106 into pump bore 102. Pump piston 106 is
configured to move first seat 101, second seat 103, and channel 107
to closed position 115. More particularly, in closed position 115,
valve device 105 is coupled to first seat 101 and second seat 103
and configured to seal pump bore 70 from piston bore 102. Moreover,
in closed position 115, valve device 105 seals channel 107 from
piston bore 102 to prevent flow of fluid 24 from perforations, 38,
through channel 107, and into piston bore 102. Moreover, pump
piston 106 is configured to apply a second piston pressure P2 to
fluid 24 within pump bore 102 as pump piston 106 moves first valve
108 from first pump end 92 and toward second pump end 94 and to
closed position 115.
[0041] Second piston pressure P2 is greater than a formation
pressure FP of fluid 24 located in geological formation 22. Based
at least on pressure differences between second piston pressure P2
and formation pressure FP, second piston pressure P2 prevents fluid
24 flowing from geological formation 22, through perforations 38,
and into pump bore 102. Moreover, second piston pressure P2 is
greater than casing pressure CP of fluid 24 present in casing bore
32. Based at least on pressure differences between second piston
pressure P2 and casing pressure CP, second piston pressure P2
induces second valve 110 to move to open position 114. More
particularly, in open position 114, valve device 113 is decoupled
from first seat 109 and second seat 111 to facilitate movement of
fluid 24 from pump bore 102, through second pump end 94, and into
casing bore 32 for future processing. Subsequent the discharge of
fluid 24 from pump bore 102 and into casing bore 32, motor shaft 82
is configured to move pump piston 106 out of pump bore 102 and into
motor bore 70.
[0042] During an exemplary operation of pumping system 12, motor
controller 42 (shown in FIG. 1) sends a current signal 116 to
stator 72. Current signal 116 flows along track 74 and through
magnetic windings 78. A resultant magnetic field (not shown)
interacts with magnetic windings 78 and permanent magnet 88 of
motor shaft 82 to move motor shaft 82 within motor bore 70, and in
particular, from second motor end 62 toward first motor end 60.
[0043] Motor shaft 82 moves pump piston 106 from pump bore 102, and
into motor bore 70 to first position 54. Pump piston 106 creates
negative first piston pressure P1 which induces movement in fluid
24 from geological formation 22 through perforations 38, through
channel 107, and into pump bore 102. Moreover, first piston
pressure P1 induces first valve device 105 to move and to decouple
from first seat 101 and sealed seat 103 at open position 114. Seal
121 prevents fluid 24 from pump bore 102 from entering motor bore
70. First piston pressure P1 also moves second valve 110 to move
and couple to second pump end 94 to closed position 115 to prevent
fluid 24 from flowing from casing bore 32 into pump bore 102. More
particularly, first piston pressure P1 induces valve device 113 to
couple to first seat 109 and second seat 111. Alternatively, casing
pressure CP can induce valve device 113 to couple to first seat 109
and second set 111 in second position 115.
[0044] In first position 54, movement of the motor shaft 82 and
pump piston 106 allows ingress of fluid 24 from geological
formation 22, through perforations 38, through channel 107, and
into pump bore 102. Moreover, in first position 54, movement of
motor shaft 82 and pump piston 106 moves valve device 111 to couple
to second pump end 94 to seal pump bore 102 from fluids 24 present
in casing 32.
[0045] Motor controller 42 (shown in FIG. 1) sends current signal
118 to stator 72. Current signal 118 flows within magnetic windings
78 to move motor shaft 82 to second position 56. Motor shaft 82
moves pump piston 106 from motor bore 70 and into pump bore 102.
Pump piston 106 moves first valve 108 to couple first valve 108 to
pump piston 106 and moves first valve 108 towards second pump end
94. More particularly, pump piston 106 moves first seat 101 and
second seat 103 to couple to valve device 105. While moving first
valve 108 from first pump end 92 to second pump end 94, pump piston
106 creates second piston pressure P2 within fluid 24 present in
pump bore 102. Second piston pressure P2 is greater than formation
pressure FP and prevents fluid 24 flowing from geological formation
22, through perforations 38, through channel 102, and into pump
bore 102. Moreover, second piston pressure P2 is greater than
casing pressure CP and induces second valve 110 to move to open
position 114. More particularly, second piston pressure P2 induces
valve device 113 to be coupled from valve seat 109 and valve seat
111 to move to open position 114. Second piston pressure P2 induces
second valve 110 to move from second pump end 94 and discharge
fluid 24 from pump bore 102 and into casing bore 32 for further
processing by wellhead 16. At second position 56, motor controller
42 can send another current signal (not shown) to stator 72 to move
motor shaft 82 back to first position 54 to reciprocally repeat the
pumping process.
[0046] FIG. 6 is a cross-sectional side view of an alternative
pumping system 120 in first position 54. FIG. 7 is a
cross-sectional side view of pumping system 120 in second position
56. In FIGS. 6 and 7, similar components shown in FIGS. 1-5 include
the same element number shown in FIGS. 1-5. Stator 72 includes a
primary magnet assembly 122. In the exemplary embodiment, primary
magnet assembly 122 includes permanent magnet 88 coupled to inner
surface 68. Alternatively, primary magnet assembly 122 may include
at least one of a plurality of magnetic windings, an induction
cage, a magnetically permanent material having a magnetic flux
pathway such as, but not limited to, a synchronous reluctance
configuration and a switched reluctance configuration. Moreover,
motor shaft 82 includes a secondary magnet assembly 124. In the
exemplary embodiment, secondary magnet assembly 124 includes
magnetic windings 78. Primary magnet assembly 122 and secondary
magnet assembly 124 are configured to facilitate convenient and
efficient removal of magnetic windings 78 without removal of
stationary permanent magnet 88. More particularly, motor shaft 82
can be efficiently removed from motor bore 70 to facilitate
convenient replacement of magnetic windings 78 for maintenance
and/or replacement operations. Moreover, permanent magnet 88 of
stator 72 remains coupled to inner surface 68, which reduces and/or
eliminates interference with respect to motor shaft 82 removal
and/or replacement.
[0047] During an exemplary operation, motor controller 42 (shown in
FIG. 1) sends a current signal 125 to motor shaft 82. Current
signal 125 flows through magnetic windings 78. A resultant magnetic
field (not shown) interacts with permanent magnet 88 and magnetic
windings 78 to move motor shaft 82 within motor bore 70 from second
motor end 62 to first motor end 60 and to first position 54. In
first position 54, pump piston 106 is configured to draw fluid 24
from geological formation 22, through perforations 38, through
channel 107, and into pump bore 102 as previously described.
Moreover, pump piston 106 is configured to move first valve 108 to
open position 114. Additionally, second valve 110 is moved to
closed position 115 and is configured to prevent flow of fluid 24
from casing bore 32 and into pump bore 102 as previously
described.
[0048] Motor controller 42 (shown in FIG. 1) sends another current
signal 127 to motor shaft 82. Current signal 127 flows through
magnetic windings 78. A resultant magnetic field (not shown)
interacts with permanent magnet 88 and magnetic windings 78 to move
motor shaft 82 within motor bore 70 from first motor end 60 towards
second motor end 62 and second position 56. In second position 56,
pump piston 106 is configured to push first valve 108 from first
pump end 92 to second pump end 94 and to closed position 115. Pump
piston 106 moves fluid 24 within pump bore 102 toward casing bore
32. Moreover, pump piston 106 is configured to move fluid 24
through second pump end 94 to move second valve 110 to open
position 114. In open position 114, pump piston 106 moves fluid 24
from pump bore 102, through second pump end 94, and into casing
bore 32 for future processing.
[0049] FIG. 8 is a cross-sectional side view of an alternative
pumping system 126 in a first position 128. FIG. 9 is a cross
sectional view of pumping system 126 in a second position 130. In
FIGS. 8 and 9 similar components shown in FIGS. 1-7 include the
same element numbers as shown in FIGS. 1-7. In the exemplary
embodiment, stator 72 includes primary magnet assembly 76 having
magnetic windings 78 coupled to track 74. Moreover, motor shaft 82
includes secondary magnet assembly 86 having permanent magnet 88.
Alternatively, secondary magnet assembly 86 may include at least
one of a plurality of magnetic windings, an induction cage, a
magnetically permanent material having a magnetic flux pathway such
as, but not limited to, a synchronous reluctance configuration and
a switched reluctance configuration. Pumping system 12 also
includes another pump 132 coupled to linear motor 18. Pump 132
includes a pump housing 134 and a pump piston 136. Pump housing 134
includes a first pump end 138, a second pump end 140, and a pump
body 142. Pump body 142 includes an outer surface 144 facing well
casing 26 (shown in FIG. 1) and an inner surface 146 defining a
pump bore 148. First pump end 138 is coupled to first motor end 60.
Second pump end 140 is coupled to a well casing end 149. In the
exemplary embodiment, coupler 104 couples pump housing 134 to motor
housing 58. Moreover, perforations 38 are coupled in flow
communication to geological formation 22 and pump bore 148. Seal
assembly 40 includes a first valve 150 and a second valve 152.
[0050] During an exemplary operation of pumping system 12, motor
controller 42 (shown in FIG. 1) sends current signal 116 to stator
72. Current signal 116 flows along track 74 and through magnetic
windings 78. A resultant magnetic field (not shown) interacts with
permanent magnet 88 and magnetic windings 78 to move motor shaft 82
within motor bore 70 from second motor end 62 to first motor end 60
and first position 128. In first position 128, pump piston 106 is
configured to draw fluid 24 from geological formation 22, through
perforations 38, through channel 107, and into pump bore 102 as
previously described. Pump piston 106 is configured to move first
valve 108 to open position 114. Additionally, in first position
128, second valve 110 is moved to closed position 115 to prevent
flow of fluid 24 from casing bore 32 and into pump bore 102 as
previously described.
[0051] Moreover, in first position 128, motor shaft 82 moves pump
piston 136 into pump bore 148. Pump piston 136 is configured to
couple first valve 150 to pump piston 106 and move first valve 150
from first pump end 138 to second pump end 140 to closed position
115. Pump piston 136 further moves fluid 24 within pump bore 148
toward casing bore 32. Pump piston 136 is configured to move fluid
24 through second pump end 140 and move second valve 152 to open
position 114. In open position 114, pump piston 136 moves fluid 24
from pump bore 148, through casing end 149, and into casing bore 32
for future processing.
[0052] Motor controller 42 (shown in FIG. 1) sends current signal
118 (FIG. 9) to stator 72. Current signal 118 flows along track 74
and through magnetic windings 78. A resultant magnetic field (not
shown) interacts with permanent magnet 88 and magnetic windings 78
to move motor shaft 82 within motor bore 70 from first motor end 60
to second motor end 62 and second position 130. In second position
130, pump piston 106 is configured to push first valve 108 from
first pump end 92 to second pump end 94 and to closed position 115.
Pump piston 106 moves fluid 24 within pump bore 102 toward casing
bore 32. Moreover, pump piston 106 is configured to move second
valve 110 to open position 114. In open position 114, pump piston
106 moves fluid 24 from pump bore 102, through second pump end 94,
and into to casing bore 33 for future processing as previously
described. In the exemplary embodiment, casing bore 32 and casing
bore 33 may be coupled in flow communication with each other
through a common connection 35 such as, but not limited to, a
T-connection, a bushing connection, and a valve. Alternatively,
casing bore 32 and casing bore 33 may independently connect to
string 52 (shown in FIG. 1) and/or wellhead 16 (shown in FIG.
1).
[0053] Moreover, in second position 130, pump piston 136 is
configured to draw fluid 24 from geological formation 22, through
perforations 38, through channel 107, and into pump bore 148 as
previously described. In second position 130, first valve 150 is
moved to open position 114 and configured to prevent flow of fluid
24 from pump bore 148 and into motor bore 70. Moreover, in second
position 130, second valve 152 is moved to closed position 115 to
prevent flow of fluid 24 from casing bore 32 and into pump bore
148.
[0054] FIG. 10 is a cross-sectional side view of a pumping system
154 in first position 128. FIG. 11 is a cross-sectional side view
of pumping system 154 in second position 130. In FIGS. 10 and 11,
similar components shown in FIGS. 1-9 include the same element
numbers as components shown in FIGS. 1-9. In the exemplary
embodiment, stator 72 includes primary magnet assembly 122 having
permanent magnet 88. Alternatively, primary magnet assembly 72 may
include at least one of a plurality of magnetic windings, an
induction cage, a magnetically permanent material having a magnetic
flux pathway such as, but not limited to, a synchronous reluctance
configuration and a switched reluctance configuration. Moreover,
motor shaft 82 includes secondary magnet assembly 124 having
magnetic windings 78. Pumping system 154 also includes pump 132
coupled to linear motor 18. Pump 132 includes pump housing 134 and
pump piston 136. Pump housing 134 includes first pump end 138,
second pump end 140, and pump body 142. Pump body 142 includes
outer surface 144 and inner surface 146 defining pump bore 148.
First pump end 138 is coupled to first motor end 60. Second pump
end 140 is coupled to well casing end 149. In the exemplary
embodiment, coupler 104 couples the pump housing 134 to motor
housing 58. Moreover, perforations 38 are coupled in flow
communications to geological formation 22 and pump bore 148. Seal
assembly 40 includes first valve 150 and second valve 152 coupled
to second pump end 140.
[0055] During the exemplary operation, motor controller 42 (shown
in FIG. 1) sends current signal 125 to motor shaft 82. Current
signal 125 flows along motor shaft 82 and through magnetic windings
78. A resultant magnetic field (not shown) interacts with permanent
magnet 88 and magnetic windings 78 to move motor shaft 82 within
motor bore 70 from second motor end 62 and first motor end 60. In
first position 128, pump piston 106 is configured to draw fluid 24
from geological formation 22, through perforations 38, through
channel 107, and into pump bore 102 as previously described. In
first position 128, first valve 108 is configured to move to open
position 114. Seal 121 prevents flow of fluid 24 from pump bore 102
and into motor bore 70. Moreover, in first position 128, second
valve 110 is moved to closed position 115 to prevent flow of fluid
24 from casing bore 32 and into pump bore 102.
[0056] Moreover, in first position 128, motor shaft 82 is
configured to move pump piston 136 into pump bore 148. Pump piston
136 is configured to push first valve 150 from first pump end 138
to second pump end 140 to closed position 115. Pump piston 136
further moves fluid 24 within pump bore 148 toward casing bore 32.
Pump piston 136 is configured to move fluid 24 through second pump
end 140 and move second valve 152 to open position 114. In open
position 114, pump piston 136 moves fluid 24 from pump bore 148 to
casing bore 32 for future processing.
[0057] Motor controller 42 (shown in FIG. 1) sends current signal
127 (FIG. 11) to stator 72. Current signal 127 flows along motor
shaft 82 and through magnetic windings 78. A resultant magnetic
field (not shown) interacts with permanent magnet 88 and magnetic
windings 78 to move motor shaft 82 within motor bore 70 from first
motor end 60 to second motor end 62 and second position 130. In
second position 130, pump piston 106 is configured to push first
valve 108 from first pump end 92 to second pump end 94 and to
closed position 115. Pump piston 106 moves fluid 24 within pump
bore 102 toward casing bore 32. Moreover, pump piston 106 is
configured to move second valve 110 to open position 114. In open
position 114, pump piston 106 moves fluid 24 from pump bore 102 to
casing bore 32 for future processing.
[0058] Moreover, in second position 130, pump piston 136 is
configured to draw fluid 24 from geological formation 22, through
perforations 38, through channel 107, and into pump bore 148 as
previously described. In second position 130, first valve 150 is
moved to open position 114. Seal 121 prevents flow of fluid 24 from
pump bore 148 and into motor bore 70. Moreover, in second position
130, second valve 152 is moved to closed position 115 to prevent
flow of fluid 24 from casing bore 32 and into pump bore 148.
[0059] FIG. 12 is a flowchart illustrating an exemplary method 1200
of assembling a pumping system, such as pumping system 12 (shown in
FIG. 3). Method 1200 includes coupling 1202 stator 72 (shown in
FIG. 3), to motor housing 58 (shown in FIG. 3). The stator includes
a primary magnet assembly, such as primary magnet assembly 76
(shown in FIG. 3). In the exemplary method 1200, assembling the
primary magnet assembly includes coupling a plurality of magnetic
windings 78 (shown in FIG. 4), to a track 74 (shown in FIG. 4), of
the stator. A motor shaft 82 (shown in FIG. 3), is coupled 1204 to
the stator. The motor shaft includes a secondary magnet assembly,
such as secondary magnet assembly 86 (shown in FIG. 3). In the
exemplary method 1200, assembling the secondary magnet assembly
includes coupling a permanent magnet 88 (shown in FIG. 4), to the
motor shaft. The motor shaft further includes a first diameter D1
(shown in FIG. 4).
[0060] Method 1200 includes coupling 1206 a pump housing 90 (shown
in FIG. 4), to the motor housing. Method 1200 further includes
coupling 1208 a pump piston 106 (shown in FIG. 4), to the motor
shaft. The pump piston has a second diameter D2 (shown in FIG. 4),
which is less than the first diameter. The pump piston is
configured to reciprocate within the pump housing between a first
position 54 (shown in FIG. 4), to a second position 56 (shown in
FIG. 5). Method 1200 further includes coupling 1210 a seal assembly
40 (shown in FIG. 4), to the motor housing and the piston housing,
wherein the seal is configured to seal the pump housing when the
pump piston is in the second position and seal the motor housing
when the pump piston is in the first position.
[0061] FIG. 13 is a cross-sectional view of a pump piston 156 and a
valve 158 for use with pumping system 12 (shown in FIG. 1).
Alternatively, pump piston 156 and valve 158 can be used with any
of pumping systems shown in FIGS. 1-11. Valve 158 includes a first
seat 160, a second seat 162, and valve device 164 removably coupled
thereto. Valve device 164 includes a one-way flow valve such as,
but not limited to, a ball check valve, a swing check valve, and a
diaphragm check valve. First seat 160 and second seat 162 are
coupled to pump piston 156 by a fastener 166 such as, but not
limited to, a flange, a weld, and an arm. Moreover, first seat 160
and second seat 162 include grooves 168 which are configured to
hold a seal 170, for example O-rings.
[0062] First seat 160, second seat 162, and pump piston 156 are
configured to define a channel 172 therein. In the exemplary
embodiment, channel 172 includes a first channel portion 174 and a
second channel portion 176. First channel portion 174 includes at
least one end 178 in flow communication with well casing 26 (shown
in FIG. 1) and/or perforations 38 (shown in FIG. 1). First channel
portion 174 is also coupled in flow communication with second
channel portion 176 at an angle 180 having a range from about
0.degree. to about 90.degree.. Alternatively, angle 180 may include
any range to enable pump system 12 to function. Second channel
portion 176 is in flow communication with piston bore 102. The
angular orientation of first channel portion 174 and second channel
portion 176 facilitate directing flow of fluid 24 (shown in FIGS.
4-11) from perforations 38, through channel portions 174, 176, and
into piston bore 102.
[0063] FIG. 14 is a cross-sectional view of a pump piston 182 and a
valve 184. In FIG. 14, similar components have similar element
numbers as shown in FIG. 13. Pump piston 182 and valve 184 can be
used with any of pumping systems shown in FIGS. 1-11. Valve 184
includes first seat 160, second seat 162, and valve device 164
removably coupled thereto. Valve device 164 includes a one-way flow
valve such as, but not limited to, a ball check valve, a swing
check valve, and a diaphragm check valve. First seat 160 and second
seat 162 are coupled to pump piston by fastener 166 such as, but
not limited to, a flange, a weld, and an arm. Moreover, first seat
160 and second seat 162 include grooves 168 which are configured to
hold seal 170, for example O-rings.
[0064] First seat 160, second seat 162, and pump piston 182 are
configured to define a channel 186 therein. In the exemplary
embodiment, channel 186 includes a first channel portion 188 and a
second channel portion 190. First channel portion 188 includes at
least one end 192 in flow communication with well casing 26 (shown
in FIG. 1) and/or perforations 38 (shown in FIG. 1). First channel
portion 188 is also coupled in flow communication with second
channel portion 190 at an angle 194 having a range from about
0.degree. to about 45.degree.. Alternatively, angle 198 may include
any range to enable pump system 12 to function. Second channel
portion 190 is in flow communication with piston bore 102 (shown in
FIGS. 4-11). The angular orientation of first channel portion 188
and second channel portion 190 facilitate directing flow of fluid
24 (shown in FIGS. 4-11) from perforations 38, through channel
portions 188, 190, and into piston bore 102.
[0065] FIG. 15 is a cross-sectional view of a pump piston 196 and a
valve 198 for use with pumping system 12 (shown in FIG. 1). Pump
piston 196 and valve 198 can be used with any of pumping systems
shown in FIGS. 1-11. Valve 198 includes first seat 160, second seat
160, and valve device 169 removably coupled thereto. Valve device
169 includes a one-way flow valve such as, but not limited to, a
ball check valve, a swing check valve, and a diaphragm check valve.
Moreover, first seat 160 and second seat 162 include grooves 168
which are configured to hold seal 170, for example O-rings. First
seat 160, second seat 162, and pump piston 196 are configured to
define a channel 200 therein.
[0066] FIG. 16 is a cross-sectional view of an alternative pumping
system 202 in first position 54. FIG. 17 is a cross-sectional view
of pumping system 202 in second position 56. In FIGS. 16 and 17,
similar components showed in FIGS. 1-15 include the same element
numbers shown in FIGS. 1-15. More particularly, pumping system 202
includes similar components shown in FIGS. 4 and 5. Alternatively,
pumping system 202 may include similar components shown in FIGS.
6-15. Pumping system 202 may work with any system shown in FIGS.
1-15.
[0067] In the exemplary embodiment, motor 82 includes a motor
channel 204 disposed within motor body 84. Moreover, pump 20
includes a pump channel 206 disposed within pump piston 106. Pump
channel 206 is coupled in flow communication to channel 107 of
first valve 108 and in flow communication to motor channel 204.
Motor channel 204 is coupled in flow communication to a flow device
208 such as, but not limited to, a conduit, a pipe, a groove, a
sleeve, a channel, and a casing. Flow device 208 is coupled in flow
communication to formation 22 via perforations 38.
[0068] In first position 54 (FIG. 4), motor shaft 82 is configured
to move pump piston 106 into motor bore 70. Pump piston 106 is
configured to draw fluid 24, under a first piston pressure P1, from
geological formation 22, through perforations 38, and into channel
107. More particularly, first piston pressure P1 induces flow of
fluid 24 from formation 22, through flow device 208, and into motor
channel 204 and piston channel 206. First piston pressure P1 in
channel 107 induces valve device 105 to move to an open position
114, represented by hash lines within valve 108. More particularly,
in open position 114, valve device 105 is decoupled from first seat
101 and second seat 103 to facilitate flow of fluid 24 from
perforations 38, through channels 107, 204, and 206, and into
piston bore 102. In first position 54, first piston pressure P1 in
pump bore 102 is less than casing pressure CP of fluid 24 located
in casing bore 32. Based at least on the pressure differential
between first piston pressure P1 and casing pressure CP, casing
pressure CP induces second valve 110 to move to closed position
115. More particularly, in closed position 115, valve device 113 is
coupled to first seat 109 and second seat 111 and configured to
seal pump bore 102 from casing bore 32. Moreover, in closed
position 115, valve device 113 prevents fluid 24 in casing bore 32
from entering pump bore 102 and prevents fluid 24 in pump bore 102
from entering casing bore 32.
[0069] In second position 56 (FIG. 17), motor shaft 82 is
configured to move pump piston 106 into pump bore 102. Pump piston
106 is configured to move first seat 101, second seat 103, and
channel 107 to closed position 115. More particularly, in closed
position 115, valve device 105 is coupled to first seat 101 and
second seat 103 and configured to seal pump bore 70 from piston
bore 102. Moreover, in closed position 115, valve device 105 seals
channel 107 from piston bore 102 to prevent flow of fluid 24 from
perforations, 38, through channel 107, and into piston bore 102.
Moreover, pump piston 106 is configured to apply second piston
pressure P2 to fluid 24 within pump bore 102 as pump piston 106
moves first valve 108 from first pump end 92 and toward second pump
end 94 and to closed position 115.
[0070] Second piston pressure P2 is greater than casing pressure CP
of fluid 24 present in casing bore 32. Based at least on pressure
differences between second piston pressure P2 and casing pressure
CP, second piston pressure P2 induces second valve 110 to move to
open position 114. More particularly, in open position 114, valve
device 113 is decoupled from first seat 109 and second seat 111 to
facilitate movement of fluid 24 from pump bore 102, through second
pump end 94, and into casing bore 32 for future processing.
Subsequent the discharge of fluid 24 from pump bore 102 and into
casing bore 32, motor shaft 82 is configured to move pump piston
106 out of pump bore 102 and into motor bore 70.
[0071] FIG. 18 is a cross-sectional view of an alternative pumping
system 210. In FIG. 18, similar components showed in FIGS. 1-17
include the same element numbers shown in FIGS. 1-17. More
particularly, pumping system 210 includes similar components shown
in FIGS. 4 and 5. Alternatively, pumping system 210 may include
similar components shown in FIGS. 6-17. Pumping system 202 may work
with any system shown in FIGS. 1-17.
[0072] In the exemplary embodiment, pumping system 210 includes a
heat transfer device 212 coupled in flow communication to formation
22 via perforations 38 and in flow communication to piston bore
102. Heat transfer device 212 includes devices such as, but not
limited to, a conduit, a pipe, a groove, a sleeve, a channel, and a
casing. Heat transfer device 212 is further coupled in flow
communication to motor housing 58. For illustrative purposed only,
Heat transfer device 212 is shown coupled adjacent to an upper
portion of motor housing 58. Alternatively, Heat transfer device
212 may be coupled to any portion of motor housing 58. Heat
transfer device 212 is configured to direct fluid 24 from formation
22, through perforations 38 and into piston bore 102. More
particularly, Heat transfer device 212 is configured to direct
fluid 24 adjacent and/or in contact with motor housing 58 to
facilitate heat transfer from motor housing 58 and into fluid 24.
Accordingly, fluid 24 present within flow device 212 facilitates
heat transfer from motor housing 58 to facilitate cooling motor
18.
[0073] The exemplary embodiments described herein provide for a
submersible linear motor and pump for cost effective pumping of
production fluids from a well. The exemplary embodiments described
positively displace a production fluid at different production
rates, such as, but not limited to, a high rate of fluid production
in the early phase of the well life and a lower rate of fluid
production for the remainder of the well life due to lower levels
of available production fluid. Moreover, the exemplary embodiments
reduce interference and enhance electromagnetic performance of a
pumping system by removing seals and/or encapsulation material
between a motor shaft and motor stator which reduces a space
between the motor shaft and the motor stator.
[0074] The exemplary embodiments described herein locate a pump
housing outboard of a motor housing to facilitate sizing a pump
piston less than a motor shaft to provide more surface area for
magnetic forces in the linear motor to act upon the motor shaft
which reduces a length of the linear motor. Moreover, the exemplary
embodiments provide a linear motor having a motor shaft with a
permanent magnet and a stator having magnetic windings wherein the
permanent magnet supports the magnetic windings during motor
operations which enhances motor life. Further, the exemplary
embodiments described herein provide a linear motor having a motor
shaft with a plurality of magnetic windings and a stator having a
permanent magnet wherein the linear motor provides for convenient
and efficient removal of magnetic windings with reduced or no
interference from the permanent magnet. Still further, the
exemplary embodiments described herein facilitate pumping of
production fluids at precise dynamic rates by controlling the
electronic actuation of a linear motor. The exemplary embodiments
describe herein seal a motor bore from production fluids to
facilitate small tolerances between a motor shaft and a motor
stator. The exemplary embodiments described herein can operate in a
push configuration and/or a pull configuration wherein valve
devices can be positioned on either side of valve seats and/or
positioned in pump bores or casing bores.
[0075] A technical effect of the systems and methods described
herein includes at least one of: (a) positively displacing a
production fluid by a reciprocating pump driven by a linear motor;
(b) reducing an axial length of a linear motor; (c) pumping
multiphase fluids at precise dynamic rates by controlling the
electronic actuation of a linear motor; (d) locating a pump housing
outboard of a motor housing to facilitate sizing a pump piston
different than a motor shaft to optimize a flow rate and a pressure
capacity; (e) providing stationary support to stator windings
during pumping operations; (f) facilitating convenient and
efficient removal of magnetic windings with reduced or no
interference from a permanent magnet; (g) sealing a motor bore from
fluids to facilitate small tolerances between a motor shaft and a
motor stator; and (h) decreasing design, installation, operational,
maintenance, and/or replacement costs for a pumping system for a
well site.
[0076] Exemplary embodiments of a pumping system and methods for
assembling a pumping are described herein. The methods and systems
are not limited to the specific embodiments described herein, but
rather, components of systems and/or steps of the methods may be
utilized independently and separately from other components and/or
steps described herein. For example, the methods may also be used
in combination with other manufacturing systems and methods, and
are not limited to practice with only the systems and methods as
described herein. Rather, the exemplary embodiment may be
implemented and utilized in connection with many other fluid and/or
gas applications.
[0077] Although specific features of various embodiments of the
invention may be shown in some drawings and not in others, this is
for convenience only. In accordance with the principles of the
invention, any feature of a drawing may be referenced and/or
claimed in combination with any feature of any other drawing.
[0078] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to practice the invention, including making and
using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they have structural elements that do not differ
from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal languages of the claims.
* * * * *