Systems and methods for enabling rotation for a shuttle electrical submersible pump assembly

Abstract

An electrical submersible pump system includes an electrical submersible pump (ESP) and a motor connector assembly (MCA) coupled to the ESP, such that the MCA includes an upper annular body including an outer circumferential annular surface, a lower annular body coupled to the upper annular body via a threaded connection, and a bearing sleeve assembly that includes a bearing sleeve, such that the bearing sleeve assembly is configured to mount on the outer circumferential annular surface.

Description

SYSTEMS AND METHODS FOR ENABLING ROTATION FOR A SHUTTLE ELECTRICAL SUBMERSIBLE PUMP ASSEMBLYCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of Singapore Provisional Application No. 10202400390R, entitled “TORQUE REDUCTION SLEEVE FOR SHUTTLE ESP” filed February 13, 2024, and Singapore Provisional Application No. 10202400413W entitled “MECHANICAL SWIVEL FOR SHUTTLE ESP” filed February 15, 2024, both of which are incorporated by reference herein in their entirety for all purposes.BACKGROUND

[0002] The present disclosure generally relates to an Electrical Submersible Pump (ESP) and a corresponding rigless shuttle system. In particular, the present disclosure relates to the implementation of a system configured to enable rotation of a housing associated with the ESP for power connection purposes.

[0003] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and / or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it may be understood that these statements are to be read in this light, and not as admissions of prior art.

[0004] To meet consumer and industrial demand for natural resources, companies often invest significant amounts of time and money in searching for and extracting oil, natural gas, hydrocarbons, and other subterranean resources from the earth. Particularly, once a desired subterranean resource such as oil or natural gas is discovered, drilling and production systems are often employed to access and extract the resource. These systems may be located onshore or offshore depending on the location of the desired resource. Common methods include deploying the drilling and production systems on the surface or on a floating platform disposed above the discovered resources, and drilling a borehole straight down into the surface of the earth to procure the desired resources.

[0005] However, in some scenarios, accessing and extracting the resources from below the surface proves to be more complicated. For example, in some cases, the drilling and production systems may employ artificial lift systems designed to provide a boost to the subterranean resources to ensure that they reach the surface production systems. An electrical submersible pump (ESP) is a common type of artificial lift system utilized downhole in a drilling system to maximize the production of the subterranean resource through the borehole. As consumer and industrial demand for these natural, subterranean resources increase, the scope of these extraction processes correspondingly expand, leading operators to drill larger diameter boreholes and employ drilling and production systems configured to process higher volumes of the resources. As a result, the ESPs utilized in these larger holes are correspondingly larger and heavier to adequately process the increased resource output. Efforts to improve the efficiency and maneuverability of these larger ESPs during drilling operations may be advantageous.SUMMARY

[0006] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, not is it intended to be used as an aid in determining or limiting the scope of the claimed subject matter as set forth in the claims.

[0007] In certain embodiments, an electrical submersible pump system includes an electrical submersible pump (ESP) and a motor connector assembly (MCA) coupled to the ESP, such that the MCA includes an upper annular body including an outer circumferential annular surface, a lower annular body coupled to the upper annular body via a threaded connection, and a bearing sleeve assembly that includes a bearing sleeve, such that the bearing sleeve assembly is configured to mount on the outer circumferential annular surface.

[0008] In certain embodiments, an electrical submersible pump system includes an electrical submersible pump (ESP) and a mechanical swivel coupled to the ESP, such that the mechanical swivel includes an upper body that includes an annular outer surface, a first annular chamber, and a first receptacle, and a middle body that includes a second annular chamber and a second receptacle, such that the mechanical swivel is configured to enable rotational motion between the upper body and the middle body, and the second annular chamber is configured to receive the annular outer surface of the upper body.

[0009] In certain embodiments, an electrical submersible pump system includes an electrical submersible pump (ESP) and a slip ring assembly coupled to the ESP. The slip ring assembly includes a top annular portion, a middle annular portion that includes a first annular chamber configured to receive the top annular portion and a first threaded interface, a lower tool body portion that includes a second annular chamber and a second threaded interface configured to couple to the first threaded interface, a bearing disposed between the top annular portion and the middle annular portion, such that the bearing is configured to enable rotational motion between the top annular portion and the middle portion, and a slip ring disposed within the second annular chamber, such that the slip ring includes one or more electrical connections along a rotatable interface configured to maintain electrical connectivity during the rotational motion.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The subject disclosure is further described in the following detailed description, and the accompanying drawings and schematics of non-limiting embodiments of the subject disclosure. The features depicted in the figures are not necessarily shown to scale. Certain features of the embodiments may be shown exaggerated in scale or in somewhat schematic form, and some details of elements may not be shown in the interest of clarity and conciseness. These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts through the drawings, wherein:

[0011] FIG. 1 is a schematic view of an Electrical Submersible Pump (ESP) rigless shuttle system, in accordance with aspects of the present disclosure;

[0012] FIG. 2 is a section view through an embodiment of the ESP with a helical connection interface with a docking station assembly (DSA), in accordance with aspects of the present disclosure;

[0013] FIG. 3 is a section view through an embodiment of the ESP with a helical connection interface with the DSA, in accordance with aspects of the present disclosure;

[0014] FIG. 4 is a perspective view of an embodiment of the ESP of FIGS. 1-3 with a bearing sleeve assembly, in accordance with aspects of the present disclosure;

[0015] FIG. 5 is a section view through an embodiment of the ESP with the bearing sleeve assembly as illustrated in FIG. 4, in accordance with aspects of the present disclosure;

[0016] FIG. 6 is a top view of an embodiment of the ESP of FIGS. 1-3 with a mechanical swivel and torsion spring, in accordance with aspects of the present disclosure;

[0017] FIG. 7 is a section view through an embodiment of the ESP with the mechanical swivel and torsion spring as illustrated in FIG. 6, in accordance with aspects of the present disclosure;

[0018] FIG. 8 is a schematic view of various configurations of the ESPs in specified rotational positions, in accordance with aspects of the present disclosure;

[0019] FIG. 9 is a top view of an embodiment of the ESP of FIGS. 1-3 with a slip ring, in accordance with aspects of the present disclosure;

[0020] FIG. 10 is a section view through an embodiment of the ESP with the slip ring as illustrated in FIG. 9, in accordance with aspects of the present disclosure;

[0021] FIG. 11 is a perspective view of an embodiment of a pancake slip ring that may be utilized in the embodiment of the ESP with the slip ring as illustrated in FIGS. 9 and 10, in accordance with aspects of the present disclosure;

[0022] FIG. 12 is a perspective view of an embodiment of the pancake slip ring that may be utilized in the embodiment of the ESP with the slip ring as illustrated in FIGS. 9, 10, and 11, in accordance with aspects of the present disclosure;

[0023] FIG. 13 is a perspective view of an embodiment of a through bore slip ring that may be utilized in the embodiment of the ESP with the slip ring as illustrated in FIGS. 9 and 10, in accordance with aspects of the present disclosure; and

[0024] FIG. 14 is a perspective view of an embodiment of the through bore slip ring that may be utilized in the embodiment of the ESP with the slip ring as illustrated in FIGS. 9, 10, and 13, in accordance with aspects of the present disclosure.DETAILED DESCRIPTION

[0025] Certain embodiments commensurate in scope with the present disclosure are summarized below. These embodiments are not intended to limit the scope of the disclosure, but rather these embodiments are intended only to provide a brief summary of certain disclosed embodiments. Indeed, the present disclosure may encompass a variety of forms that may be similar to or different from the embodiments set forth below.

[0026] As used herein, the term “coupled” or “coupled to” may indicate establishing either a direct or indirect connection (e.g., where the connection may not include or include intermediate or intervening components between those coupled), and is not limited to either unless expressly referenced as such. The term “set” may refer to one or more items. Wherever possible, like or identical reference numerals are used in the figures to identify common or the same elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale for purposes of clarification.

[0027] As used herein, the terms “inner” and “outer”; “up” and “down”; “upper” and “lower”; “upward” and “downward”; “above” and “below”; “inward” and “outward”; and other like terms as used herein refer to relative positions to one another and are not intended to denote a particular direction or spatial orientation. The terms “couple,” “coupled,” “connect,” “connection,” “connected,” “in connection with,” and “connecting” refer to “in direct connection with” or “in connection with via one or more intermediate elements or members.” Commonly, these terms relate to a reference point at the surface from which drilling operations are initiated as being the top point and the total depth being the lowest point, wherein the well (e.g., wellbore, borehole) is vertical, horizontal or slanted relative to the surface.

[0028] Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and / or within less than 0.01% of the stated amount. As another example, in certain embodiments, the terms “generally parallel” and “substantially parallel” or “generally perpendicular” and “substantially perpendicular” refer to a value, amount, or characteristic that departs from exactly parallel or perpendicular, respectively, by less than or equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, or 0.1 degree.

[0029] Furthermore, when introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment,” “an embodiment,” or “some embodiments” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, the phrase A “based on” B is intended to mean that A is at least partially based on B. Moreover, unless expressly stated otherwise, the term “or” is intended to be inclusive (e.g., logical OR) and not exclusive (e.g., logical XOR). In other words, the phrase A “or” B is intended to mean A, B, or both A and B.

[0030] Certain terms are used throughout the description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name, but not function.

[0031] For decades, humans have relied on resources found below the earth’s surface to meet increasing energy demands. These resources include but are not limited to natural gas, coal, hydrocarbons, petroleum, and other materials suitable to generate energy for consumption by humans. As energy demands increase, significant efforts are expended to extract an appropriate supply of energy to meet the increasing demand. Included in these efforts are systems and methods that enable expanded extraction of the resources, increases to the efficiency of the extraction process, and technological advances that permit extraction and exploration in areas that were previously inaccessible for energy production.

[0032] Recently, one area of exploration that has grown with the advance of energy exploration related technology is artificial lift systems used to improve production. In some cases, the resources disposed beneath the earth’s surface may have trouble (e.g., reduced pressure, resource viscosity, etc.) reaching the drilling and production systems disposed on the surface without aid from an artificial lift system. An electrical submersible pump (ESP) is a common version of an artificial lift system utilized downhole in a drilling system to maximize the production of the subterranean resource through the borehole. That is, the ESP typically includes multiple centrifugal pump sections ordered together in series that are configured to help drive production resources from a reservoir to the surface. As consumer and industrial demand for these natural, subterranean resources increase, the scope of these extraction processes correspondingly expand, leading operators to drill larger diameter boreholes and employ drilling and production systems configured to process higher volumes of the resources. As a result, the ESPs utilized in these larger holes are correspondingly larger and heavier to adequately process the increased resource output.

[0033] With this added size, operators may encounter mobility and maneuverability issues associated with larger-scale ESPs during an installation process downhole. For example, in some cases, the ESP may connect to a docking station assembly (DSA) in the borehole in order to receive electrical power to operate the components within the ESP. In some cases, the DSA may include a set of electrical connectors configured to mate with an additional set of electrical connectors disposed on the ESP. By virtue of this electrical power connection being initiated downhole, the ESPs may be configured to revolve around an axis of a drill string to ensure that the electrical connectors on the ESP align with the electrical connectors on the DSA. However, as mentioned above, as the sizes of the artificial lift systems increase, the path of angular rotation necessitated by to make the connection may increase as well. To further complicate this connection, in some embodiments of the ESP, the electrical connectors may be axially asymmetrically spaced on the ESP, further increasing a potential angular rotation to electrically couple to the DSA. This increased rotation may introduce additional undesired stresses, torques, and strains on the ESP. As such, efforts to improve the efficiency and maneuverability of these larger ESPs may be advantageous.

[0034] Present embodiments may be directed towards enabling relative rotation between the components of the ESP. In some embodiments, the ESP may include a bearing sleeve assembly configured to reduce a coefficient of friction between a rotational interface of an inner surface of a casing of the borehole and an outer circumferential surface of the ESP. That is, the bearing sleeve assembly may include a bearing sleeve configured to possess improved lubricity characteristics, thereby enabling the ESP to more easily rotate within the borehole.

[0035] In some embodiments, the ESP may be divided into a top tool portion and a bottom tool portion, such that the top tool portion and the bottom tool portion are rotatably coupled together via a mechanical swivel assembly. In part, the mechanical swivel assembly may include one or more bearings configured to enable the bottom tool portion to rotate relative to the top tool portion. In some embodiments, the mechanical swivel assembly may include a torsion spring configured to enact a counteracting rotational force on the bottom tool portion to drive the bottom tool portion back to a neutral “non-rotated position.” Additionally or alternatively, the ESP may include a slip ring disposed between the top tool portion and the bottom tool portion, such that the slip ring is configured to maintain electrical connectivity between electrical connectors running through the top tool portion and electrical connectors running through the bottom tool portion, even as the bottom tool portion rotates with respect to the top tool portion. As a result, present embodiments may enable the ESP to reliably engage and maintain electrical connections with the DSA during installation procedures, while reducing mechanical stresses and strains within the structure of the ESP.

[0036] Turning to the drawings, FIG. 1 is a schematic view of an electrical submersible pump (ESP) rigless shuttle system (ESP system) 100 in a borehole 116. In the illustrated embodiment, the ESP system 100 includes a seal assembly 102, an electrical submersible pump (ESP) 104, a sensor or gauge 108, a motor connector assembly (MCA) 112, and a docking station assembly (DSA) 114. The ESP 104 is positioned inside an annular region of tubing 110, while the tubing 110 may be positioned within an annular region of a casing 106. In some embodiments, the ESP 104 may be configured to receive and pump production resources (e.g., liquid oil, natural gas, petroleum, crude oil, etc.) from a subterranean reservoir to the surface through the tubing 110. The seal assembly 102 may be configured to isolate a pressure in the ESP 104, such that the pressure generated by the ESP 104 may be substantially applied to the production resources while traveling through the tubing 110 of the ESP system 100. In some embodiments, the seal assembly 102 may include a plurality of seals (e.g., annular seals) arranged in a configuration to act as a unidirectional pressure barrier (e.g., to isolate a pressure in a first direction down the borehole 116, isolate a pressure in a second direction up the borehole 116, or in both directions).

[0037] The ESP 104 may include multiple pump stages of pump sections (e.g., centrifugal pump sections) arranged in series along axial length of the borehole 116. In some embodiments, the ESP 104 may be configured to receive the production resource in a first pump stage disposed lower in the borehole, and apply pressure energy to the production resource to facilitate the production resource along its path to the surface. That is, the production resource may enter and exit through various pump stages of the ESP 104, such that, even if the production resource has characteristics (e.g., high viscosity, insufficient pressure, heavy weight, etc.) that complicate traveling to the surface, the ESP 104 may ensure that the production resource may arrive at the surface.

[0038] The ESP system 100 includes a gauge 108 disposed proximate to the ESP 104 within the borehole 116. The gauge 108 may be configured to measure a pressure within the borehole 116. In some embodiments, the gauge 108 may include communication circuitry configured to output a signal to the surface indicative of the measured pressure within the borehole 116. Based on this measurement, an operator at the surface may adjust operational parameters of the ESP 104 to increase or decrease a power output to the ESP 104. In certain embodiments, the ESP system 100 may include multiple gauges 108. For example, one gauge 108 may be disposed lower than the ESP 104 to measure a pressure of the production resource prior to entering the ESP 104, while a second gauge 108 may be disposed above the ESP 104 to measure a pressure of the production resource as it leaves a final pump stage of the ESP 104. In a non-limiting embodiment, the ESP system 100 may include a gauge 108 at an outlet of each pump stage of the ESP 104. In certain embodiments, the gauges 108 may include pressure gauges, temperature gauges, flow meters or gauges, fluid composition gauges, or any combination thereof.

[0039] The ESP system 100 may include a motor connector assembly (MCA) 112 configured to make an electrical power connection with a docking station assembly (DSA) 114. As illustrated, the DSA 114 may be disposed in the tubing 110 of the borehole 116 and the MCA 112 may be configured to travel down the borehole with the ESP 104. The MCA 112 may form a portion of a retrievable string attached to the bottom of the ESP 104. In some embodiments, the MCA 112 may include a flange configured to mechanically couple to a corresponding flange at the bottom of the ESP 104. As discussed in further detail in FIGS. 2 and 3, the MCA 112 may be configured to electrically couple to the DSA 114 via multiple electrical connectors (e.g., 2, 3, 4, 5, or more electrical connectors). In some embodiments, the electrical connectors on the MCA 112 may be female Wetmate electrical connectors and the electrical connectors on the DSA 114 may be male Wetmate electrical connectors, or vice versa. The DSA 114 is configured to receive electrical power from the surface, and in turn configured to provide electrical power to the ESP 104 via the aforementioned electrical connectors. In some embodiments, the MCA 112 may include one or more electrical connectors, fluid connectors, mechanical connectors, fiber optic connectors, or any combination thereof. Additionally, the electrical connectors may include electrical power connectors, data transmission or communication connectors, or any combination thereof.

[0040] FIG. 2 is a section view through an embodiment of the ESP system 100 and illustrates a helical connection interface 200 between the MCA 112 and the DSA 114. In the illustrated embodiment shown in FIG. 2, the helical connection interface 200 is shown prior to the connection being made between the MCA 112 and the DSA 114, as the ESP 104 is lowered into the borehole 116 from the surface in an axial direction along a borehole axis 202. As illustrated, the MCA 112 includes a helical connective spear 210 that includes a tapered tip portion 212 (e.g., V-shaped tip portion formed in an otherwise annular sleeve) and multiple female Wetmate electrical connectors 214 (e.g., three connectors). The female Wetmate electrical connectors 214, taken together, have a female electrical connector axis 216. As shown, the helical connective spear 210 and tapered tip portion 212 form a “pen top” profile that resembles a shape of an ink dispensing portion of a fountain pen. Additionally, the DSA 114 includes a helical connective receptacle 220 that includes tapered receptacle portion 222 (e.g., V-shaped receptacle portion formed in an otherwise annular sleeve), and multiple male Wetmate electrical connectors 224 (e.g., three connectors). The male Wetmate electrical connectors 224, taken together, have a male electrical connector axis 226. As mentioned above, FIG. 2 illustrates the helical connection interface 200 prior to the electrical connection being initiated. As such, the female electrical connector axis 216 is substantially not aligned with the male electrical connector axis 226.

[0041] As the ESP 104 is lowered, the tapered tip portion 212 of the helical connective spear 210 is configured to interface with the tapered receptacle portion 222 of the helical connective receptacle 220. In some embodiments, the tapered tip portion 212 may include a taper angle (e.g., 5°, 10°, 15°, 25°, etc.) and in other embodiments, the taper angle may gradually increase along the length of the helical connective spear 210 in an axial direction (e.g., along the borehole axis 202). Additionally or alternatively, the helical connective receptacle 220 may include a taper angle (e.g., 5°, 10°, 15°, 25°, etc.) and in other embodiments, the taper angle may gradually increase along the length of the helical connective receptacle 220 in an axial direction (e.g., along the borehole axis 202). The tapered tip portion 212 of the helical connective spear 210 may be configured to interface with the tapered receptacle portion 222 of the helical connective receptacle. That is, as the ESP 104 is lowered, the helical connective receptacle 220 of the DSA 114 may enact a rotational force upon the helical connective spear 210 of the MCA 112, thereby causing the MCA 112 to rotate about a central axis of the ESP system 100. The rotation induced by engagement of the helical connective receptacle 220 and the helical connective spear 210 is configured to rotationally align the female and male Wetmate electrical connectors 214 and 224 when connecting the MCA 112 and the DSA 114, such that the female and male Wetmate electrical connectors 214 and 224 can be axially coupled to one another.

[0042] FIG. 3 is a section view through an embodiment of the ESP system 100 and illustrates the helical connection interface 200 between the MCA 112 and the DSA 114. In the illustrated embodiment shown in FIG. 3, the helical connection interface 200 is shown after the connection is executed between the MCA 112 and the DSA 114. As discussed above, the rotational force enacted upon the helical connection spear 210 by the helical connection receptacle 220 as the ESP 104 and MCA 112 is lowered into the borehole. That is, as the helical connective spear 210 is driven to rotate, the MCA 112 is also driven to rotate. By further extension, the female electrical connector axis 216 is driven to rotate such that it substantially aligns with the male electrical connector axis 226 of the helical connective receptacle 220. As the MCA 112 rotates into alignment such that the female electrical connector axis 216 substantially aligns with the male electrical connector axis 226, the MCA 112 may electrically couple with the DSA 114. By virtue of this connection, the ESP 104 (and its associated components) may receive electrical power and output this electrical power to the production resources as the resources flow to the surface. In this way, as the MCA 112 and ESP 104 are lowered into the borehole 116, regardless of the orientation of the MCA 112 in relation to the DSA 114 when the helical connective spear 210 meets the helical connective receptacle 220, the MCA 112 may be driven to rotate such that the female Wetmate electrical connectors 214 may electrically couple to the male Wetmate electrical connectors 224. As such, the electrical cables 230 may be electrically energized via the electrical energy provided by the DSA 114 via the electrical connectors.

[0043] In certain embodiments, the helical connection interface 200 helps align and orientate the Wetmate Connectors and the final mating / docking sequence is achieved in a weight assisted manner. Intuitively, the weight assisted docking sequence will be highly impacted by deviations and incongruencies within the borehole 116, which may cause an outer circumferential surface of the MCA 112 to contact an inner circumferential surface of the DSA 114 and generate a friction force. This friction force may manifest in a direction opposite the motion of the MCA 112 in the form of torque and drag as the ESP 104 is being lowered into the well. This friction force, torque, and drag may introduce undesired effects upon the ESP system 100.

[0044] FIG. 4 is a perspective view of an embodiment of an ESP 104 of FIGS. 1-3 with a bearing sleeve assembly 300. The ESP 104 with a bearing sleeve assembly 300 may include a lower tool body portion 304 coupled to a spool 370 of a bearing sleeve assembly 320, and an upper tool body portion 302 coupled to an upper annular body 322 of the bearing sleeve assembly 320. The lower tool body portion 304 may include an outer annular shell 306 with a recessed taper portion 308 cut out of the outer annular shell 306. As discussed above in relation to FIGS. 2 and 3, as the lower tool body portion 304 rotates such that a corresponding helical connective spear of the DSA 114 may interface with the recessed taper portion 308. In the illustrated embodiment, the recessed taper portion 308 includes a vertex 310 and multiple walls 312. Taken together the vertex 310 and the multiple walls 312 of the recessed tapered portion 308 may define the geometry of the recessed taper portion 308. In the illustrated embodiment, the female Wetmate electrical connectors 214 may extend through the lower tool body portion 304, such that the female Wetmate electrical connectors 214 may connect with corresponding male Wetmate electrical connectors 224 of the DSA 114. In addition to the recessed tapered portion 308, the lower tool body portion 304 may include the helical connective spear 210 as discussed previously during the discussion of FIGS. 2 and 3. In the illustrated embodiment, the helical connective spear 210 is formed in the outer annular shell 306.

[0045] The bearing sleeve assembly 320 may include an upper annular body 322, a bearing sleeve 324, a lower annular body 350, a bearing sleeve retainer 360, and a spool 370. The lower annular body 350, the bearing sleeve retainer 360, and the spool 370 will be discussed in further detail below in the discussion accompanying FIG. 5. As discussed above, the upper annular body 322 may be configured to couple to the upper tool body portion 302. In some embodiments, the upper annular body 322 may couple to the upper tool body portion 302 via a threaded connection, a flanged connection, or otherwise suitable mechanical connection. In the illustrated embodiment, the upper annular body 322 couples to the upper tool body portion 302 via a threaded connection.

[0046] The bearing sleeve 324 is disposed on an annular surface of the upper annular body 322. The bearing sleeve 324 may have a rigid body design. In some embodiments, the bearing sleeve may be made from a self-lubricating material, such that the bearing sleeve 324 is impregnated with a lubricant and the lubricant is released through pores in the bearing sleeve as it rotates. Additionally or alternatively, the bearing sleeve may be made from a low friction material (e.g., having a coefficient of friction between 0.05-0.025, 0.10 – 0.20, 0.13 – 0.18, or otherwise appropriate value). In certain embodiments, the bearing sleeve 324 may be made from graphite (up to 500C), copper, copper alloy (e.g., BeCu), nickel, nickel alloy (e.g., monel), bronze, polymer, and / or a metal polymer (e.g., composite bearing material with steel and bronze backing and impregnated with polytetrafluoroethylene (PTFE)). In certain embodiments, the monel material may be advantageous due to good lubricity and good corrosion resistance characteristics. In the illustrated embodiment, the bearing sleeve 324 is configured to rotatably translate with respect to the upper annular body 322. Additionally or alternatively, the bearing sleeve 324 may provide an interface between the upper annular body 322 and the bearing sleeve 324 that has a reduced coefficient of friction, based in part due to improved lubricity characteristics of the bearing sleeve 324. In some embodiments, the bearing sleeve 324 may provide resistance to scale build up in the tubing 110 in subsequent installs.

[0047] The bearing sleeve 324 may include an outer bearing sleeve annular surface 326 that includes a set of one or more curved protrusions 328 and a corresponding set of one or more curved grooves 330 (e.g., flow by grooves). As illustrated, the bearing sleeve 324 alternatives between the curved protrusions 328 and the curved grooves 330 about a circumference of the bearing sleeve 324. Each individual curved protrusion 328 and curved groove 330 may span an axial length of the bearing sleeve 324 and curve or spiral along a portion of the outer bearing sleeve annular surface in a circumferential direction (e.g., 5°, 10°, 15°, 25°, etc.). The set of one or more curved protrusions 328 are configured to interface with an inner circumferential surface of the tubing 110, such that the curved grooves 330 between adjacent curved protrusions 328 may enable production resources to flow past the bearing sleeve 324 and up the tubing 110 to the surface. In some embodiments, the bearing sleeve 324 may include eight (8) individual curved protrusions 328 and curved grooves 330, but in other embodiments, the bearing sleeve 324 may have greater or fewer (e.g., 2, 3, 4, 5, 6, 7, 9, 10, 12, etc.) curved protrusions 328 and curved grooves 330.

[0048] FIG. 5 is a section view through an embodiment of the ESP 104 with a bearing sleeve assembly 300 as illustrated in FIG. 4. As mentioned above, the ESP 104 with a bearing sleeve assembly 300 may include an upper tool body portion 302, a lower tool body portion 304, a bearing sleeve assembly 320, a bearing sleeve retainer 360, and a spool 370. The bearing sleeve assembly 320 includes an upper annular body 322 that couples to the upper tool body portion 302 and a lower annular body 350 that couples to the spool 370. The bearing sleeve assembly 320 may include the bearing sleeve 324 that enables the ESP 104 with a bearing sleeve assembly 300 to rotate within the tubing 110, thereby reducing stresses and strains within the assembly as the MCA 112 electrically couples to the DSA 114.

[0049] In the illustrated embodiment, the upper annular body 322 includes a first annular portion 323 and a second annular portion 325 separated by a shoulder (e.g., an annular shoulder) 342. The first annular portion 323 includes a coupling interface utilized to couple the upper annular body 322 to the upper tool body portion 302. In some embodiments, the coupling interface of the first annular portion 323 may be configured to include a radial seal 332 to provide a fluid barrier within the threaded connection. Additionally or alternatively, the second annular portion 325 includes an additional threading interface (internal threads) 340 configured to couple to a corresponding threaded interface (external threads) 356 of the lower annular body 350. In some embodiments, this additional threading interface may include a radial seal 344 to similarly provide a fluid barrier within the additional threaded connection.

[0050] Additionally, the second annular portion 325 may include an annular surface 336 to mount a wear sleeve (e.g., an annular wear sleeve) 334. The wear sleeve 334 may slide over the annular surface 336 and abut against the shoulder 342 of the upper annular body 322. In some embodiments, the wear sleeve 334 may be configured to provide a layer of protection against premature wear or degradation for the upper annular body 322. In this way, as the wear sleeve 334 and upper annular body 322 rotate in relation to the bearing sleeve 324, if the wear sleeve 334 begins to show signs of wear, the wear sleeve 334 may be replaced with relative ease rather than replace the entire upper annular body 322. In certain embodiments, the wear sleeve 334 may be made from a material that has a lower hardness than the bearing sleeve 324, ensuring that the wear sleeve 334, rather than the bearing sleeve 324, is the sacrificial part within the assembly. In certain embodiments, the wear sleeve 334 is assembled onto the annular surface 336 of the upper annular body via a press fit. In some embodiments, the wear sleeve 334 may be made from a material configured to facilitate rotation between the wear sleeve 334 and the bearing sleeve 324.

[0051] The upper annular body 322 and the lower annular body 350 may have a substantially similar inner annular diameter 338 along an axial length of the respective bodies. The inner annular diameter 338 may be of a sufficient size such that the electrical cables 230 may extend through the inner annular diameter 338 from the ESP 104 to the DSA 114. In this embodiment, as the ESP 104 with a bearing sleeve assembly 300 rotates together as a unit, the electrical cables 230 are not at risk of tangling, tearing, or otherwise similar wear concerns.

[0052] The bearing sleeve retainer 360 (e.g., annular retainer) is configured to assemble onto an outer annular surface 352 of the lower annular body 350. The outer annular surface 352 has an outer diameter 354, so correspondingly, the bearing sleeve retainer 360 may have an inner diameter greater than the outer diameter 354. In the illustrated embodiment, the bearing sleeve retainer 360 has an annular shape and is configured to block the wear sleeve 334 and the bearing sleeve 324 from translating axially along the bearing sleeve assembly 320. In the illustrated embodiment, the bearing sleeve retainer 360 includes multiple radial holes spaced circumferentially around the bearing sleeve retainer 360. These radial holes are configured to receive a plurality of retainer fasteners 362 that assemble radially from an outer annular circumferential surface of the bearing sleeve retainer 360 and configured to removably couple the bearing sleeve retainer 360 to the lower annular body 350. In this way, the bearing sleeve retainer 360 may be fixed in an axial position within the bearing sleeve assembly 320, while blocking the wear sleeve 334 and the bearing sleeve 324 from translating axially. In some embodiments, the bearing sleeve retainer 360 may be configured to receive four (4) retainer fasteners, while in other embodiments, the bearing sleeve retainer 360 may be configured to receive greater or fewer (e.g., 2, 3, 5, 6, 8, 10 etc.) retainer fasteners 362. In some embodiments, the bearing sleeve retainer 360 may be coupled to the lower annular body 350 via a threaded interface therebetween, one or more locking pins, the retainer fasteners 362, or any combination thereof.

[0053] The spool 370 is configured to couple the lower annular body 350 with the lower tool body portion 304. In some embodiments, the spool 370 includes a first flange configured to couple to the lower tool body portion 304 and a second flange configured to couple to the lower annular body 350. As illustrated, the spool 370 may be configured to receive multiple spool to upper annular body fasteners 372 and also receive multiple spool to lower tool body portion fasteners 374.

[0054] FIG. 6 is a top view of an embodiment of an ESP 104 of FIGS. 1-3 with a mechanical swivel 500. As illustrated, the ESP 104 with a mechanical swivel 500 includes a upper tool body portion 502 and a lower tool body portion 503. The lower tool body portion 503 may be substantially similar to the lower tool body portion as illustrated in FIG. 4, and may include similar features. For example, the lower tool body portion 503 may include the recessed tapered portion 308, the female Wetmate electrical connectors 214, and the helical connective spear 210 as described above.

[0055] The upper tool body portion 502 includes an external spline 504 disposed on an outer annular surface of the upper tool body portion 502. The external spline 504 may include an external spline profile, and may be configured to interface with a mating internal spline profile disposed on an inner annular surface of the tubing 110. In some embodiments, the external spline 504 may assemble with the mating internal spline profile of the tubing 110, thereby creating a spline connection and preventing rotation of the upper tool body portion 502 while the spline connection is engaged. However, the lower tool body portion 503 is configured to rotate relative to the upper tool body portion 502 via the mechanical swivel 500.

[0056] FIG. 7 is a section view through the embodiment of the ESP 104 with the mechanical swivel 500 as illustrated in FIG. 6. In the illustrated embodiment, the ESP 104 with the mechanical swivel 500 includes an upper body 506, a middle body 520, and a threaded collar 508, each having an annular construction. The upper body 506 may include a first upper body annular portion 507 and a second upper body annular portion 509. The upper body annular portion 507 may include an internal threaded interface (internal threads) configured to couple to the upper tool body portion 502. Additionally or alternatively, the second upper body annular portion 509 may be configured to assemble (e.g., slide) into a middle body annular chamber 521. The upper body 506 may also include an upper body annular chamber 511 configured to house a torsion spring 510. As will be discussed in more detail below, the torsion spring 510 is configured to provide a biasing rotational force to counteract a relative rotational motion between the upper body 506 and the middle body 520.

[0057] The middle body 520 may include a first threaded connection 523 and a second threaded connection 525. In certain embodiments, the first threaded connection 523 may be disposed on a lower axial end of the middle body 520 and configured to assemble (e.g., interface) with the lower tool body portion 503. Additionally or alternatively, the second threaded connection 525 may be configured to interface with the threaded collar 508. In some embodiments, the first threaded connection 523 and the second threaded connection 525 may both include external threads.

[0058] The middle body 520 includes a middle body annular chamber 521, previously discussed as configured to receive the second upper body annular portion 509. Additionally or alternatively, the middle body annular chamber 521 may be configured to receive one or more thrust washers (e.g., annular thrust washers) 522. The thrust washers 522 may be configured to receive a thrust force during operation of the ESP 104 with the mechanical swivel 500, thereby protecting the middle body 520 from premature wear. The middle body annular chamber 521 may also receive a middle body bearing sleeve 524 configured to enable rotation between the second upper body annular portion 509 and the middle body 520. In some embodiments, the middle body bearing sleeve 524 may be made from a low-friction materials configured to reduce a rotational coefficient of friction between the upper body 506 and the middle body 520. The middle body 520 may include a fill port 534 configured to enable an operator to fill the internal chambers of the mechanical swivel with fluid. In certain embodiments, the mechanical swivel may be filled with dielectric oil via the fill port 534.

[0059] The ESP 104 with the mechanical swivel 500 may include a threaded collar 508 configured to house and provide mechanical support for a floating stop 518 (e.g., annular rotational bearing). In some embodiments, the floating stop 518 may be configured to provide a hard stop to limit a scope of rotational distance that the mechanical swivel may rotate. Further discussion of this embodiment of the floating stop 518 will be discussed in further detail in FIG. 8.

[0060] However, in some embodiments, the floating stop 518 may be configured to reduce a rotational coefficient of friction between the upper body 506 and the middle body 520. In other embodiments, the floating stop 518 may be a bearing (e.g., cylindrical roller bearing, spherical roller bearing, tapered roller bearing, etc.). The floating stop 518 may abut with a split ring 516. In some embodiments, the split ring (e.g., annular split ring) 516 may provide a mating shoulder 528 to interface with the threaded collar 508. For example, the threaded collar 508 may be configured to slide over the floating stop 518 and threadedly engage with the second threaded connection 525 of the middle body 520. In this way, the threaded collar 508 may provide a clamping force on the mating shoulder 528 of the split ring 516, thereby setting an axial location of the floating stop 518. In some embodiments, the clamping force provided by the threaded collar 508 onto the mating shoulder 528 of the split ring 516, transferred to the floating stop 518 may sufficiently preload the floating stop 518 (e.g., bearing), thereby improving performance of the bearing.

[0061] The torsion spring 510 is configured to be housed in the annular chamber 511 of the upper body 506. In the illustrated embodiment, the torsion spring 510 includes an upper end of the coil 512 (e.g., axial portion) and a lower end of the coil 514 (e.g., axial portion), such that the upper end of the coil 512 is configured to slide into a receptacle 513 (e.g., axial receptacle) of the upper body 506, and the lower end of the coil 514 is configured to slide into a receptacle 515 (e.g., axial receptacle) of the middle body 520. A spiral or helical coil portion 517 of the torsion spring 510 is disposed between the upper and lower ends of the coil 512 and 514. Taken by itself, the torsion spring 510 may be configured to apply a counteracting rotational biasing force in response to a rotational (e.g., twisting force) being applied at one or more of the ends 512, 514 of the torsion spring 510 due to rotational motion between the upper body 506 and the middle body 520. For example, if a counter clockwise rotational external force was applied to the first end 512 of the spring 510, the torsion spring 510 is configured to generate a substantially equal opposite clockwise force to try and return the torsion spring 510 and the rotationally coupled upper and middle bodies 506 and 520 to their neutral state. In the illustrated embodiment, the first end of the coil 512 being positioned in the receptacle of the upper body 506 and the second end of the coil 514 being positioned in the receptacle of the middle body 520 enables the torsion spring 510 to generate a counteracting force as a result of relative rotational motion between the upper body 506 and the middle body 520.

[0062] As shown the electrical cables 230 may run through an inner diameter of the torsion spring 510 and extend through the mechanical swivel 500. As discussed previously, as the MCA 112 may rotate to align the electrical connectors 214, 224 between the MCA 112 and the DSA 114. As a result of this configuration, the electrical cables 230 include a first counter-clockwise (CCW) coil 530 (e.g., spiral winding) on the upper body 506 side of the electrical cable 230, and a clockwise (CW) coil 532 (e.g., spiral winding) on the middle body 520 portion of the electrical cable 230. By virtue of these oppositely wound coils 530 and 532 in the electrical cables 230, the mechanical swivel 500 may enable the upper body 506 to rotate with respect to the middle body 520 (e.g., and the upper tool body portion 502 in relation to the lower tool body portion 503) without interrupting the electrical connection or tearing the cables 230. In some embodiments, the coil 530 may be wound clockwise and the coil 532 may be wound counter-clock wise, just as long as the coils 530 and 532 are wound opposite of each other. In some embodiments, the mechanical swivel 500 may be used with a slip ring, such as illustrated in FIGS. 9-14, to maintain electrical connections during rotation between the upper and middle bodies 506 and 520.

[0063] FIG. 8 is a schematic view of various rotational configurations of the ESP 104 with the mechanical swivel 500. As shown in block 550, to enable restricted rotational movement, a floating stop 518, 560 is introduced which performs the rotational movement, handles radial and axial loads and allow a hard stop limit of approximately 200 degrees on either direction of the mechanical swivel. The rotor 564 has a shoulder 562 that pushes the floating stop 518, 560 either in clockwise (positive angular value) or counterclockwise (negative angular value) direction. A rotational restriction or hard stop limit was integrated in the design to block excessive rotation from damaging the cable 230. This hard stop limit is achieved via a shoulder 568 on the stator 566 that restricts the floating stop 518, 560 from more than 200 degrees of rotation in either direction (e.g., clockwise or counter-clockwise).

[0064] In the neutral position block 550, the shoulder 562 on the rotor 564 and the shoulder 568 on the stator 566 are both top down center (0 degrees from a six o’clock position on a clock). As shown in block 552, the stator 566 and the stator shoulder 568 remain stationary, but the rotor 564 and the rotor shoulder 562 has driven the floating stop 518, 560 clockwise 90 degrees. As shown in block 554, the rotor 564 and the rotor shoulder 562 has driven the floating stop 518, 560 clockwise 200 degrees, causing the floating stop 518, 560 to contact the stator shoulder 568. As a result, the rotor 564 is blocked from rotating the floating stop 518, 560 any further, thereby preventing undesired damage to the electrical cables 230. Blocks 556 and 558 illustrate substantially similar situations as blocks 552 and 554, only in the opposite (counter-clockwise) direction.

[0065] FIG. 9 is a top view of an embodiment of an ESP 104 of FIGS. 1-3 with a slip ring 600. In this embodiment, the ESP 104 with the slip ring 600 is substantially similar to the embodiment of the ESP 104 with the mechanical swivel 500 as illustrated in FIG. 6. For example, the ESP 104 with a slip ring 600 includes an upper tool body portion 502 with an external spline 504, and a lower tool body portion 503 with the recessed tapered portion 308. Further, the lower tool body portion 503 similarly includes the female Wetmate electrical connectors 214 and the helical connective spear 210. As discussed below in the description of FIG. 10, the slip ring 600 is configured to maintain electrical connections during rotational movement between the upper tool body portion 502 and the lower tool body portion 503, such as by enabling sliding electrical contacts in annular contact arrangements of the slip ring 600.

[0066] FIG. 10 is a section view through the embodiment of the ESP 104 with the slip ring 600 as illustrated in FIG. 9. In the illustrated embodiment, the ESP 104 with the slip ring 600 includes a top annular portion 602 threadedly coupled to a middle portion 604 via a threaded interface 610. In some embodiments, the top annular portion 602 may include external threads while the middle portion 604 may include internal threads, or vice versa. The top annular portion 602 and the middle portion 604 may each include an annular passageway 614 configured to house the electrical cables 230. The electrical cables 230 may run to a slip ring 606 disposed within the lower tool body portion 503. In some embodiments, the slip ring 606 may be configured to electrically couple the electrical cables 230 from the ESP 104 to the electrical cables 230 of the MCA 112, and enable the upper tool body portion 502 to rotate in relation to the lower tool body portion 503, while still maintaining electrical connection between the two portions.

[0067] In some embodiments, the middle portion 604 may include a bearing 608 configured to enable and facilitate relative rotation between the top annular portion 602 and the middle portion 604. In certain embodiments, the bearing 608 may be a spherical roller bearing, while in other embodiments, the bearing 608 may be tapered roller bearing, a cylindrical roller bearing, etc. In some embodiments, the slip ring 600 may be used in the ESP 104 of FIGS. 6-8.

[0068] The slip ring 606 in FIG. 10 may have one of several configurations. For example, FIGS. 11 and 12 are perspective views of an embodiment of a pancake style slip ring 700, 606 that may be utilized in the embodiment of the ESP 104 with the slip ring 600. FIG. 11 illustrates the pancake style slip ring 700, 606 including a planar disk 710 configured to house multiple concentric conductive rings 751, 752, 753, and 754. Electrical cables 740 may be electrically coupled respectively to one of the conductive rings 751, 752, 753, and 754. Additionally or alternatively, the electrical cables 720 may be electrically coupled to a conductive sled 730. The conductive sled 730 is configured to rotate around the planar disk 710 while maintaining electrical connectivity between the respective electrical cables 720 and the conductive rings, 751, 752, 753, and 754.

[0069] FIG. 12 illustrates an embodiment of a pancake style slip ring 800, 606 such that the electrical cables 720 are grouped together in a second column 820 and the electrical cables 740 are grouped together in a first column 810. In the illustrated embodiment, the planar disk 830 may include multiple disks, and either the top disk 831 may be configured to rotate with respect to the bottom disk 832, the bottom disk 832 may be configured to rotate with respect to the top disk 831, or a combination thereof. The electrical connections between the top and bottom disks 831 and 832 may be substantially the same as illustrated in FIG. 11. In certain embodiments, the top disk 831 may be configured to operate in a similar manner as the conductive sled 730 in FIG. 11, while in other embodiments, the bottom disk 832 may be configured to operate in a similar manner as the conductive sled 730 in FIG. 11.

[0070] FIGS. 13 and 14 are perspective views of an embodiment of a through bore slip ring 900, 606 that may be utilized in the embodiment of the ESP 104 with the slip ring 600. FIG. 13 illustrates the through bore style slip ring 900, 606 including a planar disk 910 coupled to a cylindrical portion 920. The cylindrical portion 920 is configured to house multiple conductive rings 951, 952, 953, and 954. Electrical cables 720 may be electrically coupled respectively to one of the conductive rings 951, 952, 953, and 954. Additionally or alternatively, the electrical cables 720 may be electrically coupled to a conductive sled 930. The conductive sled 930 is configured to rotate around the cylindrical portion 920 while maintaining electrical connectivity between the respective electrical cables 720 and the conductive rings, 951, 952, 953, and 954.

[0071] FIG. 14 illustrates an embodiment of a through bore style slip ring 1000, 606, such that the electrical cables 720 are grouped together in a second column 1020 and the electrical cables 740 are grouped together in a first column 1010. In the illustrated embodiment, the cylindrical portion 920 may include an inner shell 1060 and and outer shell 1070 configured to rotate with respect to one another, such that the outer shell 1070 may be configured to operate in a similar manner as the conductive sled 930. In certain embodiments, the electrical connections may be substantially the same as illustrated in FIG. 13.

[0072] The technical effect of the disclosed embodiments include an improved efficiency, maneuverability, and reduction in stress on the housing of the ESP systems. For example, by enabling relative rotation between a top portion of the ESP and a bottom portion of the ESP, the ESP system may connect to the DSA without introducing potentials for wear and breakage of the electrical cables that extend through the ESP. Additionally, present embodiments enable larger diameter ESP systems to utilize axially asymmetric electrical cable configurations while still maintaining electrical connectivity between the DSA and the ESP.

[0073] The subject matter described in detail above may be defined by one or more clauses, as set forth below.

[0074] An electrical submersible pump system includes an electrical submersible pump (ESP) and a motor connector assembly (MCA) coupled to the ESP, such that the MCA includes an upper annular body including an outer circumferential annular surface, a lower annular body coupled to the upper annular body via a threaded connection, and a bearing sleeve assembly that includes a bearing sleeve, such that the bearing sleeve assembly is configured to mount on the outer circumferential annular surface.

[0075] The electrical submersible pump system of the preceding clause, wherein the bearing sleeve includes a self-lubricating material, a low friction material, or a combination thereof.

[0076] The electrical submersible pump system of any preceding clause, wherein the bearing sleeve includes at least one of graphite, copper, copper alloy, nickel, nickel alloy, bronze, polymer, metal polymer, or any combination thereof.

[0077] The electrical submersible pump system of any preceding clause, wherein the bearing sleeve includes an outer bearing annular surface, wherein the outer bearing annular surface includes a plurality of curved protrusions and a plurality of curved grooves, wherein the plurality of curved grooves and the plurality of curved protrusions alternate around a circumference of the outer bearing annular surface.

[0078] The electrical submersible pump system of any preceding clause, wherein the bearing sleeve assembly includes a wear sleeve disposed radially between the outer circumferential annular surface and the bearing sleeve, wherein the wear sleeve is configured to mount on the outer circumferential annular surface of the upper annular body.

[0079] The electrical submersible pump system of any preceding clause, including a bearing sleeve retainer configured to mount on an additional outer circumferential annular surface of the lower annular body, wherein the bearing sleeve retainer is configured to block the bearing sleeve assembly from translating axially.

[0080] The electrical submersible pump system of any preceding clause, wherein the upper annular body includes an inner annular diameter configured to house electrical cables that extend through the inner annular diameter from the ESP to a docking station assembly (DSA).

[0081] The electrical submersible pump system of any preceding clause, including an upper tool body portion configured to couple the upper annular body with the ESP, a lower tool body portion configured to electrically couple the electrical cables to the DSA via a helical connective interface, and a spool configured to couple the lower tool body portion with the lower annular body.

[0082] The electrical submersible pump system of any preceding clause, wherein the helical connective interface includes a helical connective spear disposed on the lower tool body portion, wherein the helical connective spear includes a tapered tip portion, and a helical connective receptacle disposed on the DSA, wherein the helical connective receptacle includes a tapered receptacle portion, and wherein the tapered receptacle portion is configured to interface with the tapered tip portion. The helical connective interface also includes a first set of electrical connectors including a first electrical connector axis and a second set of electrical connectors including a second electrical connector axis, wherein the interface between the tapered tip portion and the tapered receptacle portion is configured to align the first electrical connector axis and the second electrical connector axis with one another.

[0083] An electrical submersible pump system includes an electrical submersible pump (ESP) and a mechanical swivel coupled to the ESP, such that the mechanical swivel includes an upper body that includes an annular outer surface, a first annular chamber, and a first receptacle, and a middle body that includes a second annular chamber and a second receptacle, such that the mechanical swivel is configured to enable rotational motion between the upper body and the middle body, and the second annular chamber is configured to receive the annular outer surface of the upper body.

[0084] The electrical submersible pump system of the previous clause, including a torsion spring disposed in the first annular chamber, wherein the torsion spring includes an upper end configured to slide into the first receptacle, a lower end configured to slide into the second receptacle, and a helical coil portion, wherein the helical coil portion is configured to apply a rotational biasing force in response to a rotational force applied at one or more of the upper end or the lower end.

[0085] The electrical submersible pump system of any preceding clause, including a bearing sleeve disposed in the second annular chamber, wherein the bearing sleeve is configured to facilitate rotational motion between the upper body and the middle body.

[0086] The electrical submersible pump system of any preceding clause, including a threaded collar assembly configured to couple the upper body to the middle body, wherein the threaded collar assembly includes a split annular ring including a first shoulder, wherein the split annular ring is configured to assemble into an annular groove of the upper body, a floating stop configured to facilitate rotational motion between the upper body and the middle body, and a threaded collar including a second shoulder and a threaded interface, wherein the threaded interface is configured to assemble to an additional threaded interface disposed on the middle body, and wherein the second shoulder is configured to apply an axial force to the first shoulder.

[0087] The electrical submersible pump system of any preceding clause, wherein the floating stop is configured to provide a hard stop to limit the rotational motion between the upper body and the middle body.

[0088] The electrical submersible pump system of any preceding clause, wherein the floating stop is configured to limit the rotational motion between a positive 200° of angular rotation in a clockwise direction, and a negative 200° of angular rotation in a counter-clockwise direction.

[0089] An electrical submersible pump system includes an electrical submersible pump (ESP) and a slip ring assembly coupled to the ESP. The slip ring assembly includes a top annular portion, a middle annular portion that includes a first annular chamber configured to receive the top annular portion and a first threaded interface, a lower tool body portion that includes a second annular chamber and a second threaded interface configured to couple to the first threaded interface, a bearing disposed between the top annular portion and the middle annular portion, such that the bearing is configured to enable rotational motion between the top annular portion and the middle portion, and a slip ring disposed within the second annular chamber, such that the slip ring includes one or more electrical connections along a rotatable interface configured to maintain electrical connectivity during the rotational motion.

[0090] The electrical submersible pump of the previous clause, wherein the bearing includes a spherical bearing, a cylindrical bearing, a tapered roller bearing, or a combination thereof

[0091] The electrical submersible pump system of any preceding clause, wherein the slip ring includes a pancake style slip ring.

[0092] The electrical submersible pump system of any preceding clause, wherein the slip ring includes a through bore style slip ring.

[0093] The electrical submersible pump system of any preceding clause, including an upper tool portion coupled to the top annular portion, wherein the upper tool portion includes an external spline.

[0094] The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. Moreover, the order in which the elements of the methods described herein are illustrated and described may be re-arranged, and / or two or more elements may occur simultaneously. The embodiments were chosen and described in order to best explain the principals of the disclosure and its practical applications, to thereby enable others skilled in the art to best utilize the disclosure and various embodiments with various modifications as are suited to the particular use contemplated.

[0095] Finally, the techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function]…” or “step for [perform]ing [a function]…”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f). 

Claims

1. An electrical submersible pump system, comprising:an electrical submersible pump (ESP); anda motor connector assembly (MCA) coupled to the ESP, wherein the MCA comprises:an upper annular body comprising an outer circumferential annular surface; a lower annular body coupled to the upper annular body via a threaded connection; anda bearing sleeve assembly comprising a bearing sleeve, wherein the bearing sleeve assembly is configured to mount on the outer circumferential annular surface.

2. The electrical submersible pump system of claim 1, wherein the bearing sleeve comprises a self-lubricating material, a low friction material, or a combination thereof.

3. The electrical submersible pump system of claim 1, wherein the bearing sleeve comprises at least one of graphite, copper, copper alloy, nickel, nickel alloy, bronze, polymer, metal polymer, or any combination thereof.

4. The electrical submersible pump system of claim 1, wherein the bearing sleeve comprises an outer bearing annular surface, wherein the outer bearing annular surface comprises:a plurality of curved protrusions; anda plurality of curved grooves, wherein the plurality of curved grooves and the plurality of curved protrusions alternate around a circumference of the outer bearing annular surface.

5. The electrical submersible pump system of claim 1, wherein the bearing sleeve assembly comprises a wear sleeve disposed radially between the outer circumferential annular surface and the bearing sleeve, wherein the wear sleeve is configured to mount on the outer circumferential annular surface of the upper annular body.

6. The electrical submersible pump system of claim 1, comprising a bearing sleeve retainer configured to mount on an additional outer circumferential annular surface of the lower annular body, wherein the bearing sleeve retainer is configured to block the bearing sleeve assembly from translating axially.

7. The electrical submersible pump system of claim 1, wherein the upper annular body comprises an inner annular diameter configured to house electrical cables that extend through the inner annular diameter from the ESP to a docking station assembly (DSA).

8. The electrical submersible pump system of claim 7, comprising:an upper tool body portion configured to couple the upper annular body with the ESP;a lower tool body portion configured to electrically couple the electrical cables to the DSA via a helical connective interface; anda spool configured to couple the lower tool body portion with the lower annular body.

9. The electrical submersible pump system of claim 8, wherein the helical connective interface comprises:a helical connective spear disposed on the lower tool body portion, wherein the helical connective spear comprises a tapered tip portion; a helical connective receptacle disposed on the DSA, wherein the helical connective receptacle comprises a tapered receptacle portion, and wherein the tapered receptacle portion is configured to interface with the tapered tip portion; a first set of electrical connectors comprising a first electrical connector axis; and a second set of electrical connectors comprising a second electrical connector axis;wherein the interface between the tapered tip portion and the tapered receptacle portion is configured to align the first electrical connector axis and the second electrical connector axis with one another.

10. An electrical submersible pump system, comprising:an electrical submersible pump (ESP); anda mechanical swivel coupled to the ESP, wherein the mechanical swivel comprises:an upper body comprising an annular outer surface, a first annular chamber, and a first receptacle; anda middle body comprising a second annular chamber and a second receptacle, wherein the mechanical swivel is configured to enable rotational motion between the upper body and the middle body, and the second annular chamber is configured to receive the annular outer surface of the upper body.

11. The electrical submersible pump system of claim 10, comprising:a torsion spring disposed in the first annular chamber, wherein the torsion spring comprises:an upper end configured to slide into the first receptacle;a lower end configured to slide into the second receptacle; anda helical coil portion, wherein the helical coil portion is configured to apply a rotational biasing force in response to a rotational force applied at one or more of the upper end or the lower end.

12. The electrical submersible pump system of claim 10, comprising a bearing sleeve disposed in the second annular chamber, wherein the bearing sleeve is configured to facilitate rotational motion between the upper body and the middle body.

13. The electrical submersible pump system of claim 12, comprising a threaded collar assembly configured to couple the upper body to the middle body, wherein the threaded collar assembly comprises: a split annular ring comprising a first shoulder, wherein the split annular ring is configured to assemble into an annular groove of the upper body;a floating stop configured to facilitate rotational motion between the upper body and the middle body; anda threaded collar comprising a second shoulder and a threaded interface, wherein the threaded interface is configured to assemble to an additional threaded interface disposed on the middle body, and wherein the second shoulder is configured to apply an axial force to the first shoulder.

14. The electrical submersible pump system of claim 13, wherein the floating stop is configured to provide a hard stop to limit the rotational motion between the upper body and the middle body.

15. The electrical submersible pump system of claim 14, wherein the floating stop is configured to limit the rotational motion between a positive 200° of angular rotation in a clockwise direction, and a negative 200° of angular rotation in a counter-clockwise direction.

16. An electrical submersible pump system, comprising:an electrical submersible pump (ESP); and a slip ring assembly coupled to the ESP, wherein the slip ring assembly comprises:a top annular portion;a middle annular portion comprising a first annular chamber configured to receive the top annular portion and a first threaded interface;a lower tool body portion comprising a second annular chamber and a second threaded interface configured to couple to the first threaded interface; a bearing disposed between the top annular portion and the middle annular portion, wherein the bearing is configured to enable rotational motion between the top annular portion and the middle portion; anda slip ring disposed within the second annular chamber, wherein the slip ring comprises one or more electrical connections along a rotatable interface configured to maintain electrical connectivity during the rotational motion.

17. The electrical submersible pump system of claim 16, wherein the bearing comprises a spherical bearing, a cylindrical bearing, a tapered roller bearing, or a combination thereof.

18. The electrical submersible pump system of claim 16, wherein the slip ring comprises a pancake style slip ring.

19. The electrical submersible pump system of claim 16, wherein the slip ring comprises a through bore style slip ring.

20. The electrical submersible pump system of claim 16, comprising an upper tool portion coupled to the top annular portion, wherein the upper tool portion comprises an external spline.

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