Auxiliary lifting electric underground pump system

Abstract

A well apparatus includes a conduit disposed in a well and forming a flow passage to a surface level, a positive displacement pump having a rotating fluid displacer, a rotating actuator configured to rotate the fluid displacer, a pump fluid passage between a pump inlet port and a pump outlet port, the fluid displacer disposed in the pump fluid passage, a bypass fluid passage between the bypass inlet port and the bypass outlet port, the pump fluid passage being separate from the bypass fluid passage, and the rotary actuator being operably driven to pump production fluid through the pump fluid passage.

Description

Technical Field

[0001] The presently disclosed subject matter relates generally to the field of oil and gas wells, and more particularly to subsurface pump systems. Background Art

[0002] Without assistance in lifting the formation fluids to the surface, there is often not enough pressure to allow the well to produce at a commercially viable level. Therefore, artificial lift devices are used to pump oil or other liquids from the well or underground to the surface or ground level.

[0003] A common method for moving production fluids to the surface involves the use of submersible pumps. These pumps are installed within the well itself, typically at the lower end of the production tubing. One type of such submersible pump typically consists of a cylindrical housing with an internal reciprocating piston located at the bottom of the production line. The pump has an inlet at the bottom end of the piston and an outlet at the top end. During the upstroke, the pump forces a first volume of fluid upward within the production tubing, while during the downstroke, it forces a second volume of fluid upward within the tubing. The piston is reciprocated axially within the wellbore by a linear magnetic motor. This linear magnetic motor, with a series of windings acting on an inner shaft, is located below the pump. The motor is powered by a cable extending from the surface to the bottom of the well. The power supply generates a magnetic field within the motor's coils, which in turn exerts an oscillating force on the motor's shaft. This causes the shaft to translate vertically, either up and down, or linearly, within the well. The shaft is connected to the pump's piston via a connecting rod, thereby imparting translational or linear motion to the pump piston. Thus, the linear motor enables the pump's piston to reciprocate vertically, lifting fluid toward the well's surface with each stroke of the piston.

[0004] U.S. Patent No. 1,655,825, issued on January 10, 1928, discloses a linear electromagnetic motor coupled to an oil well pump. A solenoid is mounted within a housing and arranged to actuate a core. The core consists of a series of stacked magnetizable components interspersed between non-magnetizable components. The core is coupled to a pump plunger. An upper valve and two lower valves allow fluid to flow only upward. By sequentially applying current to the raising and then lowering solenoids, the core and pump plunger are reciprocated, forcing fluid upward through the valves.

[0005] U.S. Patent No. 5,049,046 teaches a downhole electromagnetic motor-pump assembly having an armature with permanent magnets and a stator with multiple coils, a pump with a reciprocating piston, a downhole switch motor controller, and a remote wireless monitoring station. The patent teaches a motor-pump assembly having a motor-pump barrel unit supported downhole in a casing assembly of an oil well and connected to the surface by piping and cables. The pump is shown and described as having an outer barrel containing a piston. A check valve is disposed below the piston, and a second check valve is disposed above the piston.

[0006] U.S. Patent No. 5,831,353 discloses a motor-pump assembly having a pump and a brushless DC linear motor for reciprocating the pump, allowing fluid in a production tubing to be lifted to the surface. A motor controller is configured to control the linear motor and provide a predetermined number of DC pulses to the motor. A coupling device connects the pump to the motor. The motor is described as having a modular construction comprising a plurality of interconnected stator modules or units and at least one modular cylindrical mover. The stator unit is described as comprising multiple pairs of spaced-apart, oppositely wound annular coils. The mover is described as comprising annular, radially polarized permanent magnets stacked on a shaft with alternating polarity, interleaved with bearing units that share the overall frictional stress by spacing the magnets. The pump is described as operating much like a rod pump, with a piston coupled to the motor mover so as to move in unison. Well fluid is pumped through a borehole in the center of the motor, thereby allowing most of the heat generated by the motor to be dissipated into the well fluid. Summary of the Invention

[0007] By reference to the corresponding components, parts or surfaces of the disclosed embodiments, for illustrative purposes only and not in a limiting manner, a well apparatus (15, 415) is provided, comprising: a conduit (17) disposed in a well (18) and forming a flow passage for a fluid originating from below the surface level to the surface level; a first motor pump housing (101, 201, 301) disposed in the well; a first positive displacement pump (110, 210, 310) disposed in the first housing and having a first rotary fluid displacer (113, 212, 213, 214); a first rotary actuator (120, 220, 320) disposed in the housing and configured to actuate the first rotary fluid displacer; the first rotary actuator comprising a first stator (124, 224, 324) and a first rotor (125, 225, 325), the first rotor configured and arranged to rotate in a direction indicated by the first stator; the first pump fluid channel being configured to rotate relative to the first stator under the influence of a magnetic field generated by the rotor; the first rotor being connected to the first rotary fluid displacer; a first pump inlet port (151, 251, 351) and a first pump outlet port (141, 241, 341) in the first housing; a first pump fluid channel (170, 270, 370, 380) between the first pump inlet port and the first pump outlet port, and the first rotary fluid displacer being disposed in the first pump fluid channel; a first bypass inlet port (161, 261, 361) and a first bypass outlet port (162, 262, 362) in the first housing; a first bypass fluid channel (160, 260, 360) between the first bypass inlet port and the first bypass outlet port; and the first pump fluid channel being separated from the first bypass fluid channel; wherein the first rotary actuator is operably driven to pump production fluid through the first pump fluid channel.

[0008] The first positive displacement pump may include a vane pump (110, 310) or a screw pump (210), and the first rotary fluid displacer may include vanes (113) or screws (212, 213, 214) of the vane pump or the screw pump. The first positive displacement pump may include a multi-stage vane pump (310). The multi-stage vane pump may include a first stage (305) and a second stage (306, 307); the second stage may be operably configured in series with the first stage; and the first rotary actuator may be operably driven to pump production fluid through the first and second stages through the series first pump fluid channel (370). The multi-stage vane pump may include a first stage (305) and a second stage (306, 307); the second stage may be operably configured in parallel with the first stage; and the first rotary actuator may be operably driven to pump production fluid through the first and second stages through the parallel first pump fluid channel (380).

[0009] The first motor pump housing may include a first control input connection (164, 264, 364), a first control bypass output connection (166, 266, 366), and a conductor (165, 365) between the first control input connection and the first control bypass output connection. The well apparatus may include a cable (24, 424) that supplies power from the surface level to the first control input connection. The well apparatus may include a cable (24, 424) that supplies power from the surface level to the first stator (124) via the first control input connection.

[0010] The well apparatus may include a first controller housing (96) and a first driver (33) for a first actuator disposed in the first controller housing. The first controller housing may include a first fluid passageway (70) and a second fluid passageway (60) separate from the first fluid passageway. A first pump fluid passageway (170, 270, 370, 380) may be operably connected to the first fluid passageway (70), and a first bypass fluid passageway (160, 260, 360) may be operably connected to the second fluid passageway (60). The first controller housing may include an input connection (86), a motor output connection (84), and a conductor (80) between the input connection and the motor output connection.

[0011] The well apparatus may include: a second motor pump housing (101A, 301A) disposed in the well; a second positive displacement pump (110A, 310A) disposed in the second housing and having a second rotary fluid displacer; a second rotary actuator (120A, 320A) disposed in the second housing and configured to actuate the second rotary fluid displacer; the second rotary actuator having a second stator and a second rotor, the second rotor configured and arranged to rotate relative to the second stator under the influence of a magnetic field generated by the second stator; the second rotor connected to the second rotary fluid displacer; a second pump inlet port (151A, 351A) and a second pump outlet port in the second housing (141A, 341A); a second pump fluid channel (170A, 370A, 380A) between the second pump inlet port and the second pump outlet port, and a second rotary fluid displacer is disposed in the second pump fluid channel; a second bypass inlet port (161A, 361A) and a second bypass outlet port (162A, 362A) in the second housing; a second bypass fluid channel (160A, 360A) between the second bypass inlet port and the second bypass outlet port; and the second pump fluid channel is separated from the first bypass fluid channel; wherein the second rotary actuator can be operably driven to pump production fluid through the second pump fluid channel.

[0012] The first pump fluid channel can be operably connected to the second pump fluid channel, and the production fluid can be operably pumped in series through the first pump fluid channel and the second pump fluid channel ( Figure 28 、 Figure 31 、 Figure 41 and Figure 44 The first pump outlet port may be operably connected to the second pump inlet port, and the second rotary actuator may be operably driven to pump production fluid from the first pump fluid channel through the second pump fluid channel.

[0013] The first pump fluid channel may be operably connected to the second bypass fluid channel, the first bypass fluid channel may be operably connected to the second pump fluid channel, and production fluid may be operably pumped in parallel through the first pump fluid channel and the second pump fluid channel ( Figure 29 、 Figure 32 、 Figure 42 and Figure 45 The first pump outlet port may be operably connected to the second bypass inlet port, and the first rotary actuator may be operably driven to pump production fluid from the first pump fluid channel through the second bypass fluid channel. The first bypass outlet port may be operably connected to the second pump inlet port, and the second rotary actuator may be operably driven to pump production fluid from the first bypass fluid channel through the second pump fluid channel.

[0014] The first pump may include a multi-stage vane pump (300). The multi-stage vane pump may include a first stage (305) and a second stage (306, 307); the second stage may be operably configured in series with the first stage; and the first rotary actuator may be operably driven to pump production fluid in series through the first pump fluid channel through the first stage and the second stage (370). The multi-stage vane pump may include a first stage (305) and a second stage (306, 307); the second stage may be operably configured in parallel with the first stage; and the first rotary actuator may be operably driven to pump production fluid in parallel through the first pump fluid channel through the first stage and the second stage (380).

[0015] The first pump fluid channel can be operably connected to the second pump fluid channel or the second bypass fluid channel; the second pump fluid channel can be operably connected to the first pump fluid channel or the first bypass fluid channel; the production fluid can be operably connected in series ( Figure 28 、 Figure 31 、 Figure 41 and Figure 44 ) or in parallel ( Figure 29 、 Figure 32 、 Figure 42 and Figure 45 ) pumping through a first pump fluid channel and a second pump fluid channel; the first pump may include a first multi-stage vane pump (300); the first multi-stage vane pump may include a first stage (305) and a second stage (306, 307); the second stage may be operably configured to be connected in series or in parallel with the first stage; and the first rotary actuator may be operably driven to pump production fluid in series (370) or in parallel (380) through the first pump fluid channel through the first stage and the second stage. The second pump may include a second multi-stage vane pump (310A); the second multi-stage vane pump may include a third stage (305A) and a fourth stage (306A, 307A); the fourth stage may be operably configured to be connected in series or in parallel with the third stage; and the second rotary actuator may be operably driven to pump production fluid in series (370A) or in parallel (380A) through the second pump fluid channel through the third stage and the fourth stage.

[0016] The first motor pump housing may include a first control input connection (164), a first control bypass output connection (166), and a conductor (165) between the first control input connection and the first control bypass output connection; the second motor pump housing may include a second control input connection (164A), a second control bypass output connection (166A), and a conductor (165A) between the second control input connection and the second control bypass output connection; and the second control bypass output connection may be connected to the first control input connection. The well apparatus may include a cable (24, 424) that supplies power from the surface level to the second control input connection. The well apparatus may include a cable (24, 424) that supplies power from the surface level to the first stator (124) via the second control input connection.

[0017] The well apparatus may include: a first controller housing (96) and a first driver (33) for a first actuator disposed in the first controller housing; and a second controller housing (96A) and a second driver (33A) for a second actuator disposed in the second controller housing. The first controller housing may include a first input connection (86), a first motor output connection (84), a first fluid passageway (60), and a second fluid passageway (70) separate from the first fluid passageway; the second controller housing may include a second input connection (86A), a second motor output connection (84A), a third fluid passageway (60A), and a fourth fluid passageway (70A) separate from the third fluid passageway; the second input connection (86A) of the second controller housing may be conductively connected to the first input connection (86) of the first controller housing; the first pump fluid passageways (170, 370, 380) may be The second controller housing includes a first fluid passageway (60) and a second fluid passageway (70) operatively connected to one of the first fluid passageway (60) and the second fluid passageway (70); a first bypass fluid passageway (160, 360) operatively connected to the other of the first fluid passageway (60) and the second fluid passageway (70); a second pump fluid passageway (170A, 370A, 380A) operatively connected to one of the third fluid passageway (60A) and the fourth fluid passageway (70); and a second bypass fluid passageway (160A, 360A) operatively connected to the other of the third fluid passageway (60) and the fourth fluid passageway (70). The second controller housing includes a second input connection (86A) operatively connected to the first input connection (86) of the first controller housing via a bypass conduit (165A) in the second motor pump housing.

[0018] The first motor pump housing may include a first actuator housing portion (121, 321) defining a first chamber substantially isolated from the well, and the first stator and the first rotor may be disposed in the first chamber. The first actuator housing portion may include a first end, and the first actuator may include a first rotor shaft (126, 226, 326) connected to the first rotor, and the first rotor shaft may include a portion that sealably passes through the first end of the first actuator housing portion. The first motor pump housing may include a pump housing portion (111, 211, 311) connected to the first actuator housing portion, the first rotary fluid displacer may include a first pump shaft (115, 215, 315) disposed in the pump housing portion, and the first pump shaft may be connected to the portion of the first rotor shaft that sealably passes through the first end of the first actuator housing portion for rotational movement therewith. The first end of the first actuator housing portion may include a seal.

[0019] The first motor pump housing may include a first pump housing portion (111, 211, 311), and the first pump may be disposed in the first pump housing portion, and the first motor pump housing may include a first actuator housing portion (121, 221, 321), and the first rotary actuator may be disposed in the first actuator housing portion. The first motor pump housing may include a first manifold housing portion (140, 240, 340) and a second manifold housing portion (150, 250, 350). The first pump inlet port and the first bypass inlet port may be in the first manifold housing portion, and the first pump outlet port and the first bypass outlet port may be in the second manifold housing portion.

[0020] In another aspect, a well apparatus (515) is provided, comprising: a conduit (17) disposed in a well (18) and forming a flow passage for a fluid originating from below the surface level to the surface level; a first motor housing (591) disposed in the well; a first rotary actuator (520) disposed in the first motor housing; a first pump housing (501, 601) disposed in the well; a first positive displacement pump (510, 610, 611) disposed in the first pump housing and having a first rotary fluid displacer (512); the first rotary actuator comprising a first stator (524) and a first rotor (525), the first rotor being configured and arranged to rotate relative to the first stator under the influence of a magnetic field generated by the first stator; the first rotor being connected to the first rotary fluid displacer such that the first The rotary actuator is operably configured to actuate a first rotary fluid displacer; a first pump inlet port (551, 651) and a first pump outlet port (541, 641) in a first pump housing; a first pump fluid channel (570, 670, 680) between the first pump inlet port and the first pump outlet port, and the first rotary fluid displacer is disposed in the first pump fluid channel; a first bypass inlet port (561, 661) and a first bypass outlet port (564, 664) in the first pump housing; a first bypass fluid channel (565, 665) between the first bypass inlet port and the first bypass outlet port; and the first pump fluid channel is separate from the first bypass fluid channel; wherein the first rotary actuator is operably driven to pump production fluid through the first pump fluid channel.

[0021] The well apparatus may include: a second pump housing (501A, 601A) disposed in the well; a second positive displacement pump (510A, 610A, 611A) disposed in the second pump housing and having a second rotary fluid displacer; a first rotor connected to the second rotary fluid displacer such that the first rotary actuator is operably configured to actuate the second rotary fluid displacer; a second pump inlet port (551A, 651A) and a second pump outlet port (541A, 641A) in the second pump housing; and a first positive displacement pump (510A, 610A, 611A) disposed in the second pump housing and having a second rotary fluid displacer. The well apparatus includes two pump fluid passages (570A, 670A, 680A), with a second rotary fluid displacer disposed in the second pump fluid passage; a second bypass inlet port (561A, 661A) and a second bypass outlet port (564A, 664A) in the second pump housing; a second bypass fluid passage (565A, 665A) between the second bypass inlet port and the second bypass outlet port; and the second pump fluid passage is separate from the second bypass fluid passage; wherein the first rotary actuator is operably driven to pump production fluid through the second pump fluid passage. The well apparatus may include a shaft (529, 529A) connecting the first rotor of the first rotary actuator to the first rotary fluid displacer and the second rotary fluid displacer, such that the first fluid displacer and the second fluid displacer rotate with rotation of the first rotor of the first rotary actuator.

[0022] The first pump housing may include a first pump shaft inlet port (534) and a first pump shaft outlet port (535), and the second pump housing may include a second pump shaft inlet port (534A). The well apparatus may include a shaft (526, 529, 529A) extending through the first pump shaft inlet port, the first pump shaft outlet port, and the second pump shaft inlet port, and the shaft connects the first rotor of the first rotary actuator to the first rotary fluid displacer and the second rotary fluid displacer so that the first fluid displacer and the second fluid displacer rotate with the rotation of the first rotor of the first rotary actuator. The first motor housing may include an end, and the shaft may include a portion (526) that sealably penetrates the end of the first motor housing. The first pump housing may be connected to the first motor housing, the first rotary fluid displacer may include a first pump rotor (512) disposed in the first pump housing, and the first pump rotor may be connected to the shaft for rotational movement therewith. The second pump housing may be connected to the first pump housing, the second rotary fluid displacer may include a second pump rotor disposed in the second pump housing, and the second pump rotor may be connected to the shaft for rotational movement therewith.

[0023] The first pump fluid channel may be operably connected to the second pump fluid channel, and the production fluid may be operably pumped in series through the first pump fluid channel and the second pump fluid channel ( Figure 53 、 Figure 59 and Figure 61). The first pump outlet port may be operably connected to the second pump inlet port, and the second rotary fluid displacer may be operably driven to pump production fluid from the first pump fluid channel through the second pump fluid channel.

[0024] The first pump fluid channel may be operably connected to the second bypass fluid channel, the first bypass fluid channel may be operably connected to the second pump fluid channel, and production fluid may be operably pumped in parallel through the first pump fluid channel and the second pump fluid channel ( Figure 54 、 Figure 56 、 Figure 60 and Figure 62 The first pump outlet port may be operably connected to the second bypass inlet port, and the first rotary fluid displacer may be operably driven to pump production fluid from the first pump fluid channel through the second bypass fluid channel. The first bypass outlet port may be operably connected to the second pump inlet port, and the second rotary fluid displacer may be operably driven to pump production fluid from the first bypass fluid channel through the second pump fluid channel.

[0025] The first pump fluid channel can be operably connected to the second pump fluid channel or the second bypass fluid channel; the second pump fluid channel can be operably connected to the first pump fluid channel or the first bypass fluid channel; the production fluid can be operably pumped in series or in parallel through the first pump fluid channel and the second pump fluid channel; the first pump can include a first multi-stage vane pump (600); the first multi-stage vane pump can include a first stage (610) and a second stage (611); the second stage can be operably configured to be in series (670) or in parallel (680) with the first stage; and the rotary actuator can be operably driven to pump the production fluid through the first pump fluid channel through the first stage and the second stage in series or in parallel. The second pump may include a second multi-stage vane pump (600A); the second multi-stage vane pump may include a third stage (610A) and a fourth stage (611A); the fourth stage may be operably configured to be connected in series (670A) or in parallel (680A) with the third stage; and the rotary actuator may be operably driven to pump production fluid through the second pump fluid channel through the third and fourth stages in series or in parallel.

[0026] The well equipment may include: a second motor housing (591A) disposed in the well; a second rotary actuator (520A) disposed in the second motor housing and having a second stator and a second rotor, the second rotor being configured and arranged to rotate relative to the second stator under the influence of a magnetic field generated by the second stator; and the second rotor of the second rotary actuator may be connected to the first rotary fluid displacer so that the second rotary actuator is operably configured to actuate the first rotary fluid displacer; wherein the first rotary actuator and the second rotary actuator are operably driven to pump production fluid through the first pump fluid channel.

[0027] The first motor housing may include a first motor shaft outlet port (527), and the second motor housing may include a second motor shaft inlet port (528A) and a second motor shaft outlet port (527A). The well apparatus may include a shaft (526, 523, 526A) extending through the first shaft outlet port, the second shaft inlet port, and the second shaft outlet port, and the shaft rotationally couples the first rotor of the first rotary actuator to the second rotor of the second rotary actuator such that the first rotor and the second rotor rotate together.

[0028] The well apparatus may include: a second pump housing (501A, 601A) disposed in the well; a second positive displacement pump (510A, 610A, 611A) disposed in the second pump housing and having a second rotary fluid displacer; a first rotor connectable to the second rotary fluid displacer such that a first rotary actuator is operably configured to actuate the second rotary fluid displacer; a second rotor connectable to the second rotary fluid displacer such that a second rotary actuator is operably configured to actuate the second rotary fluid displacer; a second pump inlet port (551A, 651A) and a second pump outlet port (541A, 641A) in the second pump housing; ; a second pump fluid channel (570A, 670A, 680A) between the second pump inlet port and the second pump outlet port, and a second rotary fluid displacer is disposed in the second pump fluid channel; a second bypass inlet port (561A, 661A) and a second bypass outlet port (564A, 664A) in the second pump housing; a second bypass fluid channel (565A, 665A) between the second bypass inlet port and the second bypass outlet port; and the second pump fluid channel is separated from the second bypass fluid channel; wherein the first rotary actuator and the second rotary actuator are operably driven to pump production fluid through the second pump fluid channel.

[0029] The first motor housing may include a first motor shaft outlet port (527), the second motor housing may include a second motor shaft inlet port (528A) and a second motor shaft outlet port (527A), the first pump housing may include a first pump shaft inlet port (534) and a first pump shaft outlet port (535), and the second pump housing may include a second pump shaft inlet port (534A). The well apparatus may include a shaft (526, 523, 526A, 529, 529A) extending through the first motor shaft outlet port, the second motor shaft inlet port, the second motor shaft outlet port, the first pump shaft inlet port, the first pump shaft outlet port, and the second pump shaft inlet port, and the shaft may rotationally couple the first rotor of the first rotary actuator, the second rotor of the second rotary actuator, the first rotor of the first rotary actuator, the first rotary fluid displacer, and the second rotary fluid displacer so that the first rotor, the second rotor, the first fluid displacer, and the second fluid displacer rotate together. The well apparatus may include: an intake housing (537, 637) disposed in the well between a first motor housing and a first pump housing; an intake inlet port (530, 630) and an intake outlet port (531, 631A, 631B) in the intake housing; an intake fluid passage (536, 636A, 636B) between the intake inlet port and the intake outlet port; an intake shaft inlet port (532) and an intake shaft outlet port (533) in the intake housing; and a shaft may extend through the intake shaft inlet port and the intake shaft outlet port.

[0030] The well apparatus may include an intake housing (537, 637) disposed in the well between a first motor housing and a first pump housing; an intake inlet port (530, 630) and an intake outlet port (531, 631A, 631B) in the intake housing; an intake fluid passage (536, 636A, 636B) between the intake inlet port and the intake outlet port; and the intake outlet port operatively connected to the first pump inlet port. The intake housing may include an intake shaft inlet port (532) and an intake shaft outlet port (533).

[0031] The well apparatus may include: a first intake housing (537) disposed in the well between the first motor housing and the first pump housing; a first intake inlet port (530) and a first intake outlet port (531) in the first intake housing; a first intake fluid passage (536) between the first intake inlet port and the first intake outlet port; the first intake outlet port operably connected to the first pump inlet port in the first pump housing; a second intake housing (537A) disposed in the well between the first pump housing and the second pump housing; a second intake inlet port (530A) and a second intake outlet port (531A) in the second intake housing; a second intake fluid passage (536B) between the second intake inlet port and the second intake outlet port; and the second intake outlet port operably connected to the second pump inlet port in the second pump housing.

[0032] The well apparatus may include: an intake housing (637) disposed in the well; a first intake inlet port (630) and a first intake outlet port (631A) in the intake housing; a first intake fluid passage (636A) between the first intake inlet port and the first intake outlet port; a second intake inlet port (630) and a second intake outlet port (631B) in the input housing; a second intake fluid passage (636B) between the second intake inlet port and the second intake outlet port; and the first intake outlet port being separated from the second intake outlet port. The intake housing may be disposed in the well between the first motor housing and the first pump housing. The first intake outlet port may be operably connected to a first pump inlet port in the first pump housing, and the second intake outlet port may be operably connected to a first bypass inlet port in the first pump housing. The first bypass outlet port in the first pump housing may be operably connected to a second pump inlet port in the second pump housing. The first intake inlet port and the second intake inlet port may include the same port (630). BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The accompanying drawings are incorporated herein as part of the specification. The drawings described herein illustrate embodiments of the subject matter of the present disclosure and illustrate selected principles and teachings of the present disclosure. However, the drawings do not illustrate all possible implementations of the subject matter of the present disclosure and are not intended to limit the scope of the present disclosure in any way.

[0034] Figure 1 is a schematic vertical cross-sectional view of an embodiment of an oil well assembly having an embodiment of an improved actuator and pump system.

[0035] Figure 2 yes Figure 1 An isometric partial cutaway view of the actuator and pump module is shown.

[0036] Figure 3 yes Figure 2 A first partial vertical cross-sectional view of the actuator and pump module is shown.

[0037] Figure 4 yes Figure 2 A second partial vertical cross-sectional view of the actuator and pump module is shown.

[0038] Figure 5 yes Figure 4 An enlarged partial cross-sectional view of the actuator and pump module is shown.

[0039] Figure 6 yes Figure 5 The actuator and pump module are shown along the Figure 5 A transverse cross-sectional view taken along line 6-6.

[0040] Figure 7 yes Figure 1 An isometric partial cutaway view of the top manifold block of the actuator and pump module is shown.

[0041] Figure 8 yes Figure 7 A vertical cross-sectional view of a first portion of the manifold block is shown.

[0042] Figure 9 yes Figure 7 A second partial vertical cross-sectional view of the manifold block is shown.

[0043] Figure 10 yes Figure 1 An isometric partial cutaway view of the bottom manifold block of the actuator and pump module is shown.

[0044] Figure 11 yes Figure 10 A vertical cross-sectional view of a first portion of the manifold block is shown.

[0045] Figure 12 yes Figure 10 A second partial vertical cross-sectional view of the manifold block is shown.

[0046] Figure 13 yes Figure 1 A front plan view of the controller module is shown.

[0047] Figure 14 yes Figure 13 An isometric view of the controller module is shown.

[0048] Figure 15 yes Figure 14 An isometric view of the top of the controller module is shown.

[0049] Figure 16 yes Figure 14 An isometric view of the bottom end of the controller module is shown.

[0050] Figure 17 yes Figure 14 Schematic view of the controller board of the controller module is shown.

[0051] Figure 18 The pump configuration is based on Figure 3 Schematic view of the dual-unit actuator and pump downhole drive system.

[0052] Figure 19 In parallel pump configuration Figure 14 Schematic view of a dual-unit actuator and pump downhole drive system is shown.

[0053] Figure 20 is based on the combined series and parallel pump configuration Figure 3 Schematic view of a downhole drive system of at least four units of actuators and pumps.

[0054] Figure 21 yes Figure 2 An isometric partial cutaway view of a first alternative embodiment of an actuator and pump module is shown.

[0055] Figure 22 yes Figure 21 A first partial vertical cross-sectional view of a first alternative actuator and pump module is shown.

[0056] Figure 23 yes Figure 21 A second partial vertical cross-sectional view of a first alternative actuator and pump module is shown.

[0057] Figure 24 yes Figure 23 An enlarged partial cross-sectional view of a first alternative actuator and pump module is shown.

[0058] Figure 25 yes Figure 2 A first partial vertical cross-sectional view of a second alternative embodiment of an actuator and pump module is shown.

[0059] Figure 26 yes Figure 25 A second partial vertical cross-sectional view of a second alternative actuator and pump module is shown.

[0060] Figure 27 yes Figure 26 An enlarged partial cross-sectional view of a second alternative actuator and pump module is shown.

[0061] Figure 28 Is in series stage and series pump configuration according to Figure 25 Schematic view of the dual-unit actuator and pump downhole drive system.

[0062] Figure 29 In parallel pump configuration Figure 28 Schematic view of a dual-unit actuator and pump downhole drive system is shown.

[0063] Figure 30 is in series and combined series and parallel pump configurations according to Figure 25 Schematic view of a downhole drive system of at least four units of actuators and pumps.

[0064] Figure 31 The pumps are arranged in parallel and in series according to Figure 25 Schematic view of the dual-unit actuator and pump downhole drive system.

[0065] Figure 32 In parallel pump configuration Figure 31 Schematic view of a dual-unit actuator and pump downhole drive system is shown.

[0066] Figure 33 is in parallel stages and combined series and parallel pump configurations according to Figure 25 Schematic view of a downhole drive system of at least four units of actuators and pumps.

[0067] Figure 34 is a schematic view of multiple linked controller modules in a master control configuration.

[0068] Figure 35 is a schematic view of the controller logic for a multi-unit actuator and pump system in a series pump configuration and a master control configuration.

[0069] Figure 36 is a schematic view of the controller logic for a multi-unit actuator and pump system in a parallel pump configuration and a master control configuration.

[0070] Figure 37 is a schematic view of multiple linked controller modules in a parallel control configuration.

[0071] Figure 38 is a schematic view of the surface pressure management controller logic for a multi-unit actuator and pump system in a series pump configuration and a master control configuration.

[0072] Figure 39 is a schematic vertical cross-sectional view of an alternative embodiment of an oil well assembly having an alternative embodiment of an improved actuator and pump system.

[0073] Figure 40 yes Figure 39 Schematic diagram of an isometric partial cutaway view of the flow direction of a dual-linked actuator and pump module in a top drive system.

[0074] Figure 41 The pump configuration is based on Figure 2 Schematic view of the dual-unit actuator and pump top drive system.

[0075] Figure 42 In parallel pump configuration Figure 41 Schematic view of the dual unit actuator and pump top drive system shown.

[0076] Figure 43 is based on the combined series and parallel pump configuration Figure 2 Schematic view of a top drive system of at least four units of actuators and pumps.

[0077] Figure 44 Is in series stage and series pump configuration according to Figure 25 Schematic view of the dual-unit actuator and pump top drive system.

[0078] Figure 45 In parallel pump configuration Figure 44 Schematic view of the dual unit actuator and pump top drive system shown.

[0079] Figure 46 is in series and combined series and parallel pump configurations according to Figure 25 Schematic view of a top drive system of at least four units of actuators and pumps.

[0080] Figure 47 The pumps are arranged in parallel and in series according to Figure 25 Schematic view of the dual-unit actuator and pump top drive system.

[0081] Figure 48 In parallel pump configuration Figure 47 Schematic view of the dual unit actuator and pump top drive system shown.

[0082] Figure 49 is in parallel stages and combined series and parallel pump configurations according to Figure 25 Schematic view of a top drive system of at least four units of actuators and pumps.

[0083] Figure 50 is a schematic vertical cross-sectional view of a second alternative embodiment of an oil well apparatus having a second alternative embodiment of an improved actuator and pump system.

[0084] Figure 51 yes Figure 50 A partial vertical cross-sectional view of an actuator module is shown.

[0085] Figure 52 yes Figure 50A partial vertical cross-sectional view of a pump module is shown.

[0086] Figure 53 The pump configuration is based on Figure 50 Schematic view of a dual actuator unit and dual pump unit system.

[0087] Figure 54 In parallel pump configuration Figure 53 Schematic view of a dual actuator unit and dual pump unit system shown.

[0088] Figure 55 is Figure 50 Schematic view of a dual actuator unit and single pump unit system in a well shown.

[0089] Figure 56 is Figure 50 Schematic view of a single actuator unit and dual pump unit system in a well shown.

[0090] Figure 57 In series configuration Figure 50 Schematic view of a system of dual actuator units and a multi-stage pump unit in a well is shown.

[0091] Figure 58 In cascade configuration Figure 57 Schematic view of a system with dual actuator units and one multi-stage pump unit is shown.

[0092] Figure 59 In series stage configuration and series pump configuration Figure 50 Schematic view of a dual actuator unit and dual multistage pump unit system in a well shown.

[0093] Figure 60 In series stage and parallel pump configuration Figure 59 Schematic view of a dual actuator unit and dual multi-stage pump unit system shown.

[0094] Figure 61 In parallel stage and series pump configuration Figure 59 Schematic view of a dual actuator unit and dual multi-stage pump unit system shown.

[0095] Figure 62 In parallel stage and parallel pump configuration Figure 59 Schematic view of a dual actuator unit and dual multi-stage pump unit system shown. DETAILED DESCRIPTION

[0096] First, it should be clearly understood that the same reference numerals are intended to consistently identify the same structural elements, parts or surfaces throughout the several figures, so that such elements, parts or surfaces can be further described or explained throughout the written specification, of which this detailed description is an integral part. Unless otherwise indicated, the drawings are intended to be read together with the specification (e.g., cross-hatching, arrangement of parts, proportions, extent, etc.), and the drawings should be considered part of the entire written specification of the invention. As used in the following description, the terms "horizontal," "vertical," "left," "right," "upper," and "lower," and their adjective and adverb derivatives (e.g., "horizontally," "rightwardly," "upwardly," etc.), refer only to the direction of the structure shown when the specific figure faces the reader. Similarly, the terms "inwardly" and "outwardly" generally refer to the direction of a surface relative to its axis of extension or axis of rotation, as the case may be.

[0097] It should be understood that the specific components and systems shown in the drawings and described in the following description are merely exemplary embodiments. Therefore, unless otherwise expressly stated in the claims, specific dimensions, directions, or other physical characteristics related to the disclosed embodiments should not be considered limiting. Furthermore, although they may not be, similar elements in the various embodiments described herein may generally be referred to by similar reference numerals throughout this section of the application.

[0098] It is to be understood that the present teachings are presented by way of example only, and not by way of limitation. The concepts herein are not limited to use or application with a specific system or method. Thus, although the approach described herein is for ease of explanation and is shown and described with respect to exemplary embodiments, it will be understood that the principles herein are equally applicable to other types of systems and methods involving pump systems.

[0099] Unless otherwise stated, the terms "first," "second," and the like used herein do not necessarily indicate any sequence, order, or priority, but are simply used to more clearly distinguish one element or group of elements from another element or group of elements.

[0100] Referring now to the drawings, and more particularly to Figure 1 An oil well pump and motor system is provided, a first embodiment of which is generally indicated at 15. As shown, a wellbore extends horizontally from the surface to a point below the surface. The wellbore is lined with a casing 16 to form a wellbore 18, which includes perforations that provide fluid communication between the wellbore 18 and the surrounding oil and gas-bearing formations. A pump system 15 is disposed at the bottom of the wellbore 18 and is configured to artificially lift production fluids from the wellbore 18 through a tubing string 17 to a collection point at the surface.

[0101] The pump system 15 may generally include one or more control units 95 and one or more pump units 100, 200 and / or 300 having connected manifold ends 140, 150, 240, 250, 340, 350. Figure 1 In the embodiment shown, the pump system 15 includes a control unit 95, a pump unit 100, and connected manifold ends 140 and 150. The control unit 95 is connected to the surface controller 20 via lines 23 and 24. Signals and commands are communicated via a signal cable 23 that extends from the controller box 20 at the surface of the well 18 to the control electronics in the control unit 95. Power is transmitted via a power cable 24 that extends from the surface controller 20 at the surface of the well 18 to the drive electronics in the control unit 95.

[0102] Now refer to Figure 2-Figure 20 An exemplary embodiment of a single-stage vane pump of a positive displacement pump unit is generally indicated at 100. In this embodiment, the pump unit 100 generally includes a single-stage vane pump 110 driven by an electric motor 120, all contained within a cylindrical unit 101. The cylindrical unit housing 101 includes a pump housing portion 111 that houses the pump 110 and a motor housing portion 121 that houses the motor 120. Distribution manifold blocks 140 and 150 are provided at either end of the housing 101 so that multiple control units 95 and pump units 100 can be stacked coaxially with the production fluid flow path arranged in series or parallel to provide the desired level of lift, as further described below.

[0103] In this embodiment, a vane pump 110 generally includes a centrally supported rotor 114 having radially extending vanes 113 that rotate within a pump ring 117 when rotor 114 is driven by a connected motor 120. Vanes 113 can have variable lengths and can be biased to maintain contact with ring 117 as the pump rotates. When vanes 113, attached to pump rotor 114, are rotationally driven by motor 120, this rotational motion of vanes 113 transports fluid from the pump's inlet to its outlet. Pump unit 100 has an inlet 151 connected to manifold block 150 and an outlet 141 connected to manifold block 140, with a fluid passage 170 therebetween. During normal operation, production fluid is directed to flow in through inlet 151 of manifold block 150, flow through the pump's inlet port via fluid passage 170 to vanes 113, and then through the pump's outlet port and out through outlet 141 of manifold block 140 via fluid passage 170.

[0104] Motor 120 is a brushless DC variable-speed servo motor powered by an electric current. The speed and output of pump unit 100 vary as the speed of motor 120 changes. The solid shaft 115 of pump rotor 114 of pump 110 is connected to a solid output shaft 126 of motor 120. Motor 120 has an inner rotor 125 with permanent magnets and an outer, non-rotating stator 124 with coil windings. Stator 124 is fixed to first motor housing portion 121 so that it does not rotate relative to housing 121. When an appropriate current is applied through the coils of stator 124, a magnetic field is induced. The interaction of the magnetic fields between stator 124 and rotor 125 generates torque, which can rotate output shaft 126. Thus, motor 120 selectively applies torque to shaft 126 at varying speeds about axis xx.

[0105] The pump unit 100 includes a pump inlet 151 in a manifold block 150 for receiving production fluid or well fluid, and a pump outlet 141 in a manifold block 140 for outputting well fluid at a higher pressure than the pump inlet 151. The pump unit 100 also includes power and data input connections 164 in the manifold block 140 for inputting power to the motor 120. The manifold block 150 with the pump inlet 151 is disposed at the bottom end of the housing 101, while the manifold block 140 with the pump outlet 141 and the input connection 164 is disposed at the top end of the housing 101. Thus, the pump unit 100 forces a volume of fluid upward within the production tubing 17.

[0106] Pump unit 100 includes a bypass channel 160, separate from fluid channel 170 through pump 110, and a bypass power and command connection 165 for transmitting data, commands, and power to lower units in the production line. Bypass channel 160 includes a bypass inlet 161 in manifold block 150 and a bypass outlet 162 in manifold block 150. Pump unit 100 does not provide a pressure differential between bypass inlet 161 and bypass outlet 162. Bypass power and command connection 165 includes a bypass input connection 167 in manifold block 140 and a bypass output connection 166 in manifold block 150. Manifold block 150, bypass inlet 161, and output connection 166 are located at the bottom end of housing 601, while manifold block 140, bypass outlet 162, and input connection 167 are located at the top end of housing 601. Although in this embodiment the bypass passage 160 is shown as a conduit, alternative passages may be used. For example, a separate volume within the interior of the housing 101 may be used to provide the bypass passage.

[0107] refer to Figure 13-Figure 17, the rotary actuator or motor 120 is powered by a motor control unit 95 having a motor drive 33 connected to a cable 24 that extends from a controller box 20 at the surface to provide power and data to an input connection 86 of the control unit 95 at the bottom of the wellbore 18. The power supplied from the control unit 95 to the pump unit 100 via the output connection 84 of the control unit 95 and the input connection 164 of the connection manifold block 140 then generates a magnetic field within the corresponding coils of the stator 124, which in turn exerts a rotational force on the magnetic rotor 125 and the actuator shaft 126, and in turn exerts a rotational force on the pump shaft 115 and the rotor 114 with the blades 113. The blades 113 are thereby rotated, allowing fluid to be lifted toward the surface of the well 18 as a result of this rotation.

[0108] As shown, the control unit 95 generally includes control electronics contained within a cylindrical housing 96. The cylindrical housing 96 includes an electrical connection block 40 and a fluid connection block 50 at either end of the housing 96. In this embodiment, the control unit 95 provides fluid, data, and power connections for the pump unit 100, allowing multiple control units and pump units to be stacked coaxially with the production fluid flow path in a series or parallel arrangement to provide the desired level of lift, as further described below, as well as providing power and data communications in a primary or parallel configuration, as further described below. The control unit 95 includes a fluid inlet 51 and a fluid outlet 41, with a fluid passage 70 therebetween. The control unit 95 also includes a fluid inlet 61 and a fluid outlet 62, with a fluid passage 60 therebetween, which is separate from the fluid passage 70. The connection block 50 with the fluid inlets 51 and 61 is disposed at the bottom end of the housing 96, while the connection block 40 with the fluid outlets 41 and 62 is disposed at the top end of the housing 96. In normal operation, production fluid from pump unit 100 can be directed to flow in through inlet port 51 and out through outlet port 41 via fluid channel 70. Production fluid from pump unit 100 can also be directed to flow in through inlet port 61 and out through fluid channel 60 through outlet port 62.

[0109] In this embodiment, the control unit 95 includes data and power input connections 86, bypass output connections 87, and motor output connections 84. Input connections 86 are configured to connect directly to lines 23 and 24 from the surface controller 20, or to output connections 166 of a pump unit directly above the production line (such as connection 166A of pump unit 100A). Output connections 87 of the control unit 95 are configured to connect to bypass input connections 167 of pump unit 100. Output connections 84 of the control unit 95 are configured to connect to motor input connections 164, thereby connecting power from the drive 33 of the control unit 95 to the motor 120 of the pump unit 100. A bypass power and command bus 80 connects input connections 86 in the control block 40 and output connections 87 in the control block 50. Connection block 50 and output connections 84 and 87 are located at the bottom end of the housing 96, while connection block 40 and input connections 86 are located at the top end of the housing 96. Connections 83 in block 40 may be connected to connections 163 of a pump unit directly above the production line, such as pump unit 100A, although in this configuration they are only blind support connections.

[0110] Now refer to Figure 17 The controller unit 95 includes a communication board 30, a main board 31, an actuator control board 32, and an actuator driver 33. The communication board 30 is configured to provide communication with the surface controller 20 and / or other controller units (such as Figure 18 and Figure 19 The controller unit 95A shown or Figure 20 The communication board 30 transmits data, commands, and status, including to the main controller 31. The controller 31 controls and supervises the operation of the pump unit 100, including controlling power to the actuator 120 via the driver 33. The controller 32 and the driver 33 control and provide power to the actuator 120. Figure 18 and Figure 19 In the dual configuration of FIG, controller unit 95 is configured to provide commands to pump unit 100, and controller unit 95A is configured to provide commands to pump unit 100A. In this embodiment, the master controller 31A of controller 95A also has the ability to control and instruct motor controller 95.

[0111] like Figures 18-20As shown, by way of example and not limitation, a plurality of pump units 100, 100A, 100B, and 100C and corresponding control units 95, 95A, 95B, and 95C can be stacked coaxially with the production flow path 19 in series, parallel, or a combination thereof, utilizing a bypass conduit 160 and a bypass power and command connection 165 to provide the desired level of lift, as further described below. The pump units 100A, 100B, and 100C have the same overall configuration as the pump unit 100 described above. The controller units 95A, 95B, and 95C have the same overall configuration as the controller unit 95 described above.

[0112] like Figure 18 As shown, two pump units 100 and 100A and their corresponding top control units 95 and 95A, respectively, can be stacked in a series pumping configuration, wherein the pumping actions add to provide increased lift pressure. As shown, the pump outlet port 141 of the pump unit 100 is connected to the pump inlet port 151A of the pump unit 100A via the control unit fluid channel 70. In this manner, the pump fluid channels 170 and 170A are connected to provide series pumping action.

[0113] like Figure 19 As shown, alternatively, pump units 100 and 100A and their top control units 95 and 95A, respectively, can be stacked in a parallel pumping configuration, wherein the pumping action of each pumping unit is independent of the other to provide twice the volume of a single pumping unit. As shown, the pump outlet port 141 of pump unit 100 is connected to the bypass inlet port 161A of pump unit 100A via the control unit fluid channel 70, while the pump inlet port 151A of pump unit 100A is connected to the bypass outlet port 162 of pump unit 100 via the control unit fluid channel 60. In this way, the bypass fluid channel 160 of pump unit 100 is connected to the pump fluid channel 170 of pump unit 100A, while the pump fluid channel 170 of pump unit 100 is connected to the bypass fluid channel 160A of pump unit 100A.

[0114] Figure 20 A four-pump unit in a combined series and parallel configuration is shown in FIG. Figure 20As shown, pump units 100 and 200 and their corresponding top control units 95 and 195 are stacked in a series pumping configuration. As shown, the pump outlet port 141 of pump unit 100 is connected to the pump inlet port 151A of pump unit 100A via control unit fluid channel 70. In this way, pump fluid channels 170 and 170A are connected to provide a series pumping action. Pump units 100B and 100C and their corresponding top control units 95B and 95C are also stacked in a series pumping configuration. As shown, the pump outlet port 141B of pump unit 100B is connected to the pump inlet port 151C of pump unit 100C via control unit fluid channel 70B. In this way, pump fluid channels 170B and 170C are connected to provide a series pumping action.

[0115] Pump units 100 and 100A are also configured to operate in parallel with pump units 100B and 100C. As shown, the bypass outlet port 162 of pump unit 100 is connected to the bypass inlet port 161A of pump unit 100A via control unit fluid channel 60. In this way, bypass fluid channel 160 and 160A are connected. The bypass outlet port 162B of pump unit 100B is connected to the bypass inlet port 161C of pump unit 100C via control unit fluid channel 60B. In this way, bypass fluid channel 160B and 160C are connected. However, the pump outlet port 141A of pump unit 100A is connected to the bypass inlet port 161B of pump unit 100B via control unit fluid channel 70A, while the pump inlet port 151B of pump unit 100B is connected to the bypass outlet port 162A of pump unit 100A via control unit fluid channel 60A. In this way, the bypass fluid channels 160 and 160A of the pump units 100 and 100A are connected to the pump fluid channels 170B and 170C of the pump units 100B and 100C, respectively, while the pump fluid channels 170 and 170A of the pump units 100 and 100A are connected to the bypass fluid channels 160B and 160C of the pump units 100B and 100C.

[0116] Now refer to Figure 21-24 An exemplary embodiment of a progressive cavity pump of a positive displacement pump unit is generally designated 200. The pump unit 200 generally includes a progressive cavity pump 210 driven by a motor 220, all contained within a cylindrical housing 201. The cylindrical housing 201 includes a pump housing portion 211 that houses the pump 210 and a motor housing portion 221 that houses the motor 220. Distribution manifold blocks 240 and 250 are provided at either end of the housing 201 so that multiple control units 95 and pump units 200 can be stacked coaxially with the production fluid flow path arranged in series or parallel to provide a desired level of lift, as further described below.

[0117] In this embodiment, the screw pump 210 is a dual-port screw pump and generally includes three interlocking rotors or screws 212, 213, and 214. Screws 212 and 213 are driven screws, while screw 214 is a driving screw or power transmission screw driven by motor 220. The motor pump unit 200 has a pump inlet 251 connected to a manifold block 250 and a pump outlet 241 connected to a manifold block 240, with a fluid passage 270 therebetween. During normal operation, production fluid is directed to flow in through the inlet 251 of the manifold block 250 and, via the fluid passage 270, through the inlet port of the pump 210 to the gaps between the interlocking screws 212, 213, and 214. The fluid then flows through the outlet port of the pump 210 and out through the outlet 241 of the manifold block 240 via the fluid passage 270.

[0118] Motor 220 is a brushless DC variable-speed servo motor powered by an electric current. The speed and output of pump unit 200 vary with the speed of motor 220. The solid shaft 215 of pump 210's drive screw 214 is connected to a solid output shaft 226 of motor 220. Motor 220 has an inner rotor 225 with permanent magnets and an outer, non-rotating stator 224 with coil windings. Stator 224 is fixed to first motor housing portion 221 so that it does not rotate relative to housing 221. When an appropriate current is applied through the coils of stator 224, a magnetic field is induced. The interaction of the magnetic fields between stator 224 and rotor 225 generates torque, which rotates output shaft 226. Thus, motor 220 selectively applies torque to shaft 226 at varying speeds about axis xx.

[0119] Pump unit 200 includes a pump inlet 251 in manifold block 250 for receiving production fluid or well fluid, and a pump outlet 241 in manifold block 240 for outputting well fluid at a higher pressure than pump inlet 251. Pump unit 200 also includes power and data input connections 264 in manifold block 240 for inputting power to motor 220. Manifold block 250 with pump inlet 251 is located at the bottom end of housing 201, while manifold block 240 with pump outlet 241 and input connections 264 is located at the top end of housing 201. Because motor 220 is configured to be located below pump 210 in well 18 in this embodiment, power and data input connections 264 are connected to motor 220 via a pump section bypass opening, bus, channel, or conduit that extends from block 240 above pump housing portion 211, through pump housing portion 221, to motor housing portion 221 below pump housing portion 211. Thus, the pump 200 forces a volume of fluid upward within the production tubing 17 .

[0120] Pump unit 200 includes a bypass channel 260, separate from the fluid channel 270 passing through screws 212, 213, and 214, and a bypass power and command connection for transmitting data, commands, and power to lower units in the production line. Bypass channel 260 includes a bypass inlet 261 in manifold block 250 and a bypass outlet 262 in manifold block 240. Pump unit 200 does not provide a pressure differential between bypass inlet 261 and bypass outlet 262. The bypass power and command connections include a bypass input connection 267 in manifold block 240 and a bypass output connection 266 in manifold block 250. Manifold block 250, bypass inlet 261, and output connection 266 are located at the bottom end of housing 201, while manifold block 240, bypass outlet 262, and input connection 267 are located at the top end of housing 201. Although in this embodiment the bypass passage 260 is shown as a conduit, alternative passages may be used. For example, a separate volume within the interior of the housing 201 may be used to provide the bypass passage.

[0121] As with motor 120, rotary actuator or motor 220 can be powered by a motor control unit 95 having a motor drive 33 connected to a cable 24 extending from a controller box 20 at the surface to provide power and data to an input connection 86 of the control unit 95 at the bottom of the wellbore 18. Power supplied from the control unit 95 to the pump unit 200 via the output connection 84 of the control unit 95 and the input connection 264 of the manifold block 240 then generates a magnetic field within the corresponding coils of the stator 224, which in turn exerts a rotational force on the magnetic rotor 225 and the actuator shaft 226, and in turn exerts a rotational force on the drive screw 214 and the driven screws 212 and 213. The screws 212 and 213 thereby counter-rotate toward each other, enabling fluid to be lifted toward the surface of the well 18 as a result of this rotation.

[0122] Utilizing the bypass conduit 260 and bypass power and command connections, multiple screw pump units 200 and corresponding control units 95 can be stacked coaxially with the production flow path 19 in series or parallel or a combination thereof to provide the desired level of lift, as further described below. For example, but not limitation, in Figures 18-20 In the configuration shown, multiple progressive cavity pump units 200 and corresponding control units 95 can be coaxially stacked to provide series flow, parallel flow, or a combination of series and parallel flow as desired.

[0123] Now refer to Figure 25-27, an exemplary embodiment of a multi-stage vane pump of a pump unit is generally indicated at 300. The pump unit 300 generally includes a multi-stage vane pump 310 driven by a motor 320, all contained within a cylindrical housing 301. The cylindrical housing 301 includes a pump housing portion 311 containing pump stages 305, 306, and 307, and a motor housing portion 321 containing the motor 320. Distribution manifold blocks 340 and 350 may be provided at either end of the housing 301 so that multiple control units 95 and pump units 300 may be stacked coaxially with the production fluid flow path arranged in series or parallel to provide a desired level of lift, as further described below.

[0124] In this embodiment, a vane pump 310 has three stages 305, 306, and 307 and generally includes three stacked and centrally supported rotors 312, 313, and 314, each having radially extending vanes that rotate within pump rings 302, 303, and 304, respectively. The vanes can have variable lengths and can be biased to maintain contact with the rings 302, 303, and 304, respectively, as the pump rotates. The pump rotors 312, 313, and 314 are driven by a motor 320. When the vanes attached to the pump rotors 312, 313, and 314 are rotationally driven by the motor 320, this rotational motion of the vanes transports fluid from the inlet of the pump unit to the outlet of the pump unit. The pump unit 300 has an inlet 351 connected to a manifold block 350 and an outlet 341 connected to a manifold block 340, with a fluid passage 370 therebetween. In normal operation, production fluid is directed to flow in through inlet 351 of connecting manifold block 350 and, via fluid passage 370 and, depending on whether the stage orientation is in parallel or series (as further described below), through one or more inlet ports of the three stages of the pump to the corresponding blades of rotors 312, 313, and 314, and then through one or more outlet ports of the three stages of the pump and out through outlet 341 of connecting manifold block 340 via fluid passage 370.

[0125] Motor 320 is a brushless DC variable-speed servo motor powered by current. The speed and output of pump system 300 vary with the speed of motor 320. The solid shaft 315 of pump rotors 312, 313, and 314 of pump 310 is connected to a solid output shaft 326 of motor 320. Motor 320 has an inner rotor 325 with permanent magnets and an outer, non-rotating stator 324 with coil windings. Stator 324 is fixed to first motor housing portion 321 so that it does not rotate relative to housing 301. When current is applied appropriately through the coils of stator 324, a magnetic field is induced. The interaction of the magnetic fields between stator 324 and rotor 325 generates torque, which can rotate output shaft 326. Thus, motor 320 selectively applies torque to shaft 326 at varying speeds about axis xx.

[0126] The pump unit 300 includes a pump inlet 351 in a manifold block 350 for receiving production fluid or well fluid, and a pump outlet 341 in a manifold block 340 for outputting well fluid at a higher pressure than the pump inlet 351. The pump unit 300 also includes power and data input connections 364 in the manifold block 340 for inputting power to the motor 320. The manifold block 350 with the pump inlet 351 is disposed at the bottom end of the housing 301, while the manifold block 340 with the pump outlet 341 and the input connection 364 is disposed at the top end of the housing 301. Thus, the pump 300 forces a volume of fluid upward within the production tubing 17.

[0127] Pump unit 300 includes a bypass channel 360, separate from the fluid channels 370 through pump stages 305, 306, and 307, and a bypass power and command connection 365 for transmitting data, commands, and power to lower units in the production line. Bypass channel 360 includes a bypass inlet 361 in manifold block 350 and a bypass outlet 362 in manifold block 350. Pump unit 300 does not provide a pressure differential between bypass inlet 361 and bypass outlet 362. Bypass power and command connection 365 includes a bypass input connection 367 in manifold block 340 and a bypass output connection 366 in manifold block 350. Manifold block 350, bypass inlet 361, and output connection 366 are located at the bottom end of housing 301, while manifold block 340, bypass outlet 362, and input connection 367 are located at the top end of housing 301.

[0128] As with motors 120 and 220, rotary actuator or motor 320 can be powered by a motor control unit 95 having a motor drive 33 connected to a cable 24 extending from a controller box 20 at the surface to provide power and data to an input connection 86 of the control unit 95 at the bottom of the wellbore 18. Power supplied from the control unit 95 to the pump unit 300 via the output connection 84 of the control unit 95 and the input connection 364 of the manifold block 340 then generates a magnetic field within the corresponding coils of the stator 324, which in turn exerts a rotational force on the magnetic rotor 325 and the actuator shaft 326, and in turn on the pump rotors 312, 313, and 314. The blades of the pump rotors 312, 313, and 314 are thereby rotated, enabling fluid to be lifted toward the surface of the well 18 in response to such rotation.

[0129] The pump unit 300 may be configured and terminated to provide serial flow and serial fluid passages 370 through the stages 305, 306, and 307, or alternatively, may be configured and terminated to provide parallel flow and parallel fluid passages 380 through the stages 305, 306, and 307, as described below with reference to FIG. Figures 28-33 Further described.

[0130] like Figures 28-30 As shown, with pump stages 305, 306, and 307 arranged to provide a serial flow path 370, and with bypass conduits 360 and bypass power and command connections 365, multiple pump units 300, 300A, 300B, and 300C and corresponding control units 95, 95A, 95B, and 95C can be stacked coaxially with the production fluid flow path 19 arranged in series or in parallel or in combination to provide the desired level of lift, as further described below. The pump units 300A, 300B, and 300C have the same overall configuration as the pump unit 300 described above, with the stages 305, 306, and 307 in a serial pump stage configuration to provide a serial flow path 370. As shown Figure 28 As shown, in this series pump stage configuration, stages 305, 306, and 307 of pump 300 are terminated in a series stage pumping configuration in which the pumping action of the three stages of the pump unit is added to provide an increased lift pressure at pump unit 300. As shown, in this series stage pumping configuration, fluid passage 370 extends in series through each of stages 305, 306, and 307, extending from pump inlet port 351 to the input of first stage 305, through the blades of rotor 312, from the output of first stage 305 to the input of second stage 306, through the blades of rotor 313, from the output of second stage 306 to the input of third stage 307, through the blades of rotor 312, and from the output of third stage 307 to pump outlet port 341. The fluid passages 370A, 370B, and 370C of the pump units 300A, 300B, and 300C have the same overall serial configuration as the fluid passages 370 of the pump unit 300 described above.

[0131] like Figure 28 As shown, pump units 300 and 300A and their corresponding top control units 95 and 95A, respectively, can be stacked in a serial pumping configuration, wherein the pumping action of each pump unit is added to provide further increased lift pressure. As shown, the pump outlet port 341 of pump unit 300 is connected to the pump inlet port 351A of pump unit 300A via the control unit fluid channel 70. In this manner, the pump fluid channels 370 and 370A are connected to provide serial pumping action.

[0132] like Figure 29As shown, alternatively, pump units 300 and 300A and their top control units 95 and 95A, respectively, can be stacked in a parallel pumping configuration, wherein the pumping action of each pumping unit is independent of the other to provide twice the volume of a single pumping unit. As shown, the pump outlet port 341 of pump unit 300 is connected to the bypass inlet port 361A of pump unit 300A via the control unit fluid channel 70, and the pump inlet port 351A of pump unit 300A is connected to the bypass outlet port 362 of pump unit 300 via the control unit fluid channel 60. In this way, the bypass fluid channel 360 of pump unit 300 is connected to the pump fluid channel 370A of pump unit 300A, and the pump fluid channel 370 of pump unit 300 is connected to the bypass fluid channel 360A of pump unit 300A.

[0133] Figure 30 A combination of series and parallel configurations of four pump units with a series stage pumping configuration is shown in FIG. Figure 30 As shown, pump units 300 and 300A and their corresponding top control units 95 and 95A are stacked in a series unit pumping configuration. As shown, the pump outlet port 341 of pump unit 300 is connected to the pump inlet port 351A of pump unit 300A via the control unit fluid channel 70. In this way, pump fluid channels 370 and 370A are connected to provide a series unit pumping action. Pumps 300B and 300C and their corresponding top control units 95B and 95C are also stacked in a series pumping configuration. As shown, the pump outlet port 341B of pump unit 300B is connected to the pump inlet port 351C of pump unit 300C via the control unit fluid channel 70B. In this way, pump fluid channels 370B and 370C are connected to provide a series pumping action.

[0134] Pump units 300 and 300A are also configured to operate in parallel with pump units 300B and 300C. As shown, the bypass outlet port 362 of pump unit 300 is connected to the bypass inlet port 361A of pump unit 300A via control unit fluid passage 60. In this way, bypass fluid passage 360 and 360A are connected. The bypass outlet port 362 of pump unit 300B is connected to the bypass inlet port 361C of pump unit 300C via control unit fluid passage 60B. In this way, bypass fluid passage 360B and 360C are connected. However, the pump outlet port 341A of pump unit 300A is connected to the bypass inlet port 361B of pump unit 300B via control unit fluid passage 70A, while the pump inlet port 351B of pump unit 300B is connected to the bypass outlet port 362A of pump unit 300A via control unit fluid passage 60A. In this way, the bypass fluid channels 360 and 360A of the pump units 300 and 300A are connected to the pump fluid channels 370B and 370C of the pump units 300B and 300C, respectively, while the pump fluid channels 370 and 370A of the pump units 300 and 300A are connected to the bypass fluid channels 360B and 360C of the pump units 300B and 300C.

[0135] like Figure 31-Figure 33 As shown, with pump stages 305, 306, and 307 arranged to provide a parallel flow path 380, and with bypass conduits 360 and bypass power and command connections 365, multiple pump units 300, 300A, 300B, and 300C and corresponding control units 95, 95A, 95B, and 95C can be stacked coaxially with the production flow path 19 arranged in series or parallel or in combination to provide the desired level of lift, as further described below. Pump units 300A, 300B, and 300C have the same overall configuration as pump unit 300 described above, but utilize stages 305, 306, and 307 in a parallel pump stage configuration to provide the parallel fluid paths 380. As shown Figure 31 As shown, in this parallel pump stage configuration, the stages 305, 306, and 307 of the pump 300 are terminated in a parallel stage pumping configuration, wherein the pumping action of each stage 305, 306, and 307 of the pump unit is independent of the other stages to provide three times the volume of a single stage pump unit. As shown, in this parallel stage pumping configuration, the fluid channel 380 extends in parallel through each of the stages 305, 306, and 307, extends in parallel from the pump inlet port 351 to each input end of each of the first stage 305, the second stage 306, and the third stage 307, extends in parallel through each of the corresponding blades of the rotors 312, 313, and 314, and extends from the output end of each of the first stage 305, the second stage 306, and the third stage 307 to the pump outlet port 341. Figure 31-Figure 33The fluid passages 380A, 380B and 380C of the middle pump units 300A, 300B and 300C have the same Figure 31 The fluid passages 380 of the pump unit 300 have the same overall parallel configuration.

[0136] like Figure 31 As shown, pump units 300 and 300A and their corresponding top control units 95 and 95A, respectively, can be stacked in a series unit pumping configuration, wherein the pumping action of each pump unit is added to provide further increased lift pressure. As shown, the pump outlet port 341 of pump unit 300 is connected to the pump inlet port 351A of pump unit 300A via the control unit fluid channel 70. In this manner, the pump fluid channels 380 and 380A are connected to provide series unit pumping action.

[0137] like Figure 32 As shown, alternatively, pump units 300 and 300A and their top control units 95 and 95A, respectively, can be stacked in a parallel unit pumping configuration, wherein the pumping action of each pumping unit is independent of the other to provide twice the volume of a single pumping unit. As shown, the pump outlet port 341 of pump unit 300 is connected to the bypass inlet port 361A of pump unit 300A via the control unit fluid channel 70, while the pump inlet port 351A of pump unit 300A is connected to the bypass outlet port 362 of pump unit 300 via the control unit fluid channel 60. In this manner, the bypass fluid channel 360 of pump unit 300 is connected to the pump fluid channel 380A of pump unit 300, while the pump fluid channel 380 of pump unit 300 is connected to the bypass fluid channel 360A of pump unit 300A.

[0138] Figure 33 The four pump units with parallel stage pumping configuration are shown in Figure 1. Figure 33 As shown, pump units 300 and 300A and their corresponding top control units 95 and 95A are stacked in a series unit pumping configuration. As shown, the pump outlet port 341 of pump unit 300 is connected to the pump inlet port 351A of pump unit 300A via control unit fluid channel 70. In this way, pump fluid channels 380 and 380A are connected to provide parallel stages and series unit pumping action. Pumps 300B and 300C and their corresponding top control units 95B and 95C are also stacked in a series unit pumping configuration. As shown, the pump outlet port 341B of pump unit 300B is connected to the pump inlet port 351C of pump unit 300C via control unit fluid channel 70B. In this way, pump fluid channels 380B and 380C are connected to provide parallel stages and series unit pumping action.

[0139] Pump unit 300 and 300A are also configured to operate in parallel with pump units 300B and 300C. As shown, the bypass outlet port 362 of pump unit 300 is connected to the bypass inlet port 361A of pump unit 300A via control unit fluid passage 60. In this way, bypass fluid passage 360 and 360A are connected. The bypass outlet port 362B of pump unit 300B is connected to the bypass inlet port 361C of pump unit 300C via control unit fluid passage 60B. In this way, bypass fluid passage 360B and 360C are connected. However, the pump outlet port 341A of pump unit 300A is connected to the bypass inlet port 361B of pump unit 300B via control unit fluid passage 70A, while the pump inlet port 351B of pump unit 300B is connected to the bypass outlet port 362A of pump unit 300A via control unit fluid passage 60A. In this way, the bypass fluid channels 360 and 360A of the pump units 300 and 300A are connected to the pump fluid channels 380B and 370C of the pump units 300B and 300C, respectively, while the pump fluid channels 380 and 380A of the pump units 300 and 300A are connected to the bypass fluid channels 360B and 360C of the pump units 300B and 300C.

[0140] As desired, different combinations and numbers of pumping units and different series and / or parallel flow paths may be interchangeably employed. Thus, different combinations and numbers of pumping units 100, 200, and / or 300 (with series and / or parallel pump stage flow paths 370 and 380) may be stacked as desired and connected to manifold blocks 140, 150, 240, 250, 340, and 350 in different series and / or parallel combinations.

[0141] The pump systems 100, 200, and 300 may include several sensors (such as pressure sensor 499) for monitoring pump and motor operation, and the pump systems 100, 200, and 300 may receive commands from the surface. These signals and commands are transmitted via a signal cable 23 that extends from the control electronics in the control unit 95 to the controller box 20 at the surface of the well 18 via an input connection 86. The controller 31 provides command signals to the motor control board 32 and the driver 33 to properly drive the pump unit 100, 200, or 300. The motor control electronics of the controller unit 95 may be entirely contained in a housing 96 that is designed to provide protection from the surrounding environment.

[0142] The controller unit 95 and pump units 100, 200 and 300 have an architecture that allows operation in a master control configuration, an example of which is a parallel configuration, or in a parallel configuration. Figure 34 An example of this parallel configuration is shown in Figure 37 As shown. Figure 34In the master control configuration shown, for example, the top-most controller unit 95C in a four-unit pumping system communicates directly with the surface unit 20. This top-most controller unit then provides master control of each of the pump units 100, 200, and / or 300 in the system via their respective control units. Thus, all master motor commands are provided from the top control unit 95C. For example, in a four-pump unit system, signals from the master control unit 95C can be routed to the other control units from the output connection 87C of the control unit 95C on the common bus 165C of pump unit 100C, the common bus 65B of control unit 95B, the common bus 165B of pump unit 100B, the common bus 65A of control unit 95A, and the common bus 165 of pump unit 100A to the input connection 86 of the bottom control unit 95.

[0143] Figure 35 is the controller logic for a multi-unit actuator and pump system in a tandem pump configuration and a master control configuration. As shown, the master control unit 95B receives a flow rate command (Q*) and outputs a flow rate (Q) to each pump in the tandem configuration, and the controller logic for each control unit includes delay functions 36A and 36B by which the pumps above the lowest pump delay pumping relative to changes in input pressure (P) and position above the lowest pump in order to prime the system. Thus, with reference to Figure 35 , the middle module 95A provides a delay relative to the lowest module 95, and the top module 95B provides a delay relative to the middle module 95A.

[0144] Figure 36 is the controller logic for a multi-unit actuator and pump system in a parallel pump configuration and a master control configuration. As shown, the master control unit 95B outputs a flow rate (Q) as a function of the number of pump units (n) in the parallel pump configuration, and the controller logic for each control unit does not include a delay function in this embodiment.

[0145] exist Figure 37 In the parallel control configuration shown, each control unit 95, 95A, and 95B in the system communicates with the surface controller 20, which acts as a master controller. Master commands from the surface master unit 20 are routed to each controller unit 95, 95A, and 95B in, for example, a three-unit pumping system.

[0146] Figure 38Schematic diagram of surface pressure management controller logic for a multi-unit actuator and pump system in a series pump configuration and a master control configuration. As shown, downhole pressure sensor(s) 499 provide feedback to the surface control unit 20, and the surface control unit 20 provides a pressure command (P) to the topmost module 95B. The command from the master downhole controller 95B is in turn provided as a pressure command and, in the series pump configuration, is a function of the number of pump units (n) in series.

[0147] Now refer to Figure 39 A second exemplary embodiment of a top unit drive for an oil well pump and motor system is generally designated 415. As with system 15, a wellbore extends horizontally from the surface to a point below the surface and is lined with a casing 16 to form a wellbore 18, which includes perforations providing fluid communication between the wellbore 18 and the surrounding hydrocarbon-bearing formation. Pump system 415 is disposed at the bottom of wellbore 18 and is configured to artificially lift production fluids from wellbore 18 through tubing 17 to a collection point at the surface. However, in this embodiment, the motor control and drive electronics for the pump unit are contained in a controller box 420 at the surface of well 18, rather than in a downhole control unit 95. Drive power is transmitted via a power cable 424 that extends from the surface controller 420 at the surface of well 18 directly to the motors 120, 220, and / or 320 below the surface. Thus, the pump system 415 generally includes topside control and drive electronics 433 and one or more downhole pump units 100 , 200 and / or 300 having connection manifold ends 140 , 150 , 240 , 250 , 340 and / or 350 .

[0148] Figures 18-20 Shown Figure 1 An example stacked arrangement of pumps 100 , 100A, 100B, and 100C in pump system 15 is shown. Figures 40-43 Shown Figures 18-20 The same example stack arrangement of pumps 100, 100A, 100B and 100C, but in Figure 39 The top control system 415 is shown. Therefore, this arrangement does not include the control units 95, 95A, 95B and 95C. Figures 40-43 As shown, with a bypass conduit 160 and a bypass power connection 165, in system 415, multiple pump units 100, 100A, 100B and 100C can be stacked directly together coaxially with the production fluid flow path 19 arranged in series or parallel or a combination to provide the desired level of lift, as further described below.

[0149] Therefore, if Figure 40 and Figure 41As shown, two pump units 100 and 100A can be stacked directly in a series pumping configuration, where the pumping actions add to provide increased lift pressure. As shown, the pump outlet port 141 of pump unit 100 is directly connected to the pump inlet port 151A of pump unit 100A. The motor input connection 164A of pump unit 100A is directly connected to the drive line 424 from the surface controller 420, thereby connecting power from the driver 433 to the motor 120A of pump unit 100A, the bypass input connection 167 of the bypass 165A of pump unit 100A is also directly connected to the drive line 424 from the surface controller 420, and the bypass output connection 166A of the bypass 165A of pump unit 100A is directly connected to at least the motor input connection 164 of pump unit 100, thereby connecting power from the driver 433 to the motor 120 of pump unit 100 via the bypass connection 165A of pump unit 100A.

[0150] like Figure 42 As shown, alternatively, two pump units 100 and 100A can be directly stacked in a parallel pumping configuration, wherein the pumping action of each pump unit is independent of the other to provide twice the volume of a single pump unit. As shown, the pump outlet port 141 of pump unit 100 is directly connected to the bypass inlet port 161A of pump unit 100A, while the pump inlet port 151A of pump unit 100A is directly connected to the bypass outlet port 162 of pump unit 100A. Likewise, respectively, motor input connection 164A of pump unit 100A is directly connected to drive line 424 from surface controller 420, thereby connecting power from driver 433 to motor 120A of pump unit 100A, bypass input connection 167A of bypass 165A of pump unit 100A is also directly connected to drive line 424 from surface controller 420, and bypass output connection 166A of bypass 165A of pump unit 100A is directly connected to at least motor input connection 164 of pump unit 100, thereby connecting power from driver 433 to motor 120 of pump unit 100 via bypass connection 165A of pump unit 100A. In this manner, respectively, bypass fluid passage 160 of pump unit 100 is connected to pump fluid passage 170A of pump unit 100, and pump fluid passage 170 of pump unit 100 is connected to bypass fluid passage 160A of pump unit 100A.

[0151] Figure 43 The figure shows the direct combination of four pump units in series and parallel configuration. Figure 43As shown, two pump units 100 and 100A are directly stacked in a series pumping configuration. As shown, the pump outlet port 141 of pump unit 100 is directly connected to the pump inlet port 151A of pump unit 100A. In this way, pump fluid channels 170 and 170A are connected to provide a series pumping action. Pump units 100B and 100C are also directly stacked in a series pumping configuration. As shown, the pump outlet port 141B of pump unit 100B is directly connected to the pump inlet port 151C of pump unit 100C. In this way, pump fluid channels 170B and 170C are connected to provide a series pumping action.

[0152] The motor input connection 164C of pump unit 100C is directly connected to the drive line 424 from the surface controller 420, thereby connecting power from the driver 433 to the motor 120C of pump unit 100C. The bypass input connection 167C of the bypass 165C of pump unit 100C is also directly connected to the drive line 424 from the surface controller 420, and the bypass output connection 166C of the bypass 165C of pump unit 100C is directly connected to the motor input connection 164B of pump unit 100B, thereby connecting power from the driver 433 to the motor 120B of pump unit 100B via the bypass connection 165C of pump unit 100C. The bypass input connection 167B of bypass 165B of pump unit 100B is also directly connected to the bypass output connection 166C of bypass 165C of pump unit 100C, and the bypass output connection 166B of bypass 165B of pump unit 100B is directly connected to the motor input connection 164A of pump unit 100A, thereby connecting the power from the driver 433 to the motor 120A of pump unit 100A via the bypass connections 165B and 165C of pump units 100B and 100C respectively. The bypass input connection 167A of the bypass 165A of the pump unit 100A is also directly connected to the bypass output connection 166B of the bypass 165B of the pump unit 100B, and the bypass output connection 166A of the bypass 165A of the pump unit 100A is directly connected to at least the motor input connection 164 of the pump unit 100, thereby connecting the power from the drive 433 to the motor 120 of the pump unit 100 via the bypass connections 165A, 165B and 165C of the pump units 100A, 100B and 100C respectively.

[0153] Pump units 100 and 100A are also configured to operate in parallel with pump units 100B and 100C. As shown, the bypass outlet port 162 of pump unit 100 is directly connected to the bypass inlet port 161A of pump unit 100A. In this way, bypass fluid channel 160 and 160A are connected. The bypass outlet port 162B of pump unit 100B is directly connected to the bypass inlet port 161C of pump unit 100C. In this way, bypass fluid channel 160B and 160C are connected. However, the pump outlet port 141A of pump unit 100A is directly connected to the bypass inlet port 161B of pump unit 100B, and the pump inlet port 151B of pump unit 100B is directly connected to the bypass outlet port 162A of pump unit 100A. In this way, the bypass fluid channels 160 and 160A of the pump units 100 and 100A are connected to the pump fluid channels 170B and 170C of the pump units 100B and 100C, respectively, while the pump fluid channels 170 and 170A of the pump units 100 and 100A are connected to the bypass fluid channels 160B and 160C of the pump units 100B and 100C.

[0154] Figures 28-30 Shown Figure 1 An example stacked arrangement of pumps 300 , 300A, 300B, and 300C in pump system 15 is shown, along with a series pump stage orientation. Figures 44-46 Shown Figures 28-30 The same example stack arrangement of pumps 300, 300A, 300B and 300C, but in Figure 39 The top control system 415 is shown. Therefore, this arrangement does not include the control units 95, 95A, 95B and 95C. Figures 44-46 As shown, where pump stages 305, 306, and 307 are arranged to provide a serial fluid path 370, and with a bypass conduit 360 and a bypass power connection 365, in system 415, multiple pump units 300, 300A, 300B, and 300C can be stacked directly together coaxially with the production fluid flow path 19 arranged in series or parallel or in combination to provide the desired level of lift, as further described below. Figure 44 As shown, pump units 300 and 300A can be configured in a series stage orientation and stacked directly in a series pumping configuration, wherein the pumping action of each pump stage and pump unit is added to provide further increased lift pressure. As shown, stages 305, 306, and 307 of pump unit 300 are in a series stage configuration, stages 305A, 306A, and 307A of pump unit 300A are also in a series stage configuration, and the pump outlet port 341 of pump unit 300 is directly connected to the pump inlet port 351A of pump unit 300A. In this way, pump fluid channels 370 and 370A are connected to provide series pump stages and series unit pumping action.

[0155] The motor input connection 364A of the pump unit 300A is directly connected to the drive line 424 from the surface controller 420, thereby connecting the power from the driver 433 to the motor 320A of the pump unit 300A, and the bypass input connection 367A of the bypass 365A of the pump unit 300A is also directly connected to the drive line 424 from the surface controller 420, and the bypass output connection 366A of the bypass 365A of the pump unit 300A is directly connected to at least the motor input connection 364 of the pump unit 300, thereby connecting the power from the driver 433 to the motor 320 of the pump unit 300 via the bypass connection 365A of the pump unit 300A.

[0156] like Figure 45 As shown, pump units 300 and 300A can be configured in a series-stage orientation and stacked directly in a parallel pumping configuration, wherein the pumping action of each pumping unit is independent of the other to provide twice the volume of a single pumping unit. As shown, the pump outlet port 341 of pump unit 300 is directly connected to the bypass inlet port 361A of pump unit 300A, and the pump inlet port 351A of pump unit 300A is directly connected to the bypass outlet port 362 of pump unit 300. In this manner, the bypass fluid channel 360 of pump unit 300 is connected to the pump fluid channel 370A of pump unit 300A, and the pump fluid channel 370 of pump unit 300 is connected to the bypass fluid channel 360A of pump unit 300A. Similarly, the motor input connection 364A of the pump unit 300A is directly connected to the drive line 424 from the surface controller 420, thereby connecting the power from the driver 433 to the motor 320A of the pump unit 300A, the bypass input connection 367A of the bypass 365A of the pump unit 300A is also directly connected to the drive line 424 from the surface controller 420, and the bypass output connection 366A of the bypass 365A of the pump unit 300A is directly connected to at least the motor input connection 364 of the pump unit 300, thereby connecting the power from the driver 433 to the motor 320 of the pump unit 300 via the bypass connection 365A of the pump unit 300A.

[0157] Figure 46 A four-pump unit with a series stage pumping configuration is shown in FIG. Figure 46As shown, pump units 300 and 300A can be configured in a series stage orientation and stacked directly in a series unit pumping configuration. As shown, the pump outlet port 341 of pump unit 300 is directly connected to the pump inlet port 351A of pump unit 300A. In this way, pump fluid channels 370 and 370A are connected to provide both series pumping stages and series unit pumping action. Pumps 300B and 300C can also be configured in a series stage orientation and stacked directly in a series pumping configuration. As shown, the pump outlet port 341B of pump unit 300B is directly connected to the pump inlet port 351C of pump unit 300C. In this way, pump fluid channels 370B and 370C are connected to provide both series pumping stages and series unit pumping action.

[0158] The motor input connection 364C of the pump unit 300C is directly connected to the drive line 424 from the surface controller 420, thereby connecting power from the driver 433 to the motor 320C of the pump unit 300C. The bypass input connection 367C of the bypass 365C of the pump unit 300C is also directly connected to the drive line 424 from the surface controller 420, and the bypass output connection 366C of the bypass 365C of the pump unit 300C is directly connected to the motor input connection 364B of the pump unit 300B, thereby connecting power from the driver 433 to the motor 320B of the pump unit 300B via the bypass connection 365C of the pump unit 300C. The bypass input connection 367B of bypass 365B of pump unit 300B is also directly connected to the bypass output connection 366C of bypass 365C of pump unit 300C, and the bypass output connection 366B of bypass 365B of pump unit 300B is directly connected to the motor input connection 364A of pump unit 300A, thereby connecting the power from the driver 433 to the motor 320A of pump unit 300A via the bypass connections 365B and 365C of pump units 300B and 300C respectively. The bypass input connection 367A of the bypass 365A of the pump unit 300A is also directly connected to the bypass output connection 366B of the bypass 365B of the pump unit 300B, and the bypass output connection 366A of the bypass 365A of the pump unit 300A is directly connected to at least the motor input connection 364 of the pump unit 300, thereby connecting the power from the drive 433 to the motor 320 of the pump unit 300 via the bypass connections 365A, 365B and 365C of the pump units 300A, 300B and 300C respectively.

[0159] Pump unit 300 and 300A are also configured to operate in parallel with pump unit 300B and 300C. As shown, the bypass outlet port 362 of pump unit 300 is directly connected to the bypass inlet port 361A of pump unit 300A. In this way, bypass fluid channel 360 and 360A are connected. The bypass outlet port 362B of pump unit 300B is directly connected to the bypass inlet port 361C of pump unit 300C. In this way, bypass fluid channel 360B and 360C are connected. However, the pump outlet port 341A of pump unit 300A is directly connected to the bypass inlet port 361B of pump unit 300B, and the pump inlet port 351B of pump unit 300B is directly connected to the bypass outlet port 362A of pump unit 300A. In this way, the bypass fluid channels 360 and 360A of the pump units 300 and 300A are connected to the pump fluid channels 370B and 370C of the pump units 300B and 300C, respectively, while the pump fluid channels 370 and 370A of the pump units 300 and 300A are connected to the bypass fluid channels 360B and 360C of the pump units 300B and 300C.

[0160] Figure 31-Figure 33 Shown Figure 1 The pumps 300 , 300A, 300B, and 300C in the pump system 15 are shown in an example stacked arrangement and in a parallel pump stage orientation. Figures 47-49 Shown Figure 31-33 The same example stack arrangement of pumps 300, 300A, 300B and 300C, but in Figure 39 The top control system 415 is shown. Therefore, this arrangement does not include the control units 95, 95A, 95B and 95. Figures 47-49 As shown, where pump stages 305, 306, and 307 are arranged to provide parallel fluid passages 380, and have bypass conduits 360 and bypass power connections 365, in system 415, multiple pump units 300A, 300B, 300C, and 300D can be stacked directly coaxially with the production flow path 19 in series or parallel or a combination thereof to provide the desired level of lift, as further described below. Figure 47 As shown, pump units 300 and 300A can be configured in a parallel stage orientation and stacked directly in a series pumping configuration, wherein the pumping action of each pump unit is added to provide further increased lift pressure. As shown, stages 305, 306, and 307 of pump unit 300 are in a parallel stage configuration, stages 305A, 306A, and 307A of pump unit 300A are also in a parallel stage configuration, and pump outlet port 341 of pump unit 300 is directly connected to pump inlet port 351A of pump unit 300A. In this way, pump fluid channels 380 and 380A are connected to provide parallel pump stages and series unit pumping action.

[0161] like Figure 48 As shown, pump units 300 and 300A can be configured in a parallel stage orientation and also stacked directly in a parallel pumping configuration, wherein the pumping action of each pumping stage and pumping unit is independent of each other to provide three times the volume of a single-stage pump and twice the volume of a single pump unit. As shown, the pump outlet port 341 of pump unit 300 is directly connected to the bypass inlet port 361A of pump unit 300A, and the pump inlet port 351A of pump unit 300A is connected to the bypass outlet port 362 of pump unit 300. In this manner, the bypass fluid channel 360 of pump unit 300 is connected to the pump fluid channel 380A of pump unit 300, and the pump fluid channel 380 of pump unit 300 is connected to the bypass fluid channel 360A of pump unit 300A.

[0162] Figure 49 The four pump units with parallel stage pumping configuration are shown in Figure 1. Figure 49 As shown, pump units 300 and 300A can be configured in a parallel stage orientation and stacked directly in a series unit pumping configuration. As shown, the pump outlet port 341 of pump unit 300 is directly connected to the pump inlet port 351A of pump unit 300A. In this way, pump fluid channels 380 and 380A are connected to provide parallel stage and series unit pumping action. Pumps 300B and 300C can also be configured in a series stage orientation and stacked directly in a series unit pumping configuration. As shown, the pump outlet port 341B of pump unit 300B is directly connected to the pump inlet port 351C of pump unit 300C. In this way, pump fluid channels 380B and 380C are connected to provide parallel stage and series unit pumping action.

[0163] Pump unit 300 and 300A are also configured to operate in parallel with pump unit 300B and 300C. As shown, the bypass outlet port 362 of pump unit 300 is connected to the bypass inlet port 361A of pump unit 300A. In this way, bypass fluid channel 360 and 360A are connected. The bypass outlet port 362B of pump unit 300B is directly connected to the bypass inlet port 361C of pump unit 300C. In this way, bypass fluid channel 360B and 360C are connected. However, the pump outlet port 341A of pump unit 300A is directly connected to the bypass inlet port 361B of pump unit 300B, and the pump inlet port 351B of pump unit 300B is directly connected to the bypass outlet port 362A of pump unit 300A. In this way, the bypass fluid channels 360 and 360A of the pump units 300 and 300A are connected to the pump fluid channels 380B and 380C of the pump units 300B and 300C, respectively, while the pump fluid channels 380 and 380A of the pump units 300 and 300A are connected to the bypass fluid channels 360B and 360C of the pump units 300B and 300C.

[0164] Now refer to Figure 50 , a third example embodiment of a top unit drive for an oil well pump and motor system is generally indicated at 515. As with systems 15 and 415, a wellbore extends horizontally from the surface to a point below ground and the wellbore is paved with a casing 16 to form a wellbore 18 which includes perforations that provide fluid communication between the wellbore 18 and the surrounding hydrocarbon-bearing formations. The pump system 515 is disposed at the bottom of the wellbore 18 and is configured to artificially lift production fluids from the wellbore 18 through a tubing string 17 to a collection point at the surface. However, in this embodiment, not only are the motor control and drive electronics for the motor and pump units contained in a controller box 420 at the surface of the well 18, rather than in a downhole control unit 95, but the motor and pump of the system are each modular units contained in their own separate housings such that the system includes separate stackable motor units and separate stackable pump units that can be stacked with separate stackable intake units in different configurations. For example, as Figure 1 As shown, system 515 may include, for example, modular pump units 500 and 500A stacked with modular intake units 550 and 550A on modular motor units 590 and 590A in well 18. Drive power is transmitted via power cables 424 that extend from surface controller 420 at the surface of well 18 directly to motors 520A and 520 below the surface. Thus, pump system 515 generally includes topside control and drive electronics 433 and one or more downhole motor modules or units 590 and one or more pump modules or units 500 and / or 600 with one or more intake modules or units 550 and / or 650.

[0165] Now refer to Figure 51 , an example embodiment of a modular motor unit is generally indicated at 590. The motor unit 590 generally includes a motor 520 contained in a cylindrical housing 591. In this embodiment, the motor 520 generally includes a brushless DC variable speed servo motor powered by an electric current. The motor 520 has an inner rotor 525 with permanent magnets and an outer non-rotating stator 524 with coil windings. The stator 524 is fixed to the housing 591 so that the stator 524 does not rotate relative to the housing 591. When an electric current is appropriately applied through the coils of the stator 524, a magnetic field is induced. The interaction of the magnetic fields between the stator 524 and the rotor 525 produces a torque that can rotate the output shaft 526. Thus, the motor 520 will selectively apply torque on the shaft 526 at different speeds about the axis xx. The housing 591 of the motor unit 590 also includes a shaft input coupling port 528 and a shaft output coupling port 527. For example, the drive shaft of a downstream motor unit can be rotationally coupled to the shaft end 523 of the rotor 525 to the shaft input coupling port 528, and for example, the drive shaft 529 of the pump unit 500 upstream of the motor unit 590 can be rotationally coupled to the shaft end 526 of the rotor 525 to the shaft output coupling port 527. The shaft input coupling port 528 is provided at the bottom end of the housing 591, and the shaft output coupling port 527 is provided at the top end of the housing 591. The motor 520 can be powered by a drive line 424 extending from a surface controller 420 at the surface to provide power and data to the motor unit 595 at the bottom of the wellbore 18. Then, for example, power supplied from the controller 420 to the motor unit 590 generates a magnetic field within the corresponding coils of the stator 524, which in turn exerts a rotational force on the magnetic rotor 525 and the actuator shaft 526, and in turn exerts a rotational force on any coupled pump unit 500, causing the blades of the pump rotor 512 to rotate thereby so that fluid can be lifted toward the surface of the well 18 as a result of such rotation.

[0166] Now refer to Figure 52An exemplary embodiment of a modular pump unit is generally designated 500. Pump unit 500 generally includes a single-stage vane pump 510 contained within a cylindrical housing 501. In this embodiment, vane pump 510 generally includes a rotor 512 having radially extending vanes that rotate within a pump ring 502 as shaft 509 rotates. When the vanes attached to pump rotor 512 are rotationally driven, this rotational motion of the vanes transports fluid from the pump unit's inlet to the pump unit's outlet. Housing 501 of pump unit 500 has a pump inlet 551 and a pump outlet 541, with a fluid passage 570 therebetween. During normal operation, production fluid is directed to flow through inlet 551 and, via fluid passage 570, to the vanes of rotor 512 of pump 510, and out through outlet 541 via fluid passage 570. Therefore, the pump unit 500 includes a pump inlet 551 for receiving production fluid or well fluid, and a pump outlet 541 for outputting well fluid at a higher pressure than the pump inlet 551. The pump unit inlet 551 is arranged at the bottom end of the housing 501, and the pump unit outlet 541 is arranged at the top end of the housing 501. Therefore, the pump unit 500 forces a certain volume of fluid upward in the production pipe 17. The pump unit 500 includes a bypass channel 565, which is separated from the fluid channel 570 passing through the pump 510. The bypass channel 565 includes a bypass inlet 561 and a bypass outlet 564. The pump unit 500 does not provide a pressure difference between the bypass inlet 561 and the bypass outlet 564. Although in this embodiment, the bypass channel 565 is shown as a conduit, an alternative channel may also be used. For example, the internal separated volume of the housing 501 can be used to provide the bypass channel. The housing 501 of the pump unit 500 further includes a shaft input coupling port 534 and a shaft output coupling port 535. For example, the drive shaft 529 from the motor unit 590 can be rotationally coupled to the pump shaft 509 to the shaft input coupling port 534. For example, the drive shaft 529A of the pump unit 500A upstream of the pump unit 500 can be rotationally coupled to the shaft output coupling port 535. The shaft input coupling port 534 is provided at the bottom end of the housing 501, and the shaft output coupling port 535 is provided at the top end of the housing 501.

[0167] like Figure 54As shown, the intake unit 550 generally includes a housing 537 having an inlet port 530, an outlet port 531 and a fluid passage 536 therebetween. The housing 537 also includes a shaft coupling inlet port 532 and a shaft coupling outlet port 533 and a through hole therebetween for receiving a drive shaft (such as, for example, shaft 529). The housing 537 also includes a bypass inlet port 553 and a bypass outlet port 554 and a bypass 555 therebetween. Similarly, the intake unit 550A generally includes a housing 537A having an inlet port 530A, an outlet port 531A and a fluid passage 536A therebetween. The housing 537A also includes a shaft coupling inlet port 532A and a shaft coupling outlet port 533A and a through hole therebetween for receiving a drive shaft. The housing 537A also includes a bypass inlet port 553A and a bypass outlet port 554A and a bypass 555A therebetween. As shown Figure 56 As shown, intake unit 650 generally includes a housing 637 having an inlet port 630, an outlet port 631A, an outlet port 631B, a fluid passage 636A between inlet 630 and outlet port 631A, and a fluid passage 636B between inlet 630 and outlet port 631B. Housing 637 also includes a shaft coupling inlet port 632 and a shaft coupling outlet port 633 and a through hole therebetween for receiving a drive shaft (e.g., such as shaft 529).

[0168] Figures 53-62 Shown Figure 50 The top control modular system 515 is shown with various stacking arrangements of individual motor units 590 and 590A, individual intake units 550, 550B, and / or 650, and individual pump units 500, 500A, 600, and / or 600A. Figures 53-62 As shown, in system 515, one or more pump units 500, 500A, 600, and / or 600A can be stacked together with one or more intake units 550, 550A, and / or 650, coaxially with the production fluid flow path 19 arranged in series or parallel or in combination to provide a desired level of lift, as further described below. As shown, in system 515, one or more motor units 595 and / or 595A can be stacked together below one or more pump units 500, 500A, 600, and / or 600A and intake units 550, 550A, and / or 650 and coupled to such one or more pump units 500, 500A, 600, and / or 600A to drive or actuate such one or more pump units 500, 500A, 600, and / or 600A.

[0169] For example, Figure 53As shown, two motor units 595 and 595A can be stacked directly in a series motor configuration, where the torques of motors 520 and 520A are added to provide increased driving force to pump units 500 and 500A, and two pump units 500 and 500A can be stacked directly in a series pumping configuration, where the pumping actions are added to provide increased lift pressure, with a single intake unit 550 between the upper motor unit 590A and the lower pump unit 500.

[0170] like Figure 53 As shown, outlet port 531 of intake unit 550 is directly connected to pump inlet port 551 of pump unit 500, and outlet port 541 of pump unit 500 is directly connected to pump inlet port 551A of pump unit 500A, which in turn is connected to tubing string 17. Motor input connection 564A of motor unit 590A is directly connected to drive line 424 from surface controller 420, thereby connecting power from driver 433 to motor 520A of motor unit 590A. A bypass power bus 565A of motor unit 590A is also connected to drive line 424 from surface controller 420, and a bypass output connection 566A of bus 565A of motor unit 500A is directly connected to at least motor input connection 564 of motor unit 590, thereby connecting power from driver 433 to motor 520 of motor unit 500 via connection 565A of motor unit 590A.

[0171] The output shaft 526 of the motor 520 of the motor unit 590 is coupled to the motor 520A via a shaft outlet coupling port 527 in the motor unit 590 and a shaft inlet coupling port 528A in the motor unit 590A. The output shaft 526A of the motor 520A of the motor unit 590A is in turn coupled to the pump 510 through a shaft extension 529 via shaft coupling ports 532 and 533 in the intake unit 550 and a shaft inlet coupling port 534 in the pump unit 500. The shaft extension 529A couples the pump 510 of the pump unit 500 with the pump 510A of the pump unit 500A via a shaft outlet coupling port 535 in the pump unit 500 and a shaft inlet coupling port 534A in the pump unit 500A. Thus, motor 520, motor 520A, pump 510, and pump 510A are driven to rotate together on a common shaft to artificially lift production fluid from wellbore 18 through tubing string 17 to a collection point at the surface, with motors 520 and 520A providing the desired torque from a location in well 18 below pump units 500 and 500A. The number of stacked motor units, pump units, and intake units can be varied as needed to provide the desired flow rates and based on the dynamics of the target well. Thus, more than two motor units and / or more than two pump units can be stacked as needed.

[0172] like Figure 54 Alternatively, for example, two pumping units 500 and 500A may be stacked in a parallel pumping configuration, wherein the pumping action of each pumping unit is independent of the other to provide twice the volume of a single pumping unit. Figure 54 As shown, the two motor units 595 and 595A can be stacked directly in a series motor configuration, where the torques of the motors 520 and 520A are added to provide increased driving force to the pump units 500 and 500A, and the two pump units 500 and 500A can be stacked with the intake units 550 and 550A in a parallel pumping configuration, where the pumping action of each pump is independent to provide increased lift volume, where the intake unit 550 is stacked between the upper motor unit 590A and the lower pump unit 500, and the intake unit 550A is stacked between the lower pump unit 500 and the upper pump unit 500A. As shown, outlet port 531 of intake unit 550 is directly connected to pump inlet port 551 of pump unit 500, and outlet port 541 of pump unit 500 is connected to bypass inlet port 561A of pump unit 500A via bypass port 553A, bypass channel 555A, and bypass port 554A in intake unit 550A, and bypass outlet port 564A in pump unit 500A is in turn connected to tubing string 17. Outlet port 531A of intake unit 550A is directly connected to pump inlet port 551A of pump unit 500A, and outlet port 541A of pump unit 500A is in turn connected to tubing string 17.

[0173] Likewise, motor input connection 564A of motor unit 590A is directly connected to drive line 424 from surface controller 420, thereby connecting power from driver 433 to motor 520A of motor unit 590A. Bypass power bus 565A of motor unit 590A is also connected to drive line 424 from surface controller 420, and bypass output connection 566A of bus 565A of motor unit 500A is directly connected to at least motor input connection 564 of motor unit 590, thereby connecting power from driver 433 to motor 520 of motor unit 500 via connection 565A of motor unit 590A.

[0174] The output shaft 526 of the motor 520 of the motor unit 590 is coupled to the motor 520A via a shaft outlet coupling port 527 in the motor unit 590 and a shaft inlet coupling port 528A in the motor unit 590A. The output shaft 526A of the motor 520A of the motor unit 590A is coupled to the pump 510 through a shaft extension 529 via shaft coupling ports 532 and 533 in the intake unit 550 and a shaft inlet coupling port 534 in the pump unit 500. The shaft extension 529A couples the pump 510 of the pump unit 500 to the pump 510A of the pump unit 500A via a shaft outlet coupling port 535 in the pump unit 500, shaft coupling ports 532A and 533A in the intake unit 550A, and a shaft inlet coupling port 534A in the pump unit 500A. Thus, motor 520, motor 520A, pump 510 and pump 510A are driven to rotate together on a common shaft to artificially lift production fluid from wellbore 18 through tubing 17 to a collection point at the surface, where motors 520 and 520A provide the desired torque from a position in well 18 below pump units 500 and 500A.

[0175] As another example, Figure 55As shown, two motor units 595 and 595A can be stacked directly in a series motor configuration, where the torques of motors 520 and 520A are summed to provide increased driving force to a single pump unit 500, with a single intake unit 550 between the upper motor unit 590A and the pump unit 500. As shown, the outlet port 531 of the intake unit 550 is directly connected to the pump inlet port 551 of the pump unit 500, and the outlet port 541 of the pump unit 500 is in turn connected to the tubing string 17. Likewise, the motor input connection 564A of the motor unit 590A is directly connected to the drive line 424 from the surface controller 420, thereby connecting power from the driver 433 to the motor 520A of the motor unit 590A. The bypass power bus 565A of motor unit 590A is also connected to the drive line 424 from the surface controller 420, and the bypass output connection 566A of bus 565A of motor unit 500A is directly connected to at least the motor input connection 564 of motor unit 590, thereby connecting power from the driver 433 via the connection 565A of motor unit 590A to the motor 520 of motor unit 500. The output shaft 526 of motor 520 of motor unit 590 is coupled to motor 520A via a shaft outlet coupling port 527 in motor unit 590 and a shaft inlet coupling port 528A in motor unit 590A. The output shaft 526A of motor 520A of motor unit 590A is coupled to pump 510 via a shaft extension 529 via shaft coupling ports 532 and 533 in intake unit 550 and shaft inlet coupling port 534 in pump unit 500. Thus, motor 520, motor 520A and pump 510 are driven to rotate together on a common shaft to artificially lift production fluid from wellbore 18 through tubing 17 to a collection point at the surface, where motors 520 and 520A provide the desired torque from a position in well 18 below pump unit 500.

[0176] As another example, Figure 56As shown, a single motor unit 590 and two pump units 500 and 500A can be stacked with a single intake unit 650 in a parallel pumping configuration, wherein the pumping action of each pump is independent to provide increased lift volume, wherein the intake unit 650 is stacked between the lower pump unit 500 and the upper pump unit 500A. As shown, the intake unit 650 includes two separate outlet ports 631A and 631B connected to the inlet 630 via fluid channels 636A and 636B, respectively. The outlet port 631A of the intake unit 650 is directly connected to the pump inlet port 551 of the pump unit 500, the outlet port 541 of the pump unit 500 is connected to the bypass inlet port 561A of the pump unit 500A, and the bypass outlet port 564A in the pump unit 500A is in turn connected to the tubing string 17. Outlet port 631B of intake unit 650 is directly connected to bypass inlet port 561 of pump unit 500, bypass outlet port 564 of pump unit 500 is connected to pump inlet port 551A of pump unit 500A, and pump outlet port 541A in pump unit 500A is in turn connected to tubing string 17. Motor input connection 564 of motor unit 590 is directly connected to drive line 424 from surface controller 420, thereby connecting power from driver 433 to motor 520 of motor unit 590. Output shaft 526 of motor 520 of motor unit 590 is coupled to motor 520A via shaft outlet coupling port 527 in motor unit 590 and shaft inlet coupling port 528A in motor unit 590A. Output shaft 526 of motor 520 of motor unit 590 is coupled to pump 510 via shaft extension 529 via shaft coupling ports 632 and 633 in intake unit 650 and shaft inlet coupling port 534 in pump unit 500. Shaft extension 529A couples pump 510 of pump unit 500 to pump 510A of pump unit 500A via shaft outlet coupling port 535 in pump unit 500 and inlet coupling port 534A in pump unit 500A. Thus, motor 520, pump 510, and pump 510A are driven to rotate together on a common shaft to artificially lift production fluid from wellbore 18 through tubing string 17 to a collection point at the surface, with motor 520 providing the desired torque from a location in well 18 below pump units 500 and 500A.

[0177] As in other embodiments, the bypass power bus 565 of the motor unit 590 can also be connected to the drive line 424 from the surface controller 420, and the bypass output connection 566 of the bus 565 of the motor unit 500 can be connected to a sensor or telemetry system 700 below the motor unit 590 in the well 18, thereby connecting power from the driver 433 to these systems. Such a system can include various sensors, such as pressure sensors, for monitoring well conditions, fluid conditions, and pump and motor orientation and operation.

[0178] As another example, Figure 57 and Figure 58 As shown, two motor units 595 and 595A can be stacked directly in a series motor configuration, where the torques of motors 520 and 520A are summed to provide increased driving force to a multi-stage pump unit 600, with a single intake unit 550 between the upper motor unit 590A and the multi-stage pump unit 600. As shown, in this embodiment, the multi-stage pump unit 600 is a two-stage pump unit having a first-stage pump 610 and a second-stage pump 611, and a bypass channel 665 that is separate from the fluid channel 670 through the pump stages 610 and 611. The pump unit 600 can be configured and terminated to provide serial fluid channels 670 and serial flow through the stages 610 and 611, or alternatively, the pump unit 600 can be configured and terminated to provide parallel fluid channels 680 and parallel flow through the stages 610 and 611.

[0179] like Figure 57 As shown, in a series pump stage configuration, stages 610 and 611 of pump 600 are terminated in a series stage pumping configuration, wherein the pumping action of the two stages of the pump unit is added to provide an increased lift pressure at pump unit 600. As shown, in this series stage pumping configuration, fluid channel 670 extends in series through each of stages 610 and 611, extending from pump inlet port 651 to the input of first stage 610 and through the blades of pump 610, from the output of first stage 610 to the input of second stage 611 and through the blades of pump 611, and from the output of second stage 611 to pump outlet port 641. The shaft 529 from the motors 520 and 520A is coupled to both the first-stage pump 610 and the second-stage pump 611 in the pump unit 600 to drive both the first-stage pump 610 and the second-stage pump 611, so that the motor 520, motor 520A, pump 610 and pump 611 are driven to rotate together on a common shaft to artificially lift the production fluid from the wellbore 18 through the tubing 17 to a collection point at the surface, wherein the motors 520 and 520A provide the desired torque from a position in the well 18 below the pump unit 600.

[0180] like Figure 58 As shown, instead, pump unit 600 has stages 610 and 611 arranged in a parallel pump stage configuration to provide parallel fluid channels 680. Figure 58As shown, in this parallel pump stage configuration, the stages 610 and 611 of the pump 600 are terminated in a parallel stage pumping configuration, wherein the pumping action of each stage 610 and 611 of the pump unit 600 is independent of each other to provide twice the volume of a single stage pump unit. As shown, in this parallel stage pumping configuration, the fluid channel 680 extends in parallel through each of the stages 610 and 611, extends in parallel from the pump inlet port 651 to each input end of each of the first stage 610 and the second stage 611, extends in parallel through each of their respective blades, and extends from the output end of each of the first stage 610 and the second stage 611 to the pump outlet port 641.

[0181] like Figure 59 and Figure 60 As shown, where pump stages 610 and 611 are arranged to provide a serial fluid passage 670, and having a bypass conduit 665 and an intake bypass connection 555A, multiple pump units 600 and 600A and corresponding intake units 550 and 550A can be stacked coaxially with the production fluid flow path 19 arranged in series or parallel or in combination to provide the desired level of lift, as further described below.

[0182] like Figure 59 As shown, the pump unit 600A has Figure 57 1A and 1B , wherein stages 610A and 611A are in a series pump stage configuration to provide a series fluid channel 670A. As shown, pump units 600 and 600A can be stacked in a series pumping configuration, wherein the unit pumping action of each pump unit 600 and 600A is also added to provide a further increase in lift pressure. As shown, the pump outlet port 641 of pump unit 600 is connected to the pump inlet port 651A of pump unit 600A. In this way, pump fluid channels 670 and 670A are connected to provide a series unit pumping action to pipeline 17. Shaft 529 from motors 520 and 520A is coupled to first-stage pump 610 and second-stage pump 611 in pump unit 600 and, via shaft extension 529A, to first-stage pump 610A and second-stage pump 611A in pump unit 600A to drive all of pumps 610, 611, 610A, and 611A so that motor 520, motor 520A, and pumps 610, 611, 610A, and 611A are driven to rotate together on a common shaft to artificially lift production fluid from wellbore 18 through tubing string 17 to a collection point at the surface, with motors 520 and 520A providing the desired torque from a location in well 18 below pump units 600 and 600A. Thus, as Figure 59As shown, pump units 600 and 600A can be configured in a series stage orientation and stacked in a series unit pumping configuration, wherein the pumping action of each pump stage is added to provide an increased lift pressure, and the pumping action of each pump unit is added to provide a further increased lift pressure. As shown, stages 610 and 611 of pump unit 600 are in a series stage configuration, stages 610A and 611A of pump unit 600A are also in a series stage configuration, and the pump outlet port 641 of pump unit 600 is connected to the pump inlet port 651A of pump unit 600A. In this manner, pump fluid channels 670 and 670A are connected to provide series pump stages and series unit pumping action.

[0183] like Figure 60As shown, alternatively, pump units 600 and 600A can be stacked in a parallel unit pumping configuration, wherein the pumping action of each pump unit 600 and 600A is independent of the other to provide twice the volume of a single pump unit, wherein intake unit 550 is stacked between upper motor unit 590A and lower pump unit 600, and intake unit 550A is stacked between lower pump unit 600 and upper pump unit 600A. As shown, outlet port 531 of intake unit 550 is directly connected to pump inlet port 651 of pump unit 600, and outlet port 641 of pump unit 600 is connected to bypass inlet port 661A of pump unit 600A via bypass port 553A, bypass channel 555A, and bypass port 554A in intake unit 550A, and bypass outlet port 664A in pump unit 600A is in turn connected to tubing string 17. Outlet port 531A of intake unit 550A is directly connected to pump inlet port 651A of pump unit 600A, and outlet port 641A of pump unit 600A is in turn connected to tubing string 17. In this manner, serial pump fluid channel 670 of pump unit 600 is connected to bypass fluid channel 665A of pump unit 600A and in turn to tubing 17, and serial pump fluid channel 670A of pump unit 600A is separately connected to tubing 17. Serial pump fluid channels 670 and 670A each provide serial pump stage pumping and are then each connected to tubing 17 to provide parallel unit pumping action to tubing 17. Shaft 529 from motors 520 and 520A is coupled to first-stage pump 610 and second-stage pump 611 in pump unit 600 and, via shaft extension 529A, through intake unit 550A, to first-stage pump 610A and second-stage pump 611A in pump unit 600A to drive all of pumps 610, 611, 610A, and 611A so that motor 520, motor 520A, and pumps 610, 611, 610A, and 611A are driven to rotate together on a common shaft to artificially lift production fluid from wellbore 18 through tubing string 17 to a collection point at the surface, with motors 520 and 520A providing the desired torque from a location in well 18 below pump units 600 and 600A. Thus, as Figure 60 As shown, pump units 600 and 600A can be configured in a series stage orientation and then stacked in a parallel unit pumping configuration, wherein the pumping action of each pump stage is added to provide increased lift pressure, and the pumping action of each pump unit is independent of each other to provide increased volume. As shown, stages 610 and 611 of pump unit 600 are in a series stage configuration, stages 610A and 611A of pump unit 600A are also in a series stage configuration, and pump outlet port 641 of pump unit 600 is connected to bypass inlet port 661A of pump unit 600A. In this manner, pump fluid channels 670 and 670A are connected to provide series pump stages and parallel unit pumping action.

[0184] like Figure 61 and Figure 62 As shown, where pump stages 610 and 611 are arranged to provide parallel fluid channels 680, and having a bypass conduit 665 and an intake bypass connection 555A, multiple pump units 600 and 600A and corresponding intake units 550 and 550A can be stacked coaxially with the production fluid flow path 19 arranged in series or parallel or in combination to provide the desired level of lift, as further described below.

[0185] like Figure 61 As shown, the pump unit 600A has Figure 58 1A and 1B , but with stages 610A and 611A in a parallel pump stage configuration to provide parallel fluid channels 680A. As shown, pump units 600 and 600A can be stacked in a series unit pumping configuration, wherein the unit pumping actions of each pump unit 600 and 600A are added to provide an increased lift pressure at the unit level. As shown, the pump outlet port 641 of pump unit 600 is connected to the pump inlet port 651A of pump unit 600A. In this way, the parallel pump fluid channels 680 and 680A are connected to provide a series unit pumping action to pipeline 17. Shaft 529 from motors 520 and 520A is coupled to first-stage pump 610 and second-stage pump 611 in pump unit 600 and, via shaft extension 529A, to first-stage pump 610A and second-stage pump 611A in pump unit 600A to drive all of pumps 610, 611, 610A, and 611A so that motor 520, motor 520A, and pumps 610, 611, 610A, and 611A are driven to rotate together on a common shaft to artificially lift production fluid from wellbore 18 through tubing string 17 to a collection point at the surface, with motors 520 and 520A providing the desired torque from a location in well 18 below pump units 600 and 600A. Thus, as Figure 61 As shown, pump units 600 and 600A can be configured in a parallel stage orientation and then stacked in a series unit pumping configuration, wherein the pumping action of each pump stage is independent of each other to provide increased volume, and the pumping action of each pump unit is added together to provide increased lift pressure. As shown, stages 610 and 611 of pump unit 600 are in a parallel stage configuration, stages 610A and 611A of pump unit 600A are also in a parallel stage configuration, and pump outlet port 641 of pump unit 600 is connected to pump inlet port 651A of pump unit 600A. In this manner, pump fluid channels 680 and 680A are connected to provide parallel pump stage and series unit pumping action.

[0186] like Figure 62As shown, alternatively, pump units 600 and 600A can be stacked in a parallel unit pumping configuration, wherein the pumping action of each pump unit 600 and 600A is independent of the other to provide twice the volume of a single pump unit, wherein intake unit 550 is stacked between upper motor unit 590A and lower pump unit 600, and intake unit 550A is stacked between lower pump unit 600 and upper pump unit 600A. As shown, outlet port 531 of intake unit 550 is directly connected to pump inlet port 651 of pump unit 600, and outlet port 641 of pump unit 600 is connected to bypass inlet port 661A of pump unit 600A via bypass port 553A, bypass channel 555A, and bypass port 554A in intake unit 550A, and bypass outlet port 664A in pump unit 600A is in turn connected to tubing string 17. Outlet port 531A of intake unit 550A is directly connected to pump inlet port 651A of pump unit 600A, and outlet port 641A of pump unit 600A is in turn connected to tubing string 17. In this manner, parallel pump fluid channel 680 of pump unit 600 is connected to bypass fluid channel 665A of pump unit 600A and in turn to tubing 17, and parallel pump fluid channel 680A of pump unit 600A is separately connected to tubing 17. Parallel pump fluid channels 670 and 670A each provide parallel pump stage pumping and are then each connected to tubing 17 to also provide parallel unit pumping action to tubing 17. Shaft 529 from motors 520 and 520A is coupled to first-stage pump 610 and second-stage pump 611 in pump unit 600 and, via shaft extension 529A, through intake unit 550A, to first-stage pump 610A and second-stage pump 611A in pump unit 600A to drive all of pumps 610, 611, 610A, and 611A so that motor 520, motor 520A, and pumps 610, 611, 610A, and 611A are driven to rotate together on a common shaft to artificially lift production fluid from wellbore 18 through tubing string 17 to a collection point at the surface, with motors 520 and 520A providing the desired torque from a location in well 18 below pump units 600 and 600A. Thus, as Figure 62 As shown, pump units 600 and 600A can be configured in a parallel stage orientation and then stacked in a parallel unit pumping configuration, wherein the pumping action of each pump stage is independent of each other to provide increased volume, and the pumping action of each pump unit is independent of each other to provide further increased volume. As shown, stages 610 and 611 of pump unit 600 are in a parallel stage configuration, stages 610A and 611A of pump unit 600A are also in a parallel stage configuration, and pump outlet port 641 of pump unit 600 is connected to bypass inlet port 661A of pump unit 600A. In this manner, pump fluid channels 680 and 680A are connected to provide parallel pump stages and parallel unit pumping action.

[0187] As desired, different combinations and numbers of pump and motor units, pump units, motor units, intake units, and different combinations and numbers of series and parallel pump stage configurations, and / or different combinations and numbers of series and parallel unit flow path configurations may be interchangeably employed. Thus, pumping units 100, 200, and / or 300 having different numbers and combinations of series and / or parallel pump stage flow paths 370 and 380 may be stacked as desired and connected to manifold blocks 140, 150, 240, 250, 340, and 350 in different series and / or parallel combinations, and motor units 590, pump units 500, and / or 600 having different numbers and combinations of series and / or parallel pump stage flow paths 670 and 680 may be stacked as desired and connected to intake units 550 and / or 650 in different series and / or parallel combinations.

[0188] While vane and screw type positive displacement pumps have been shown and described, other types of positive displacement pumps may be used as alternatives to the pump unit, including but not limited to gear pumps.

[0189] Pump systems 15, 415, and 515 have many advantages. First, the system is easily expandable and customizable. The individual pump units and motor units can be customized to provide the desired pump displacement and motor size. Moreover, the number, type, and configuration of pump units, motor units, and control units can vary as needed for the application and conditions of the well. As a result, the system is customizable in the type of motor units used in the stack and can be expanded in size by adding motor units, pump units, and / or control units to the stack as needed. Multiple assemblies can be stacked to increase the pressure or volume output for a given application. The system also has fault tolerance built into it at both the pump level and the system level, with the ability to use multi-stage positive displacement pumps at the pump level and the ability to use not only multiple stacked units but also stacked units with different numbers or types of motors and different numbers and types of positive displacement pumps at the system level.

[0190] It should be understood that certain features of the system, which have been described for clarity in the context of different embodiments, may also be provided in combination in a single embodiment. Conversely, various features, which have been described for brevity in the context of a single embodiment, may also be provided individually or in any suitable combination. Although various embodiments have been described in detail above, it should be understood that they have been presented by way of example and not limitation. It will be clear to those skilled in the relevant art that the disclosed subject matter may be implemented in other specific forms, variations, and modifications without departing from its scope, spirit, or essential characteristics. Therefore, the above-described embodiments should be considered in all respects to be illustrative and not restrictive.

[0191] While alternative forms of improved subsurface pump systems have been shown and described, and several modifications thereof have been discussed, those skilled in the art will readily appreciate that various additional changes and modifications may be made without departing from the scope of the invention, as defined and differentiated in the claims.

Claims

1. A well equipment comprising: a conduit disposed in the well and forming a flow passage for a fluid originating below the surface level to the surface level; a first motor pump housing disposed in the well; a first positive displacement pump disposed in the first housing and having a first rotary fluid displacer; a first rotary actuator disposed in the housing and configured to actuate the first rotary fluid displacer; The first rotary actuator includes a first stator and a first rotor, the first rotor being configured and arranged to rotate relative to the first stator under the influence of a magnetic field generated by the first stator; the first rotor being connected to the first rotary fluid displacer; a first pump inlet port and a first pump outlet port in the first housing; a first pump fluid passage between the first pump inlet port and the first pump outlet port, with the first rotary fluid displacer disposed in the first pump fluid passage; a first bypass inlet port and a first bypass outlet port in the first housing; a first bypass fluid passage between the first bypass inlet port and the first bypass outlet port; and the first pump fluid passage being separate from the first bypass fluid passage; The first rotary actuator is operably driven to pump production fluid through the first pump fluid channel. 2 . The well apparatus of claim 1 , wherein the first positive displacement pump comprises a vane pump or a progressive cavity pump, and the first rotary fluid displacer comprises vanes or a screw of the vane pump or the progressive cavity pump.

3. The well apparatus of claim 2, wherein the first positive displacement pump comprises a multi-stage vane pump.

4. The well apparatus according to claim 3, wherein: The multi-stage vane pump includes a first stage and a second stage; The second stage is operably configured in series with the first stage; and The first rotary actuator is operably driven to pump the production fluid in series through the first pump fluid passage through the first stage and the second stage.

5. The well apparatus according to claim 3, wherein: The multi-stage vane pump includes a first stage and a second stage; The second stage is operably configured in parallel with the first stage; and The first rotary actuator is operably driven to pump the production fluid in parallel through the first pump fluid passage through the first stage and the second stage.

6. The well apparatus of claim 1, wherein the first motor pump housing includes a first control input connection, a first control bypass output connection, and a conductor between the first control input connection and the first control bypass output connection.

7. The well apparatus of claim 6, comprising a cable supplying power from the surface level to the first control input connection.

8. The well apparatus of claim 1, comprising a first controller housing and a first driver for the first actuator disposed in the first controller housing. 9 . The well apparatus according to claim 8 , wherein the first controller housing includes a first fluid passage and a second fluid passage separate from the first fluid passage. 10 . The well apparatus of claim 9 , wherein the first pump fluid passage is operably connected to the first fluid through passage, and the first bypass fluid passage is operably connected to the second fluid through passage.

11. The well apparatus of claim 9, wherein the controller housing includes an input connection, a motor output connection, and conductors between the input connection and the motor output connection.

12. The well apparatus of claim 1, comprising: a second motor pump housing disposed in the well; a second positive displacement pump disposed in the second housing and having a second rotary fluid displacer; a second rotary actuator disposed in the second housing and configured to actuate the second rotary fluid displacer; the second rotary actuator comprising a second stator and a second rotor, the second rotor being configured and arranged to rotate relative to the second stator under the influence of a magnetic field generated by the second stator; the second rotor being connected to the second rotational fluid displacer; a second pump inlet port and a second pump outlet port in the second housing; a second pump fluid passage between the second pump inlet port and the second pump outlet port, with the second rotary fluid displacer disposed in the second pump fluid passage; a second bypass inlet port and a second bypass outlet port in the second housing; a second bypass fluid passage between the second bypass inlet port and the second bypass outlet port; and the second pump fluid passage being separated from the second bypass fluid passage; The second rotary actuator is operably driven to pump production fluid through the second pump fluid channel.

13. The well apparatus of claim 12, wherein the first pump fluid passage is operably connected to the second pump fluid passage, and the production fluid is operably pumped in series through the first pump fluid passage and the second pump fluid passage.

14. The well apparatus of claim 13, wherein the first pump outlet port is operably connected to the second pump inlet port, and the second rotary actuator is operably driven to pump the production fluid from the first pump fluid passage through the second pump fluid passage.

15. The well apparatus of claim 12, wherein the first pump fluid passage is operably connected to the second bypass fluid passage, the first bypass fluid passage is operably connected to the second pump fluid passage, and the production fluid is operably pumped in parallel through the first pump fluid passage and the second pump fluid passage.

16. A well apparatus according to claim 15, wherein the first pump outlet port is operably connected to the second bypass inlet port, and the first rotary actuator is operably driven to pump the production fluid from the first pump fluid channel through the second bypass fluid channel, the first bypass outlet port is operably connected to the second pump inlet port, and the second rotary actuator is operably driven to pump the production fluid from the first bypass fluid channel through the second pump fluid channel.

17. The well apparatus of claim 12, wherein the first pump comprises a multi-stage vane pump.

18. The well apparatus of claim 17, wherein: The multi-stage vane pump includes a first stage and a second stage; The second stage is operably configured in series with the first stage; and The first rotary actuator is operably driven to pump the production fluid in series through the first pump fluid passage through the first stage and the second stage.

19. The well apparatus of claim 17, wherein: The multi-stage vane pump includes a first stage and a second stage; The second stage is operably configured in parallel with the first stage; and The first rotary actuator is operably driven to pump the production fluid in parallel through the first pump fluid passage through the first stage and the second stage.

20. The well apparatus of claim 12, wherein: the first pump fluid passage being operatively connected to the second pump fluid passage or the second bypass fluid passage; the second pump fluid passage being operatively connected to the first pump fluid passage or the first bypass fluid passage; The production fluid is operably pumped in series or in parallel through the first pump fluid passage and the second pump fluid passage; The first pump includes a first multi-stage vane pump; The first multi-stage vane pump includes a first stage and a second stage; The second stage is operably configured to be connected in series or in parallel with the first stage; and The first rotary actuator is operably driven to pump the production fluid in series or in parallel through the first pump fluid passage through the first stage and the second stage.

21. The well apparatus of claim 20, wherein: The second pump includes a second multi-stage vane pump; The second multi-stage vane pump includes a third stage and a fourth stage; The fourth stage is operably configured to be connected in series or in parallel with the third stage; and The second rotary actuator is operably driven to pump the production fluid in series or in parallel through the second pump fluid passage through the third stage and the fourth stage.

22. The well apparatus of claim 12, wherein: the first motor pump housing including a first control input connection, a first control bypass output connection, and a conductor between the first control input connection and the first control bypass output connection; the second motor pump housing including a second control input connection, a second control bypass output connection, and a conductor between the second control input connection and the second control bypass output connection; as well as The second control bypass output connection is connected to the first control input connection.

23. The well apparatus of claim 22, comprising a cable supplying power from the surface level to the second control input connection.

24. The well apparatus of claim 12, comprising: a first controller housing and a first driver for the first actuator disposed in the first controller housing; as well as A second controller housing and a second driver for the second actuator disposed in the second controller housing.

25. The well apparatus of claim 24, wherein: The first controller housing includes a first input connection, a first motor output connection, a first fluid passage, and a second fluid passage separate from the first fluid passage; The second controller housing includes a second input connection, a second motor output connection, a third fluid passage, and a fourth fluid passage separate from the third fluid passage; the second input connection of the second controller housing being conductively connected to the first input connection of the first controller housing; The first pump fluid passage is operatively connected to one of the first fluid passage or the second fluid passage; The first bypass fluid passage is operatively connected to the other of the first fluid passage or the second fluid passage; The second pump fluid passage is operatively connected to one of the third fluid passage or the fourth fluid passage; as well as The second bypass fluid passage is operatively connected to the other of the third fluid passing passage or the fourth fluid passing passage.

26. The well apparatus of claim 25, wherein the second input connection of the second controller housing is conductively connected to the first input connection of the first controller housing via a bypass conduit in the second motor pump housing.

27. The well apparatus of claim 1, comprising a cable supplying power to the first stator from the surface level.

28. The well apparatus of claim 1, wherein the first motor pump housing includes a first actuator housing portion defining a first chamber substantially isolated from the well, and wherein the first stator and the first rotor are disposed in the first chamber.

29. The well apparatus of claim 28, wherein the first actuator housing portion includes a first end, and the first actuator includes a first rotor shaft connected to the first rotor, and the first rotor shaft includes a portion sealingly penetrating the first end of the first actuator housing portion.

30. The well apparatus of claim 29, wherein the first motor pump housing comprises a pump housing portion connected to the first actuator housing portion, the first rotary fluid displacer comprises a first pump shaft disposed in the pump housing portion, and the first pump shaft is connected to the portion of the first rotor shaft that sealingly penetrates the first end of the first actuator housing portion for rotational movement therewith.

31. The well apparatus of claim 30, wherein the first end of the first actuator housing portion includes a seal.

32. The well apparatus of claim 1, wherein the first motor pump housing includes a first pump housing portion and the first pump is disposed in the first pump housing portion, and the first motor pump housing includes a first actuator housing portion and the first rotary actuator is disposed in the first actuator housing portion.

33. The well apparatus of claim 32, wherein the first motor pump housing comprises a first manifold housing portion and a second manifold housing portion.

34. The well apparatus of claim 33, wherein the first pump inlet port and the first bypass inlet port are in the first manifold housing portion, and the first pump outlet port and the first bypass outlet port are in the second manifold housing portion.

35. A well equipment comprising: a conduit disposed in the well and forming a flow passage for a fluid originating below the surface level to the surface level; a first motor housing disposed in the well; a first rotary actuator disposed in the first motor housing; a first pump housing disposed in the well; a first positive displacement pump disposed in the first pump housing and having a first rotary fluid displacer; The first rotary actuator includes a first stator and a first rotor, the first rotor being configured and arranged to rotate relative to the first stator under the influence of a magnetic field generated by the first stator; the first rotor rotationally coupled to the first rotary fluid displacer such that the first rotary actuator is operably configured to actuate the first rotary fluid displacer; a first pump inlet port and a first pump outlet port in the first pump housing; a first pump fluid passage between the first pump inlet port and the first pump outlet port, with the first rotary fluid displacer disposed in the first pump fluid passage; a first bypass inlet port and a first bypass outlet port in the first pump housing; a first bypass fluid passage between the first bypass inlet port and the first bypass outlet port; as well as the first pump fluid passage being separated from the first bypass fluid passage; The first rotary actuator is operably driven to pump production fluid through the first pump fluid channel.

36. The well apparatus of claim 35, wherein the first pump housing includes a first shaft inlet port and a first shaft outlet port.

37. The well apparatus of claim 35, comprising: a second pump housing disposed in the well; a second positive displacement pump disposed in the second pump housing and having a second rotary fluid displacer; the first rotor being rotationally coupled to the second rotary fluid displacer such that the first rotary actuator is operably configured to actuate the second rotary fluid displacer; a second pump inlet port and a second pump outlet port in the second pump housing; a second pump fluid passage between the second pump inlet port and the second pump outlet port, with the second rotary fluid displacer disposed in the second pump fluid passage; a second bypass inlet port and a second bypass outlet port in the second pump housing; a second bypass fluid passage between the second bypass inlet port and the second bypass outlet port; as well as the second pump fluid passage being separated from the second bypass fluid passage; The first rotary actuator is operably driven to pump the production fluid through the second pump fluid channel.

38. The well apparatus of claim 37, wherein the first pump housing includes a first pump shaft inlet port and a first pump shaft outlet port, and the second pump housing includes a second pump shaft inlet port.

39. The well apparatus of claim 38, comprising a shaft extending through the first shaft inlet port, the first shaft outlet port, and the second shaft inlet port, and connecting the first rotor of the first rotary actuator to the first rotary fluid displacer and the second rotary fluid displacer such that the first fluid displacer and the second fluid displacer rotate as the first rotor of the first rotary actuator rotates.

40. The well apparatus of claim 39, wherein the first motor housing includes an end, and the shaft includes a portion sealingly penetrating the end of the first motor housing.

41. The well apparatus of claim 40, wherein the first pump housing is connected to the first motor housing, the first rotary fluid displacer includes a first pump rotor disposed in the first pump housing, and the first pump rotor is rotationally coupled to the shaft for rotational movement therewith.

42. The well apparatus of claim 41, wherein the second pump housing is connected to the first pump housing, the second rotary fluid displacer includes a second pump rotor disposed in the second pump housing, and the second pump rotor is rotationally coupled to the shaft for rotational movement therewith.

43. The well apparatus of claim 37, wherein the first pump fluid passage is operably connected to the second pump fluid passage, and the production fluid is operably pumped in series through the first pump fluid passage and the second pump fluid passage.

44. The well apparatus of claim 43, wherein the first pump outlet port is operably connected to the second pump inlet port, and the second rotary fluid displacer is operably driven to pump the production fluid from the first pump fluid passage through the second pump fluid passage.

45. The well apparatus of claim 37, wherein the first pump fluid channel is operably connected to the second bypass fluid channel, the first bypass fluid channel is operably connected to the second pump fluid channel, and the production fluid is operably pumped in parallel through the first pump fluid channel and the second pump fluid channel.

46. A well apparatus according to claim 45, wherein the first pump outlet port is operably connected to the second bypass inlet port, and the first rotary fluid displacer is operably driven to pump the production fluid from the first pump fluid channel through the second bypass fluid channel, the first bypass outlet port is operably connected to the second pump inlet port, and the second rotary fluid displacer is operably driven to pump the production fluid from the first bypass fluid channel through the second pump fluid channel.

47. The well apparatus of claim 37, wherein: the first pump fluid passage being operatively connected to the second pump fluid passage or the second bypass fluid passage; the second pump fluid passage being operatively connected to the first pump fluid passage or the first bypass fluid passage; The production fluid is operably pumped in series or in parallel through the first pump fluid passage and the second pump fluid passage; The first pump includes a first multi-stage vane pump; The first multi-stage vane pump includes a first stage and a second stage; The second stage is operably configured to be connected in series or in parallel with the first stage; as well as The rotary actuator is operably driven to pump the production fluid in series or in parallel through the first pump fluid passage through the first stage and the second stage.

48. The well apparatus of claim 47, wherein: The second pump includes a second multi-stage vane pump; The second multi-stage vane pump includes a third stage and a fourth stage; The fourth stage is operably configured to be connected in series or in parallel with the third stage; as well as The rotary actuator is operably driven to pump the production fluid through the third stage and the fourth stage in series or in parallel through the second pump fluid passage.

49. The well apparatus of claim 35, comprising: a second motor housing disposed in the well; a second rotary actuator disposed in the second motor housing and having a second stator and a second rotor, the second rotor configured and arranged to rotate relative to the second stator under the influence of a magnetic field generated by the second stator; as well as the second rotor of the second rotary actuator being rotationally coupled to the first rotary fluid displacer such that the second rotary actuator is operably configured to actuate the first rotary fluid displacer; The first rotary actuator and the second rotary actuator are operably driven to pump the production fluid through the first pump fluid channel.

50. The well apparatus of claim 49, wherein the first motor housing includes a first motor shaft outlet port, and the second motor housing includes a second motor shaft inlet port and a second motor shaft outlet port.

51. The well apparatus of claim 50, comprising a shaft extending through the first motor shaft outlet port, the second motor shaft inlet port, and the second motor shaft outlet port, the shaft rotationally coupling the first rotor of the first rotary actuator to the second rotor of the second rotary actuator such that the first rotor and the second rotor rotate together.

52. The well apparatus of claim 49, comprising: a second pump housing disposed in the well; a second positive displacement pump disposed in the second pump housing and having a second rotary fluid displacer; the first rotor being rotationally coupled to the second rotary fluid displacer such that the first rotary actuator is operably configured to actuate the second rotary fluid displacer; the second rotor rotationally coupled to the second rotary fluid displacer such that the second rotary actuator is operably configured to actuate the second rotary fluid displacer; a second pump inlet port and a second pump outlet port in the second pump housing; a second pump fluid passage between the second pump inlet port and the second pump outlet port, with the second rotary fluid displacer disposed in the second pump fluid passage; a second bypass inlet port and a second bypass outlet port in the second pump housing; a second bypass fluid passage between the second bypass inlet port and the second bypass outlet port; as well as the second pump fluid passage being separated from the second bypass fluid passage; The first rotary actuator and the second rotary actuator are operably driven to pump the production fluid through the second pump fluid channel.

53. The well apparatus of claim 52, wherein the first motor housing comprises a first motor shaft outlet port, the second motor housing comprises a second motor shaft inlet port and a second motor shaft outlet port, the first pump housing comprises a first pump shaft inlet port and a first pump shaft outlet port, and the second pump housing comprises a second pump shaft inlet port.

54. The well apparatus of claim 53 , comprising a shaft extending through the first motor shaft outlet port, the second motor shaft inlet port, the second motor shaft outlet port, the first pump shaft inlet port, the first pump shaft outlet port, and the second pump shaft inlet port, and the shaft rotationally couples the first rotor of the first rotary actuator, the second rotor of the second rotary actuator, the first rotor of the first rotary actuator, the first rotary fluid displacer, and the second rotary fluid displacer such that the first rotor, the second rotor, the first fluid displacer, and the second fluid displacer rotate together.

55. The well apparatus of claim 54, comprising: an intake housing disposed in the well between the first motor housing and the first pump housing; an intake inlet port and an intake outlet port in the intake housing; an intake fluid passage between the intake inlet port and the intake outlet port; an intake shaft inlet port and an intake shaft outlet port in the intake housing; as well as The shaft extends through the intake shaft inlet port and the intake shaft outlet port.

56. The well apparatus of claim 35, comprising: an intake housing disposed in the well between the first motor housing and the first pump housing; an intake inlet port and an intake outlet port in the intake housing; an intake fluid passage between the intake inlet port and the intake outlet port; as well as The intake outlet port is operably connected to the first pump inlet port.

57. The well apparatus of claim 56, wherein the intake housing comprises an intake shaft inlet port and an intake shaft outlet port.

58. The well apparatus of claim 37, comprising: a first intake housing disposed in the well between the first motor housing and the first pump housing; a first intake inlet port and a first intake outlet port in said first intake housing; a first intake fluid passage between the first intake inlet port and the first intake outlet port; the first intake outlet port being operatively connected to the first pump inlet port in the first pump housing; a second intake housing disposed in the well; a second intake inlet port and a second intake outlet port in the second intake housing; a second intake fluid passage between the second intake inlet port and the second intake outlet port; the second intake housing being disposed in the well between the first pump housing and the second pump housing; as well as The second intake outlet port is operably connected to the second pump inlet port in the second pump housing.

59. The well apparatus of claim 37, comprising: an intake housing disposed in the well; a first intake inlet port and a first intake outlet port in the intake housing; a first intake fluid passage between the first intake inlet port and the first intake outlet port; a second intake inlet port and a second intake outlet port in the intake housing; a second intake fluid passage between the second intake inlet port and the second intake outlet port; as well as The first intake outlet port is separated from the second intake outlet port.

60. The well apparatus of claim 59, wherein the intake housing is disposed in the well between the first motor housing and the first pump housing.

61. The well apparatus of claim 60, wherein the first intake outlet port is operably connected to the first pump inlet port in the first pump housing, and the second intake outlet port is operably connected to the first bypass inlet port in the first pump housing.

62. The well apparatus of claim 61, wherein: The first bypass outlet port in the first pump housing is operably connected to the second pump inlet port in the second pump housing.

63. The well apparatus of claim 62, wherein the first intake inlet port and the second intake inlet port comprise the same port.

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