System and method for enabling rotation of a shuttle electric submersible pump assembly

Abstract

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

Description

[0001] Cross-references to related applications

[0002] This application claims priority and interest in Singapore Provisional Application No. 10202400390R entitled “TORQUE REDUCTION SLEEVE FOR SHUTTLE ESP”, filed on February 13, 2024, and Singapore Provisional Application No. 10202400413W entitled “MECHANICAL SWIVEL FOR SHUTTLE ESP”, filed on February 15, 2024, both of which are incorporated herein by reference in their entirety for all purposes. Background Technology

[0003] This disclosure generally relates to an electric submersible pump (ESP) and a corresponding drillless shuttle system. In particular, this disclosure relates to an embodiment of a system configured such that a housing associated with the ESP can rotate for electrical connection purposes.

[0004] This section is intended to introduce the reader to various aspects of the technology that may be related to the aspects of this disclosure described below and / or claimed. It is believed that this discussion will help provide the reader with background information to better understand the various aspects of this disclosure. Therefore, it is understood that these statements should be read in this context rather than as an admission of prior art.

[0005] To meet consumer and industrial demands for natural resources, companies often invest significant time and money in searching for and extracting oil, natural gas, hydrocarbons, and other underground resources from the earth. Specifically, once a desired underground resource, such as oil or natural gas, is discovered, drilling and production systems are typically employed to access and extract the resource. These systems can be located onshore or offshore, depending on the location of the desired resource. Common methods involve deploying drilling and production systems on the surface or on a floating platform positioned above the discovered resource, and drilling straight down into the earth's surface to obtain the desired resource.

[0006] However, in some scenarios, accessing and extracting resources from below the surface has proven more complex. For example, in some cases, drilling and production systems may employ artificial lift systems designed to provide thrust to subsurface resources to ensure their access to surface production systems. Electric submersible pumps (ESPs) are a common type of artificial lift system used downhole in drilling systems to maximize the production of subsurface resources through the borehole. As consumer and industrial demand for these natural subsurface resources increases, the scope of these extraction processes has expanded accordingly, leading operators to drill larger diameter boreholes and employ drilling and production systems configured to handle larger volumes of resources. Consequently, the ESPs used in these larger boreholes are correspondingly larger and heavier to adequately handle the increased resource production. Efforts to improve the efficiency and maneuverability of these larger ESPs during drilling operations can be advantageous. Summary of the Invention

[0007] This summary is provided to introduce some concepts that will be further described in the following detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to help determine or limit the scope of the claimed subject matter as set forth in the claims.

[0008] In some embodiments, the electric submersible pump system includes an electric submersible pump (ESP) and a motor connector assembly (MCA) coupled to the ESP, such that the MCA includes: an upper annular body including an outer peripheral annular surface; a lower annular body coupled to the upper annular body via a threaded connection; and a bearing sleeve assembly including a bearing sleeve, such that the bearing sleeve assembly is configured to be mounted on the outer peripheral annular surface.

[0009] In some embodiments, an electric submersible pump system includes an electric submersible pump (ESP) and a mechanical rotating component coupled to the ESP such that the mechanical rotating component includes an upper body and an intermediate body. The upper body includes an annular outer surface, a first annular chamber, and a first receiving portion. The intermediate body includes a second annular chamber and a second receiving portion, such that the mechanical rotating component is configured to achieve rotational movement between the upper body and the intermediate body, and the second annular chamber is configured to receive the annular outer surface of the upper body.

[0010] In some embodiments, an electric submersible pump system includes an electric submersible pump (ESP) and a slip ring assembly coupled to the ESP. The slip ring assembly includes a top annular portion, a middle annular portion, a lower tool body portion, a bearing, and a slip ring. The middle annular portion includes a first annular chamber configured to receive the top annular portion and a first threaded engagement. The lower tool body portion includes a second annular chamber and a second threaded engagement configured to engage with the first threaded engagement. The bearing is disposed between the top annular portion and the middle annular portion, such that the bearing is configured to allow rotational movement between the top annular portion and the middle portion. The slip ring is disposed within the second annular chamber, such that the slip ring includes one or more electrical connections along a rotatable interface configured to maintain electrical connectivity during rotational movement. Attached Figure Description

[0011] The present disclosure is further described in the following detailed description and in the accompanying drawings and schematic diagrams illustrating non-limiting embodiments of the present disclosure. Features depicted in the drawings are not necessarily shown to scale. Certain features of embodiments may be shown at an exaggerated scale or in a slightly schematic form, and some details of elements may not be shown for clarity and brevity. These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings, in which the same characters denote the same parts throughout the drawings, wherein:

[0012] Figure 1 This is a schematic diagram of an electric submersible pump (ESP) rig-free shuttle system according to aspects of this disclosure;

[0013] Figure 2 This is a cross-sectional view of an embodiment of an ESP according to aspects of this disclosure, the ESP having a helical connection interface with a docking station assembly (DSA);

[0014] Figure 3 This is a cross-sectional view of an embodiment of an ESP having a helical connection interface with a DSA according to aspects of this disclosure;

[0015] Figure 4 It is a bearing sleeve assembly according to aspects of this disclosure Figure 1-3 A perspective view of an embodiment of the ESP;

[0016] Figure 5 It is according to the aspects of this disclosure that the passage has such Figure 4 A cross-sectional view of an embodiment of the bearing sleeve assembly shown;

[0017] Figure 6 It is based on aspects of this disclosure and has a mechanical rotating element and a torsion spring. Figure 1-3 A top view of an embodiment of the ESP;

[0018] Figure 7 It is according to the aspects of this disclosure that the passage has such Figure 6 A cross-sectional view of an embodiment of the ESP with a mechanical rotating component and a torsion spring shown;

[0019] Figure 8 These are schematic diagrams of various configurations of an ESP in a specified rotational position according to aspects of this disclosure;

[0020] Figure 9 It is based on aspects of this disclosure and has a slip ring. Figure 1-3 A top view of an embodiment of the ESP;

[0021] Figure 10 It is according to the aspects of this disclosure that the passage has such Figure 9 A cross-sectional view of an embodiment of the slip ring ESP shown;

[0022] Figure 11 This is a perspective view of an embodiment of a flat slip ring according to aspects of this disclosure, which can be used in applications such as... Figure 9 and Figure 10 The ESP embodiment of the slip ring shown;

[0023] Figure 12 This is a perspective view of an embodiment of a flat slip ring according to aspects of this disclosure, which can be used in, for example... Figure 9 , Figure 10 and Figure 11 The embodiment of the ESP with slip ring shown;

[0024] Figure 13 This is a perspective view of an embodiment of a through-hole slip ring according to various aspects of the present disclosure, which can be used as... Figure 9 and Figure 10 The embodiment of the ESP with slip ring shown; and

[0025] Figure 14 Based on aspects of this disclosure, it can be used as follows: Figure 9 , 10 A perspective view of an embodiment of the through-hole slip ring in the ESP with slip ring shown in Figure 13. Detailed Implementation

[0026] The following outlines certain embodiments commensurate with the scope of this disclosure. These embodiments are not intended to limit the scope of this disclosure, but are merely intended to provide a brief overview of some of the disclosed embodiments. In fact, this disclosure may cover a variety of forms that may be similar to or different from the embodiments set forth below.

[0027] As used herein, the terms “link” or “linked to” may indicate the establishment of a direct or indirect connection (e.g., said connection may or may not include intermediate or intervening components between the linked entities), and are not limited to either unless explicitly stated otherwise. The term “set” may refer to one or more items. Similar or identical reference numerals are used in the accompanying drawings to identify common or identical elements whenever possible. The drawings are not necessarily drawn to scale, and for clarity, certain features and views in the drawings may be shown enlarged to scale.

[0028] As used herein, the terms “inner” and “outer”; “up” and “down”; “above” and “below”; “upward” and “downward”; “above” and “below”; “inward” and “outward”; and other similar terms as used herein refer to their relative positions to each other and are not intended to indicate a particular direction or spatial orientation. The terms “connected,” “linked,” “connected,” “connected,” “connected to,” “connected to,” and “positively connected” mean “directly connected to” or “connected to” via one or more intermediate elements or components. Typically, these terms refer to a reference point on the ground from which the drilling operation begins as the apex and the total depth as the lowest point, where the well (e.g., wellbore, borehole) is vertical, horizontal, or inclined relative to the ground.

[0029] The degree language used herein, such as the terms “approximately,” “about,” “usually,” and “substantially,” refers to a value, quantity, or characteristic that is close to the stated value, quantity, or characteristic while still performing the desired function or achieving the desired result. For example, the terms “approximately,” “about,” “usually,” and “substantially” may refer to a quantity that is less than 10%, less than 5%, less than 1%, less than 0.1%, and / or less than 0.01%. As another example, in some embodiments, the terms “generally parallel” and “substantially parallel” or “generally perpendicular” and “substantially perpendicular” refer to a value, quantity, or characteristic that deviates from perfect parallelism or perpendicularity by less than or equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, or 0.1 degrees, respectively.

[0030] Furthermore, when describing elements of various embodiments of this disclosure, the articles “a,” “an,” and “the” are intended to indicate the presence of one or more elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that additional elements may exist in addition to those listed. Additionally, it should be understood that references to “an embodiment,” “an embodiment,” or “some embodiments” in this disclosure are not intended to be construed as excluding the existence of additional embodiments that also include the described features. Furthermore, the phrase A “based on” B is intended to indicate that A is at least partially based on B. Moreover, unless explicitly stated otherwise, the term “or” is intended to be inclusive (e.g., logical OR) rather than exclusive (e.g., logical XOR). In other words, the phrase A “or” B is intended to mean A, B, or both A and B.

[0031] Certain terms are used throughout the specification and claims to refer to specific features or components. As those skilled in the art will understand, different people may use different names to refer to the same feature or component. This document is not intended to distinguish between components or features with different names but the same function.

[0032] For decades, humanity has relied on resources beneath the Earth's surface to meet its ever-growing energy needs. These resources include, but are not limited to, natural gas, coal, hydrocarbons, oil, and other materials suitable for generating energy for human consumption. As energy demands increase, significant efforts have been made to extract adequate energy supplies to meet these growing needs. These efforts include systems and methods that enable expanded resource extraction, improved efficiency in extraction processes, and technological advancements that allow for extraction and exploration in areas previously inaccessible to energy production.

[0033] Recently, one exploration area that has grown alongside advancements in energy exploration technologies is artificial lift systems for increasing production. In some situations, resources located below the surface may be difficult to reach surface drilling and production systems due to factors such as reduced pressure, resource viscosity, etc., without the assistance of artificial lift systems. Electric submersible pumps (ESPs) are a common form of artificial lift system used downhole in drilling systems to maximize the production of subsurface resources through the borehole. That is, an ESP typically comprises multiple centrifugal pump sections connected in series, configured to help drive the producing resource from the reservoir to the surface. As consumer and industrial demand for these natural subsurface resources increases, the scope of these extraction processes has expanded accordingly, leading operators to drill larger diameter boreholes and employ drilling and production systems configured to handle larger volumes of resources. Consequently, the ESPs used in these larger boreholes are correspondingly larger and heavier to adequately handle the increased resource output.

[0034] Due to this increased size, operators may encounter mobility and maneuverability issues associated with larger ESPs during downhole installation. For example, in some cases, the ESP may be connected to a docking station assembly (DSA) in the borehole to receive power to operate components within the ESP. In some cases, the DSA may contain a set of electrical connectors configured to mate with an additional set of electrical connectors mounted on the ESP. Since this power connection is initiated downhole, the ESP may be configured to rotate about the drill string axis to ensure alignment of the electrical connectors on the ESP with those on the DSA. However, as mentioned above, the angular rotation path required for connection may also increase with the size of the artificial lift system. To further complicate this connection, in some embodiments of the ESP, the electrical connectors may be axially asymmetrically spaced on the ESP, further increasing the potential for angular rotation to electrically connect to the DSA. This increased rotation may introduce additional undesirable stresses, torques, and strains on the ESP. Therefore, efforts to improve the efficiency and maneuverability of these larger ESPs may be advantageous.

[0035] This embodiment may relate to the relative rotation between components of an ESP. In some embodiments, the ESP may include a bearing sleeve assembly configured to reduce the coefficient of friction between the rotational interface of the inner surface of the drill casing and the outer peripheral surface of the ESP. That is, the bearing sleeve assembly may include a bearing sleeve configured to have improved lubrication properties, thereby enabling the ESP to rotate more easily within the borehole.

[0036] In some embodiments, the ESP may be divided into a top tooling portion and a bottom tooling portion, such that the top and bottom tooling portions are rotatably coupled together via a mechanical rotating assembly. Partially, the mechanical rotating assembly may include one or more bearings configured to allow the bottom tooling portion to rotate relative to the top tooling portion. In some embodiments, the mechanical rotating assembly may include a torsion spring configured to generate a reaction rotational force on the bottom tooling portion to drive it back to a neutral "non-rotational position." Alternatively or additionally, the ESP may include a slip ring positioned between the top and bottom tooling portions, such that the slip ring is configured to maintain electrical connectivity between electrical connectors extending through the top and bottom tooling portions even when the bottom tooling portion rotates relative to the top tooling portion. Therefore, this embodiment allows the ESP to reliably engage and maintain electrical connectivity with the DSA during installation, while reducing mechanical stress and strain within the ESP's structure.

[0037] Switch to the attached image. Figure 1This is a schematic diagram of an electric submersible pump (ESP) no-drill shuttle system (ESP system) 100 in borehole 116. In the illustrated embodiment, ESP system 100 includes a sealing assembly 102, an ESP 104, a sensor or measuring instrument 108, a motor connector assembly (MCA) 112, and a docking station assembly (DSA) 114. ESP 104 is positioned within an annular region of tubing 110, which may be positioned within an annular region of casing 106. In some embodiments, ESP 104 may be configured to receive production resources (e.g., liquid oil, natural gas, petroleum, crude oil, etc.) from a subsurface reservoir through tubing 110 and pump them to the surface. Sealing assembly 102 may be configured to isolate pressure in ESP 104 such that pressure generated by ESP 104 can be substantially applied to the production resources as they travel through tubing 110 of ESP system 100. In some embodiments, the sealing assembly 102 may include a plurality of seals (e.g., annular seals) arranged to function as a unidirectional pressure barrier (e.g., to isolate pressure in a first direction downward along the borehole 116, to isolate pressure in a second direction upward along the borehole 116, or pressure in both directions).

[0038] ESP 104 may include multiple pump stages of a pump section (e.g., a centrifugal pump section) arranged in series along the axial length of borehole 116. In some embodiments, ESP 104 may be configured to receive production resources in a first pump stage located at a lower position in the borehole and apply pressure energy to the production resources to facilitate their journey to the surface. That is, production resources can enter and exit through the various pump stages of ESP 104, ensuring that even if the production resources have characteristics that complicate their journey to the surface (e.g., high viscosity, insufficient pressure, heavy weight, etc.), ESP 104 can guarantee that the production resources can reach the surface.

[0039] The ESP system 100 includes a measuring instrument 108 disposed within a borehole 116 near an ESP 104. The measuring instrument 108 can be configured to measure pressure within the borehole 116. In some embodiments, the measuring instrument 108 may include communication circuitry configured to output a signal to the ground indicating the measured pressure within the borehole 116. Based on this measurement, an operator at the ground can adjust operating parameters of the ESP 104 to increase or decrease the power output to the ESP 104. In some embodiments, the ESP system 100 may include multiple measuring instruments 108. For example, one pressure measuring instrument 108 may be disposed below the ESP 104 to measure the pressure of the production resource before it enters the ESP 104, while a second pressure measuring instrument 108 may be disposed above the ESP 104 to measure the pressure of the production resource as it exits the final pump stage of the ESP 104. In a non-limiting embodiment, the ESP system 100 may include a measuring instrument 108 at the outlet of each pump stage of the ESP 104. In some embodiments, the measuring instrument 108 may include a pressure gauge, thermometer, flow meter, or measuring instrument, fluid composition measuring instrument, or any combination thereof.

[0040] The ESP system 100 may include a motor connector assembly (MCA) 112 configured to electrically connect with a docking station assembly (DSA) 114. As shown, the DSA 114 may be disposed within a conduit 110 of a borehole 116, and the MCA 112 may be configured to travel downwards along the borehole with the ESP 104. The MCA 112 may form part of a retrievable string attached to the bottom of the ESP 104. In some embodiments, the MCA 112 may include a flange configured to mechanically engage with a corresponding flange at the bottom of the ESP 104. Figure 2 and Figure 3 As discussed in further detail, MCA 112 can be configured to be electrically connected to DSA 114 via multiple electrical connectors (e.g., 2, 3, 4, 5, or more). In some embodiments, the electrical connectors on MCA 112 may be female wet-mating connectors, and the electrical connectors on DSA 114 may be male wet-mating connectors, or vice versa. DSA 114 is configured to receive power from the ground and is also configured to provide power to ESP 104 via the aforementioned electrical connectors. In some embodiments, MCA 112 may include one or more electrical connectors, fluid connectors, mechanical connectors, fiber optic connectors, or any combination thereof. Additionally, electrical connectors may include power connectors, data transmission or communication connectors, or any combination thereof.

[0041] Figure 2This is a cross-sectional view of an embodiment of the ESP system 100, showing the spiral connection interface 200 between MCA 112 and DSA 114. Figure 2 In the illustrated embodiment, a spiral connection interface 200 is shown prior to the connection between MCA 112 and DSA 114, at which point ESP 104 descends axially from the ground into borehole 116 along borehole axis 202. As shown, MCA 112 includes a spiral connection spear 210, which includes a tapered tip portion 212 (e.g., a V-shaped tip portion formed in a separate annular sleeve) and a plurality of female wet-fit electrical connectors 214 (e.g., three connectors). The female wet-fit electrical connectors 214 together have a female connector axis 216. As shown, the spiral connection spear 210 and the tapered tip portion 212 form a “pen tip” profile, which resembles the shape of the ink dispensing portion of a pen. Additionally, DSA 114 includes a spiral connection receiver 220, which includes a tapered receiving portion 222 (e.g., a V-shaped receiving portion formed in a separate annular sleeve) and a plurality of male wet-fit electrical connectors 224 (e.g., three connectors). The male wet-fit electrical connector 224 together has a male electrical connector shaft 226. As described above, Figure 2 The spiral connection interface 200 before the electrical connection is initiated is shown. Thus, the female connector axis 216 is substantially not aligned with the male connector axis 226.

[0042] As ESP 104 descends, the tapered tip portion 212 of the spiral connecting spear 210 is configured to engage with the tapered receiving portion 222 of the spiral connecting receiver 220. In some embodiments, the tapered tip portion 212 may include a taper angle (e.g., 5°, 10°, 15°, 25°, etc.), and in other embodiments, the taper angle may gradually increase along the length of the spiral connecting spear 210 in the axial direction (e.g., along the borehole axis 202). Additionally or alternatively, the spiral connecting receiver 220 may include a taper angle (e.g., 5°, 10°, 15°, 25°, etc.), and in other embodiments, the taper angle may gradually increase along the length of the spiral connecting receiver 220 in the axial direction (e.g., along the borehole axis 202). The tapered tip portion 212 of the spiral connecting spear 210 may be configured to engage with the tapered receiving portion 222 of the spiral connecting receiver. In other words, when the ESP 104 descends, the helical connection receiver 220 of the DSA 114 can apply a rotational force to the helical connection spear 210 of the MCA 112, thereby causing the MCA 112 to rotate around the central axis of the ESP system 100. The rotation caused by the engagement of the helical connection receiver 220 and the helical connection spear 210 is configured to rotatably align the female and male wet mating electrical connectors 214 and 224 when connecting the MCA 112 and the DSA 114, so that the female and male wet mating electrical connectors 214 and 224 can be axially connected to each other.

[0043] Figure 3 This is a cross-sectional view of an embodiment of the ESP system 100, showing the spiral connection interface 200 between MCA 112 and DSA 114. Figure 3In the illustrated embodiment, a spiral connection interface 200 is shown after a connection is made between MCA 112 and DSA 114. As described above, when ESP 104 and MCA 112 descend into the borehole, a rotational force is applied to the spiral connection spear 210 via the spiral connection receiver 220. That is, when the spiral connection spear 210 is driven to rotate, MCA 112 is also driven to rotate. By further extension, the female connector axis 216 is driven to rotate such that it is substantially aligned with the male connector axis 226 of the spiral connection receiver 220. When MCA 112 is rotated to alignment such that the female connector axis 216 is substantially aligned with the male connector axis 226, MCA 112 can be electrically connected to DSA 114. With this connection, ESP 104 (and its associated components) can receive power and output this power to production resources when resources flow to the ground. In this way, when MCA 112 and ESP 104 descend into borehole 116, and when the helical connecting spear 210 encounters the helical connecting receiver 220, MCA 112 can be driven to rotate regardless of its orientation relative to DSA 114, allowing the female wet-fit electrical connector 214 to be electrically connected to the male wet-fit electrical connector 224. Thus, cable 230 can be electrically activated via the electrical power supplied to it through the connector via DSA 114.

[0044] In some embodiments, the helical connection interface 200 facilitates the alignment and orientation of the wet-fit connector, and the final mating / docking sequence is achieved in a weight-assisted manner. Intuitively, the weight-assisted mating sequence will be affected by deviations and inconsistent heights within the borehole 116, which may cause the outer peripheral surface of the MCA 112 to contact the inner peripheral surface of the DSA 114 and generate friction. As the ESP 104 descends into the well, this friction can manifest as torque and resistance in the opposite direction to the movement of the MCA 112. This friction, torque, and resistance can have undesirable effects on the ESP system 100.

[0045] Figure 4 It has a bearing sleeve assembly 300 Figures 1 to 3 A perspective view of an embodiment of the ESP 104. The ESP 104 having the bearing sleeve assembly 300 may include a lower tool body portion 304 coupled to a spool 370 of the bearing sleeve assembly 320, and an upper tool body portion 302 coupled to an upper annular body 322 of the bearing sleeve assembly 320. The lower tool body portion 304 may include an outer annular housing 306 having a recessed tapered portion 308 cut out from the outer annular housing 306. As mentioned above regarding Figure 2 and Figure 3As discussed, when the lower tool body portion 304 rotates, the corresponding helical connecting spear of the DSA 114 can mate with the recessed conical portion 308. In the illustrated embodiment, the recessed conical portion 308 includes a vertex 310 and a plurality of walls 312. The vertex 310 and the plurality of walls 312 together define the geometry of the recessed conical portion 308. In the illustrated embodiment, the female wet connector 214 can extend through the lower tool body portion 304, allowing the female wet connector 214 to connect with the corresponding male wet connector 224 of the DSA 114. In addition to the recessed conical portion 308, the lower tool body portion 304 may include a helical connecting spear 210, as previously described... Figure 2 and Figure 3 As discussed during the previous discussion. In the illustrated embodiment, the helical connecting spear 210 is formed in the outer annular housing 306.

[0046] The bearing sleeve assembly 320 may include an upper annular body 322, a bearing sleeve 324, a lower annular body 350, a bearing sleeve retainer 360, and a spool 370. The following will describe the combination... Figure 5 The lower annular body 350, bearing sleeve retainer 360, and spool 370 are discussed in more detail below. As discussed above, the upper annular body 322 can be configured to be coupled to the upper tool body portion 302. In some embodiments, the upper annular body 322 can be coupled to the upper tool body portion 302 via a threaded connection, flange connection, or other suitable mechanical connection. In the illustrated embodiment, the upper annular body 322 is coupled to the upper tool body portion 302 via a threaded connection.

[0047] Bearing sleeve 324 is disposed on the annular surface of the upper annular body 322. Bearing sleeve 324 may have a rigid body design. In some embodiments, the bearing sleeve may be made of a self-lubricating material, such that the bearing sleeve 324 is impregnated with lubricant, and the lubricant is released through a hole in the bearing sleeve when the bearing sleeve rotates. Additionally or alternatively, the bearing sleeve may be made of a low-friction material (e.g., having a coefficient of friction between 0.05-0.025, 0.10-0.20, 0.13-0.18, or other suitable values). In some embodiments, bearing sleeve 324 may be made of graphite (up to 500°C), copper, copper alloys (e.g., BeCu), nickel, nickel alloys (e.g., Monel), bronze, polymers, and / or metal polymers (e.g., composite bearing materials with steel and bronze backings and impregnated with polytetrafluoroethylene (PTFE)). In some embodiments, Monel alloy materials may be advantageous due to their good lubricity and good corrosion resistance. In the illustrated embodiment, the bearing sleeve 324 is configured to be rotatably translated relative to the upper annular body 322. Alternatively, the bearing sleeve 324 may provide an interface between the upper annular body 322 and the bearing sleeve 324, said interface having a reduced coefficient of friction in part due to the improved lubrication properties of the bearing sleeve 324. In some embodiments, the bearing sleeve 324 may provide resistance to scale buildup in the conduit 110 during subsequent installation.

[0048] The bearing sleeve 324 may include an outer bearing sleeve annular surface 326, which includes one or more curved protrusions 328 and a corresponding set of one or more curved grooves 330 (e.g., for flow through the grooves). As shown, the bearing sleeve 324 alternates between the curved protrusions 328 and the curved grooves 330 around its circumference. Each individual curved protrusion 328 and curved groove 330 may span the axial length of the bearing sleeve 324 and bend or spiral in the circumferential direction (e.g., 5°, 10°, 15°, 25°, etc.) along a portion of the outer bearing sleeve annular surface. One or more curved protrusions 328 are configured to intersect with the inner circumferential surface of the conduit 110 such that the curved grooves 330 between adjacent curved protrusions 328 allow production resources to flow through the bearing sleeve 324 and upward along the conduit 110 to the ground. In some embodiments, the bearing sleeve 324 may include eight (8) individual curved protrusions 328 and curved grooves 330, but in other embodiments, the bearing sleeve 324 may have more or fewer (e.g., 2, 3, 4, 5, 6, 7, 9, 10, 12, etc.) curved protrusions 328 and curved grooves 330.

[0049] Figure 5 Is passing through with such Figure 4The diagram shows a cross-sectional view of an embodiment of the ESP 104 with the bearing sleeve assembly 300. As described above, the ESP 104 with the bearing sleeve assembly 300 may include an upper tool body portion 302, a lower tool body portion 304, a bearing sleeve assembly 320, a bearing sleeve retainer 360, and a spool 370. The bearing sleeve assembly 320 includes an upper annular body 322 coupled to the upper tool body portion 302 and a lower annular body 350 coupled to the spool 370. The bearing sleeve assembly 320 may include a bearing sleeve 324, which allows the ESP 104 with the bearing sleeve assembly 300 to rotate within the tubing 110, thereby reducing stress and strain within the assembly when the MCA 112 is electrically connected to the DSA 114.

[0050] In the illustrated embodiment, the upper annular body 322 includes a first annular portion 323 and a second annular portion 325 separated by a shoulder (e.g., annular shoulder) 342. The first annular portion 323 includes a coupling interface for engaging the upper annular body 322 to the upper tool body portion 302. In some embodiments, the coupling interface of the first annular portion 323 may be configured to include a radial seal 332 to provide a fluid barrier within the threaded connection. Additionally or alternatively, the second annular portion 325 includes an additional threaded engagement (internal thread) 340 configured to engage a corresponding threaded engagement (external thread) 356 of the lower annular body 350. In some embodiments, the additional threaded engagement may include a radial seal 344 to similarly provide a fluid barrier within the additional threaded connection.

[0051] Additionally, the second annular portion 325 may include an annular surface 336 for mounting a wear-resistant sleeve (e.g., an annular wear-resistant sleeve) 334. The wear-resistant sleeve 334 may slide on the annular surface 336 and abut against the shoulder 342 of the upper annular body 322. In some embodiments, the wear-resistant sleeve 334 may be configured to provide a protective layer against premature wear or deterioration of the upper annular body 322. In this way, if the wear-resistant sleeve 334 begins to show signs of wear as the wear-resistant sleeve 334 and the upper annular body 322 rotate relative to the bearing sleeve 324, the wear-resistant sleeve 334 can be replaced relatively easily, rather than the entire upper annular body 322. In some embodiments, the wear-resistant sleeve 334 may be made of a material with a lower hardness than the bearing sleeve 324, thereby ensuring that the wear-resistant sleeve 334, rather than the bearing sleeve 324, is a sacrificial component within the assembly. In some embodiments, the wear-resistant sleeve 334 is press-fitted onto the annular surface 336 of the upper annular body. In some embodiments, the wear-resistant sleeve 334 may be made of a material configured to facilitate rotation between the wear-resistant sleeve 334 and the bearing sleeve 324.

[0052] The upper annular body 322 and the lower annular body 350 may have substantially similar inner annular diameters 338 along the axial length of the respective bodies. The inner annular diameter 338 may be large enough that the cable 230 can pass through the inner annular diameter 338 from the ESP 104 to the DSA 114. In this embodiment, when the ESP 104 with the bearing sleeve assembly 300 rotates together as a unit, there is no risk of tangling, tearing, or other similar wear problems with the cable 230.

[0053] A bearing sleeve retainer 360 (e.g., an annular retainer) is configured to be assembled onto the outer annular surface 352 of a lower annular body 350. The outer annular surface 352 has an outer diameter 354, and therefore, the bearing sleeve retainer 360 may accordingly have an inner diameter larger than the outer diameter 354. In the illustrated embodiment, the bearing sleeve retainer 360 has an annular shape and is configured to prevent the wear-resistant sleeve 334 and the bearing sleeve 324 from axially translating along the bearing sleeve assembly 320. In the illustrated embodiment, the bearing sleeve retainer 360 includes a plurality of radially spaced holes circumferentially around the bearing sleeve retainer 360. These radial holes are configured to receive a plurality of retainer fasteners 362 that are radially assembled from the outer annular circumferential surface of the bearing sleeve retainer 360 and are configured to detachably connect the bearing sleeve retainer 360 to the lower annular body 350. In this way, the bearing sleeve retainer 360 can be fixed in an axial position within the bearing sleeve assembly 320, while preventing axial translation of the wear-resistant sleeve 334 and the bearing sleeve 324. In some embodiments, the bearing sleeve retainer 360 can be configured to receive four (4) retainer fasteners, while in other embodiments, the bearing sleeve retainer 360 can be configured to receive more or fewer (e.g., 2, 3, 5, 6, 8, 10, etc.) retainer fasteners 362. In some embodiments, the bearing sleeve retainer 360 can be coupled to the lower annular body 350 via a threaded engagement between the bearing sleeve retainer 360 and the lower annular body 350, one or more locking pins, retainer fasteners 362, or any combination thereof.

[0054] The spool 370 is configured to connect the lower annular body 350 to the lower tool body portion 304. In some embodiments, the spool 370 includes a first flange and a second flange, the first flange being configured to connect to the lower tool body portion 304 and the second flange being configured to connect to the lower annular body 350. As shown, the spool 370 can be configured to receive a plurality of spools to an upper annular body fastener 372 and also to a plurality of spools to a lower tool body portion fastener 374.

[0055] Figure 6 It has a mechanical rotating part of 500. Figures 1 to 3A top view of an embodiment of the ESP 104. As shown, the ESP 104, which has a mechanical rotating member 500, includes an upper tool body portion 502 and a lower tool body portion 503. The lower tool body portion 503 can be substantially similar to... Figure 4 The lower tool body portion shown may include similar features. For example, the lower tool body portion 503 may include the recessed tapered portion 308, the female wet-fit electrical connector 214, and the spiral connecting spear 210 as described above.

[0056] The upper tool body portion 502 includes an external spline 504 disposed on the outer annular surface of the upper tool body portion 502. The external spline 504 may include an external spline profile and may be configured to engage with a mating internal spline profile disposed on the inner annular surface of the tube 110. In some embodiments, the external spline 504 may be assembled with the mating internal spline profile of the tube 110 to create a spline connection and prevent the upper tool body portion 502 from rotating when the spline connection is engaged. However, the lower tool body portion 503 is configured to rotate relative to the upper tool body portion 502 via a mechanical rotator 500.

[0057] Figure 7 Is passing through with such Figure 6 A cross-sectional view of an embodiment of the ESP 104 with the mechanical rotating member 500 shown. In the illustrated embodiment, the ESP 104 with the mechanical rotating member 500 includes an upper body 506, an intermediate body 520, and a threaded collar 508, each having an annular configuration. The upper body 506 may include a first upper body annular portion 507 and a second upper body annular portion 509. The first upper body annular portion 507 may include an internally threaded engagement (internal thread) configured to engage with an upper tool body portion 502. Additionally or alternatively, the second upper body annular portion 509 may be configured to assemble (e.g., slide) into an intermediate body annular chamber 521. The upper body 506 may also include an upper body annular chamber 511 configured to house a torsion spring 510. As will be discussed in more detail below, the torsion spring 510 is configured to provide a biasing rotational force to counteract relative rotational movement between the upper body 506 and the intermediate body 520.

[0058] The intermediate body 520 may include a first threaded connector 523 and a second threaded connector 525. In some embodiments, the first threaded connector 523 may be disposed on the lower axial end of the intermediate body 520 and configured to assemble (e.g., mate) with the lower tool body portion 503. Alternatively, the second threaded connector 525 may be configured to interface with a threaded collar 508. In some embodiments, both the first threaded connector 523 and the second threaded connector 525 may include external threads.

[0059] The intermediate body 520 includes an intermediate body annular chamber 521, previously discussed as configured to receive the second upper body annular portion 509. Additionally or alternatively, the intermediate body annular chamber 521 may be configured to receive one or more thrust washers (e.g., annular thrust washers) 522. The thrust washers 522 may be configured to receive thrust during operation of the ESP 104 with the mechanical rotating component 500, thereby protecting the intermediate body 520 from premature wear. The intermediate body annular chamber 521 may also receive an intermediate body bearing sleeve 524 configured to rotate between the second upper body annular portion 509 and the intermediate body 520. In some embodiments, the intermediate body bearing sleeve 524 may be made of a low-friction material configured to reduce the coefficient of rotational friction between the upper body 506 and the intermediate body 520. The intermediate body 520 may include a fill port 534 configured to allow an operator to fill the internal chamber of the mechanical rotating component with fluid. In some embodiments, the mechanical rotating component may be filled with dielectric oil via the filling port 534.

[0060] The ESP 104, having a mechanical rotating component 500, may include a threaded collar 508 configured to receive a floating stop 518 (e.g., a ring-shaped rotary bearing) and provide mechanical support for the floating stop. In some embodiments, the floating stop 518 may be configured to provide a hard stop to limit the range of rotational distances the mechanical rotating component can rotate. Further discussion of this embodiment of the floating stop 518 will follow. Figure 8 This will be discussed in more detail later.

[0061] However, in some embodiments, the floating stop 518 may be configured to reduce the coefficient of rotational friction between the upper body 506 and the intermediate body 520. In other embodiments, the floating stop 518 may be a bearing (e.g., a cylindrical roller bearing, a spherical roller bearing, a tapered roller bearing, etc.). The floating stop 518 may abut against the cotter ring 516. In some embodiments, the cotter ring (e.g., an annular cotter ring) 516 may provide a mating shoulder 528 to engage with a threaded collar 508. For example, the threaded collar 508 may be configured to slide on the floating stop 518 and threadedly engage with a second threaded connection 525 of the intermediate body 520. In this way, the threaded collar 508 may provide a clamping force on the mating shoulder 528 of the cotter ring 516, thereby setting the axial position of the floating stop 518. In some embodiments, the clamping force provided by the threaded collar 508 to the mating shoulder 528 of the open ring 516 and transmitted to the floating stop 518 can adequately preload the floating stop 518 (e.g., a bearing), thereby improving the performance of the bearing.

[0062] A torsion spring 510 is configured to be received within an annular cavity 511 of an upper body 506. In the illustrated embodiment, the torsion spring 510 includes an upper end (e.g., an axial portion) of a coil 512 and a lower end (e.g., an axial portion) of a coil 514, such that the upper end of the coil 512 is configured to slide into a receiving portion 513 (e.g., an axial receiving portion) of the upper body 506, and the lower end of the coil 514 is configured to slide into a receiving portion 515 (e.g., an axial receiving portion) of an intermediate body 520. A coiled or helical coil portion 517 of the torsion spring 510 is disposed between the upper and lower ends of the coils 512 and 514. The torsion spring 510 itself can be configured to apply a reaction rotational biasing force in response to rotation (e.g., torsional force) applied at one or more of the ends 512, 514 of the torsion spring 510 due to rotational movement between the upper body 506 and the intermediate body 520. For example, if a counterclockwise rotational force is applied to the first end 512 of the spring 510, the torsion spring 510 is configured to generate substantially equal and opposite clockwise forces in an attempt to return the torsion spring 510, as well as the rotatably connected upper body 506 and intermediate body 520, to their neutral state. In the illustrated embodiment, the first end of the coil 512 is located in the receiving portion of the upper body 506, and the second end of the coil 514 is located in the receiving portion of the intermediate body 520, such that the torsion spring 510 can generate a reaction force due to the relative rotational movement between the upper body 506 and the intermediate body 520.

[0063] As shown, cable 230 can pass through the inner diameter of torsion spring 510 and extend through mechanical rotating member 500. As previously described, MCA 112 can be rotated to align with electrical connectors 214, 224 between MCA 112 and DSA 114. Due to this configuration, cable 230 includes a first counterclockwise (CCW) coil 530 (e.g., a helical winding) on ​​the upper body 506 side of cable 230, and a clockwise (CW) coil 532 (e.g., a helical winding) on ​​the middle body 520 portion of cable 230. By means of these counter-wound coils 530 and 532 in cable 230, mechanical rotating member 500 can allow upper body 506 to rotate relative to middle body 520 (e.g., and upper tool body portion 502 relative to lower tool body portion 503) without interrupting the electrical connection or breaking cable 230. In some embodiments, coil 530 may be wound clockwise and coil 532 may be wound counterclockwise, as long as coils 530 and 532 are wound in opposite directions. In some embodiments, the mechanical rotating element 500 may be used with a slip ring, such as... Figures 9 to 14 As shown, the electrical connection is maintained during rotation between the upper body 506 and the middle body 520.

[0064] Figure 8 This is a schematic diagram of various rotational configurations of the ESP 104 with mechanical rotating element 500. As shown in box 550, to achieve restricted rotational movement, floating stops 518, 560 are introduced, which perform rotational movement, handle radial and axial loads, and allow for hard stop restriction of approximately 200 degrees in either direction of mechanical rotation. The rotor 564 has a shoulder 562 that pushes the floating stops 518, 560 in a clockwise (positive angle value) or counterclockwise (negative angle value) direction. Rotational restriction or hard stop restriction is integrated into the design to prevent excessive rotation from damaging the cable 230. This hard stop restriction is achieved via a shoulder 568 on the stator 566, which limits the floating stops 518, 560 to rotate more than 200 degrees in either direction (e.g., clockwise or counterclockwise).

[0065] In neutral position block 550, the shoulder 562 on rotor 564 and the shoulder 568 on stator 566 are both centered from top to bottom (0 degrees from the six o'clock position on a clock). As shown in box 552, stator 566 and stator shoulder 568 remain stationary, but rotor 564 and rotor shoulder 562 have driven the floating stops 518, 560 90 degrees clockwise. As shown in box 554, rotor 564 and rotor shoulder 562 have driven the floating stops 518, 560 200 degrees clockwise, causing the floating stops 518, 560 to contact stator shoulder 568. As a result, rotor 564 is prevented from further rotating the floating stops 518, 560, thereby preventing undesirable damage to cable 230. Boxes 556 and 558 show essentially similar cases to boxes 552 and 554, only in the opposite (counterclockwise) direction.

[0066] Figure 9 It has a slip ring 600. Figures 1 to 3 A top view of an embodiment of the ESP 104. In this embodiment, the ESP 104 with slip ring 600 is substantially similar to... Figure 6 The embodiment of the ESP 104 shown has a mechanical rotating member 500. For example, the ESP 104 with a slip ring 600 includes an upper tool body portion 502 with an external spline 504 and a lower tool body portion 503 with a recessed tapered portion 308. Furthermore, the lower tool body portion 503 similarly includes a female wet-fit electrical connector 214 and a spiral connecting spear 210. As shown below... Figure 10 As discussed in the description, slip ring 600 is configured to maintain electrical connection during rotational movement between upper tool body portion 502 and lower tool body portion 503, such as by achieving sliding electrical contact in an annular contact arrangement of slip ring 600.

[0067] Figure 10 Is passing through with such Figure 9A cross-sectional view of an embodiment of the slip ring 600 in the ESP 104 is shown. In the illustrated embodiment, the ESP 104 having the slip ring 600 includes a top annular portion 602 threaded to a middle portion 604 via a threaded engagement 610. In some embodiments, the top annular portion 602 may include external threads, while the middle portion 604 may include internal threads, and vice versa. The top annular portion 602 and the middle portion 604 may each include an annular channel 614 configured to receive a cable 230. The cable 230 may extend to a slip ring 606 disposed within a lower tool body portion 503. In some embodiments, the slip ring 606 may be configured to electrically connect the cable 230 from the ESP 104 to the cable 230 of the MCA 112, and to allow the upper tool body portion 502 to rotate relative to the lower tool body portion 503 while maintaining electrical connection between the two portions.

[0068] In some embodiments, the intermediate portion 604 may include a bearing 608 configured to allow and facilitate relative rotation between the top annular portion 602 and the intermediate portion 604. In some embodiments, the bearing 608 may be a spherical roller bearing, while in other embodiments, the bearing 608 may be a tapered roller bearing, a cylindrical roller bearing, etc. In some embodiments, a slip ring 600 may be used. Figures 6 to 8 In ESP 104.

[0069] Figure 10 The slip ring 606 in the middle can have one of several configurations. For example, Figure 11 and Figure 12 This is a perspective view of an embodiment of a flat slip ring 700, 606 that can be used in an embodiment of an ESP 104 having slip ring 600. Figure 11 Flat slip rings 700 and 606 are shown, each including a flat disk 710 configured to accommodate a plurality of concentric conductive rings 751, 752, 753, and 754. Cables 740 can be electrically connected to one of the conductive rings 751, 752, 753, and 754, respectively. Alternatively, cables 720 can be electrically connected to a conductive slide plate 730. The conductive slide plate 730 is configured to rotate about the flat disk 710 while maintaining the electrical connection between the respective cables 720 and the conductive rings 751, 752, 753, and 754.

[0070] Figure 12Embodiments of flat slip rings 800, 606 are shown, such that cables 720 are grouped together in the second column 820 and cables 740 are grouped together in the first column 810. In the illustrated embodiment, the flat disk 830 may include multiple disks, and the top disk 831 may be configured to rotate relative to the bottom disk 832, the bottom disk 832 may be configured to rotate relative to the top disk 831, or a combination thereof. The electrical connection between the top disk 831 and the bottom disk 832 may be... Figure 11 The electrical connections described herein are largely the same. In some embodiments, the top disk 831 can be configured to connect with... Figure 11 The conductive slide plate 730 operates in a similar manner to the conductive slide plate 730 in other embodiments, while in other embodiments, the bottom plate 832 may be configured to operate in a manner similar to the conductive slide plate 730 in the conductive slide plate 730. Figure 11 It operates in a similar manner to the conductive slide plate 730 in the middle.

[0071] Figure 13 and Figure 14 This is a perspective view of an embodiment of a through-hole slip ring 900, 606 that can be used in an implementation of the ESP 104 having slip ring 600. Figure 13 A through-hole slip ring 900, 606 is shown, which includes a flat disk 910 coupled to a cylindrical portion 920. The cylindrical portion 920 is configured to receive a plurality of conductive rings 951, 952, 953, and 954. A cable 720 can be electrically connected to one of the conductive rings 951, 952, 953, and 954, respectively. Alternatively, the cable 720 can be electrically connected to a conductive slide plate 930. The conductive slide plate 930 is configured to rotate about the cylindrical portion 920 while maintaining the electrical connection between the respective cable 720 and the conductive rings 951, 952, 953, and 954.

[0072] Figure 14 Embodiments of through-hole slip rings 1000 and 606 are shown, such that cables 720 are grouped together in the second column 1020, and cables 740 are grouped together in the first column 1010. In the illustrated embodiment, the cylindrical portion 920 may include an inner shell 1060 and an outer shell 1070 configured to rotate relative to each other, such that the outer shell 1070 may be configured to operate in a manner similar to that of the conductive slide plate 930. In some embodiments, the electrical connection may be with... Figure 13 The two are essentially the same.

[0073] The technical advantages of the disclosed embodiments include improved efficiency, maneuverability, and reduced stress on the housing of the ESP system. For example, by enabling relative rotation between the top and bottom portions of the ESP, the ESP system can be connected to the DSA without introducing the possibility of wear and breakage of the cables extending through the ESP. Additionally, this embodiment allows larger diameter ESP systems to utilize axially asymmetrical cable configurations while still maintaining electrical connection between the DSA and the ESP.

[0074] The subject matter described in detail above may be defined by one or more clauses, as follows.

[0075] The electric submersible pump system includes an electric submersible pump (ESP) and a motor connector assembly (MCA) coupled to the ESP, such that the MCA includes: an upper annular body having an outer peripheral annular surface; a lower annular body being connected to the upper annular body via a threaded connection; and a bearing sleeve assembly having a bearing sleeve, such that the bearing sleeve assembly is configured to be mounted on the outer peripheral annular surface.

[0076] According to the electric submersible pump system described in the foregoing clauses, the bearing sleeve comprises a self-lubricating material, a low-friction material, or a combination thereof.

[0077] The electric submersible pump system according to any one of the foregoing clauses, wherein the bearing sleeve comprises at least one of graphite, copper, copper alloy, nickel, nickel alloy, bronze, polymer, metallic polymer, or any combination thereof.

[0078] The electric submersible pump system according to any one of the foregoing clauses, wherein the bearing sleeve includes an outer bearing annular surface, wherein the outer bearing annular surface includes a plurality of curved protrusions and a plurality of curved grooves, wherein the plurality of curved grooves and the plurality of curved protrusions alternate around the circumference of the outer bearing annular surface.

[0079] The electric submersible pump system according to any one of the foregoing clauses, wherein the bearing sleeve assembly includes a wear-resistant sleeve radially disposed between the outer peripheral annular surface and the bearing sleeve, wherein the wear-resistant sleeve is configured to be mounted on the outer peripheral annular surface of the upper annular body.

[0080] The electric submersible pump system according to any one of the foregoing clauses includes a bearing sleeve retainer configured to be mounted on an additional outer peripheral annular surface of the lower annular body, wherein the bearing sleeve retainer is configured to prevent axial translation of the bearing sleeve assembly.

[0081] According to any of the foregoing clauses, the electric submersible pump system includes an inner annular diameter configured to accommodate a cable extending from the ESP through the inner annular diameter to the docking station assembly (DSA).

[0082] The electric submersible pump system according to any one of the foregoing clauses includes: an upper tool body portion configured to connect the upper annular body to the ESP; a lower tool body portion configured to electrically connect the cable to the DSA via a helical connection interface; and a spool configured to connect the lower tool body portion to the lower annular body.

[0083] The electric submersible pump system according to any one of the foregoing clauses, wherein the helical connection interface comprises: a helical connection spear disposed on the lower tool body portion, wherein the helical connection spear includes a tapered tip portion; and a helical connection receiver disposed on the DSA, wherein the helical connection receiver includes a tapered receiving portion, and wherein the tapered receiving portion is configured to engage with the tapered tip portion. The helical connection interface further comprises a first set of electrical connectors and a second set of electrical connectors, the first set of electrical connectors including a first electrical connector axis, and the second set of electrical connectors including a second electrical connector axis, wherein the interface between the tapered tip portion and the tapered receiving portion is configured to align the first electrical connector axis and the second electrical connector axis with each other.

[0084] An electric submersible pump system includes an electric submersible pump (ESP) and a mechanical rotating component connected to the ESP such that the mechanical rotating component includes an upper body and an intermediate body. The upper body includes an annular outer surface, a first annular chamber, and a first receiving portion. The intermediate body includes a second annular chamber and a second receiving portion, such that the mechanical rotating component is configured to achieve rotational movement between the upper body and the intermediate body, and the second annular chamber is configured to receive the annular outer surface of the upper body.

[0085] The electric submersible pump system according to the foregoing clauses includes a torsion spring disposed in the first annular chamber, wherein the torsion spring includes: an upper end configured to slide into the first receiving portion; a lower end configured to slide into the second receiving portion; and a helical coil portion wherein the helical coil portion is configured to apply a rotational biasing force in response to a rotational force applied at one or more of the upper end or the lower end.

[0086] The electric submersible pump system according to any one of the foregoing clauses includes a bearing sleeve disposed in the second annular chamber, wherein the bearing sleeve is configured to facilitate rotational movement between the upper body and the intermediate body.

[0087] The electric submersible pump system according to any one of the foregoing clauses includes a threaded collar assembly configured to connect the upper body to the intermediate body, wherein the threaded collar assembly includes: an open annular ring including a first shoulder, wherein the open annular ring is configured to assemble into an annular groove in the upper body; a floating stop configured to facilitate rotational movement between the upper body and the intermediate body; and a threaded collar including a second shoulder and a threaded engagement portion, wherein the threaded engagement portion is configured to assemble into an additional threaded engagement portion disposed on the intermediate body, and wherein the second shoulder is configured to apply an axial force to the first shoulder.

[0088] In any of the foregoing clauses, the electric submersible pump system wherein the floating stop is configured to provide a hard stop to limit rotational movement between the upper body and the intermediate body.

[0089] In any of the preceding clauses, the electric submersible pump system wherein the floating stop is configured to limit the rotational movement between a positive 200° rotation in the clockwise direction and a negative 200° rotation in the counterclockwise direction.

[0090] The electric submersible pump system includes an electric submersible pump (ESP) and a slip ring assembly coupled to the ESP. The slip ring assembly includes a top annular portion, a middle annular portion, a lower tool body portion, a bearing, and a slip ring. The middle annular portion includes a first annular chamber configured to receive the top annular portion and a first threaded engagement. The lower tool body portion includes a second annular chamber and a second threaded engagement configured to engage with the first threaded engagement. The bearing is disposed between the top annular portion and the middle annular portion, such that the bearing is configured to allow rotational movement between the top annular portion and the middle portion. The slip ring is disposed within the second annular chamber, such that the slip ring includes one or more electrical connections along a rotatable interface configured to maintain electrical connectivity during rotational movement.

[0091] According to the foregoing clauses, the electric submersible pump, wherein the bearing includes a spherical bearing, a cylindrical bearing, a tapered roller bearing, or a combination thereof.

[0092] The electric submersible pump system according to any one of the foregoing clauses, wherein the slip ring comprises a flat slip ring.

[0093] The electric submersible pump system according to any one of the foregoing clauses, wherein the slip ring comprises a through-hole slip ring.

[0094] The electric submersible pump system according to any one of the foregoing clauses includes an upper tool portion coupled to the top annular portion, wherein the upper tool portion includes an external spline.

[0095] For purposes of explanation, the foregoing description has been given by reference to specific embodiments. However, the illustrative discussion above is not intended to be exhaustive or to limit this disclosure to the precise forms disclosed. In view of the foregoing teachings, many modifications and variations are possible. Furthermore, the order of elements illustrating and describing the methods described herein may be rearranged, and / or two or more elements may occur simultaneously. The embodiments were chosen and described in order to best explain the principles of this disclosure and its practical application, thereby enabling others skilled in the art to best utilize this disclosure and various embodiments with various modifications suitable for the intended particular use.

[0096] Finally, the techniques proposed and claimed herein are referenced and applied to material objects and specific examples of practical nature, which significantly improve the field of technology, and are therefore not abstract, intangible, or purely theoretical. Furthermore, if any claim appended to the end of this specification contains one or more elements designated as “means for [performing] [function]…” or “steps for [performing] [function]…”, such elements are intended to be interpreted according to 35 USC112(f). However, for any claim containing elements designated in any other manner, such elements are not intended to be interpreted according to 35 USC112(f).

Claims

1. An electric submersible pump system, comprising: Electric Submersible Pump (ESP); and A motor connector assembly (MCA) is coupled to the ESP, wherein the MCA includes: The upper annular body includes an outer annular surface; The lower annular body is connected to the upper annular body via a threaded connection; and A bearing sleeve assembly, the bearing sleeve assembly including a bearing sleeve, wherein the bearing sleeve assembly is configured to be mounted on the outer peripheral annular surface.

2. The electric submersible pump system according to claim 1, wherein, The bearing sleeve comprises a self-lubricating material, a low-friction material, or a combination thereof.

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

4. The electric submersible pump system according to claim 1, wherein, The bearing sleeve includes an outer bearing annular surface, wherein the outer bearing annular surface includes: Multiple curved protrusions; and Multiple curved grooves, wherein the multiple curved grooves and the multiple curved protrusions alternate circumferentially around the annular surface of the outer bearing.

5. The electric submersible pump system according to claim 1, wherein, The bearing sleeve assembly includes a wear-resistant sleeve radially disposed between the outer circumferential annular surface and the bearing sleeve, wherein the wear-resistant sleeve is configured to be mounted on the outer circumferential annular surface of the upper annular body.

6. The electric submersible pump system according to claim 1, wherein, The electric submersible pump system includes a bearing sleeve retainer configured to be mounted on a further outer circumferential annular surface of the lower annular body, wherein the bearing sleeve retainer is configured to prevent axial translation of the bearing sleeve assembly.

7. The electric submersible pump system according to claim 1, wherein, The upper annular body includes an inner annular diameter configured to accommodate a cable that extends from the ESP to the docking station assembly (DSA) through the inner annular diameter.

8. The electric submersible pump system according to claim 7, comprising: The upper tool body portion is configured to connect the upper annular body to the ESP; The lower tool body portion is configured to electrically connect the cable to the DSA via a spiral connection interface; and A spool configured to connect the lower tool body portion to the lower annular body.

9. The electric submersible pump system according to claim 8, wherein, The spiral connection interface includes: A spiral connecting spear, wherein the spiral connecting spear is disposed on the lower tool body portion, and wherein the spiral connecting spear includes a tapered tip portion; A spiral connection receiver is disposed on the DSA, wherein the spiral connection receiver includes a tapered receiver portion, and wherein the tapered receiver portion is configured to engage with the tapered tip portion; A first set of electrical connectors, the first set of electrical connectors including a first electrical connector shaft; and The second set of electrical connectors includes a second electrical connector axis; The interface between the tapered tip portion and the tapered receiving portion is configured to align the axes of the first electrical connector and the second electrical connector with each other.

10. An electric submersible pump system, comprising: Electric Submersible Pump (ESP); and A mechanical rotating component, the mechanical rotating component being coupled to the ESP, wherein the mechanical rotating component includes: The upper body includes an annular outer surface, a first annular chamber, and a first receiving part; and An intermediate body includes a second annular chamber and a second receiving portion, wherein the mechanical rotating member is configured to rotate between the upper body and the intermediate body, and the second annular chamber is configured to receive the annular outer surface of the upper body.

11. The electric submersible pump system according to claim 10, comprising: A torsion spring, wherein the torsion spring is disposed in the first annular chamber, wherein the torsion spring comprises: The upper end is configured to slide into the first receiving part; The lower end is configured to slide into the second receiving section; and A helical coil portion, wherein the helical coil portion is configured to apply a rotational bias force in response to a rotational force applied at one or more of the upper or lower ends.

12. The electric submersible pump system according to claim 10, comprising a bearing sleeve disposed in the second annular chamber, wherein, The bearing sleeve is designed to facilitate rotational movement between the upper body and the middle body.

13. The electric submersible pump system of claim 12, further comprising a threaded collar assembly configured to connect the upper body to the intermediate body, wherein, The threaded collar assembly includes: An open annular ring, the open annular ring including a first shoulder, wherein the open annular ring is configured to be assembled into an annular groove of the upper body; A floating stop, configured to facilitate rotational movement between the upper body and the intermediate body; and A threaded collar, the threaded collar including a second shoulder and a threaded engagement portion, wherein the threaded engagement portion is configured to be assembled to an additional threaded engagement portion disposed on the intermediate body, and wherein the second shoulder is configured to apply an axial force to the first shoulder.

14. The electric submersible pump system according to claim 13, wherein, The floating stop is configured to provide a hard stop to limit rotational movement between the upper body and the intermediate body.

15. The electric submersible pump system according to claim 14, wherein, The floating stop is configured to restrict the rotational motion to between a positive 200° rotation in the clockwise direction and a negative 200° rotation in the counterclockwise direction.

16. An electric submersible pump system, comprising: Electric Submersible Pump (ESP); and A slip ring assembly, coupled to the ESP, wherein the slip ring assembly includes: Top ring section; The intermediate annular portion includes a first annular chamber and a first threaded engagement portion, the first annular chamber being configured to receive the top annular portion; The lower tool body portion includes a second annular chamber and a second threaded engagement portion, the second threaded engagement portion being configured to connect to the first threaded engagement portion; A bearing, disposed between the top annular portion and the middle annular portion, wherein the bearing is configured to rotate between the top annular portion and the middle portion; and A slip ring disposed within the second annular chamber, wherein the slip ring includes one or more electrical connections along a rotatable interface configured to maintain electrical connectivity during the rotational movement.

17. The electric submersible pump system according to claim 16, wherein, The bearings include spherical bearings, cylindrical bearings, tapered roller bearings, or combinations thereof.

18. The electric submersible pump system according to claim 16, wherein, The slip ring includes a flat slip ring.

19. The electric submersible pump system according to claim 16, wherein, The slip ring includes a through-hole slip ring.

20. The electric submersible pump system of claim 16, comprising an upper tool portion coupled to the top annular portion, wherein, The upper tool section includes external splines.

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