EP-4739884-A1 - CURRENT-CONTROLLED CIRCUIT BREAKER FOR ELECTRICAL SUBMERSIBLE PUMP MOTOR LEADS

Abstract

Some implementations include an apparatus configured to, in a wellbore, eliminate voltage on one or more first conductors that are electrically connected to a surface-based power source. The apparatus may include a shorting ring electrically connectable to the first conductors and configured to electrically short the first conductors upon establishing an electrical connection with the first conductors. The apparatus may include a solenoid assembly to actuate in response to power on the first conductors from the surface-based power source. The apparatus may include a pin slider assembly connected to the first conductors and configured to move, in response to actuation by the solenoid assembly, between an electrical connection with the shorting ring and an electrical connection with one or more second conductors that have an electrical connection with a permanent magnet motor winding in the wellbore.

Inventors

• MANSIR, HASSAN
• BENCZE, Andras
• DE LONG, Robert Charles

Assignees

• Halliburton Energy Services Inc.

Dates

Publication Date

20260513

Application Date

20230929

Claims (20)

1. 1. An apparatus configured to, in a wellbore, eliminate voltage on one or more first conductors that are electrically connected to a surface-based power source, the apparatus comprising: a shorting ring electrically connectable to the first conductors and configured to electrically short the first conductors upon establishing an electrical connection with the first conductors; a solenoid assembly to actuate in response to power on the first conductors from the surface-based power source; a pin slider assembly connected to the first conductors and configured to move, in response to actuation by the solenoid assembly, between an electrical connection with the shorting ring and an electrical connection with one or more second conductors that have an electrical connection with a permanent magnet motor winding in the wellbore.
2. 2. The apparatus of claim 1, wherein the surface-based power source is an alternating current power source, the apparatus further comprising: a full wave rectifier electrically connected to the solenoid assembly and configured to convert alternating current from the surfaced-based power source into direct current to cause the solenoid assembly to actuate the pin slider assembly.
3. 3. The apparatus of claim 2 further comprising: a current transformer electrically coupled to each of the first conductors and connected to the full wave rectifier and configured to step-up or step-down the alternating current.
4. 4. The apparatus of claim 1 , wherein the electrical connection with the shorting ring eliminates the electrical connection with the second conductors.
5. 5. The apparatus of claim 1, wherein the electrical connection with the second conductors includes a connection between an electrical pin of the pin slider assembly and a motor lead extension connected to an permanent magnet motor winding in the w ellbore.
6. 6. The apparatus of claim 1, wherein the pin slider assembly further includes one or more springs configured to move pins from the electrical connection with the second conductors back to the electrical connection with the shorting ring in response to losing power from the surface-based power source.
7. 7. The apparatus of claim I . wherein the solenoid assembly is configured to move the pin slider assembly from the electrical connection wi th the first conductors to the electrical connection with the second conductors in response to current flowing from the surfacebased power source.
8. 8. A system for use in a wellbore, the system comprising: a permanent magnet motor disposed in the wellbore: a circuit breaker assembly configured to eliminate voltage on one or more first conductors that are electrically connected to a surface-based power source, the circuit breaker including. a shorting device electrically connectable to the first conductors and configured to electrically short the first conductors upon establishing an electrical connection with the first conductors; a solenoid assembly to actuate in response to power on the first conductors from the surface-based power source; and a pin slider assembly connected to the first conductors and configured to move, in response to actuation by the solenoid assembly, between an electrical connection with the shorting device and an electrical connection with one or more second conductors that are electrically connected to the permanent magnet motor winding.
9. 9. The system of claim 8, wherein the circuit breaker assembly includes: a housing adapter; and an interface coupled with the housing adapter and including one or more plug-in connector cavities each including a respective power pin terminals configured to connect with a motor lead extension.
10. 10. The system of claim 8 further comprising: a flanged crossover assembly configured to couple the circuit breaker to a stator; and a rotating shaft of the permanent magnet motor passing through the circuit breaker to connect with the stator.
11. 11. The system of claim 8, wherein the circuit breaker assembly further includes: a shaft configured to connect with the shaft that has a mechanical connection with the permanent magnet motor.
12. 12. The system of claim 8 further comprising: a custom test device electrically connected to a motor winding of the permanent magnet motor through the surface power cable and configured to test integrity' of the motor w inding during installation of the permanent magnet motor into the wellbore, operation of the permanent magnet motor in the wellbore, and removal of the permanent magnet motor from the wellbore; and an industry standard test device electrically connected to the surface power cable and configured to test integrity of a surface power cable, motor lead extension, the first conductors, and the motor winding.
13. 13. The system of claim 8, wherein the surface-based power source is an alternating current pow er source, the circuit breaker assembly further comprising: a full wave rectifier electrically connected to the solenoid assembly and configured to convert alternating current from the surfaced-based power source into direct current to cause the solenoid assembly to actuate the pins.
14. 14. The system of claim 13 further comprising: a current transformer electrically coupled to each of the first conductors and connected to the full wave rectifier and configured to step-up or step-down the alternating current.
15. 15. The system of claim 8, wherein the electrical connection with the shorting ring eliminates the electrical connection with the second conductors.
16. 16. The system of claim 8, wherein the electrical connection w ith the second conductors includes a connection between an electrical pin of the pin slider assembly and a motor lead extension connected to a permanent magnet motor winding in the wellbore.
17. 17. The system of claim 8, wherein the pin slider assembly includes springs configured to move pins of first conductors from the electrical connection with the second conductors back to the electrical connection with the shorting ring in response to losing power from the surface-based power source.
18. 18. The system of claim 8, wherein the solenoid assembly is configured to move the pins of the first conductors from the electrical connection with the shorting ring to the electrical connection with the second conductors in response to current flowing from the surfacebased power source.
19. 19. A method for eliminating, in a wellbore, voltage on one or more conductors that are electrically connected to a surface-based power source, the method comprising: moving, in response to power from the surface-based power source, power pins that are connected to the conductors from a first electrical connection with a shorting device to a second electrical connection with motor leads that are connected to a permanent magnet motor winding in the wellbore; and moving, in response to losing the power from the surface-based pow er source, the power pins from the second electrical connection with motor leads back to the first electrical connection with the shorting device.
20. 20. The method of claim 19, wherein the pins are included in a pin slider assembly connected to the conductors and configured to move, in response to actuation by a solenoid assembly, from the first electrical connection with the shorting device to the second electrical connection with the permanent magnet motor winding extension leads.

Description

CURRENT-CONTROLLED CIRCUIT BREAKER FOR ELECTRICAL SUBMERSIBLE PUMP MOTOR LEADS TECHNICAL FIELD [0001] This disclosure relates generally to the field of pumping. More particularly, this disclosure relates to the field of electric submersible pumps for use downhole in a well. Still more particularly, this disclosure relates to downhole motors of the sort which may be used in electric submersible pumps, and to improve their operation. BACKGROUND [0002] Permanent magnet motors (PMM) are becoming an effective power source for downhole applications in the electrical submersible pump systems. This type of motor uses permanent magnets as part of a rotor assembly which may provide several advantages over the conventional induction machines. The advantages may include constant torque over a large speed range, higher power density per unit of active length, higher efficiency, no slip during operation, and more. [0003] Because the magnets may be electromagnetically permanently coupled with a stator winding, the rotor may spin as soon as electric power is supplied to the stator winding. In turn, when the rotor is rotated by an external load (such as a fluid passing through the pump during install/retrieval), the PMM may generate voltage in the stator windings that will energize the cable and any connected surface equipment. This voltage induced by the shaft rotation of the rotor may pose a health and safety risk to the personnel carrying out work on the powerlines to surface and on the surface equipment. The voltage also may damage equipment that is not protected against voltage surge. BRIEF DESCRIPTION OF THE DRAWINGS [0004] Implementations of the disclosure may be better understood by referencing the accompanying drawings. [0005] FIG. 1 is a diagrammatic representation of a well system. [0006] FIG. 2 is a perspective view showing an ESP motor. [0007] FIG. 3 is a diagram showing an example of a current-controlled circuit breaker arrangement. [0008] FIG. 4 is a diagram showing a longitudinal cross section through the electrical power pins of the current-controlled circuit breaker assembly in a fully retracted position (motor winding disconnected from surface power cable, power pins shorted by the shorting ring). [0009] FIG. 5 is a diagram showing a close-up longitudinal cross sectional of the current- controlled circuit breaker assembly shown in FIG. 4. [0010] FIG. 6 is a diagram showing a longitudinal cross section through the electrical power pins of the current-controlled circuit breaker assembly in a partially extended position (motor winding connected to surface power cable, pow er pins still shorted by shorting ring). [0011] FIG. 7 is a diagram show ing a close-up longitudinal cross sectional of the current- controlled circuit breaker assembly shown in FIG. 6. [0012] FIG. 8 is a diagram showing a longitudinal cross section through the electrical power pins of the current-controlled circuit breaker assembly in a fully extended position (motor w inding connected to surface power cable, pow er pins not shorted by the shorting ring). [0013] FIG. 9 is a diagram showing a close-up longitudinal cross sectional of the current- controlled circuit breaker assembly shown in FIG. 8. [0014] FIG. 10 is a diagram showing a radial cross-sectional view- of the pin slider assembly in a fully retracted position. [0015] FIG. 11 is a diagram showing a radial cross-sectional view of the pin slider assembly in a fully extended position. [0016] FIG. 12 is a diagram showing a view' onto the rear side of the pin slider assembly. [0017] FIG. 13 and FIG. 14 are diagrams showing some example components of the circuit breaker assembly. [0018] FIG. 15 is a graph showing an example of the spring force and EM force. [0019] FIG. 16 is a perspective view showing the circuit breaker assembly coupled with the motor head and stator. [0020] FIG. 17 is a diagram showing an interface between the stator and the circuit breaker assembly. [0021] FIG. 18 is a diagram showing an interface of the circuit breaker assembly. [0022] FIG. 19 is a flowchart showing operations of the current controlled circuit braker while ESP running in hole (RIH). [0023] FIG. 20 is a flowchart showing operations of the current controlled circuit braker while the motor is deployed. [0024] FIG. 21 is a flowchart showing operations of the current controlled circuit braker during well treatment operation. [0025] FIG. 22 is a flowchart showing operations of the current controlled circuit braker w hile ESP pulled out of hole (POOH). [0026] FIG. 23 is a flowchart showing operations of the current-controlled circuit braker during ESP electrical integrity test process. DESCRIPTION OF IMPLEMENTATIONS [0027] The description that follows may include example systems, methods, techniques, and program flows that embody implementations of the disclosure. However, this disclosure may be practiced without these specific details. For clarity’, some well-known instruction instances, protocols, str