ASSISTED LIFT ELECTRICAL SUBSURFACE PUMP SYSTEM

TECHNICAL FIELD

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

BACKGROUND ART

[0002]Often there is not enough pressure for wells to produce at commercially viable levels without assistance in lifting formation fluids to the surface. Artificial lift devices are therefore used to pump oil or other liquids from underground or subsurface to ground or surface level.

[0003]A common approach for moving production fluids to the surface includes the use of a submersible pump. These pumps are installed in the well itself, typically at the lower end of the production tubing. One type of such a submersible pump generally comprises a cylindrical housing and an inner reciprocating piston, which reside at the base of the production line. The pump has an inlet at the bottom end of the piston and an outlet at the top end. The pump forces a first volume of fluid upward within the production tubing during an upstroke and a second volume of fluid upward within the tubing during the pump's downstroke. The piston is reciprocated axially within the well bore by a linear magnetic motor. The linear magnetic motor having a series of windings that act upon an inner shaft is located below the pump. The motor is powered by an electrical cable extending from the surface to the bottom of the well. The power supply generates a magnetic field within the coils of the motor which, in turn, imparts an oscillating force on the shaft of the motor. The shaft thereby is translated in an up and down or linear fashion within the well. The shaft is connected, through a linkage, to the piston of the pump and thus imparts translational or lineal movement to the pump piston. The linear electric motor thus enables the piston of the pump to reciprocate vertically, thereby enabling fluids to be lifted with each stroke of the piston towards the surface of the well.

[0004]U.S. Pat. No. 1,655,825, which issued Jan. 10, 1928, discloses a linear electromagnetic motor coupled to an oil well pump. Solenoids are mounted within a casing and arranged to actuate a core. The core is made up of a stacked series of magnetizable members interspersed between non-magnetizable members. The core is coupled to a pump plunger. An upper valve and two lower valves allow only upwards flow of fluid. By sequentially applying current to the elevating solenoids, and then the depressing solenoids, the core and pump plunger are caused to reciprocate, which forces fluid to flow upwards through the valves.

[0005]U.S. Pat. No. 5,049,046 teaches a down hole electromagnetic motor-pump assembly having an armature with permanent magnets and a stator with multiple coils, a pump having a reciprocating piston, a down hole switching motor controller, and a remote wireless monitoring station. The patent teaches a motor-pump assembly having a motor-pump cartridge unit that is supported down hole in a sleeve assembly of an oil well and connected to the surface through tubing and a cable. The pump is shown and described as having an outer barrel that contains a piston within. A check valve is arranged below the piston and a second check valve is arranged above the piston.

[0006]U.S. Pat. No. 5,831,353 discloses a motor-pump assembly having a pump and a brushless DC linear motor for driving the pump reciprocatively to allow the fluids in the production tube to be lifted to the upper ground level. A motor controller is provided for controlling the linear motor and supplies the motor with a certain number of direct current pulses. A coupling arrangement connects the pump to the motor. The motor is described as being of modular construction with a plurality of interconnected stator modules or units and at least one modular cylindrically shaped mover. The stator units are described as having a plurality of spaced apart pairs of oppositely wound toroidal coils. The mover is described as having ring shaped, radially polarized permanent magnets stacked on a shaft in alternating polarities interleaved with bearing units, which share the total frictional stress by being spaced between the respective magnets. The pump is described as working much like a sucker rod pump and has a plunger coupled to the motor mover so as to move together in unison. Well fluid is pumped through a bore in the center of motor, thus enabling much of the heat generated by the motor to be dissipated into the well fluid.

BRIEF SUMMARY

[0007]With parenthetical reference to the corresponding parts, portions or surfaces of the disclosed embodiment, merely for purposes of illustration and not by way of limitation, a well installation (15, 415) is provided comprising: tubing (17) arranged in a well (18) and forming a flow channel to a surface level for fluids originating from below 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) configured and arranged to rotate relative to the first stator under the effect of a magnetic field generated by the first stator; the first rotor 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 passage (170, 270, 370, 380) between the first pump inlet port and the first pump outlet port, and the first rotary fluid displacer disposed in the first pump fluid passage; 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 passage (160, 260, 360) between the first bypass inlet port and the first bypass outlet port; and the first pump fluid passage separate from the first bypass fluid passage; wherein the first rotary actuator is operatively driven to pump a production fluid through the first pump fluid passage.

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

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

[0010]The well installation may comprise a first controller housing (96) and a first drive (33) for the first actuator disposed in the first controller housing. The first controller housing may comprise a first fluid through passage (70) and a second fluid through passage (60) separate from the first fluid through passage. The first pump fluid passage (170, 270, 370, 380) may be operatively connected to the first fluid through passage (70) and the first bypass fluid passage (160, 260, 360) may be operatively connected to the second fluid through passage (60). The first controller housing may comprise an input connection (86), a motor output connection (84), and conductivity (80) between the input connection and the motor output connection.

[0011]The well installation may comprise: 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 configured and arranged to rotate relative to the second stator under the effect 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 (141A, 341A) in the second housing; a second pump fluid passage (170A, 370A, 380A) between the second pump inlet port and the second pump outlet port, and the second rotary fluid displacer disposed in the second pump fluid passage; a second bypass inlet port (161A, 361A) and a second bypass outlet port (162A, 362A) in the second housing; a second bypass fluid passage (160A, 360A) between the second bypass inlet port and the second bypass outlet port; and the second pump fluid passage separate from the first bypass fluid passage; wherein the second rotary actuator may be operatively driven to pump a production fluid through the second pump fluid passage.

[0012]The first pump fluid passage may be operatively connected to the second pump fluid passage and the production fluid may be operatively pumped in series through the first pump fluid passage and the second pump fluid passage (FIGS. 28, 31, 41 and 44). The first pump outlet port may be operatively connected to the second pump inlet port and the second rotary actuator may be operatively driven to pump the production fluid through the second pump fluid passage from the first pump fluid passage.

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

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

[0015]The first pump fluid passage may be operatively connected to the second pump fluid passage or the second bypass fluid passage; the second pump fluid passage may be operatively connected to the first pump fluid passage or the first bypass fluid passage; the production fluid may be operatively pumped in series (FIGS. 28, 31, 41 and 44) or in parallel (FIGS. 29, 32, 42 and 45) through the first pump fluid passage and the second pump fluid passage; the first pump may comprise a first multiple stage vane pump (300); the first multiple stage vane pump may comprise a first stage (305) and a second stage (306, 307); the second stage may be operatively configured in series or in parallel with the first stage; and the first rotary actuator may be operatively driven to pump the production fluid through the first pump fluid passage in series (370) or in parallel (380) through the first stage and the second stage. The second pump may comprise a second multiple stage vane pump (310A); the second multiple stage vane pump may comprise a third stage (305A) and a fourth stage (306A, 307A); the fourth stage may be operatively configured in series or in parallel with the third stage; and the second rotary actuator may be operatively driven to pump the production fluid through the second pump fluid passage in series (370A) or in parallel (380A) through the third stage and the fourth stage.

[0016]The first motor pump housing may comprise a first control input connection (164), a first control bypass output connection (166), and conductivity (165) between the first control input connection and the first control bypass output connection; the second motor pump housing may comprise a second control input connection (164A), a second control bypass output connection (166A), and conductivity (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 installation may comprise a cable (24, 424) supplying electric power from the surface level to the second control input connection. The well installation may comprise a cable (24, 424) supplying electric power from the surface level to the first stator (124) via the second control input connection.

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

[0018]The first motor pump housing may comprise a first actuator housing section (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 section may comprise a first end portion and the first actuator may comprise a first rotor shaft (126, 226, 326) connected to the first rotor and the first rotor shaft may comprise a portion sealingly penetrating the first end portion of the first actuator housing section. The first motor pump housing may comprise a pump housing section (111, 211, 311) connected to the first actuator housing section, the first rotary fluid displacer may comprise a first pump shaft (115, 215, 315) disposed in the pump housing section, and the first pump shaft may be connected to the portion of the first rotor shaft sealingly penetrating the first end portion of the first actuator housing section for rotational movement therewith. The first end portion of the first actuator housing section may comprise a seal.

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

[0020]In another aspect, a well installation (515) is provided comprising: tubing (17) arranged in a well (18) and forming a flow channel to a surface level for fluids originating from below 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) configured and arranged to rotate relative to the first stator under the effect of a magnetic field generated by the first stator; the first rotor connected to the first rotary fluid displacer such that the first rotary actuator is operatively configured to actuate the first rotary fluid displacer; a first pump inlet port (551, 651) and a first pump outlet port (541, 641) in the first pump housing; a first pump fluid passage (570, 670, 680) between the first pump inlet port and the first pump outlet port, and the first rotary fluid displacer disposed in the first pump fluid passage; a first bypass inlet port (561, 661) and a first bypass outlet port (564, 664) in the first pump housing; a first bypass fluid passage (565, 665) between the first bypass inlet port and the first bypass outlet port; and the first pump fluid passage separate from the first bypass fluid passage; wherein the first rotary actuator is operatively driven to pump a production fluid through the first pump fluid passage.

[0021]The well installation may comprise: 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; the first rotor connected to the second rotary fluid displacer such that the first rotary actuator is operatively 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 passage (570A, 670A, 680A) between the second pump inlet port and the second pump outlet port, and the 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 separate from the second bypass fluid passage; wherein the first rotary actuator is operatively driven to pump the production fluid through the second pump fluid passage. The well installation may comprise 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 comprise a first pump shaft inlet port (534) and a first pump shaft outlet port (535) and the second pump housing may comprise a second pump shaft inlet port (534A). The well installation may comprise 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 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. The first motor housing may comprise an end portion and the shaft may comprise a portion (526) sealingly penetrating the end portion of the first motor housing. The first pump housing may be connected to the first motor housing, the first rotary fluid displacer may comprise 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 comprise 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 passage may be operatively connected to the second pump fluid passage and the production fluid may be operatively pumped in series through the first pump fluid passage and the second pump fluid passage (FIGS. 53, 59 and 61). The first pump outlet port may be operatively connected to the second pump inlet port and the second rotary fluid displacer may be operatively driven to pump the production fluid through the second pump fluid passage from the first pump fluid passage.

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

[0025]The first pump fluid passage may be operatively connected to the second pump fluid passage or the second bypass fluid passage; the second pump fluid passage may be operatively connected to the first pump fluid passage or the first bypass fluid passage; the production fluid may be operatively pumped in series or in parallel through the first pump fluid passage and the second pump fluid passage; the first pump may comprise a first multiple stage vane pump (600); the first multiple stage vane pump may comprise a first stage (610) and a second stage (611); the second stage may be operatively configured in series (670) or in parallel (680) with the first stage; and the rotary actuator may be operatively driven to pump the production fluid through the first pump fluid passage in series or in parallel through the first stage and the second stage. The second pump may comprise a second multiple stage vane pump (600A); the second multiple stage vane pump may comprise a third stage (610A) and a fourth stage (611A); the fourth stage may be operatively configured in series (670A) or in parallel (680A) with the third stage; and the rotary actuator may be operatively driven to pump the production fluid through the second pump fluid passage in series or parallel through the third stage and the fourth stage.

[0026]The well installation may comprise: 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 configured and arranged to rotate relative to the second stator under the effect 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 such that the second rotary actuator is operatively configured to actuate the first rotary fluid displacer; wherein the first rotary actuator and the second rotary actuator are operatively driven to pump the production fluid through the first pump fluid passage.

[0027]The first motor housing may comprise a first motor shaft outlet port (527) and the second motor housing may comprise a second motor shaft inlet port (528A) and a second motor shaft outlet port (527A). The well installation may comprise a shaft (526, 523, 526A) extending through the first shaft outlet port, the second shaft inlet port, and the second shaft outlet port and 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.

[0028]The well installation may comprise: 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; the first rotor may be connected to the second rotary fluid displacer such that the first rotary actuator is operatively configured to actuate the second rotary fluid displacer; the second rotor may be connected to the second rotary fluid displacer such that the second rotary actuator is operatively 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 passage (570A, 670A, 680A) between the second pump inlet port and the second pump outlet port, and the 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 separate from the second bypass fluid passage; wherein the first rotary actuator and the second rotary actuator are operatively driven to pump the production fluid through the second pump fluid passage.

[0029]The first motor housing may comprise a first motor shaft outlet port (527), the second motor housing may comprise a second motor shaft inlet port (528A) and a second motor shaft outlet port (527A), the first pump housing may comprise a first pump shaft inlet port (534) and a first pump shaft outlet port (535), and the second pump housing may comprise a second pump shaft inlet port (534A). The well installation may comprise 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 such that the first rotor, the second rotor, the first fluid displacer, and the second fluid displacer rotate together. The well installation may comprise: an intake housing (537, 637) disposed in the well between the first motor housing and the 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 the shaft may extend through the intake shaft inlet port and the intake shaft outlet port.

[0030]The well installation may comprise: an intake housing (537, 637) disposed in the well between the first motor housing and the 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 comprise an intake shaft inlet port (532) and an intake shaft outlet port (533).

[0031]The well installation may comprise: 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 operatively 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 operatively connected to the second pump inlet port in the second pump housing.

[0032]The well installation may comprise: 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 intake 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 separate 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 operatively connected to the first pump inlet port in the first pump housing and the second intake outlet port may be operatively connected to the first bypass inlet port in the first pump housing. The first bypass outlet port in the first pump housing may be operatively connected to the second pump inlet port in the second pump housing. The first intake inlet port and the second intake inlet port may comprise 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 presently disclosed subject matter and are illustrative of selected principles and teachings of the present disclosure. However, the drawings do not illustrate all possible implementations of the presently disclosed subject matter and are not intended to limit the scope of the present disclosure in any way.

[0034]FIG. 1 is a schematic vertical sectional view of an embodiment of an oil-well installation with an embodiment of an improved actuator and pump system.

[0035]FIG. 2 is an isometric partial cutaway view of the actuator and pump module shown in FIG. 1.

[0036]FIG. 3 is a first partial vertical cross-sectional view of the actuator and pump module shown in FIG. 2.

[0037]FIG. 4 is a second partial vertical cross-sectional view of the actuator and pump module shown in FIG. 2.

[0038]FIG. 5 is an enlarged partial cross-sectional view of the actuator and pump module shown in FIG. 4.

[0039]FIG. 6 is a transverse cross-sectional view of the actuator and pump module shown in FIG. 5, taken generally on line 6-6 of FIG. 5.

[0040]FIG. 7 is an isometric partial cutaway view of the top manifold block of the actuator and pump module shown in FIG. 1.

[0041]FIG. 8 is a first partial vertical cross-sectional view of the manifold block shown in FIG. 7.

[0042]FIG. 9 is a second partial vertical cross-sectional view of the manifold block shown in FIG. 7.

[0043]FIG. 10 is an isometric partial cutaway view of the bottom manifold block of the actuator and pump module shown in FIG. 1.

[0044]FIG. 11 is a first partial vertical cross-sectional view of the manifold block shown in FIG. 10.

[0045]FIG. 12 is a second partial vertical cross-sectional view of the manifold block shown in FIG. 10.

[0046]FIG. 13 is a front plan view of the controller module shown in FIG. 1.

[0047]FIG. 14 is an isometric view of the controller module shown in FIG. 13.

[0048]FIG. 15 is an isometric view of the top end of the controller module shown in FIG. 14.

[0049]FIG. 16 is an isometric view of the bottom end of the controller module shown in FIG. 14.

[0050]FIG. 17 is a schematic view of the controller board of the controller module shown in FIG. 14.

[0051]FIG. 18 is a schematic view of a two unit actuator and pump downhole drive system in accordance with FIG. 3 in a serial pump configuration.

[0052]FIG. 19 is a schematic view of the two unit actuator and pump downhole drive system shown in FIG. 14 in a parallel pump configuration.

[0053]FIG. 20 is a schematic view of at least a four unit actuator and pump downhole drive system in accordance with FIG. 3 in a combined serial and parallel pump configuration.

[0054]FIG. 21 is an isometric partial cutaway view of a first alternative embodiment of the actuator and pump module shown in FIG. 2.

[0055]FIG. 22 is a first partial vertical cross-sectional view of the first alternative actuator and pump module shown in FIG. 21.

[0056]FIG. 23 is a second partial vertical cross-sectional view of the first alternative actuator and pump module shown in FIG. 21.

[0057]FIG. 24 is an enlarged partial cross-sectional view of the first alternative actuator and pump module shown in FIG. 23.

[0058]FIG. 25 is a first partial vertical cross-sectional view of a second alternative embodiment of the actuator and pump module shown in FIG. 2.

[0059]FIG. 26 is a second partial vertical cross-sectional view of the second alternative actuator and pump module shown in FIG. 25.

[0060]FIG. 27 is an enlarged partial cross-sectional view of the second alternative actuator and pump module shown in FIG. 26.

[0061]FIG. 28 is a schematic view of a two unit actuator and pump downhole drive system in accordance with FIG. 25 in a serial stage and serial pump configuration.

[0062]FIG. 29 is a schematic view of the two unit actuator and pump downhole drive system shown in FIG. 28 in a parallel pump configuration.

[0063]FIG. 30 is a schematic view of at least a four unit actuator and pump downhole drive system in accordance with FIG. 25 in a serial stage and a combined serial and parallel pump configuration.

[0064]FIG. 31 is a schematic view of a two unit actuator and pump downhole drive system in accordance with FIG. 25 in a parallel stage and serial pump configuration.

[0065]FIG. 32 is a schematic view of the two unit actuator and pump downhole drive system shown in FIG. 31 in a parallel pump configuration.

[0066]FIG. 33 is a schematic view of at least a four unit actuator and pump downhole drive system in accordance with FIG. 25 in a parallel stage and a combined serial and parallel pump configuration.

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

[0068]FIG. 35 is a schematic view of a controller logic for a multiple unit actuator and pump system in a serial pump configuration and a master control configuration.

[0069]FIG. 36 is a schematic view of a controller logic for a multiple unit actuator and pump system in a parallel pump configuration and a master control configuration.

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

[0071]FIG. 38 is a schematic view of a surface pressure managed controller logic for a multiple unit actuator and pump system in a serial pump configuration and a master control configuration.

[0072]FIG. 39 is a schematic vertical sectional view of an alternative embodiment of an oil-well installation with an alternative embodiment of an improved actuator and pump system.

[0073]FIG. 40 is an isometric partial cutaway schematic view of the flow direction of two linked actuator and pump modules in the topside drive system of FIG. 39.

[0074]FIG. 41 is a schematic view of a two unit actuator and pump topside drive system in accordance with FIG. 2 in a serial pump configuration.

[0075]FIG. 42 is a schematic view of the two unit actuator and pump topside drive system shown in FIG. 41 in a parallel pump configuration.

[0076]FIG. 43 is a schematic view of at least a four unit actuator and pump topside drive system in accordance with FIG. 2 in a combined serial and parallel pump configuration.

[0077]FIG. 44 is a schematic view of a two unit actuator and pump topside drive system in accordance with FIG. 25 in a serial stage and serial pump configuration.

[0078]FIG. 45 is a schematic view of the two unit actuator and pump topside drive system shown in FIG. 44 in a parallel pump configuration.

[0079]FIG. 46 is a schematic view of at least a four unit actuator and pump topside drive system in accordance with FIG. 25 in serial stage and a combined serial and parallel pump configuration.

[0080]FIG. 47 is a schematic view of a two unit actuator and pump topside drive system in accordance with FIG. 25 in a parallel stage and serial pump configuration.

[0081]FIG. 48 is a schematic view of the two unit actuator and pump topside drive system shown in FIG. 47 in a parallel pump configuration.

[0082]FIG. 49 is a schematic view of at least a four unit actuator and pump topside drive system in accordance with FIG. 25 in parallel stage and a combined serial and parallel pump configuration.

[0083]FIG. 50 is a schematic vertical sectional view of a second alternative embodiment of an oil-well installation with a second alternative embodiment of an improved actuator and pump system.

[0084]FIG. 51 is a partial vertical cross-sectional view of an actuator module shown in FIG. 50.

[0085]FIG. 52 is a partial vertical cross-sectional view of a pump module shown in FIG. 50.

[0086]FIG. 53 is a schematic view of a two actuator unit and two pump unit system in accordance with FIG. 50 in a serial pump configuration.

[0087]FIG. 54 is a schematic view of the two actuator unit and two pump unit system shown in FIG. 53 in a parallel pump configuration.

[0088]FIG. 55 is a schematic view of a two actuator unit and one pump unit system in the well shown in FIG. 50.

[0089]FIG. 56 is a schematic view of a one actuator unit and two pump unit system in the well shown in FIG. 50.

[0090]FIG. 57 is a schematic view of a two actuator unit and one multiple stage pump unit system in the well shown in FIG. 50 in a serial stage configuration.

[0091]FIG. 58 is a schematic view of the two actuator unit and one multiple stage pump unit system shown in FIG. 57 in a parallel stage configuration.

[0092]FIG. 59 is a schematic view of a two actuator unit and two multiple stage pump unit system in the well shown in FIG. 50 in a serial stage configuration and serial pump configuration.

[0093]FIG. 60 is a schematic view of the two actuator unit and two multiple stage pump unit system shown in FIG. 59 in a serial stage and parallel pump configuration.

[0094]FIG. 61 is a schematic view of the two actuator unit and two multiple stage pump unit system shown in FIG. 59 in a parallel stage and serial pump configuration.

[0095]FIG. 62 is a schematic view of the two actuator unit and two multiple stage pump unit system shown in FIG. 59 in a parallel stage and parallel pump configuration.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0096]At the outset, it should be clearly understood that like reference numerals are intended to identify the same structural elements, portions or surfaces consistently throughout the several drawing figures, as such elements, portions or surfaces may be further described or explained by the entire written specification, of which this detailed description is an integral part. Unless otherwise indicated, the drawings are intended to be read (e.g., crosshatching, arrangement of parts, proportion, degree, etc.) together with the specification, and are to be considered a portion of the entire written description of this invention. As used in the following description, the terms “horizontal”, “vertical”, “left”, “right”, “up” and “down”, as well as adjectival and adverbial derivatives thereof (e.g., “horizontally”, “rightwardly”, “upwardly”, etc.), simply refer to the orientation of the illustrated structure as the particular drawing figure faces the reader. Similarly, the terms “inwardly” and “outwardly” generally refer to the orientation of a surface relative to its axis of elongation, or axis of rotation, as appropriate.

[0097]It is to be understood that the specific assemblies and systems illustrated in the attached drawings and described in the following specification are simply exemplary embodiments. Hence, specific dimensions, directions, or other physical characteristics relating to the embodiments disclosed are not to be considered as limiting, unless expressly stated otherwise in a claim. Also, although they may not be, like elements in various embodiments described herein may be commonly referred to with like reference numerals within this section of the application.

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

[0099]Where they are used herein, the terms “first,” “second,” and so forth, do not necessarily denote any ordinal, sequential or priority relation, but are simply used to distinguish one element or set of elements more clearly from another element or set of elements, unless specified otherwise.

[0100]Referring now to the drawings, and more particularly to FIG. 1, an oil well pump and electric motor system is provided, a first embodiment of which is generally indicated at 15. As shown, a well hole extends from the surface level to a point below ground. The well hole is lined with casing 16 to form well bore 18 that includes perforations providing fluid communication between well bore 18 and a hydrocarbon-bearing formation there around. Pump system 15 is disposed at the bottom of well bore 18 and is provided to artificially lift production fluid from well bore 18 through tubing string 17 to a collection point at the surface.

[0101]Pump system 15 may generally comprises one or more control units 95 and one or more pump units 100, 200 and/or 300 with connected manifold ends 140, 150, 240, 250, 340, 350. In the embodiment shown in FIG. 1, pump system 15 includes control unit 95, pump unit 100 and connected manifold ends 140 and 150. Control unit 95 is connected by lines 23 and 24 to surface controller 20. Signals and commands are communicated by signal cable 23, which extends from controller cabinet 20 at the surface of well 18 to control electronics in control unit 95. Power is communicated by power cable 24, which extends from surface controller 20 at the surface of well 18 to drive electronics in control unit 95.

[0102]Referring now to FIGS. 2-20, a single stage vane pump example embodiment of a positive displacement pump unit is general indicated at 100. In this embodiment, pump unit 100 generally comprises single stage vane pump 110 driven by electric motor 120, all of which are contained in cylindrical unit 101. Cylindrical unit housing 101 comprises pump housing section 111 containing pump 110 and motor housing section 121 containing motor 120. Distribution manifold blocks 140 and 150 are provided at either end of housing 101 such that multiple control units 95 and pump units 100 may be stacked coaxially with a production fluid flow path arranged in series or in parallel to provide the desired level of lift as further described below.

[0103]In this embodiment, vane pump 110 generally comprises centrically supported rotor 114 having radially extending vanes 113 that rotate in pump ring 117 when rotor 114 is driven by connected motor 120. Vanes 113 may have variable lengths and may 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, such rotary motion of vanes 113 carries fluid from the inlet of the pump to the outlet of the pump. Pump unit 100 has inlet 151 of connected manifold block 150 and outlet 141 of connected manifold block 140 and fluid passage 170 therebetween. In normal operation, production fluid is directed to flow in through inlet 151 of connected manifold block 150 and, via fluid passage 170, through the inlet port of the pump to vanes 113, and then through the outlet port of the pump and, via fluid passage 170, out through outlet 141 of connected manifold block 140.

[0104]Motor 120 is a brushless D.C. variable-speed servo-motors that is supplied with a current. The speed and output of pump unit 100 is variable with variations in the speed of motor 120. Solid shaft 115 of pump rotor 114 of pump 110 is connected to solid output shaft 126 of electric motor 120. Motor 120 has inner rotor 125 with permanent magnets and outer non-rotating stator 124 with coil windings. Stator 124 is fixed to first motor housing section 121 such that stator 124 does not rotate relative to housing 121. When current is appropriately applied through the coils of stator 124, a magnetic field is induced. The magnetic field interaction between stator 124 and rotor 125 generates torque which may rotate the output shaft 126. Accordingly, motor 120 will selectively apply a torque on shaft 126 about axis x-x at varying speeds.

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

[0106]Pump unit 100 includes bypass channel 160, which is separate from fluid passage 170 through pump 110, and bypass power and command connection 165 for passing data, commands, and power to lower units in the production line. Bypass passage 160 comprises bypass inlet 161 in manifold block 150 and 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 comprises bypass input connection 167 in manifold block 140 and bypass output connection 166 in manifold block 150. Manifold block 150 and bypass inlet 161 and output connection 166 are disposed at the bottom end of housing 601 and manifold block 140 and bypass outlet 162 and input connection 167 are disposed at the top end of housing 601. While in this embodiment bypass passage 160 is shown as a conduit, alternative passages may be used. For example, a partitioned volume of the interior of housing 101 may be used to provide the bypass passage.

[0107]With reference to FIGS. 13-17, rotary actuator or motor 120 is powered by motor control unit 95 having motor drive 33 connected to electric cable 24 extending from controller cabinet 20 at the surface to provide power and data to input connection 86 of control unit 95 at the bottom of well bore 18. The power then supplied from control unit 95, via output connection 84 of control unit 95 and input connection 164 of connected manifold block 140 to pump unit 100, generates a magnetic field within the respective coils of stator 124, which in turn imparts a rotary force on magnetic rotor 125 and actuator shaft 126, and in turn pump shaft 115 and rotor 114 with vanes 113. Vanes 113 are thereby rotated to enable fluids to be lifted with such rotation towards the surface of well 18.

[0108]As shown, control unit 95 generally comprises control electronics contained in cylindrical housing 96. Cylindrical housing 96 comprises electric and fluid connection blocks 40 and 50 at either end of housing 96. In this embodiment, control unit 95 provides fluid, data, and power connectivity for pump unit 100 so as to allow multiple control units and pump units to be stacked coaxially with a production fluid flow path arranged in series or in parallel to provide the desired level of lift as further described below and with power and data communications provided in a master or a parallel configuration as further described below. Control unit 95 includes fluid inlet 51 and fluid outlet 41 and fluid passage 70 therebetween. Control unit 95 also includes fluid inlet 61 and fluid outlet 62 and fluid passage 60 therebetween, which is separate from fluid passage 70. Connection block 50 with fluid inlets 51 and 61 are disposed at the bottom end of housing 96 and connection block 40 with fluid outlets 41 and 62 are disposed at the top end of housing 96. In normal operation, production fluid from pump unit 100 may be directed to flow in through inlet port 51 and, via fluid passage 70, out through outlet port 41. Production fluid from pump unit 100 may also be directed to flow in through inlet port 61 and, via fluid passage 60, out through outlet port 62.

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

[0110]Referring now to FIG. 17, controller unit 95 includes communication board 30, master board 31, actuator control board 32, and actuator driver 33. Communication board 30 is configured to provide the data communication interface with surface controller 20 and/or other controller units, such as controller unit 95A shown in FIGS. 18 and 19 or controller unit 95C shown in FIG. 20. Communications board 30 communicates data, commands, and states, including to master controller 31. Controller 31 controls and supervises operation of pump unit 100, including the control of power to actuator 120 via driver 33. Controller 32 and driver 33 control and provide power to actuator 120. In the dual configuration of FIGS. 18 and 19, 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, master controller 31A of controller 95A also has the capacity to control and instruct motor controller 95.

[0111]As shown in FIGS. 18-20 by way of example and without limitation, with bypass conduit 160 and bypass power and command connection 165, multiple pump units 100, 100A, 100B and 100C and corresponding control units 95, 95A, 95B and 95C may be stacked coaxially with a production fluid flow path 19 arranged in series or in parallel or in a combination to provide the desired level of lift as further described below. Pump units 100A, 100B and 100C have the same general configuration as pump unit 100 described above. Controller units 95A, 95B and 95C have the same general configuration as controller unit 95 described above.

[0112]As shown in FIG. 18, two pump units 100 and 100A with their respective top side control units 95 and 95A, respectively, may be stacked in a serial pumping configuration in which the pumping action is summed to provide for an increased lift pressure. As shown, pump outlet port 141 of pump unit 100 is connected to pump inlet port 151A of pump unit 100A, via control unit fluid passage 70. In this way, pump fluid passages 170 and 170A are connected to provide serial pumping action.

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

[0114]A four pump unit combination serial and parallel configuration is shown in FIG. 20. As shown in FIG. 20, pump units 100 and 200 with their respective top side control units 95 and 195 are stacked in a serial pumping configuration. As shown, pump outlet port 141 of pump unit 100 is connected to pump inlet port 151A of pump unit 100A, via control unit fluid passage 70. In this way, pump fluid passages 170 and 170A are connected to provide serial pumping action. Pump units 100B and 100C with their respective top side control units 95B and 95C are also stacked in a serial pumping configuration. As shown, pump outlet port 141B of pump unit 100B is connected to pump inlet port 151C of pump unit 100C, via control unit fluid passage 70B. In this way, pump fluid passages 170B and 170C are connected to provide serial pumping action.

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

[0116]Referring now to FIGS. 21-24, a screw pump example embodiment of a positive displacement pump unit is general indicated at 200. Pump unit 200 generally comprises screw pump 210 driven by electric motor 220, all of which are contained in cylindrical housing 201. Cylindrical housing 201 comprises pump housing section 211 containing pump 210 and motor housing section 221 containing motor 220. Distribution manifold blocks 240 and 250 are provided at either end of housing 201 such that multiple control units 95 and pump units 200 may be stacked coaxially with a production fluid flow path arranged in series or in parallel to provide the desired level of lift as further described below.

[0117]In this embodiment, screw pump 210 is a two-port screw pump and generally comprises three meshed rotors or screws 212, 213 and 214. Screws 212 and 213 are driven or idler screws, and screw 214 is a drive or power screw driven by electric motor 220. Motor pump unit 200 has pump inlet 251 of connected manifold block 250 and pump outlet 241 of connected manifold block 240 and fluid passage 270 therebetween. In normal operation, production fluid is directed to flow in through inlet 251 of connected manifold block 250 and, via fluid passage 270, through the inlet port of pump 210 to gaps between interlocking screws 212, 213 and 214, and then through the outlet port of pump 210 and, via fluid passage 270, out through outlet 241 of connected manifold block 240.

[0118]Motor 220 is a brushless D.C. variable-speed servo-motors that is supplied with a current. The speed and output of pump unit 200 is variable with variations in the speed of motor 220. Solid shaft 215 of drive screw 214 of pump 210 is connected to solid output shaft 226 of electric motor 220. Motor 220 has inner rotor 225 with permanent magnets and outer non-rotating stator 224 with coil windings. Stator 224 is fixed to first motor housing section 221 such that stator 224 does not rotate relative to housing 221. When current is appropriately applied through the coils of stator 224, a magnetic field is induced. The magnetic field interaction between stator 224 and rotor 225 generates torque which may rotate the output shaft 226. Accordingly, motor 220 will selectively apply a torque on shaft 226 about axis x-x at varying speeds.

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

[0120]Pump unit 200 includes bypass channel 260, which is separate from fluid passage 270 through screws 212, 213 and 214, and a bypass power and command connection for passing data, commands, and power to lower units in the production line. Bypass passage 260 comprises bypass inlet 261 in manifold block 250 and 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 connection comprises bypass input connection 267 in manifold block 240 and bypass output connection 266 in manifold block 250. Manifold block 250 and bypass inlet 261 and output connection 266 are disposed at the bottom end of housing 201 and manifold block 240 and bypass outlet 262 and input connection 267 are disposed at the top end of housing 201. While in this embodiment bypass passage 260 is shown as a conduit, alternative passages may be used. For example, a partitioned volume of the interior of housing 201 may be used to provide the bypass passage.

[0121]As with motor 120, rotary actuator or motor 220 may be powered by motor control unit 95 having motor drive 33 connected to electric cable 24 extending from controller cabinet 20 at the surface to provide power and data to input connection 86 of control unit 95 at the bottom of well bore 18. The power then supplied from control unit 95, via output connection 84 of control unit 95 and input connection 264 of connected manifold block 240 to pump unit 200, generates a magnetic field within the respective coils of stator 224, which in turn imparts a rotary force on magnetic rotor 225 and actuator shaft 226, and in turn drive screw 214 and driven screws 212 and 213. Screws 212 and 213 are thereby counterrotated towards each other to enable fluids to be lifted with such rotation towards the surface of well 18.

[0122]With bypass conduit 260 and the bypass power and command connection, multiple screw pump units 200 and corresponding control units 95 may be stacked coaxially with a production fluid flow path 19 arranged in series or in parallel or in a combination to provide the desired level of lift as further described below. For example, and without limitation, multiple screw pump units 200 and corresponding control units 95 may be stacked coaxially in the configurations shown in FIGS. 18-20 to provide serial flow, parallel flow, or a combination of serial and parallel flow as desired.

[0123]Referring now to FIGS. 25-27, a multiple stage vane pump example embodiment of a pump unit is general indicated at 300. Pump unit 300 generally comprises multiple stage vane pump 310 driven by electric motor 320, all of which are contained in cylindrical housing 301. Cylindrical housing 301 comprises pump housing section 311 containing pump stages 305, 306 and 307 and motor housing section 321 containing motor 320. Distribution manifold blocks 340 and 350 may be provided at either end of housing 301 such that multiple control units 95 and pump units 300 may be stacked coaxially with a production fluid flow path arranged in series or in parallel to provide the desired level of lift as further described below.

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

[0125]Motor 320 is a brushless D.C. variable-speed servo-motors that is supplied with a current. The speed and output of pump system 300 is variable with variations in the speed of motor 320. Solid shaft 315 of pump rotors 312, 313 and 314 of pump 310 is connected to solid output shaft 326 of electric motor 320. Motor 320 has inner rotor 325 with permanent magnets and outer non-rotating stator 324 with coil windings. Stator 324 is fixed to first motor housing section 321 such that stator 324 does not rotate relative to housing 301. When current is appropriately applied through the coils of stator 324, a magnetic field is induced. The magnetic field interaction between stator 324 and rotor 325 generates torque which may rotate the output shaft 326. Accordingly, motor 320 will selectively apply a torque on shaft 326 about axis x-x at varying speeds.

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

[0127]Pump unit 300 includes bypass channel 360, which is separate from fluid passage 370 through pump stages 305, 306 and 307, and bypass power and command connection 365 for passing data, commands, and power to lower units in the production line. Bypass passage 360 comprises bypass inlet 361 in manifold block 350 and 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 comprises bypass input connection 367 in manifold block 340 and bypass output connection 366 in manifold block 350. Manifold block 350 and bypass inlet 361 and output connection 366 are disposed at the bottom end of housing 301 and manifold block 340 and bypass outlet 362 and input connection 367 are disposed at the top end of housing 301.

[0128]As with motors 120 and 220, rotary actuator or motor 320 may be powered by motor control unit 95 having motor drive 33 connected to electric cable 24 extending from controller cabinet 20 at the surface to provide power and data to input connection 86 of control unit 95 at the bottom of well bore 18. The power then supplied from control unit 95, via output connection 84 of control unit 95 and input connection 364 of connected manifold block 340 to pump unit 300, generates a magnetic field within the respective coils of stator 324, which in turn imparts a rotary force on magnetic rotor 325 and actuator shaft 326, and in turn pump rotors 312, 313 and 314. The vanes of pump rotors 312, 313 and 314 are thereby rotated to enable fluids to be lifted with such rotation towards the surface of well 18.

[0129]Pump unit 300 may be configured and ported to provide serial fluid passage 370 and serial flow through stages 305, 306 and 307 or alternatively may be configured and ported to provide parallel fluid passage 380 and parallel flow through stages 305, 306 and 307, as further described below with reference to FIGS. 28-33.

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

[0131]As shown in FIG. 28, pump units 300 and 300A with their respective top side control units 95 and 95A, respectively, may be stacked in a serial pumping configuration in which the pumping action of each pump unit is summed to provide for a further increased lift pressure. As shown, pump outlet port 341 of pump unit 300 is connected to pump inlet port 351A of pump unit 300A, via control unit fluid passage 70. In this way, pump fluid passages 370 and 370A are connected to provide serial pumping action.

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

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

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

[0135]As shown in FIGS. 31-33, with pump stages 305, 306 and 307 arranged to provide parallel flow passage 380, and with bypass conduit 360 and bypass power and command connection 365, multiple pump units 300, 300A, 300B and 300C and corresponding control units 95, 95A, 95B and 95C may be stacked coaxially with a production fluid flow path 19 arranged in series or in parallel or in a combination to provide the desired level of lift as further described below. Pump units 300A, 300B, and 300C have the same general configuration as pump unit 300 described above, but with stages 305, 306 and 307 in a parallel pump stage configuration to provide parallel fluid passage 380. As shown in FIG. 31, in this parallel pump stage configuration, stages 305, 306 and 307 of pump 300 are ported in a parallel stage pumping configuration in which the pumping action of each stage 305, 306 and 307 of the pumping unit is independent of the others to provide three times the volume of a single stage pump unit. As shown, in this parallel stage pumping configuration, fluid passage 380 extends through each of stages 305, 306 and 307 in parallel, extending from pump inlet port 351 to each of the inputs of each of first stage 305, second stage 306 and third stage 307, in parallel, through each of the respective vanes of rotor 312, 313 and 314 in parallel, and from the output of each of first stage 305, second stage 306 and third stage 307 to pump outlet port 341. Fluid passages 380A, 380B and 380C of pump units 300A, 300B, and 300C in FIGS. 31-33 have the same general parallel configuration as fluid passage 380 of pump unit 300 in FIG. 31 described above.

[0136]As shown in FIG. 31, pump units 300 and 300A with their respective top side control units 95 and 95A, respectively, may be stacked in a serial unit pumping configuration in which the pumping action of each pump unit is summed to provide for a further increased lift pressure. As shown, pump outlet port 341 of pump unit 300 is connected to pump inlet port 351A of pump unit 300A, via control unit fluid passage 70. In this way, pump fluid passages 380 and 380A are connected to provide serial unit pumping action.

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

[0138]A four pump unit combination serial and parallel configuration with a parallel stage pumping configuration is shown in FIG. 33. As shown in FIG. 33, pump units 300 and 300A with their respective top side control units 95 and 95A are stacked in a serial unit pumping configuration. As shown, pump outlet port 341 of pump unit 300 is connected to pump inlet port 351A of pump unit 300A, via control unit fluid passage 70. In this way, pump fluid passages 380 and 380A are connected to provide parallel stage and serial unit pumping action. Pumps 300B and 300C with their respective top side control units 95B and 95C are also stacked in a serial unit pumping configuration. As shown, pump outlet port 341B of pump unit 300B is connected to pump inlet port 351C of pump unit 300C, via control unit fluid passage 70B. In this way, pump fluid passages 380B and 380C are connected to provide parallel stage and serial unit pumping action.

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

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

[0141]Pump systems 100, 200 and 300 may include several sensors for monitoring pump and motor operations, such as pressure transducer 499, and may receive commands from the surface. Such signals and commands are communicated by signal cable 23, which extends from control electronics in control unit 95, via input connection 86 to controller cabinet 20 at the surface of well 18. Controller 31 provides motor control board 32 and driver 33 with command signals to properly drive pump unit 100, 200 or 300. The motor control electronics of controller unit 95 may all be contained in housing 96 designed to provide protection from the surrounding environment.

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

[0143]FIG. 35 is a controller logic for a multiple unit actuator and pump system in a serial pump configuration and a master control configuration. As shown, master control unit 95B receives a flow rate command (Q*) and outputs a flow rate (Q) to each pump in the serial configuration and the controller logic for each control unit includes a delay function, 36A and 36B, by which the pumps above the lowest most pump are delayed from pumping as a function of input pressure (P) and position above the lower most pump so as to prime the system. Accordingly, with reference to FIG. 35, middle module 95A provides a delay relative to lower most module 95, and top module 95B provides a delay relative to middle module 95A.

[0144]FIG. 36 is a controller logic for a multiple unit actuator and pump system in a parallel pump configuration and a master control configuration. As shown, master control unit 95B outputs a flow rate (Q) that is 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 in this embodiment a delay function.

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

[0146]FIG. 38 is a schematic view of a surface pressure managed controller logic for a multiple unit actuator and pump system in a serial pump configuration and a master control configuration. As shown, downhole pressure transducer(s) 499 provide feedback to surface control unit 20, and surface control unit 20 provides a pressure command (P) to top-most module 95B. The commands from master downhole controller 95B are in turn provided as pressure commands and, in a series pump configuration, are a function of the number of pump units (n) in the series.

[0147]Referring now to FIG. 39, a top unit driven second example embodiment of an oil well pump and electric motor system is generally indicated at 415. As in system 15, a well hole extends from the surface level to a point below ground and the well hole is lined with casing 16 to form well bore 18 that includes perforations providing fluid communication between well bore 18 and a hydrocarbon-bearing formation there around. Pump system 415 is disposed at the bottom of well bore 18 and is provided to artificially lift production fluid from well bore 18 through tubing string 17 to a collection point at the surface. However, in this embodiment, the motor control and drive electronics for the pump units are contained in controller cabinet 420 at the surface of well 18 and not in a downhole control unit 95. Drive power is communicated by power cable 424, which extends from surface controller 420 at the surface of well 18 directly to motors 120, 220, and/or 320 below the surface. Pump system 415 thus generally comprises topside control and drive electronics 433 and one or more downhole pump units 100, 200 and/or 300 with connected manifold ends 140, 150, 240, 250, 340 and/or 350.

[0148]FIGS. 18-20 show example stacking arrangements of pumps 100, 100A, 100B and 100C in the pump system 15 shown in FIG. 1. FIGS. 40-43 show the same example stacking arrangements of pumps 100, 100A, 100B and 100C of FIGS. 18-20, but in the top controlled system 415 shown in FIG. 39. Thus, such arrangements do not include control units 95, 95A, 95B and 95C. As shown in FIGS. 40-43, with bypass conduit 160 and bypass power connection 165, in system 415 multiple pump units 100, 100A, 100B and 100C may be stacked directly together coaxially with a production fluid flow path 19 arranged in series or in parallel or in a combination to provide the desired level of lift as further described below.

[0149]Thus, as shown in FIGS. 40 and 41, two of pump units 100 and 100A may be stacked directly in a serial pumping configuration in which the pumping action is summed to provide for an increased lift pressure. As shown, pump outlet port 141 of pump unit 100 is connected directly to pump inlet port 151A of pump unit 100A. Motor input connection 164A of pump unit 100A is connected directly to drive line 424 from surface controller 420 to thereby connect power from driver 433 to motor 120A of pump unit 100A, bypass input connection 167 of bypass 165A of pump unit 100A is also connected directly to drive line 424 from surface controller 420, and bypass output connection 166A of bypass 165A of pump unit 100A is connected directly to at least motor input connection 164 of pump unit 100 to thereby connect power from driver 433 to motor 120 of pump unit 100 via bypass connection 165A of pump unit 100A.

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

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

[0152]Motor input connection 164C of pump unit 100C is connected directly to drive line 424 from surface controller 420 to thereby connect power from driver 433 to motor 120C of pump unit 100C. Bypass input connection 167C of bypass 165C of pump unit 100C is also connected directly to drive line 424 from surface controller 420, and bypass output connection 166C of bypass 165C of pump unit 100C is connected directly to motor input connection 164B of pump unit 100B to thereby connect power from driver 433 to motor 120B of pump unit 100B via bypass connection 165C of pump unit 100C. Bypass input connection 167B of bypass 165B of pump unit 100B is also connected directly to bypass output connection 166C of bypass 165C of pump unit 100C, and bypass output connection 166B of bypass 165B of pump unit 100B is connected directly to motor input connection 164A of pump unit 100A to thereby connect power from driver 433 to motor 120A of pump unit 100A via bypass connections 165B and 165C of pump units 100B and 100C, respectively. Bypass input connection 167A of bypass 165A of pump unit 100A is also connected directly to bypass output connection 166B of bypass 165B of pump unit 100B, and bypass output connection 166A of bypass 165A of pump unit 100A is connected directly to at least motor input connection 164 of pump unit 100 to thereby connect power from driver 433 to motor 120 of pump unit 100 via bypass connections 165A, 165B and 165C of 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, bypass outlet port 162 of pump unit 100 is connected directly to bypass inlet port 161A of pump unit 100A. In this way, bypass fluid passages 160 and 160A are connected. Bypass outlet port 162B of pump unit 100B is connected directly to bypass inlet port 161C of pump unit 100C. In this way, bypass fluid passages 160B and 160C are connected. However, pump outlet port 141A of pump unit 100A is connected directly to bypass inlet port 161B of pump unit 100B, and pump inlet port 151B of pump unit 100B is connected directly to bypass outlet port 162A of pump unit 100A. In this way, bypass fluid passages 160 and 160A of pump units 100 and 100A are connected to pump fluid passages 170B and 170C of pump units 100B and 100C and pump fluid passages 170 and 170A of pump units 100 and 100A are connected to bypass fluid passages 160B and 160C of pump units 100B and 100C, respectively.

[0154]FIGS. 28-30 show example stacking arrangements of pumps 300, 300A, 300B and 300C in the pump system 15 shown in FIG. 1 and a serial pump stage orientation. FIGS. 44-46 show the same example stacking arrangements of pumps 300, 300A, 300B and 300C of FIGS. 28-30, but in the top controlled system 415 shown in FIG. 39. Thus, such arrangements do not include control units 95, 95A, 95B and 95C. As shown in FIGS. 44-46, with pump stages 305, 306 and 307 arranged to provide series flow passage 370, and with bypass conduit 360 and bypass power connection 365, in system 415 multiple pump units 300, 300A, 300B and 300C may be stacked directly together coaxially with a production fluid flow path 19 arranged in series or in parallel or in a combination to provide the desired level of lift as further described below. Thus, as shown in FIG. 44, pump units 300 and 300A may be configured in a serial stage orientation and stacked directly in a serial pumping configuration in which the pumping action of each pump stage and pump unit is summed to provide for a further increased lift pressure. As shown, stages 305, 306 and 307 of pump unit 300 are in a serial stage configuration, stages 305A, 306A and 307A of pump unit 300A are also in a serial stage configuration, and pump outlet port 341 of pump unit 300 is connected directly to pump inlet port 351A of pump unit 300A. In this way, pump fluid passages 370 and 370A are connected to provide serial pump stage and serial unit pumping action.

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

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

[0157]A four pump unit direct combination serial and parallel configuration with a serial stage pumping configuration is shown in FIG. 46. As shown in FIG. 46, pump units 300 and 300A may be configured in a serial stage orientation and stacked directly in a serial unit pumping configuration. As shown, pump outlet port 341 of pump unit 300 is connected directly to pump inlet port 351A of pump unit 300A. In this way, pump fluid passages 370 and 370A are connected to provide both serial pump stage and serial unit pumping action. Pumps 300B and 300C may also be configured in a serial stage orientation and stacked directly in a serial pumping configuration. As shown, pump outlet port 341B of pump unit 300B is connected directly to pump inlet port 351C of pump unit 300C. In this way, pump fluid passages 370B and 370C are connected to provide both serial pump stage and serial unit pumping action.

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

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

[0160]FIGS. 31-33 show example stacking arrangements of pumps 300, 300A, 300B and 300C in the pump system 15 shown in FIG. 1 and in a parallel pump stage orientation. FIGS. 47-49 show the same example stacking arrangements of pumps 300, 300A, 300B and 300C of FIGS. 31-33, but in the top controlled system 415 shown in FIG. 39. Thus, such arrangements do not include control units 95, 95A, 95B and 95. As shown in FIGS. 47-49, with pump stages 305, 306 and 307 arranged to provide parallel flow passage 380, and with bypass conduit 360 and bypass power connection 365, in system 415 multiple pump units 300A, 300B, 300C and 300D may be stacked directly coaxially with a production fluid flow path 19 arranged in series or in parallel or in a combination to provide the desired level of lift as further described below. Thus, as shown in FIG. 47, pump units 300 and 300A may be configured in a parallel stage orientation and stacked directly in a serial pumping configuration in which the pumping action of each pump unit is summed to provide for a 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 connected directly to pump inlet port 351A of pump unit 300A,. In this way, pump fluid passages 380 and 380A are connected to provide parallel pump stage and serial unit pumping action.

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

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

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

[0164]Referring now to FIG. 50, a top unit driven third example embodiment of an oil well pump and electric motor system is generally indicated at 515. As in system 15 and 415, a well hole extends from the surface level to a point below ground and the well hole is lined with casing 16 to form well bore 18 that includes perforations providing fluid communication between well bore 18 and a hydrocarbon-bearing formation there around. Pump system 515 is disposed at the bottom of well bore 18 and is provided to artificially lift production fluid from well bore 18 through 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 controller cabinet 420 at the surface of well 18 and not 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 comprises separate stackable motor units and separate stackable pump units that may be stacked in different configurations with separate stackable intake units. For example, as shown in FIG. 1, system 515 may comprise 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 communicated by power cable 424, which extends from surface controller 420 at the surface of well 18 directly to motors 520A and 520 below the surface. Pump system 515 thus generally comprises 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]Referring now to FIG. 51, an example embodiment of a modular motor unit is general indicated at 590. Motor unit 590 generally comprises motor 520 which is contained in cylindrical housing 591. In this embodiment, motor 520 generally comprises a brushless D.C. variable-speed servo-motors that is supplied with a current. Motor 520 has inner rotor 525 with permanent magnets and outer non-rotating stator 524 with coil windings. Stator 524 is fixed to housing 591 such that stator 524 does not rotate relative to housing 591. When current is appropriately applied through the coils of stator 524, a magnetic field is induced. The magnetic field interaction between stator 524 and rotor 525 generates torque which may rotate output shaft 526. Accordingly, motor 520 will selectively apply a torque on shaft 526 about axis x-x at varying speeds. Housing 591 of motor unit 590 also includes shaft input coupling port 528, to which a drive shaft of a downstream motor unit may be rotationally coupled to shaft end 523 of rotor 525, for example, and shaft output coupling port 527, to which drive shaft 529 to pump unit 500 upstream from motor unit 590 may be rotationally coupled to shaft end 526 of rotor 525, for example. Shaft input coupling port 528 is disposed at the bottom end of housing 591 and shaft output coupling port 527 is disposed at the top end of housing 591. Motor 520 may be powered by drive line 424 extending from surface controller 420 at the surface to provide power and data to motor unit 595 at the bottom of well bore 18. The power then supplied from controller 420 to motor unit 590 generates a magnetic field within the respective coils of stator 524, which in turn imparts a rotary force on magnetic rotor 525 and actuator shaft 526, and in turn any coupled pump units 500 such that the vanes of pump rotor 512 are thereby rotated to enable fluids to be lifted with such rotation towards the surface of well 18, for example.

[0166]Referring now to FIG. 52, an example embodiment of a modular pump unit is general indicated at 500. Pump unit 500 generally comprises single stage vane pump 510 which is contained in cylindrical housing 501. In this embodiment, vane pump 510 generally comprises rotor 512, which has radially extending vanes that rotate in pump ring 502 with rotation of shaft 509. When the vanes attached to pump rotor 512 are rotationally drive, such rotary motion of the vanes carries fluid from the inlet of the pump unit to the outlet of the pump unit. Housing 501 of pump unit 500 has pump inlet 551 and pump outlet 541 and fluid passage 570 therebetween. In normal operation, production fluid is directed to flow in through inlet 551 and, via fluid passage 570, to the vanes of rotor 512 of pump 510, and, via fluid passage 570, out through outlet 541. Thus, pump unit 500 includes pump inlet 551 for receiving production or well fluids, and pump outlet 541 for outputting well fluids at a higher pressure than pump inlet 551. Pump unit inlet 551 is disposed at the bottom end of housing 501 and pump unit outlet 541 is disposed at the top end of housing 501. Accordingly, pump unit 500 forces a volume of fluid upward within production tubing 17. Pump unit 500 includes bypass channel 565, which is separate from fluid passage 570 through pump 510. Bypass passage 565 comprises bypass inlet 561 and bypass outlet 564. Pump unit 500 does not provide a pressure differential between bypass inlet 561 and bypass outlet 564. While in this embodiment bypass passage 565 is shown as a conduit, alternative passages may be used. For example, a partitioned volume of the interior of housing 501 may be used to provide the bypass passage. Housing 501 of pump unit 500 also includes shaft input coupling port 534, to which drive shaft 529 from motor unit 590 may be rotationally coupled to pump shaft 509, for example, and shaft output coupling port 535, to which drive shaft 529A to pump unit 500A upstream from pump unit 500 may be rotationally coupled, for example. Shaft input coupling port 534 is disposed at the bottom end of housing 501 and shaft output coupling port 535 is disposed at the top end of housing 501.

[0167]As shown in FIG. 54, intake unit 550 generally comprises housing 537 having inlet port 530, outlet port 531 and fluid passage 536 therebetween. Housing 537 also includes shaft coupling inlet port 532 and shaft coupling outlet port 533 and a passthrough therebetween for receiving a drive shaft, such as shaft 529 for example. Housing 537 also includes bypass inlet port 553 and bypass outlet port 554 and bypass 555 therebetween. Similarly, intake unit 550A generally comprises housing 537A having inlet port 530A, outlet port 531A and fluid passage 536A therebetween. Housing 537A also includes shaft coupling inlet port 532A and shaft coupling outlet port 533A and a passthrough therebetween for receiving a drive shaft. Housing 537A also includes bypass inlet port 553A and bypass outlet port 554A and bypass 555A therebetween. As shown in FIG. 56, intake unit 650 generally comprises housing 637 having inlet port 630, outlet port 631A, outlet port 631B, fluid passage 636A between inlet 630 and outlet port 631A, and fluid passage 636B between inlet 630 and outlet port 631B. Housing 637 also includes shaft coupling inlet port 632 and shaft coupling outlet port 633 and a passthrough therebetween for receiving a drive shaft, such as shaft 529 for example.

[0168]FIGS. 53-62 show various stacking arrangements of separate pump units 500, 500A, 600, and/or 600A and separate motor units 590 and 590A with separate intake units 550, 550B and/or 650 in the top controlled modular system 515 shown in FIG. 50. As shown in FIGS. 53-62, in system 515 one or more pump units 500, 500A, 600, and/or 600A may be stacked with one or more intake units 550, 550A and/or 650 together coaxially with a production fluid flow path 19 arranged in series or in parallel or in a combination to provide the desired level of lift as further described below. As shown, in system 515 one or more motor units 595 and/or 595A may 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, as shown in FIG. 53, two motor units 595 and 595A may be stacked directly in a serial motor configuration in which the torque of motors 520 and 520A is summed to provide for an increased drive power to pump units 500 and 500A, and two pump units 500 and 500A may be stacked directly in a serial pumping configuration in which the pumping action is summed to provide for an increased lift pressure, with single intake unit 550 between upper motor unit 590A and lower pump unit 500.

[0170]As shown in FIG. 53, outlet port 531 of intake unit 550 is connected directly to pump inlet port 551 of pump unit 500, and outlet port 541 of pump unit 500 is connected directly 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. Motor input connection 564A of motor unit 590A is connected directly to drive line 424 from surface controller 420 to thereby connect 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 connected directly to at least motor input connection 564 of motor unit 590 to thereby connect power from driver 433 to motor 520 of motor unit 500 via connection 565A of motor unit 590A.

[0171]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 526A of motor 520A of motor unit 590A is in turn coupled to pump 510 by shaft extension 529 via shaft coupling ports 532 and 533 in intake unit 550 and shaft inlet coupling port 534 in pump unit 500. Shaft extension 529A couples pump 510 of pump unit 500 with pump 510A of pump unit 500A via shaft outlet coupling port 535 in pump unit 500 and shaft inlet coupling port 534A in 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 well bore 18 through tubing string 17 to a collection point at the surface, with motors 520 and 520A providing the desired torque from a position in well 18 below pump units 500 and 500A. The number of stacked motor units, pump units and intake units may be varied as needed to provide the desired flow and based on the dynamics of the subject well. Thus, more than two motor units may be stacked and/or more than two pump units may be stacked as needed.

[0172]As shown in FIG. 54, alternatively for example two pump units 500 and 500A may be stacked in a parallel pumping configuration in which the pumping action of each pumping unit is independent of the other to provide twice the volume of a single pump unit. Thus, as shown in FIG. 54, two motor units 595 and 595A may be stacked directly in a serial motor configuration in which the torque of motors 520 and 520A is summed to provide for an increased drive power to pump units 500 and 500A, and two pump units 500 and 500A may be stacked with intake units 550 and 550A in a parallel pumping configuration in which the pumping action of each pump is independent to provide for an increased lift volume, with intake unit 550 stacked between upper motor unit 590A and lower pump unit 500 and intake unit 550A stacked between lower pump unit 500 and upper pump unit 500A. As shown, outlet port 531 of intake unit 550 is connected directly to pump inlet port 551 of pump unit 500, and outlet port 541 of pump unit 500 is connected to bypass inlet port 561 A of pump unit 500A, via bypass port 553A, bypass passage 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 connected directly 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]Again, motor input connection 564A of motor unit 590A is connected directly to drive line 424 from surface controller 420 to thereby connect 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 connected directly to at least motor input connection 564 of motor unit 590 to thereby connect power from driver 433 to motor 520 of motor unit 500 via connection 565A of motor unit 590A.

[0174]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 526A of motor 520A of motor unit 590A is coupled to pump 510 by shaft extension 529 via shaft coupling ports 532 and 533 in intake unit 550 and shaft inlet coupling port 534 in pump unit 500. Shaft extension 529A couples pump 510 of pump unit 500 with pump 510A of pump unit 500A via shaft outlet coupling port 535 in pump unit 500, shaft coupling ports 532A and 533A in intake unit 550A, and shaft inlet coupling port 534A in 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 well bore 18 through tubing string 17 to a collection point at the surface, with motors 520 and 520A providing the desired torque from a position in well 18 below pump units 500 and 500A.

[0175]As another example, as shown in FIG. 55, two motor units 595 and 595A may be stacked directly in a serial motor configuration in which the torque of motors 520 and 520A is summed to provide for an increased drive power to single pump unit 500, with single intake unit 550 between upper motor unit 590A and pump unit 500. As shown, outlet port 531 of intake unit 550 is connected directly to pump inlet port 551 of pump unit 500 and outlet port 541 of pump unit 500 is in turn connected to tubing string 17. Again, motor input connection 564A of motor unit 590A is connected directly to drive line 424 from surface controller 420 to thereby connect 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 connected directly to at least motor input connection 564 of motor unit 590 to thereby connect power from driver 433 to motor 520 of motor unit 500 via connection 565A of motor unit 590A. 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 526A of motor 520A of motor unit 590A is coupled to pump 510 by 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 well bore 18 through tubing string 17 to a collection point at the surface, with motors 520 and 520A providing the desired torque from a position in well 18 below pump unit 500.

[0176]As another example, as shown in FIG. 56, a single motor unit 590 and two pump units 500 and 500A may be stacked with a single intake unit 650 in a parallel pumping configuration in which the pumping action of each pump is independent to provide for an increased lift volume, with intake unit 650 stacked between lower pump unit 500 and upper pump unit 500A. As shown, intake unit 650 includes two separate outlet ports 631A and 631B connected to inlet 630 via fluid passages 636A and 636B, respectively. Outlet port 631A of intake unit 650 is connected directly to pump inlet port 551 of pump unit 500, outlet port 541 of pump unit 500 is connected to bypass inlet port 561A of pump unit 500A, and bypass outlet port 564A in pump unit 500A is in turn connected to tubing string 17. Outlet port 631B of intake unit 650 is connected directly 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 connected directly to drive line 424 from surface controller 420 to thereby connect 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 by 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 with 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 well bore 18 through tubing string 17 to a collection point at the surface, with motors 520 providing the desired torque from a position in well 18 below pump units 500 and 500A.

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

[0178]As another example, as shown in FIGS. 57 and 58, two motor units 595 and 595A may be stacked directly in a serial motor configuration in which the torque of motors 520 and 520A is summed to provide for an increased drive power to multiple stage pump unit 600, with single intake unit 550 between upper motor unit 590A and multiple stage pump unit 600. As shown, in this embodiment multiple stage pump unit 600 is a two stage pump unit having first stage pump 610 and second stage pump 611 and bypass channel 665, which is separate from fluid passage 670 through pump stages 610 and 611. Pump unit 600 may be configured and ported to provide serial fluid passage 670 and serial flow through stages 610 and 611 or alternatively may be configured and ported to provide parallel fluid passage 680 and parallel flow through stages 610 and 611.

[0179]As shown in FIG. 57, in a serial pump stage configuration, stages 610 and 611 of pump 600 are ported in a serial stage pumping configuration in which the pumping action of the two stages of the pump unit is summed to provide for an increased lift pressure at pump unit 600. As shown, in this serial stage pumping configuration, fluid passage 670 extends through each of stages 610 and 611 in series, extending from pump inlet port 651 to the input of first stage 610 and through the vanes of pump 610, from the output of first stage 610 to the input of second stage 611 and through the vanes of pump 611, and from the output of second stage 611 to pump outlet port 641. Shaft 529 from motors 520 and 520A is coupled to both first stage pump 610 and second stage pump 611 in pump unit 600 to drive both first and second stage pumps 610 and 611 such that motor 520, motor 520A, pump 610 and pump 611 are driven to rotate together on a common shaft to artificially lift production fluid from well bore 18 through tubing string 17 to a collection point at the surface, with motors 520 and 520A providing the desired torque from a position in well 18 below pump unit 600.

[0180]As shown in FIG. 58, alternatively pump unit 600 has stages 610 and 611 arranged in a parallel pump stage configuration to provide parallel fluid passage 680. As shown in FIG. 58, in this parallel pump stage configuration, stages 610 and 611 of pump 600 are ported in a parallel stage pumping configuration in which the pumping action of each stage 610 and 611 of pumping unit 600 is independent of the other to provide twice the volume of a single stage pump unit. As shown, in this parallel stage pumping configuration, fluid passage 680 extends through each of stages 610 and 611 in parallel, extending from pump inlet port 651 to each of the inputs of each of first stage 610 and second stage 611, in parallel, through each of their respective vanes in parallel, and from the output of each of first stage 610 and second stage 611 to pump outlet port 641.

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

[0182]As shown in FIG. 59, pump unit 600A has the same general configuration as pump unit 600 described in FIG. 57, with stages 610A and 611A in a serial pump stage configuration to provide serial fluid passage 670A. As shown, pump units 600 and 600A may be stacked in a serial pumping configuration in which the unit pumping action of each pump unit 600 and 600A is also summed to provide for a further increased lift pressure. As shown, pump outlet port 641 of pump unit 600 is connected to pump inlet port 651A of pump unit 600A. In this way, pump fluid passages 670 and 670A are connected to provide serial 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, to first stage pump 610A and second stage pump 611A in pump unit 600A to drive all of pumps 610, 611, 610A and 611A such 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 well bore 18 through tubing string 17 to a collection point at the surface, with motors 520 and 520A providing the desired torque from a position in well 18 below pump units 600 and 600A. Thus, as shown in FIG. 59, pump units 600 and 600A may be configured in a serial stage orientation and stacked in a serial unit pumping configuration in which the pumping action of each pump stage is summed to provide increase lift pressure and the pumping action of each pump unit is summed to provide for further increased lift pressure. As shown, stages 610 and 611 of pump unit 600 are in a serial stage configuration, stages 610A and 611A of pump unit 600A are also in a serial stage configuration, and pump outlet port 641 of pump unit 600 is connected to pump inlet port 651A of pump unit 600A. In this way, pump fluid passages 670 and 670A are connected to provide serial pump stage and serial unit pumping action.

[0183]As shown in FIG. 60, alternatively pump units 600 and 600A may be stacked in a parallel unit pumping configuration in which 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, with intake unit 550 stacked between upper motor unit 590A and lower pump unit 600 and intake unit 550A stacked between lower pump unit 600 and upper pump unit 600A. As shown, outlet port 531 of intake unit 550 is connected directly 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 passage 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 connected directly 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 way, serial pump fluid passage 670 of pump unit 600 is connected to bypass fluid passage 665A of pump unit 600A and in turn tubing 17, and serial pump fluid passage 670A of pump unit 600A is connected to tubing 17 separately. Serial pump fluid passages 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 such 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 well bore 18 through tubing string 17 to a collection point at the surface, with motors 520 and 520A providing the desired torque from a position in well 18 below pump units 600 and 600A. Thus, as shown in FIG. 60, pump units 600 and 600A may be configured in a serial stage orientation and then stacked in a parallel unit pumping configuration in which the pumping action of each pump stage is summed to provide for increased lift pressure and the pumping action of each pump unit is independent of the other to provide for increased volume. As shown, stages 610 and 611 of pump unit 600 are in a serial stage configuration, stages 610A and 611A of pump unit 600A are also in a serial stage configuration, and pump outlet port 641 of pump unit 600 is connected to bypass inlet port 661A of pump unit 600A. In this way, pump fluid passages 670 and 670A are connected to provide serial pump stage and parallel unit pumping action.

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

[0185]As shown in FIG. 61, pump unit 600A has the same general configuration as pump unit 600 described in FIG. 58, but with stages 610A and 611A in a parallel pump stage configuration to provide parallel fluid passage 680A. As shown, pump units 600 and 600A may be stacked in a serial unit pumping configuration in which the unit pumping action of each pump unit 600 and 600A is summed to provide for increased lift pressure at the unit level. As shown, pump outlet port 641 of pump unit 600 is connected to pump inlet port 651A of pump unit 600A. In this way, parallel pump fluid passages 680 and 680A are connected to provide serial 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, to first stage pump 610A and second stage pump 611A in pump unit 600A to drive all of pumps 610, 611, 610A and 611A such 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 well bore 18 through tubing string 17 to a collection point at the surface, with motors 520 and 520A providing the desired torque from a position in well 18 below pump units 600 and 600A. Thus, as shown in FIG. 61, pump units 600 and 600A may be configured in a parallel stage orientation and then stacked in a serial unit pumping configuration in which the pumping action of each pump stage is independent of the other to provide increased volume and the pumping action of each pump unit is summed to provide for 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 way, pump fluid passages 680 and 680A are connected to provide parallel pump stage and serial unit pumping action.

[0186]As shown in FIG. 62, alternatively pump units 600 and 600A may be stacked in a parallel unit pumping configuration in which 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, with intake unit 550 stacked between upper motor unit 590A and lower pump unit 600 and intake unit 550A stacked between lower pump unit 600 and upper pump unit 600A. As shown, outlet port 531 of intake unit 550 is connected directly 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 passage 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 connected directly 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 way, parallel pump fluid passage 680 of pump unit 600 is connected to bypass fluid passage 665A of pump unit 600A and in turn tubing 17, and parallel pump fluid passage 680A of pump unit 600A is connected to tubing 17 separately. Parallel pump fluid passages 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 such 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 well bore 18 through tubing string 17 to a collection point at the surface, with motors 520 and 520A providing the desired torque from a position in well 18 below pump units 600 and 600A. Thus, as shown in FIG. 62, pump units 600 and 600A may be configured in a parallel stage orientation and then stacked in a parallel unit pumping configuration in which the pumping action of each pump stage is independent of the other to provide for increased volume and the pumping action of each pump unit is independent of the other to provide for 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 way, pump fluid passages 680 and 680A are connected to provide parallel pump stage and parallel unit pumping action.

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

[0188]While vane and screw type positive displacement pumps have been shown and described, other types of positive displacements pumps may be used as alternatives for the pump unit, including without limitation gear pumps.

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

[0190]It should be appreciated that certain features of the system, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable combination. While 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 apparent to persons skilled in the relevant arts that the disclosed subject matter may be embodied in other specific forms, variations, and modifications without departing from the scope, spirit, or essential characteristics thereof. The embodiments described above are therefore to be considered in all respects as illustrative, and not restrictive.

[0191]While alternative forms of the improved subsurface pump system have been shown and described, and several modifications thereof discussed, persons skilled in this 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 by the claims.