High-Speed, Multi-Power Submersible Pumps and Compressors

Abstract

An apparatus, method and system for removing fluids from a well comprising a rotary pump for positioning within the well, the rotary pump including an inlet end and a discharge end, the rotary pump comprising at least one pump impeller intermediate the inlet end and discharge end, the at least one pump impeller rotating at a rate greater than 3600 rpm; a driver for driving the at least one pump impeller to a rate greater than 3600 rpm, the driver positioned within the wellbore and operatively connected to the rotary pump; a magnetic bearing system, the magnetic bearing system operatively connected to the rotary pump and/or driver; and a digital controller positioned within the wellbore to control the magnetic bearing system. A method for removing liquids from a well and an apparatus and method for producing gas from a wellbore or injecting a fluid into a wellbore are also provided.

1 . An apparatus for removing fluids from a well, the apparatus comprising:
 a) a rotary pump for positioning within the well, the rotary pump including an inlet end and a discharge end, the rotary pump comprising at least one pump impeller intermediate the inlet end and discharge end, the at least one pump impeller rotating at a rate greater than 3600 rpm;   b) a driver for driving the at least one pump impeller to a rate greater than above 3600 rpm, the driver positioned within the wellbore and operatively connected to the rotary pump;   c) a magnetic bearing system, the magnetic bearing system operatively connected to the rotary pump and/or driver; and   d) a digital controller positioned within the wellbore to control the magnetic bearing system.   
     
     
         2 . The apparatus of  claim 1 , wherein the driver is selected from a gas-powered expander, an electric motor, a hydraulic motor and combinations thereof 
     
     
         3 . The apparatus of  claim 2 , wherein the driver is a gas-powered expander having an inlet and a discharge end, the gas-powered expander driven by high-pressure gas from a down hole gas production zone. 
     
     
         4 . The apparatus of  claim 3 , wherein the down hole gas production zone is regulated with a surface-controlled flow-control mechanism. 
     
     
         5 . The apparatus of  claim 3 , wherein the gas-powered expander is driven by injected gas lift gas. 
     
     
         6 . The apparatus of  claim 5 , wherein the injected gas lift gas enters the gas-powered expander inlet through a down hole gas lift mandrel. 
     
     
         7 . The apparatus of  claim 5 , wherein the rotational speed of the gas-powered expander is varied by adjusting characteristics of the gas lift gas. 
     
     
         8 . The apparatus of  claim 3 , wherein the expanded gas is exhausted to the pump discharge. 
     
     
         9 . The apparatus of  claim 3 , wherein the expanded gas is exhausted to a conduit to the surface. 
     
     
         10 . The apparatus of  claim 2 , further comprising additional electronic control and/or monitoring components, wherein the additional electronic control and/or monitoring components and the digital controller are cooled with gas at the discharge end of the gas-powered expander. 
     
     
         11 . The apparatus of  claim 2 , wherein the gas-powered expander operates at the same rotational speed as the rotary pump. 
     
     
         12 . The apparatus of  claim 2 , wherein the driver is an electric motor. 
     
     
         13 . The apparatus of  claim 12 , wherein the electric motor is a canned, seal-less motor. 
     
     
         14 . The apparatus of  claim 13 , wherein the electric motor is magnetically coupled to the rotary pump. 
     
     
         15 . The apparatus of  claim 14 , further comprising a variable speed drive to control the rate of the electric motor. 
     
     
         16 . The apparatus of  claim 2 , wherein the driver is a hydraulic motor, the hydraulic motor having a power fluid inlet and a power fluid discharge. 
     
     
         17 . The apparatus of  claim 16 , further comprising a source of power fluid, the power fluid provided to the power fluid inlet from the surface through a conduit. 
     
     
         18 . The apparatus of  claim 17 , further comprising a surface power fluid pump, wherein the rate of the hydraulic motor is controlled by the output of the surface power fluid pump. 
     
     
         19 . The apparatus of  claim 17 , wherein the power fluid is provided to the hydraulic motor from a high-pressure liquid-producing zone. 
     
     
         20 . The apparatus of  claim 19 , wherein the high-pressure liquid-producing zone is regulated from a surface-controlled, flow-control mechanism. 
     
     
         21 . The apparatus of  claim 16 , wherein spent power fluid is discharged with the pump fluid. 
     
     
         22 . The apparatus of  claim 1 , further comprising a generator for converting a portion of the rotational energy of the apparatus to electrical power. 
     
     
         23 . The apparatus of  claim 22 , wherein the magnetic bearing system is powered and controlled by the power produced by the generator. 
     
     
         24 . The apparatus of  claim 23 , wherein the magnetic bearing system is canned to prevent encroachment of wellbore fluids and improve reliability. 
     
     
         25 . The apparatus of  claim 1 , wherein the driver is connected to the rotary pump by a magnetic gear. 
     
     
         26 . The apparatus of  claim 25 , wherein the magnetic gear generates electricity for onboard use. 
     
     
         27 . The apparatus of  claim 26 , further comprising onboard sensors, wherein at least a portion of the electricity generated powers the onboard sensors. 
     
     
         28 . The apparatus of  claim 27 , wherein the onboard sensors are used for closed-loop control of the rotary pump. 
     
     
         29 . The apparatus of  claim 26 , wherein the electricity generated powers wireless communications. 
     
     
         30 . The apparatus of  claim 1 , further comprising an electric or fiber optic cable run in conjunction with a deployment device to relay sensor and control information to the surface. 
     
     
         31 . The apparatus of  claim 1 , further comprising permanent sensors for incorporating into a completion to provide operational support. 
     
     
         32 . The apparatus of  claim 1 , further comprising one or more fluid control devices for incorporating into a completion to provide an additional well control barrier. 
     
     
         33 . The apparatus of  claim 1  further comprising a Y-tool, the Y-tool when the rotary pump is placed in the well. 
     
     
         34 . The apparatus of  claim 1 , wherein the driver drives the rotary pump to a rate greater than 7200 rpm. 
     
     
         35 . The apparatus of  claim 1 , wherein the driver drives the rotary pump to a rate greater than 10,000 rpm. 
     
     
         36 . The apparatus of  claim 1 , wherein the driver drives the rotary pump to a rate greater than 20,000 rpm. 
     
     
         37 . A method of removing fluids from a well, comprising:
 a) installing an apparatus in a wellbore, the apparatus comprising a rotary pump having an inlet end and a discharge end, the rotary pump including at least one pump impeller intermediate the inlet end and discharge end; a driver for driving the at least one pump impeller, the driver positioned within the wellbore and operatively connected to one end of the rotary pump; a magnetic bearing system, the magnetic bearing system operatively connected to the rotary pump and/or driver; and a digital controller positioned within the wellbore to control the magnetic bearing system;   b) operating the apparatus at a rate greater than 3600 rpm; and   c) removing fluids from the well.   
     
     
         38 . The method of  claim 37 , wherein the driver is selected from a gas-powered expander, an electric motor, a hydraulic motor and combinations thereof 
     
     
         39 . The method of  claim 38 , wherein the driver is a gas-powered expander having an inlet end and a discharge end. 
     
     
         40 . The method of  claim 39 , further comprising the step of providing high- pressure gas from a down hole gas production zone to drive the gas-powered expander. 
     
     
         41 . The method of  claim 40 , further comprising the step of regulating the down hole gas production zone with a surface-controlled flow-control mechanism. 
     
     
         42 . The method of  claim 39 , further comprising the step of injecting gas-lift gas. 
     
     
         43 . The method of  claim 41 , further comprising the step of controlling the rotational speed of the gas-powered expander by adjusting the characteristics of the gas-lift gas. 
     
     
         44 . The method of  claim 38 , wherein the driver is a canned, seal-less electric motor. 
     
     
         45 . The method of  claim 44 , further comprising the step of magnetically coupling the electric motor to the rotary pump. 
     
     
         46 . The method of  claim 44 , further comprising the step of controlling the rate of the electric motor using a variable speed drive. 
     
     
         47 . The method of  claim 38 , wherein the driver is a hydraulic motor, the hydraulic motor having a power fluid inlet and a power fluid discharge. 
     
     
         48 . The method of  claim 47 , further comprising the step of providing a source of power fluid to the power fluid inlet from the surface through a conduit. 
     
     
         49 . The method of  claim 48 , wherein the source of power fluid includes a surface power fluid pump. 
     
     
         50 . The method of  claim 49 , further comprising the step of controlling the rate of the hydraulic motor by the output of the surface power fluid pump. 
     
     
         51 . The method of  claim 47 , further comprising the step of providing a source of power fluid to the hydraulic motor from a high-pressure liquid-producing zone. 
     
     
         52 . The method of  claim 51 , further comprising the step of regulating the power fluid from the high-pressure liquid-producing zone from a surface-controlled, flow-control mechanism. 
     
     
         53 . The method of  claim 37 , further comprising the step of converting a portion of the rotational energy of the apparatus to electrical power. 
     
     
         54 . The method of  claim 53 , wherein the magnetic bearing system is powered and controlled by the power converted from rotational energy. 
     
     
         55 . The method of  claim 54 , wherein the magnetic bearing system is canned to prevent encroachment of wellbore fluids and improve reliability. 
     
     
         56 . The method of  claim 37 , further comprising connecting the driver to the rotary pump by a magnetic gear. 
     
     
         57 . The method of  claim 56 , further comprising the step of generating electricity for onboard use using the magnetic gear. 
     
     
         58 . The method of  claim 57 , wherein at least a portion of the electricity generated powers sensors onboard the apparatus. 
     
     
         59 . The method of  claim 58 , further comprising the step of using signals from the onboard sensors to provide closed-loop control of the rotary pump. 
     
     
         60 . The method of  claim 37 , wherein the driver drives the rotary pump to a rate greater than 7200 rpm. 
     
     
         61 . The method of  claim 37 , wherein the driver drives the rotary pump to a rate greater than 10,000 rpm. 
     
     
         62 . The method of  claim 37 , wherein the driver drives the rotary pump to a rate greater than 20,000 rpm. 
     
     
         63 . An apparatus for producing fluids from a wellbore or injecting a fluid into a wellbore, the apparatus comprising:
 a) a rotary compressor including an inlet end and a discharge end, the rotary compressor comprising at least one compressor stage intermediate the inlet end and discharge end, the at least one compressor stage rotating at a rate greater than 3600 rpm;   b) a driver for driving the at least one compressor stage to a rate greater than 3600 rpm, the driver positioned within the wellbore and operatively connected to the rotary compressor;   c) a magnetic bearing system, the magnetic bearing system operatively connected to the high speed compressor and/or driver;   d) a digital controller positioned within the wellbore to control the magnetic bearing system.   
     
     
         64 . The apparatus of  claim 63 , wherein the driver is selected from a gas-powered expander, an electric motor, a hydraulic motor and combinations thereof 
     
     
         65 . The apparatus of  claim 63 , further comprising a generator for converting a portion of the rotational energy of the apparatus to electrical power. 
     
     
         66 . The apparatus of  claim 63 , wherein the driver is connected to the rotary compressor by a magnetic gear, the magnetic gear generating electricity for onboard use. 
     
     
         67 . The apparatus of  claim 63 , wherein the produced fluid is gas. 
     
     
         68 . The apparatus of  claim 63 , wherein the driver drives the rotary compressor to a rate greater than 10,000 rpm. 
     
     
         69 . The apparatus of  claim 63 , wherein the driver drives the rotary compressor to a rate greater than 100,000 rpm. 
     
     
         70 . A method of producing fluids from a wellbore or injecting a fluid into a wellbore, comprising:
 a) installing an apparatus in a wellbore, the apparatus comprising a rotary compressor including an inlet end and a discharge end, the rotary compressor comprising at least one compressor stage intermediate the inlet end and discharge end, the at least one compressor stage rotating at a rate greater than 3600 rpm; a driver for driving the at least one compressor stage, the driver positioned within the wellbore and operatively connected to one end of the rotary compressor; and a magnetic bearing system, the magnetic bearing system operatively connected to the rotary compressor and/or driver; and a digital controller positioned within the wellbore to control the magnetic bearing system;   b) operating the apparatus at a rate greater than 3600 rpm; and   c) removing fluids from the well.   
     
     
         71 . The method of  claim 70 , wherein the driver is selected from a gas-powered expander, an electric motor, a hydraulic motor and combinations thereof 
     
     
         72 . The method of  claim 71 , wherein the driver is a gas-powered expander having an inlet end and a discharge end. 
     
     
         73 . The method of  claim 71 , wherein the electric motor is magnetically coupled to the rotary compressor. 
     
     
         74 . The method of  claim 70 , wherein the driver is connected to the rotary compressor by a magnetic gear. 
     
     
         75 . The method of  claim 74 , further comprising the step of generating electricity for onboard use using the magnetic gear. 
     
     
         76 . The method of  claim 75 , wherein at least a portion of the electricity generated powers sensors onboard the apparatus. 
     
     
         77 . The method of  claim 76 , further comprising the step of using signals from the onboard sensors to provide closed-loop control of the rotary compressor. 
     
     
         78 . The method of  claim 70 , wherein the produced fluid is gas. 
     
     
         79 . The method of  claim 70 , wherein the driver drives the at least one compressor stage to a rate greater than 10,000 rpm. 
     
     
         80 . The method of  claim 70 , wherein the driver drives the at least one compressor stage to a rate greater than 100,000 rpm. 
     
     
         81 . A wellbore comprising:
 a) a borehole in fluid communication with a subterranean reservoir;   b) an apparatus for removing or injecting fluids, the apparatus installed within the wellbore and comprising i) a rotary pump or rotary compressor, the rotary pump or rotary compressor including an inlet end and a discharge end, and at least one pump impeller or at least one intermediate compressor stage rotating at a rate greater than about 3600 rpm; ii) a driver for driving the at least one pump impeller or at least one intermediate compressor stage to a rate greater than above about 3600 rpm, the driver positioned within the wellbore and operatively connected to the rotary pump or rotary compressor; iii) a magnetic bearing system, the magnetic bearing system operatively connected to the rotary pump or rotary compressor and/or driver; and iv) a digital controller positioned within the wellbore to control the magnetic bearing system.   
     
     
         82 . The wellbore of  claim 81 , wherein the driver is selected from a gas-powered expander, an electric motor, a hydraulic motor and combinations thereof 
     
     
         83 . The wellbore of  claim 81 , wherein the apparatus comprises a rotary pump for the production of reservoir fluids. 
     
     
         84 . The wellbore of  claim 81 , wherein the apparatus comprises a rotary pump for the injection of fluids. 
     
     
         85 . The wellbore of  claim 81 , wherein the apparatus comprises a rotary pump for the separation of production fluids. 
     
     
         86 . The wellbore of  claim 81 , wherein the apparatus comprises a rotary compressor for enhancing fluid flow in a gas well. 
     
     
         87 . The wellbore of  claim 81 , wherein the apparatus comprises a rotary compressor for increasing the gas velocity in a production well.