Abstract:
A test device for testing the integrity of a seal has a clear t-shaped liquid reservoir with three ends. A guide adapter is connected to the first end of the liquid reservoir and extends axially therefrom along an axis of the reservoir. A shaft adapter is connected to the second end of the body, opposite the first end. A test shaft with first and second ends extends axially through the first and second ends of the body and test and shaft adapters along the axis. The first end of the shaft is adapted to be connected to the rotating shaft of pump assembly.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to provisional application 61/050,488, filed May 5, 2008. 
    
    
     FIELD OF THE INVENTION 
     This disclosure relates to a tool to check the proper assembly and seating of inboard and outboard mechanical face seals. 
     BACKGROUND OF THE INVENTION 
     Electrical submersible pumps (ESPs) have been used to lift fluid from bore holes, particularly for oil production. In operation, a pump of an electrical submersible pump is placed below the fluid level in the bore hole. The well fluid often contains corrosive compounds such as brine water, CO 2 , and H 2 S that can shorten the run life of an ESP when the ESP is submerged in the well fluid. Corrosion resistant units have been developed that have motors that utilize seals and barriers to exclude the corrosive agents from the internal mechanisms of the ESP. 
     A typical submersible pump has a motor, a pump above the motor, and a seal section between the motor and the pump. The seal section allows for expansion of the dielectric oil contained in the rotor gap of the motor. Temperature gradients resulting from an ambient and motor temperature rise cause the dielectric oil to expand. The expansion of the oil is accommodated by the seal section. Additionally, the seal section is provided to equalize the casing annulus pressure with the internal dielectric motor fluid. The equalization of pressure across the motor helps keep well fluid from leaking past sealed joints in the motor. It is important to keep well fluids away from the motor because well fluid that gets into the motor will cause early dielectric failure. Measures commonly employed to prevent well fluids from getting into the motor include the use of elastomeric bladders as well as labyrinth style chambers to isolate the well fluid from the clean dielectric motor fluid. Multiple mechanical shaft seals keep the well fluid from leaking down the shaft. The elastomeric bladder provides a positive barrier to the well fluid. The labyrinth chambers provide fluid separation based on the difference in densities between well fluid and motor oil. Any well fluid that gets past the upper shaft seals or the top chamber is contained in the lower labyrinth chambers as a secondary protection means. 
     As electric submersible seals are assembled and disassembled, a number of inboard and outboard mechanical shaft seals are dismantled and installed. If a mechanical seal is damaged or not properly sealing, a leak is typically not identified until the seal assembly is complete. This often requires disassembly of the entire seal. A technique is desirable to efficiently test each mechanical shaft seal during assembly or disassembly to ensure its integrity, thereby ensuring the integrity of the seal assembly once fully constructed. 
     SUMMARY OF THE INVENTION 
     A device for testing the integrity of mechanical shaft seals has a clear, t-shaped liquid reservoir with three ends. A guide adapter is connected to the first end of the reservoir and extends axially therefrom along an axis of the reservoir. The guide adapter has an opening extending axially therethrough and is adapted to connect to a seal guide of an electric submersible seal. A shaft adapter is connected to the second end of the reservoir, opposite the first end, and has an opening positioned in and extending axially therethrough. A test shaft has first and second ends and extends axially through the first and second ends of the body and the openings in the test and the shaft adapters along the axis. The test shaft is adapted to connect to a rotating shaft of an electrical submersible seal assembly. The third end of the body is perpendicular to the first and second ends and is open to allow fluid to be poured into the liquid reservoir. 
     In an alternate embodiment, the device for testing the integrity of a seal also has a head adapter connected to the guide adapter opposite the body. The head adapter has a connector flange adapted to connect to a seal head and a sealing section extending axially along the axis therefrom. The sealing section is adapted to sealingly engage the seal head. 
     In order to test the integrity of a seal, the test shaft is connected to a seal shaft. The liquid reservoir is then placed over and around the test shaft. The guide adapter is then inserted into a seal port, thereby connecting the liquid reservoir to the seal section to be tested. The liquid reservoir is filled with a clear liquid. Pressure is then applied to the backside of the mechanical seal and the clear liquid in the reservoir is observed for the existence of bubbles. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an isometric view of a face seal integrity verification tool. 
         FIG. 2  is an isometric cross section of the face seal integrity verification tool of  FIG. 1 . 
         FIG. 3  is an isometric view of the face seal integrity verification tool of  FIG. 1  with attachments for testing of an outboard seal face. 
         FIG. 4  is an isometric view of the verification tool and attachments of  FIG. 3 , connected to a seal head. 
         FIG. 5  is a sectional view of a shaft seal assembly with the verification tool connected to an outboard seal head. 
         FIG. 6  is an isolated and enlarged view of  FIG. 5 . 
         FIG. 7  is an isometric view of the verification tool of  FIG. 1  attached to an outboard seal guide assembly. 
         FIG. 8  is a sectional view of a guide seal assembly with the verification tool connected to an inboard guide seal. 
         FIG. 9  is an isolated and enlarged view of  FIG. 8 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIGS. 1 and 2 , a face seal verification tool  11  is comprised of a clear plastic t-shaped liquid reservoir  13 , guide adapter  15 , and shaft adapter  23 . In an alternate embodiment, liquid reservoir  13  could be constructed from a non-clear material. Liquid reservoir  13  is cylindrical in shape, and tool  11  has openings at each of its three ends. In an alternate embodiment, reservoir  13  could be shaped differently, such as a square or rectangle. At one end of reservoir  13 , guide adapter  15  is connected. Guide adapter  15  is comprised of adapter flange  16 , reservoir connector section  20 , and seal connector section  18 , all of which are cylindrical in shape and form one solid structure. In an alternate embodiment, the various components of adapter  15  could be shaped differently, such as squares or rectangles. The reservoir connection section  20  of adapter  15  connects to reservoir  13  by means of a set of O-rings  21  located on the outer diameter of section  20 . The outer diameter of section  20  is slightly less than the inner diameter of reservoir  13 . O-rings  21  ensure an air tight connection between adapter  15  and reservoir  13 . On the other side of flange  16 , seal connector section  18  extends outwards from flange  16  and a set of O-rings  19  are located on the outer diameter of section  18 . The outer diameter of connector section  18  is designed to be slightly smaller than the inner diameter of the connection port. O-ring  19  will create an air-tight seal between the adapter  15  and any connection port. A hole  17  runs through the center of adapter  15  and is designed to accept a shaft. 
     On the end of reservoir  13  opposite adapter  15 , shaft adapter  23  is located. Shaft adapter  23  is comprised of cap section  24  and connector section  26 . Both cap section  24  and connector section  26  are cylindrical in shape. In an alternate embodiment, sections  24  and  26  could be shaped differently, such as squares or rectangles. The outer diameter of cap  24  is larger than the outer diameter of reservoir  13 , creating a cap on the end of reservoir  13 . Connector section  26  extends from cap  24  and a set of O-rings  27  are located on the outer diameter of section  26 . The outer diameter of connector section  26  is slightly smaller than the inner diameter of reservoir  13 , and connects shaft adapter  23  to reservoir  13 . O-rings  27  ensure an air tight connection between adapter  23  and reservoir  13 . A hole  25  extends through the center of adapter  23  and is designed to accept a shaft. An O-ring  29  is located on the inner diameter of section  26 , and ensures an air tight seal between a shaft and verification tool  11 . The third end of reservoir  13  remains open, and allows a testing liquid to be held in reservoir  13  of verification tool  11 . 
     Verification tool  11  can be used to test both inboard and outboard mechanical seal faces for rotating shafts. The tool  11  ensures the proper assembly and seating of the seals, by detecting any leaks within the mechanical face seal. The testing can be conducted when assembling or disassembling seal sections. In order to test an outboard mechanical face seal, additional attachments are added to verification tool  11 . Referring to  FIG. 3 , verification tool  11  ( FIGS. 1 and 2 ) is attached to an outboard head adapter  30 . Head adapter  30  is comprised of mounting flange  31 , sealing section  34 , and connector section  37 , all of which are cylindrical in shape and form one solid structure. In an alternate embodiment, the various components of adapter  30  could be shaped differently, such as squares or rectangles. Mounting flange  31  contains bolt holes  33  that allow it to be secured to a seal head. Sections  34  and  37  are designed to connect to and seal the adapter  30  to a seal head. The outer diameter of section  34  is slightly larger than the outer diameter of section  37 . An O-ring  35  is located on the outer diameter of section  34 , and ensures an air-tight seal between the adapter  30  and a seal head (not shown). Section  34  extends from section  37  and is designed to fully extend into a seal head. A flat ring seal  39  is located on the end of section  37  and acts to seal off a pressure equalization port when connected to a seal head. Flat ring seal  39  surrounds a hole  41  which extends throughout adapter  30 . A testing shaft  42  extends through adapter  30  and testing tool  11 . Threaded end  43  of shaft  42  allows the testing shaft  42  to be connected to the seal shaft (not shown). 
     Referring to  FIGS. 4 through 6 , when an outboard mechanical seal assembly  71  is to be tested the following procedures are implemented. Head adapter  30  is inserted into seal head  51 . O-ring  35  ensures an air-tight seal between the adapter  30  and inner surface of seal head  51 . Flat ring seal  39  seals off pressure equalization port  57  when adapter  30  is connected to seal head  51 , preventing any flow through port  57 . Bolts  49  are inserted into flange  31  and are screwed into seal head  51 , securely connecting head adapter  30  to seal head  51 . Test shaft  42  is then threaded into the end of seal shaft  69 . Reservoir  13  and guide adapter  15  are placed on the shaft  42  through hole  17 , and adapter  15  is inserted into flange  31  of adapter  30 . O-rings  19  ensure an air tight seal between adapter  15  and adapter  30 . Test unit  11  is held in engagement with adapter  30  by friction of its seals  19 . Testing shaft  42  is lubricated with a lubricant such as oil. Adapter  23  is placed on shaft  42  through hole  25  and inserted into reservoir  13 . O-rings  27  ensure an air tight seal between reservoir  13  and adapter  23 . O-ring  29  ( FIG. 2 ) ensures an air tight seal between adapter  23  and test shaft  42 . 
     Verification tool  11  is now fully assembled and connected to seal head  51  for testing. Reservoir  13  is filled with a liquid  52  ( FIG. 4 ) through the open port of reservoir  13 . For example, this liquid  52  could be oil or another clear liquid that will allow bubbles to be seen through the clear plastic reservoir  13 . Once the reservoir  13  has been filled with the liquid  52 , the testing shaft  42  is rotated in order to allow any trapped air bubbles in the assembly to make their way through the liquid and out the open port of verification tool  11 . Once no bubbles can be seen in the liquid  52 , the mechanical seal assembly  71  is ready to be tested. 
     As shown in  FIG. 6 , a fill adapter  53  is attached to the vent port  55  located on seal head  51 . An air source (not shown) is then attached to a test regulator (not shown), which is then attached to fill adapter  53 . The test regulator (not shown) is adjusted until the air reaches a desired pressure, for example 5 psi. The air enters the seal head  51  through adapter  53  and port  55 , and pressurizes the shaft seal sections on the backside of the mechanical face seal  71 . The backside is the side opposite test unit  11 . The mechanical seal  71  is comprised of spring keeper  73 , spring  75 , spring and bellows housing  77 , rotating seal face  79 , and stationary seal face  81 . A rubber bellows (not visible) is contained within the spring and bellows housing  77 , and seals around seal shaft  69 . The rotating seal face  79  is attached to the rubber bellows (not visible). Spring  75  applies a force against the seal face  79  and bellows housing  77  that ensures that rotating seal face  79  stays in constant contact with stationary seal face  81 . Spring  75  is located on the exterior side of seal face  79  and on an outboard end of the seal section. As indicated by the labels, rotating seal face  79  rotates with seal shaft  69 , whereas the stationary seal face  81  does not rotate with shaft  69  and is stationary. O-ring  83  seals around the stationary seal face  81  and ensures an air tight seal between seal  81  and seal head  51 . 
     As air pressure is applied to the backside of mechanical seal assembly  71 , the air pressure acts against seal faces  79 ,  81 . The clear reservoir  13  of tool  11  is monitored for air bubbles. The mechanical seal  71  can be tested for proper sealing with axial movement by pulling out a small increment on the testing shaft  42 . The axial movement of testing shaft  42  is translated to the seal shaft  69  which also moves axially, placing the seal shaft  69  in tension. Again, the clear reservoir  13  of tool  11  is monitored for bubbles. The mechanical seal can be tested for proper sealing with rotational movement by rotating testing shaft  42  several times. Seal shaft  69  rotates in unison with test shaft  42 . Again, the clear reservoir  13  of tool  11  is monitored for bubbles. If no bubbles are seen in clear reservoir  13  of tool  11  within a specific time, for example one minute, of performing the procedures above, the shaft seal  71  is intact and did not leak. If air bubbles are seen in the reservoir  13 , test shaft  42  is rotated to eliminate any air that may be trapped within or behind the testing assembly. If the bubbles continue after rotating test shaft  42 , the shaft seal  71  may have been compromised. 
     Once seal  71  has been properly tested, the air pressure is reduced to zero. The air hose (not shown) is removed from fill adapter  53 , and fill adapter  53  is removed from vent port  55 . The liquid  52  in reservoir  13  is dumped into a catch basin (not shown), and the verification tool  11  and seal adapter  30  are removed in the reverse order of how they were installed. 
     Referring to  FIGS. 7 through 9 , when an inboard mechanical seal assembly  101  is to be tested, the following procedures are implemented. Reservoir  13  and guide adapter  15  are placed on seal shaft  63  through hole  17  and adapter  15  is inserted into guide seal  62  of the guide seal assembly  61 . O-rings  19  ensure an air tight seal between adapter  15  and guide seal  62 . Seal shaft  63  is lubricated with a lubricant such as oil. Adapter  23  is then placed on seal shaft  63  through hole  25  and inserted into reservoir  13 . O-rings  27  ensure an air tight seal between reservoir  13  and adapter  23 . O-ring  29  ( FIG. 2 ) ensures an air tight seal between adapter  23  and seal shaft  63 . Adapter  30  ( FIG. 3 ) is not required because seal section coupling  62  is threaded between two parts of the seal section, as shown in  FIG. 5 , and does not have a bolt flange pattern. Connector section  18  inserts sealingly into the passage surrounding seal section shaft  63  and is held by friction of its seals  19 . The vent port plug (not shown) and construction port plug (not shown) are removed from the guide assembly  62 . A fill adapter  123  is inserted into vent port  121  and securely tightened in place. A construction blocking tool  127  is inserted into construction port  125  and securely tightened in place. The blocking tool  127  ensures that no air can travel through construction port  125 . 
     Verification tool  11  is now fully assembled and connected to guide seal assembly  62  for testing. Reservoir  13  is filled with a liquid  52  through the open port of reservoir  13 . For example, this liquid  52  could be oil or another clear liquid that will allow bubbles to be seen through the clear plastic reservoir  13 . Once the reservoir  13  has been filled with the liquid  52 , the seal shaft  63  is rotated in order to allow any trapped air bubbles in the assembly to make their way through the liquid and out the open port of verification tool  11 . Once no bubbles can be seen in the liquid  52 , the mechanical seal assembly  101  is ready to be tested. 
     An air source (not shown) is then attached to a test regulator (not shown), which is then attached to fill adapter  123 . The test regulator (not shown) is adjusted until the air reaches a desired pressure, for example 5 psi. The air enters the seal head guide assembly  62  through fill adapter  123  and port  121 , and pressurizes the seal sections on the backside of the mechanical seal  101 . 
     The mechanical seal  101  is comprised of spring keeper  103 , spring  105 , spring and bellows housing  107 , rotating seal face  109 , and stationary seal face  111 . A rubber bellows (not visible) is contained within the spring and bellows housing  107 , and seals around the shaft  63 . The rotating seal face  109  is attached to the rubber bellows (not visible). Spring  105  applies a force against the spring, and bellows housing  107  that ensures that rotating seal face  109  stays in constant contact with stationary seal face  111 . As indicated by the labels, rotating seal face  109  rotates with seal shaft  63 , whereas the stationary seal face  111  does not rotate with shaft  63  and is stationary. O-ring  113  seals between the stationary seal face  111  and seal guide  61 . Spring  105  is located on the interior side of rotating seal face  111 . 
     As air pressure is applied to the backside of mechanical seal assembly  101 , the air pressure acts against seal faces  109 ,  111 . The clear reservoir  13  of tool  11  is monitored for air bubbles. If bubbles immediately appear in reservoir  13 , blocking tool  127  is tightened until the bubbles stop. If blocking tool  127  is tightened down and bubbles persist at a quick rate, the rubber part of blocking tool  127  may need to be replaced. The blocking tool  127  is removed and the rubber is replaced. Blocking tool  127  is reinserted into construction port  125 , and the test is run again. After no air bubbles are visible in reservoir  13 , no action is performed for a specific period of time, for example one minute. 
     After the specific time has passed, the mechanical seal  101  can be tested for proper sealing with axial movement by pulling out on the seal shaft  63 . Again, the clear reservoir  13  of tool  11  is monitored for bubbles. The mechanical seal can be tested for proper sealing with rotational movement by rotating seal shaft  63  several times. Again, the clear reservoir  13  of tool  11  is monitored for bubbles. If no bubbles are seen in clear reservoir  13  of tool  11  within a specific time, for example one minute, of performing the procedures above, the shaft seal  101  is intact and did not leak. If air bubbles are seen in the reservoir  13 , test shaft  63  is rotated to eliminate any air that may be trapped within or behind the testing assembly. If the bubbles continue after tightening construction tool  127 , replacing the rubber of construction tool  127 , or rotating test shaft  63 , the shaft seal  101  may have been compromised. 
     Once seal  101  has been properly tested, the air pressure is reduced to zero. The air hose (not shown) is removed from fill adapter  123 , and fill adapter  123  is removed from vent port  121 , and construction blocking tool  127  is removed from construction port  125 . The liquid  52  in reservoir  13  is dumped into a catch basin (not shown), and the verification tool  11  and seal adapter  30  are removed in the reverse order of how they were installed. 
     The seal verification tool  11  has many advantages as it allows testing of mechanical seals in rotating shaft assemblies during assembly or disassembly of the seal sections. During assembly, the tool allows each section to be tested prior to the completion of next section, ensuring that the each shaft seal is properly functioning as the structure is assembled. This prevents a situation where an entire seal assembly would have to be broken down to fix a leaking shaft seal if the structure was only tested after full assembly. 
     While the invention has been shown in only a few of its forms, it should be apparent to those skilled in the art that it is not so limited but is susceptible to various changes without departing from the scope of the invention.