Patent Publication Number: US-7913498-B2

Title: Electrical submersible pumping systems having stirling coolers

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This is a Continuation-In-Part of application Ser. No. 10/710,103, filed on Jun. 18, 2004, which claims priority of Provisional Patent Application Ser. No. 60/517,782, filed on Nov. 6, 2003. This application claims benefits of these prior applications, which are incorporated by reference in their entireties. 
    
    
     BACKGROUND OF INVENTION 
     1. Field of the Invention 
     This invention relates generally to techniques for maintaining downhole tools and their components within a desired temperature range in high-temp environments, and, more specifically, to an electrical submersible pumping system having a Stirling-Cycle cooling system. 
     2. Background Art 
     Electrical submersible pumping systems (ESPs) are used for artificial lifting of fluid from a well or reservoir. An ESP typically comprises an electrical submersible motor, a seal section (sometimes referred to in the art as a protector), and a pump having one or more pump stages inside a housing. The seal section (or protector) functions to equalize the pressure between the inside of the system and the outside and also acts as a reservoir for compensating the internal oil expansion from the motor. The protector may be formed of metal, as in a bellows device, or an elastomer. An elastomer protector is sometimes referred to as a protector bag. 
     In addition to motors, pump sections, and seals, a typical submersible pumping system may further comprise a variety of additional components, such as a connector used to connect the submersible pumping system to a deployment system. Conventional deployment systems include production tubing, cable and coiled tubing. Additionally, power is supplied to the submersible electric motor via a power cable that runs through or along the deployment system. 
     ESPs often incorporate the use of a gauge having one or more sensors and associated electronics for measuring and monitoring parameters related to the operation of the ESP and the production of fluid from the well or reservoir. These parameters may include, but are not limited to, motor temperature, well temperature, pump intake pressure, pump discharge pressure, and vibration. The gauge is typically located below the motor, from which it may draw electrical power. The sensors and associated electronics included in the gauge are housed in protective chamber to isolate them from well fluids and well conditions, such as high temperature (up to 350° F.) or pressure (up to 30,000 psi) which may compromise their operation. The power cable used to provide power to the motor may also be used as a means for transmitting data from the gauge to the surface, where the data are interpreted and the operational parameters of the ESP can be adjusted to optimize the production of fluid from the well or reservoir. 
     Currently, ESPs are rated for use up to 550° F., but the electronics controlling or monitoring the pump fails at these high temperatures and is generally not reliable above 300° F. These electronic components generally cannot function at high temperature without significant degradation of their lifetime or performance. These components are typically contained in a closed protective (insulating) chamber. The accumulation or transfer of heat into the chamber can raise the temperature inside the chamber to a point that exceeds the maximum operating temperature of the components. The heat source which raises the temperature inside the chamber may be the components themselves (e.g., electrical losses) or high temperature well fluids external to the tool. 
     In addition, in certain high temperature thermal recovery production methods, such as Steam Assisted Gravity Drainage (SAGD), ESPs will be subject to well temperatures exceeding the maximum operating temperature of the gauge (about 300° F.). These high temperatures may also destroy or weaken the seals, insulating materials, and other components of the submersible pumping system. Under these conditions, the use of a gauge for monitoring and optimizing production is compromised. This can have a substantial negative impact on the overall performance of a well and thus the economics of producing fluids from the well. As such, it is desirable to provide a means for cooling the gauge (or other components of a submersible pumping system) such that the operational temperature of the gauge and components is maintained within an acceptable temperature range conducive to reliable operation of the gauge in harsh operating environments. 
     SUMMARY OF INVENTION 
     One aspect of the invention relates to submersible pumping systems. A submersible pumping system in accordance with one embodiment of the invention includes a submersible pump; a gauge disposed proximate the submersible pump; a Stirling cooler disposed proximate the gauge, wherein the Stirling cooler has a cold end configured to remove heat from the gauge and a hot end configured to dissipate heat; and an energy source configured to power the submersible pumping system. 
     One aspect of the invention relates to methods for constructing a submersible pumping system. A method in accordance with one embodiment of the invention includes disposing a gauge proximate a submersible pump; and disposing a Stirling cooler proximate the gauge such that the Stirling cooler is configured to remove heat from the gauge. 
     One aspect of the invention relates to methods for methods for cooling a gauge of a submersible pumping system. A method in accordance with one embodiment of the invention includes providing a Stirling cooler proximate the gauge; and energizing the Stirling cooler such that heat is removed from the gauge. 
     Other aspects and advantages of the invention will be apparent from the following description and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  shows a submersible pumping system in accordance with one embodiment of the invention disposed in a borehole. 
         FIG. 2  shows an expanded section of the submersible pumping system of  FIG. 1 . 
         FIG. 3  shows a schematic illustrating heat transfer using a Stirling cooler in accordance with one embodiment of the invention. 
         FIG. 4  shows a free-piston Stirling cooler in accordance with one embodiment of the invention. 
         FIG. 5  shows a diagram illustrating a Stirling cycle. 
         FIG. 6  shows a schematic illustrating various states of the pistons in the Stirling cooler in a Stirling cycle. 
         FIG. 7  shows a schematic illustrating a Stirling cooler coupled to a gauge of a submersible pumping system in accordance with one embodiment of the invention. 
         FIG. 8  shows a schematic illustrating s Stirling cooler coupled to a gauge of a submersible pumping system in accordance with another embodiment of the invention. 
         FIG. 9  illustrates a method for manufacturing an electrical submersible pumping system in accordance with one embodiment of the invention. 
         FIG. 10  illustrates a method for cooling a submersible pumping system using a Stirling cooler in accordance with one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the invention relate to the use, construction and method of using a Stirling-cycle based cooling system to cool components (e.g., electrical components and sensors in a gauge) connected to an electrical submersible pumping (ESP) system. As noted above, ESPs are typically subject to extreme high temperatures that can degrade the performance of their electronic components or sensors. A thermal management solution using a Stirling cooler as a heat pump could keep the temperature of the electronics below the temperature of the well and within its rated operating temperature range, thus drastically improving the reliability of ESP&#39;s electronic module. Part of the fluid pumped by the ESP could be forced to circulate around the hot end of the Stirling cooler to keep the Stirling cooler reject temperature close to the well temperature 
     The Stirling-cycle cooling system functions efficiently in a closed system, requires no lubrication, and can function at relatively lower pressures as compared to prior art vapor compression cooling system. A Stirling cycle cooler is based on the well known Stirling thermodynamic cycle. A Stirling cooler uses mechanical energy to produce a temperature difference between the cold end and the hot end of the cooler. This temperature difference can be used to remove heat from an object to be cooled. 
     Various configurations of Stirling engines/coolers have been devised. These can be categorized into kinematic and free-piston types. Kinematic Stirling engines use pistons attached to drive mechanisms to convert linear motions of the pistons to rotary motions. Kinematic Stirling engines can be further classified as alpha type (two pistons), beta type (piston and displacer in one cylinder), and gamma type (piston and displacer in separate cylinders). Free-piston Stirling engines use harmonic motion mechanics, which may use planar springs or magnetic field oscillations to provide the harmonic motion. 
     Due to daunting engineering challenges, Stirling cycle engines are rarely used in practical applications and Stirling cycle coolers have been limited to the specialty field of cryogenics and military use. The development of Stirling engines/coolers involves such practical considerations as efficiency, vibration, lifetime, and cost. Using Stirling engines/coolers on downhole tools presents additional difficulties because of the limited space available in a downhole tool (typically 3-6 inches in diameter) and the harsh downhole environments (e.g., temperatures up to 260° C. and pressures up to 30,000 psi or more). Stirling engines have been proposed for use as electricity generators for downhole tools (See U.S. Pat. No. 4,805,407 issued to Buchanan). 
     Embodiments of the present invention may use any Stirling cooler designs. Some embodiments use free-piston Stirling coolers. One free-piston Stirling cooler embodiment of the invention makes use of a moving magnet linear motor. 
       FIG. 1 , shows a schematic of a submersible pumping system in accordance with one embodiment of the invention. As shown in  FIG. 1 , a submersible pumping system  100  is disposed in a wellbore  11 , which penetrates the formation  10 , for pumping formation fluids to the surface via the production tubing  14 . The submersible pumping system  100  comprises a pump section  110 , a Stirling cooler  104 , and a gauge  104 . The pump section  110  comprises a motor  101 , seal section (protector)  102 , and one or more pumps  103 . Note that the order of the components shown here is for illustration only. One of ordinary skill in the art would appreciate that other arrangements are also possible without departing from the scope of the invention. 
     Power may be supplied to the motor via a power cable  13  from a power source  15  on the surface. Alternatively, power may be supplied by a battery or other power source downhole. A gauge  104 , which contains one or more sensors  104   a , is shown below the base of the motor  101 . Note that the gauge  104  may also be disposed at other locations, e.g., above the pump  103 . The gauge  104  consists of a housing that protects the various sensors and components  104   a  contained in the gauge  104 . These components  104   a  may include electronics that need to be protected from high temperatures. The components are disposed in an insulating enclosure or chamber  104   b  and connected to a Stirling cooler  22 . The Stirling cooler  22  is shown connected to the motor  101 . However, the Stirling cooler  22  may also be arranged at other locations, and other power sources may be used. In the particular arrangement shown in this figure, the Stirling cooler  22  is conveniently arranged below the motor  101  such that the submersible pumping system motor  101  can be used to power both the Stirling cooler  22  and the gauge  104 . Further, a means to remove heat from the hot end of the Stirling cooler can be incorporated in this arrangement to take advantage of the flow of well fluid passing by the motor  101  for removal of heat by convective heat transfer. 
       FIG. 2  shows an expanded section of the pumping system shown in  FIG. 1  for better illustration.  FIG. 2  shows the arrangement of gauge  104 , the Stirling cooler  22 , and the pump section  110 . As shown, the Stirling cooler  22 , which is in direct contact with the gauge  104  acts as a heat pump to remove heat from the gauge  104 . The heat may be dissipated to the well fluid flowing past the motor. In this manner, the heat removed from the gauge is effectively “pumped” to the other end of the Stirling cooler and dissipated into the flow of well fluid passing the submersible motor. 
     The Stirling cooler may be in direct contact with the object to be cooled (e.g., gauge), as shown in  FIG. 2 , or placed a some distance from the gauge and cooled with a heat transport mechanism disposed therebetween to transfer heat, as shown in  FIG. 3 .  FIG. 3  schematically illustrates that a heat pipe  35  is disposed between the Stirling cooler  22  and the gauge  104 . As shown, heat can be conducted from, the gauge  104  to the Stirling cooler  22  as illustrated by arrow Qc. The Stirling cooler  22  then dissipates this heat to the fluid flow, as illustrated by arrow Qh. Those skilled in the art will appreciate that the heat transport mechanism may be any suitable heat transport device, including those implemented with circulating fluids. Therefore, the term “heat pipe” as used herein is intended to include any suitable heat transport mechanism, which may or may not comprise a “pipe.” Embodiments of the invention may also be implemented with heat transport mechanisms on the cold side, or both the cold side and the hot side (not shown). 
     Stirling coolers may have various configurations, using pistons and/or displacers.  FIG. 4  shows a schematic of a free-piston type Stirling cooler that may be used with embodiments of the invention. As shown, the Stirling cooler  22  is attached to an object  47  to be cooled. As noted above, in some embodiments, a heat pipe may be used to conduct heat between the object  47  and the Stirling cooler  22 . The Stirling cooler  22  includes two pistons  42 ,  44  disposed in cylinder  46 . The cylinder  46  is filled with a working gas, typically air, helium or hydrogen at a pressure of several times (e.g., 20 times) the atmospheric pressure. The piston  42  is coupled to a permanent magnet  45  that is in proximity to an electromagnet  48  fixed on the housing. When the electromagnet  48  is energized, its magnetic field interacts with that of the permanent magnet  45  to cause linear motion (in the left and right directions looking at the figure) of piston  42 . Thus, the permanent magnet  45  and the electromagnet  48  form a moving magnet linear motor. The particular sizes and shapes of the magnets shown in  FIG. 4  are for illustration only and are not intended to limit the scope of the invention. One of ordinary skill in the a would also appreciate that the locations of the electromagnet and the permanent magnet may be reversed, i.e., the electromagnet may be fixed to the piston and the permanent magnet fixed on the housing (not shown). 
     The electromagnet  48  and the permanent magnet  45  may be made of any suitable materials. The windings and lamination of the electromagnet are preferably selected to sustain high temperatures (e.g. up to 260° C.). In some embodiments, the permanent magnets of the linear motors are made of a samarium-cobalt (Sm—Co) alloy to provide good performance at high temperatures. The electricity required for the operation of the electromagnet may be supplied from the surface, from batteries included in downhole tools, from generators downhole, or from any other means known in the art. 
     The movement of piston  42  causes the gas volume of cylinder  46  to vary. Piston  44  can move in cylinder  46  like a displacer in the kinematic type Stirling engines. The movement of piston  44  is triggered by a pressure differential across both sides of piston  44 . The pressure differential results from the movement of piston  42 . The movement of piston  44  in cylinder  46  moves the working gas from the left of piston  44  to the right of piston  44 , and vice versa. This movement of gas coupled with the compression and decompression processes results in the transfer of heat from object  47  to heat dissipating device  43 . As a result, the temperature of the object  47  decreases. In some embodiments, the Stirling cooler  22  may include a spring mass  41  to help reduce vibrations of the cooler resulting from the movements of the pistons and the magnet motor. 
     While  FIG. 4  shows a Stirling cooler having a magnet motor that uses electricity to power the Stirling cooler, one skilled in the art would appreciate that other energy sources (or energizing mechanisms) may also be used. For example, operation of the Stirling cooler (e.g., the back and forth movements of piston  42  in  FIG. 4 ) may be implemented by mechanical means, such as a fluid-powered system that uses the energy in the fluid flow coupled to a valve system and/or a spring (not shown). The hydraulic pressure of the fluid flow could be used to push the piston in one direction, while the spring is used to move the piston in the other direction. A conventional valve system may be used to control the flow of fluid to the Stirling piston in an intermittent fashion. Thus, the coordinated action of a hydraulic system, a spring, and a valve system results in a back and forth movement of the piston  42 . 
     The movement of gas to the right and to the left of piston  44 , coupled with compression and decompression of the gas in cylinder  46  by piston  42 , creates four different states in a Stirling cycle.  FIG. 5  depicts these four states and the transitions between these states in a pressure-volume diagram.  FIG. 6  illustrates the four states and the direction of the movements of the pistons  42  and  44  in a Stirling cycle. 
     In process a (from state  1  to state  2 ), piston  44  moves from left to right in  FIG. 6 , while piston  42  remains stationary. Therefore, the volume in cylinder  46  (see  FIG. 4 ) is unchanged. The working gas in the cylinder is swept from one side of piston  44  to the other side. 
     In the second process b (from state  2  to state  3 ), piston  42  moves to the right, increasing the volume in the cylinder (shown as  46  in  FIG. 4 ). The magnet motor, for example, drives the movement of piston  42 . Due to the increased volume in the cylinder, the gas expands and absorbs heat. 
     In process c (from state  3  to state  4 ), piston  44  moves to the left, forcing the working gas to move to its right. The volume of the gas remains unchanged. 
     In process d (from state  4  back to state  1 ), piston  42  moves to the left, driven by the magnet motor, for example. This compresses the working gas. The compression results in the release of heat from the working gas. The released heat is dissipated from the heat dissipater  43  into the heat sink or environment (e.g., the drilling mud). This completes the Stirling cycle. The net result is the transport of heat from one end of the device to the other. Thus, if the Stirling device is in thermal contact (either directly or via a heat pipe) with the object to be cooled (shown as  47  in  FIG. 4 ), heat can be removed from the object. As a result, the temperature of the object is lowered or heat generated at the object can be removed. 
     To improve heat removal from the insulating chamber (e.g., the chamber  104   b  of the gauge  104  in  FIG. 2 ), auxiliary heat transfer/circulating mechanism may be used in conjunction with the Stirling coolers. For example,  FIG. 7  shows a schematic of a system for heat removal using a Stirling cooler in accordance with another embodiment of the invention. As shown, a Stirling cooler  22  is coupled to an insulating enclosure or chamber  24 . The chamber  24  is configured with an internal cavity  26  formed therein and adapted to provide an path over the component(s) to be cooled  23  housed therein. The cavity  26  may be formed using any conventional materials known in the art. A fan  27  is disposed within the chamber  24  to circulate air around the component  23  to be cooled, thereby actively transferring heat dissipating from the component(s) to the cold side of the Stirling cooler  22 . The fan  27  may be powered by the electrical supply feeding the Stirling cooler or by an independent power network (e.g. separate battery) as known in the art. This particular embodiment is equipped with a heat exchanger  28  disposed at one end of the chamber  24  to increase cooling efficiency across the cooler/chamber interface and cool the recirculating air. The heat exchanger  28  may be a conventional heat sink or another suitable device as known in the art. Other embodiments may be implemented with multiple fans  27  to increase the cooling air flow. 
       FIG. 8  shows a schematic of another system for heat removal using a Stirling cooler in accordance with an embodiment of the invention. As shown, a Stirling cooler  22  is coupled to an insulating enclosure or chamber  24 . The chamber  24  is configured with an internal liquid-coolant system  29  disposed therein. The coolant system  29  is adapted with a flow loop that allows a liquid to flow in a closed loop from the housed component(s)  23  to a heat exchanger  28  attached to the cold side of the Stirling cooler  22 . The coolant system  29  may be constructed using conventional materials known in the art (e.g., via multiple tubes). The heat exchanger  28  may be a conventional heat sink or another suitable device as known in the art. The coolant liquid, which may be water or any suitable alternative, is circulated in the flow loop via a pump  30  coupled to the flow lines and powered by the Stirling cooler  22  power network or using independent power means. 
     The Stirling cooler system of  FIG. 8  is shown with the liquid-coolant system  29  centrally disposed within the chamber  24 , such that the component(s)  23  to be cooled surround the coolant system. Those skilled in the art will appreciate that other embodiments of the invention may be implemented with the liquid-coolant system  29  in various configurations and lengths depending on space constraints. For example, embodiments of the invention may be implemented with the liquid-coolant system configured within, or forming, the walls of the insulating chamber (not shown). In such embodiments the liquid-coolant system would not be centrally disposed within the chamber  24 . Embodiments comprising the liquid-coolant system  29  render increased cooling efficiency as the liquid collects the heat dissipated in the component  23  chamber and transfers it to the cold side of the Stirling  22  via the heat exchanger  28 . In addition the use of liquid coolant, and, if desired in some embodiments, insulated coolant lines, allows a larger spatial separation between the Stirling cooler and the component to be cooled. 
     While the description related to  FIGS. 4-6  uses a free-piston Stirling cooler to illustrate embodiments of the invention, one of ordinary skill in the art would appreciate that other types of Stirling coolers may also be used, including those based on kinematic mechanisms—e.g., double-piston Stirling coolers and piston-and-displacer Stirling coolers. 
     In accordance with embodiments of the invention, Stirling coolers are used to cool electronics, sensors or other heat sensitive parts that need to function in the harsh downhole environment. In these embodiments, the electronics are disposed in an insulating chamber (e.g., a Dewar flask) and the cold end of the Stirling cooler is coupled to (either directly, via a heat pipe or another heat transport mechanism) one side of the chamber. It has been found that a substantial amount of heat (e.g., 150 W) could be removed with the cooler embodiments of the invention. Thus, it is possible to maintain an environment below 125° C. for the electronics, even when the temperature in the borehole may be 175° C. or higher. Model studies also indicate that the Stirling cooler embodiments of the invention are capable of removing heat at a rate of up to 400 W. 
     Some aspects of the invention relate to methods for producing a downhole electrical submersible pumping system having a Stirling cooling system. A schematic of a portion of a downhole electrical submersible pumping system including a Stirling cooler embodiment of the invention is illustrated in  FIG. 1 . A electrical submersible pumping system may be in oil and gas production. 
       FIG. 9  shows a process for producing an electrical submersible pumping system in accordance with one embodiment of the invention. As shown, the process  70  includes disposing an insulating chamber in a downhole tool that includes a submersible pump (step  72 ). The insulating chamber forms the wall of a gauge (shown as  104  in  FIGS. 1 and 2 ) and may be a Dewar flask or a chamber made of an insulating material suitable for downhole use. In some embodiments, the insulating chamber may be formed by a cutout on the insulating tool body. Then, the gauge electronics or sensors that need to function at relative low temperatures are placed into the insulating chamber (step  74 ). Alternatively, the electronics or sensors may be placed in the insulating chamber before the latter is placed proximate the submersible pump. Then, a Stirling cooler is disposed proximate the gauge of the submersible pumping system (step  76 ). Note that the relative order of placement of the Stirling cooler and the insulating chamber is not important, i.e., the Stirling cooler may be placed before the insulating chamber. Preferably, the Stirling cooler is placed proximate the insulating chamber. However, if space limitations do not permit placement of the Stirling cooler proximate the insulating chamber, the Stirling cooler may be placed at a distance from the insulating chamber (as shown in  FIG. 3 ) and a heat pipe or other heat transport device may be used to conduct heat from the insulating chamber to the Stirling cooler. 
       FIG. 10  shows a process for cooling a sensor or electronics in a gauge disposed in an electrical submersible pumping system in accordance with one embodiment of the invention. The process  150  includes providing a Stirling cooler in the submersible pumping system proximate a gauge having the sensor or electronics (step  151 ); and energizing the Stirling cooler such that heat is removed from the sensor or electronics in the gauge (step  152 ). 
     Advantages of the present invention include improved cooling/refrigeration techniques for submersible pumping systems. A submersible pump with a Stirling cycle cooling system in accordance with embodiments of the invention can keep the electrical components and sensors (e.g., those associated with a gauge designed for used with a submersible pumping system) at significantly lower temperatures, enabling these components to render better performance and longer service lives in harsh operating conditions. This in turn allows for improved production optimization in wells with harsh operating conditions. 
     While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.