# US 10,309,200 B2 · Sealless downhole system with magnetically supported rotor > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,309,200 B2 - Document ID: US10309200B2 - Status: Granted - Kind: B2 - Application number: 16/107,824 - Filed: 2018-08-21 - Published: 2019-03-21 - Granted: 2019-06-04 - Earliest claimed: 2017-09-20 - Assignees: Upwing Energy, LLC - Applicants: Upwing Energy, LLC - Inventors: Patrick McMullen; Herman Artinian; Kuo-Chiang Chen; David Biddick - Web page: https://patentgrep.com/patent/US10309200B2 ## CPC - H02K 7/09: with magnetic bearings - E21B 4/003: {Bearing, sealing, lubricating details (for roller bits E21B10/22)} - E21B 4/02: Fluid rotary type drives - E21B 4/04: Electric drives (E21B4/12 takes precedence) - E21B 17/028: {Electrical or electro-magnetic connections} - E21B 41/0085: {Adaptations of electric power generating means for use in boreholes} - E21B 43/121: {Lifting well fluids (monitoring of down-hole pump systems E21B47/008)} - E21B 47/008: Monitoring of down-hole pump systems, e.g. for the detection of "pumped-off" conditions - E21B 47/01: Devices for supporting measuring instruments on drill bits, pipes, rods or wirelines; Protecting measuring instruments in boreholes against heat, shock, pressure or the like - E21B 47/06: Measuring temperature or pressure - E21B 47/09: Locating or determining the position of objects in boreholes or wells {, e.g. the position of an extending arm}; Identifying the free or blocked portions of pipes - E21B 47/12: Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling - F04B 17/03: driven by electric motors - F04B 47/04: the driving means incorporating fluid means - F04D 3/00: Axial-flow pumps (priming or boosting F04D9/00) - F04D 13/026: {Details of the bearings} - F04D 13/0633: {Details of the bearings} - F04D 13/064: {Details of the magnetic circuit} - F04D 13/08: for submerged use - F04D 13/086: {the pump and drive motor are both submerged} - F04D 13/10: adapted for use in mining bore holes - F04D 25/0666: {a sensor is integrated into the pump/motor design} - F04D 29/041: Axial thrust balancing - F04D 29/046: Bearings - F04D 29/048: magnetic; electromagnetic - F04D 29/051: Axial thrust balancing - F16C 32/0402: {combined with other supporting means, e.g. hybrid bearings with both magnetic and fluid supporting means} - F16C 32/0406: {Magnetic bearings} - F16C 32/0444: {Details of devices to control the actuation of the electromagnets} - F16C 32/0446: {Determination of the actual position of the moving member, e.g. details of sensors} - F16C 32/0451: {Details of controllers, i.e. the units determining the power to be supplied, e.g. comparing elements, feedback arrangements with P.I.D. control} - F16C 32/0455: {including digital signal processing [DSP] and analog/digital conversion [A/D, D/A]} - F16C 32/0457: {Details of the power supply to the electromagnets} - F16C 32/0474: {for rotary movement} - F16C 32/0476: {with active support of one degree of freedom, e.g. axial magnetic bearings} - F16C 32/048: {with active support of two degrees of freedom, e.g. radial magnetic bearings} - F16C 32/0489: {with active support of five degrees of freedom, e.g. two radial magnetic bearings combined with an axial bearing} - F16C 37/005: {of magnetic bearings} - G01B 7/14: for measuring distance or clearance between spaced objects or spaced apertures (G01B7/30 takes precedence) - H02H 7/005: {for remote controlled apparatus; for lines connecting such apparatus} - H02K 1/2796: where both axial sides of the rotor face a stator - H02K 3/42: Means for preventing or reducing eddy-current losses in the winding heads, e.g. by shielding - H02K 5/132: Submersible electric motors (H02K5/128 takes precedence) - H02K 7/14: Structural association with mechanical loads, e.g. with hand-held machine tools or fans (with fan or impeller for cooling the machine H02K9/06) - H02K 7/1807: {Rotary generators (H02K7/006 takes precedence)} - H02K 11/20: for measuring, monitoring, testing, protecting or switching (rectifiers H02K11/04; power electronics H02K11/33) - H02K 11/21: Devices for sensing speed or position, or actuated thereby (specially adapted for machines having non-mechanical commutating devices H02K29/06, H02K29/14) - H02K 11/225: Detecting coils - H02K 11/27: Devices for sensing current, or actuated thereby (overcurrent protection responsive to temperature of the machines or parts thereof, e.g. windings, H02K11/25) - H02K 11/30: Structural association with control circuits or drive circuits - H02K 21/14: with magnets rotating within the armatures - H02P 29/40: Regulating or controlling the amount of current drawn or delivered by the motor for controlling the mechanical load - E21B 33/12: Packers; Plugs (used for cementing E21B33/134, E21B33/16) - E21B 43/128: {Adaptation of pump systems with down-hole electric drives} - E21B 43/168: {Injecting a gaseous medium} - E21B 47/07: Temperature - F04D 29/0473: {for radial pumps} - F16C 32/044: {Active magnetic bearings} - F16C 2352/00: Apparatus for drilling - F16C 2360/44: Centrifugal pumps - F16C 2380/26: Dynamo-electric machines or combinations therewith, e.g. electro-motors and generators - F16F 15/03: using {magnetic or} electromagnetic means (F16F9/53, {F16F15/005} take precedence) - H02K 1/2793: Rotors axially facing stators - H02K 5/128: using air-gap sleeves or air-gap discs - H02K 15/03: having permanent magnets - H02K 2201/12: Transversal flux machines - H02K 2205/03: Machines characterised by thrust bearings - H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53}) - E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS - F04B: POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS (machines for liquids, or pumps, of rotary-piston or oscillating-piston type F04C; non-positive-displacement pumps F04D; pumping of fluid by direct contact of another fluid or by using inertia of fluid to be pumped F04F) - F04D: NON-POSITIVE-DISPLACEMENT PUMPS (engine fuel-injection pumps F02M; ion pumps H01J41/12; electrodynamic pumps H02K44/02) - F16C: SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS - G01B: MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS - H02H: EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS (indicating or signalling undesired working conditions G01R, e.g. G01R31/00, G08B; locating faults along lines G01R31/08; emergency protective devices H01H) - H02P: CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS - F16F: SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION ## Abstract A fluid module includes a fluid rotor configured to rotatably drive or be driven by fluid produced from a wellbore. A first shaft is coupled to the fluid rotor. The first shaft is configured to rotate in unison with the fluid rotor. A thrust bearing module includes a thrust bearing rotor. A second shaft is coupled to the thrust bearing rotor. The second shaft is configured to rotate in unison with the thrust bearing rotor. The second shaft is coupled to the first shaft. An electric machine module includes an electric machine rotor. A third shaft is coupled to the electric machine rotor. A third shaft is configured to rotate in unison with the electric machine rotor. The third shaft is coupled to the second shaft. The third shaft is rotodynamically isolated from the first shaft and the second shaft. ## Claims ### Claim 1 A downhole-type artificial lift system comprising: a fluid module comprising: a fluid rotor configured to rotatably drive or be driven by fluid produced from a wellbore; a first shaft coupled to the fluid rotor, the first shaft configured to rotate in unison with the fluid rotor; and a fluid stator that surrounds the fluid rotor; a thrust bearing module comprising: a thrust bearing rotor; a second shaft coupled to the thrust bearing rotor, the second shaft configured to rotate in unison with the thrust bearing rotor, the second shaft coupled to the first shaft, the second shaft configured to transfer torque between the first shaft and the second shaft, the second shaft being rotodynamically isolated from the first shaft; and a thrust bearing stator that surrounds the thrust bearing rotor; and an electric machine module comprising: an electric machine rotor; a third shaft coupled to the electric machine rotor, the third shaft configured to rotate in unison with the electric machine rotor, the third shaft coupled to the second shaft or the first shaft, the third shaft configured to transfer torque between the second shaft and the third shaft or between the second shaft and the first shaft, the third shaft being rotodynamically isolated from the first shaft and the second shaft; and an electric stator that surrounds the electric machine rotors; wherein the system is configured to rotate the first shaft below a critical speed of the first shaft, rotate the second shaft below a critical speed of the second shaft, and rotate the third shaft below a critical speed of the third shaft. ### Claim 2 (depends on 1) The downhole-type artificial lift system of claim 1, wherein the critical speed of the first shaft, the critical speed of the second shaft, and the critical speed of the third shaft are greater than a critical speed of a single shaft of equivalent length to a sum of a length of the first shaft, a length of the second shaft, and a length of the third shaft. ### Claim 3 (depends on 1) The downhole-type artificial lift system of claim 1, wherein the system is configured to rotate the first shaft, the second shaft, and the third shaft at 10,000 revolutions per minute. ### Claim 4 (depends on 1) The downhole-type artificial lift system of claim 1, wherein the system is configured to rotate the first shaft, the second shaft, and the third shaft at 120,000 revolutions per minute. ### Claim 5 (depends on 1) The downhole-type artificial lift system of claim 1, wherein the fluid module is positioned at an uphole end of the system and the electric machine module is positioned at a downhole end of the system. ### Claim 6 (depends on 1) The downhole-type artificial lift system of claim 1, wherein the fluid module further comprises: a first magnetic radial bearing configured to support a first end of the first shaft to the fluid stator; and a second radial magnetic bearing configured to support a second end of the first shaft to the fluid stator. ### Claim 7 (depends on 1) The downhole-type artificial lift system of claim 1, wherein the electric machine module further comprises: a first magnetic radial bearing configured to support a first end of the second shaft to the electric stator; and a second radial magnetic bearing configured to support a second end of the second shaft to the electric stator. ### Claim 8 (depends on 1) The downhole-type artificial lift system of claim 1, wherein the thrust bearing module comprises a magnetic thrust bearing. ### Claim 9 (depends on 8) The downhole-type artificial lift system of claim 8, wherein the magnetic thrust bearing is an active magnetic thrust bearing. ### Claim 10 (depends on 1) The downhole-type artificial lift system of claim 1, wherein the thrust bearing module further comprises: a first magnetic radial bearing configured to support a first end of the second shaft to the thrust bearing stator; and a second radial magnetic bearing configured to support a second end of the second shaft to the thrust bearing stator. ### Claim 11 (depends on 1) The downhole-type artificial lift system of claim 1, wherein the fluid module is a first fluid module, the fluid rotor is a first fluid rotor, and the fluid stator is a first fluid stator, the downhole-type artificial lift system further comprising a second fluid module comprising: a second fluid rotor configured to rotatably drive or be driven by fluid produced from a wellbore; a fourth shaft coupled to the second fluid rotor, the fourth shaft configured to rotate in unison with the second fluid rotor, the fourth shaft being rotodynamically isolated from the first shaft, the second shaft, and the third shaft; and a second fluid stator that surrounds the second fluid rotor. ### Claim 12 (depends on 1) The downhole-type artificial lift system of claim 1, wherein the thrust bearing module is a first thrust bearing module, the thrust bearing rotor is a first thrust bearing rotor, and the thrust bearing stator is a first thrust bearing stator, the downhole-type artificial lift system further comprising a second thrust bearing module comprising: a second thrust bearing rotor; a fourth shaft coupled to the thrust bearing rotor, the fourth shaft configured to rotate in unison with the second thrust bearing rotor, the fourth shaft being rotodynamically isolated from the first shaft, the second shaft, and the third shaft; and a second thrust bearing stator that surrounds the second thrust bearing rotor. ### Claim 13 (depends on 1) The downhole-type artificial lift system of claim 1, wherein the electric machine module is a first electric machine module, the electric machine rotor is a first electric machine rotor, and the electric stator is a first electric stator, the downhole-type artificial lift system further comprising a second electric machine module comprising: a second electric machine rotor; a fourth shaft coupled to the second electric machine rotor, the fourth shaft configured to rotate in unison with the second electric machine rotor, the fourth shaft being rotodynamically isolated from the first shaft, the second shaft, and the third shaft; and a second electric stator that surrounds the second electric machine rotor. ### Claim 14 A method comprising: radially magnetically levitating a first rotor within a first stator; radially magnetically levitating a second rotor within a second stator; radially magnetically levitating a third rotor within a third stator; rotodynamically isolating the first rotor from the second rotor by a first rotodynamic isolator coupling; and rotodynamically isolating the second rotor from the third rotor by a second rotodynamic isolator; rotating the first shaft below a critical speed of the first rotor; rotating the second shaft below a critical speed of the second rotor; and rotating the third shaft below a critical speed of the third rotor. ### Claim 15 (depends on 14) The method of claim 14, further comprising rotating the first rotor, the second rotor, and the third rotor in unison at 10,000 revolutions per minute. ### Claim 16 (depends on 14) The method of claim 14, further comprising rotating the first rotor, the second rotor, and the third rotor in unison at 120,000 revolutions per minute. ### Claim 17 (depends on 14) The method of claim 14, further comprising axially supporting the first rotor, the second rotor, and the third rotor with a magnetic thrust bearing. ### Claim 18 (depends on 14) The method of claim 14, further comprising damping radial vibrations. ### Claim 19 (depends on 14) The method of claim 14, further comprising: exchanging torque between the first rotor and second rotor by a first rotodynamic isolator coupling, the first coupling configured to rotodynamically isolate the first rotor and second rotor from one another; and exchanging torque between the second rotor and the third rotor by a second rotodynamic isolator coupling, the second coupling configured to rotodynamically isolate the third rotor and second rotor from one another. ### Claim 20 (depends on 14) The method of claim 14, wherein an outer surface of the first rotor and an inner surface of the first stator form an annulus, the method further comprising flowing a wellbore production fluid through the annulus in an uphole direction. ### Claim 21 A wellbore production system comprising: a fluid module comprising: a fluid rotor configured to rotatably drive or be driven by fluid produced from a wellbore; a first shaft coupled to the fluid rotor, the first shaft configured to rotate in unison with the fluid rotor; a fluid stator that surrounds the fluid rotor; a first magnetic radial bearing configured to support a first end of the first shaft to the fluid stator; and a second radial magnetic bearing configured to support a second end of the first shaft to the fluid stator; a thrust bearing module comprising: a thrust bearing rotor; a second shaft coupled to the thrust bearing rotor, the second shaft configured to rotate in unison with the thrust bearing rotor, the second shaft coupled to the first shaft, the second shaft configured to transfer torque between the first shaft and the second shaft, the second shaft being rotodynamically isolated from the first shaft; and a thrust bearing stator that surrounds the thrust bearing rotor; and an electric machine module comprising: an electric machine rotor; a third shaft coupled to the electric machine rotor, the third shaft configured to rotate in unison with the electric machine rotor, the third shaft coupled to the second shaft or the first shaft, the third shaft configured to transfer torque between the second shaft and the third shaft or the first shaft, the third shaft being rotodynamically isolated from the first shaft and the second shaft; an electric stator that surrounds the electric machine rotor; a third magnetic radial bearing configured to support a first end of the second shaft to the electric stator; and a fourth radial magnetic bearing configured to support a second end of the second shaft to the electric stator; wherein the system is configured to rotate the first shaft below a critical speed of the first shaft, rotate the second shaft below a critical speed of the second shaft, and rotate the third shaft below a critical speed of the third shaft. ### Claim 22 (depends on 21) The wellbore production system of claim 21, wherein the system is configured to rotate the first shaft, the second shaft, and the third shaft at 60,000 revolutions per minute. ### Claim 23 (depends on 21) The wellbore production system of claim 21, wherein the thrust bearing module further comprises: a first magnetic radial bearing configured to support a first end of the second shaft to the thrust bearing stator; and a second radial magnetic bearing configured to support a second end of the second shaft to the thrust bearing stator. ### Claim 24 (depends on 21) The downhole-type artificial lift system of claim 21, wherein the thrust bearing module comprises a magnetic thrust bearing. ### Claim 25 (depends on 21) The wellbore production system of claim 21, wherein the fluid module is a first fluid module, the fluid rotor is a first fluid rotor, and the fluid stator is a first fluid stator, the wellbore production system further comprising a second fluid module comprising: a second fluid rotor configured to rotatably drive or be driven by fluid produced from a wellbore; a fourth shaft coupled to the second fluid rotor, the fourth shaft configured to rotate in unison with the second fluid rotor, the fourth shaft being rotodynamically isolated from the first shaft, the second shaft, and the third shaft; and a second fluid stator that surrounds the second fluid rotor. ### Claim 26 (depends on 21) The wellbore production system of claim 21, wherein the thrust bearing module is a first thrust bearing module, the thrust bearing rotor is a first thrust bearing rotor, and the thrust bearing stator is a first thrust bearing stator, the wellbore production system further comprising a second thrust bearing module comprising: a second thrust bearing rotor; a fourth shaft coupled to the thrust bearing rotor, the fourth shaft configured to rotate in unison with the second thrust bearing rotor, the fourth shaft being rotodynamically isolated from the first shaft, the second shaft, and the third shaft; and a second thrust bearing stator that surrounds the second thrust bearing rotor. ### Claim 27 (depends on 21) The wellbore production system of claim 21, wherein the electric machine module is a first electric machine module, the electric machine rotor is a first electric machine rotor, and the electric stator is a first electric stator, the wellbore production system further comprising a second electric machine module comprising: a second electric machine rotor; a fourth shaft coupled to the second electric machine rotor, the fourth shaft configured to rotate in unison with the second electric machine rotor, the fourth shaft being rotodynamically isolated from the first shaft, the second shaft, and the third shaft; and a second electric stator that surrounds the second electric machine rotor.