Electrical submersible pump (ESP) seal section service-less flange

A method of assembling an electric submersible pump (ESP) assembly and running it into a wellbore, comprising:

• hanging an electric motor above the wellbore, wherein the electric motor is filled with dielectric oil and comprises a drive shaft having an upper end that protrudes above the upper end of the electric motor and that defines male splines;
• lifting a seal section assembly above the electric motor, wherein the seal section assembly comprises
• a seal section having a drive shaft, wherein the seal section is filled with dielectric oil,
• a coupling assembly partially inserted into an opening at the lower end of the seal section and having a lower bore defining female splines for mating with the male splines of an upper end of the drive shaft of the electric motor, an upper bore defining female splines for mating with male splines of a lower end of the drive shaft of the seal section, and a coupling body, wherein the coupling body is substantially cylindrical and has a first outside diameter at an upper end of the coupling body, has a second outside diameter smaller than the first diameter below the portion of the coupling body having the first outside diameter, has a circumferential tapered shoulder between the portion of the coupling body having the first diameter and the portion of the coupling body having the second diameter, has a circumferential groove at the lower end of the portion of the coupling body having the second outside diameter, has a third outside diameter smaller than the second diameter below the portion of the coupling body having the second outside diameter,
• a service-less flange coupled to a lower end of the seal section, wherein the service-less flange defines a circumferential opening having a circumferential tapered shoulder on an upper edge that contacts the circumferential tapered shoulder of the coupling body,
• a retainer disposed in the circumferential grove of the coupling body that contacts a lower edge of the service-less flange, and
• an O-ring disposed between a circumferential groove in the circumferential opening of the service-less flange and the portion of the coupling body having the second diameter that provides a seal to retain the dielectric oil within the seal section;
• removing the retainer from the circumferential groove of the coupling body;
• lowering the seal section assembly to mate the female splines of the lower bore of the coupling assembly with the male splines of the drive shaft of the electric motor;
• and
• urging the coupling assembly upwards into the lower end of the seal section by the first drive shaft, wherein the female splines of the upper bore of the coupling assembly mate with male splines of a drive shaft of the seal section and the seal provided by the O-ring disposed between the circumferential opening of the service-less flange and the portion of the coupling body having the second diameter is released and fluid communication between the seal section and the electric motor is established via an annulus defined between the coupling assembly and an inside wall of the seal section.

A method of assembling an electric submersible pump (ESP) assembly and running it into a wellbore, comprising:

• hanging an electric motor above the wellbore, wherein the electric motor is filled with dielectric oil and comprises a drive shaft having an upper end that protrudes above the upper end of a motor head coupled to the upper end of the electric motor and that defines male splines;
• lifting a seal section assembly above the electric motor, wherein the seal section assembly comprises
• a seal section having a drive shaft, wherein the seal section is filled with dielectric oil,
• a coupling assembly partially inserted into an opening at the lower end of the seal section and having a lower bore defining female splines for mating with the male splines of the drive shaft of the electric motor, an upper bore defining female splines for mating with male splines of a lower end of the drive shaft of the seal section, and a coupling body, wherein the coupling body is substantially cylindrical and has a first outside diameter at an upper end of the coupling body, has a second outside diameter smaller than the first diameter below the portion of the coupling body having the first outside diameter, has a circumferential tapered shoulder between the portion of the coupling body having the first diameter and the portion of the coupling body having the second diameter, has a circumferential groove at the lower end of the portion of the coupling body having the second outside diameter, has a third outside diameter smaller than the second diameter below the portion of the coupling body having the second outside diameter,
• a service-less flange coupled to a lower end of the seal section, wherein the service-less flange defines a circumferential opening having a circumferential tapered shoulder on an upper edge that contacts the circumferential tapered shoulder of the coupling body,
• a retainer disposed in the circumferential grove of the coupling body that contacts a lower edge of the service-less flange, and
• a first O-ring disposed between a first circumferential groove in the circumferential opening of the service-less flange and the portion of the coupling body having the second diameter that provides a first seal to retain the dielectric oil within the seal section,
• a second O-ring disposed in a second circumferential groove in an outside of a lower portion of the service-less flange;
• removing the retainer from the circumferential groove of the coupling body;
• lowering the seal section assembly to mate the female splines of the lower bore of the coupling assembly with the male splines of the drive shaft of the electric motor;
• and
• urging the coupling assembly upwards into the lower end of the seal section by the drive shaft of the electric motor, wherein the female splines of the upper bore of the coupling assembly mate with the male splines of the drive shaft of the seal section, wherein the second O-ring engages with an inside diameter of the motor head making a second seal, and wherein the first seal provided by the first O-ring disposed between the first circumferential groove in the circumferential opening of the service-less flange and the portion of the coupling body having the second diameter is released after the second seal is established and fluid communication between the seal section and the electric motor is established via an annulus defined between the coupling assembly and an inside wall of the seal section.