US 11,916,451 B2
Axial flux submersible electric motor
Ketankumar Kantilal Sheth, Tulsa, OK (US); Donn J. Brown, Broken Arrow, OK (US); David Christopher Beck, Broken Arrow, OK (US); Robert Charles de Long, Sand Springs, OK (US); and Trevor Alan Kopecky, Owasso, OK (US)
Assigned to Halliburton Energy Services, Inc., Houston, TX (US)
Filed by Halliburton Energy Services, Inc., Houston, TX (US)
Filed on Mar. 9, 2021, as Appl. No. 17/196,235.
Claims priority of provisional application 63/007,052, filed on Apr. 8, 2020.
Prior Publication US 2021/0320563 A1, Oct. 14, 2021
Int. Cl. H02K 21/24 (2006.01); E21B 43/12 (2006.01); F04D 13/06 (2006.01); H02K 1/20 (2006.01); H02K 1/2796 (2022.01); H02K 5/124 (2006.01); H02K 5/132 (2006.01); H02K 5/20 (2006.01); H02K 5/22 (2006.01); H02K 7/00 (2006.01); H02K 7/108 (2006.01); H02K 9/19 (2006.01); H02K 11/21 (2016.01); H02K 16/04 (2006.01); E21B 47/008 (2012.01); E21B 49/08 (2006.01)
CPC H02K 21/24 (2013.01) [E21B 43/128 (2013.01); F04D 13/0666 (2013.01); H02K 1/20 (2013.01); H02K 1/2796 (2022.01); H02K 5/124 (2013.01); H02K 5/132 (2013.01); H02K 5/203 (2021.01); H02K 5/225 (2013.01); H02K 7/003 (2013.01); H02K 7/108 (2013.01); H02K 9/19 (2013.01); H02K 11/21 (2016.01); E21B 47/008 (2020.05); E21B 49/0875 (2020.05); H02K 16/04 (2013.01); H02K 2205/03 (2013.01); H02K 2213/12 (2013.01)] 22 Claims
OG exemplary drawing
 
1. A cooling system for an electric submersible pump (ESP) system disposed in a wellbore extending from an earth surface and penetrating a subterranean formation, comprising:
a submersible axial flux motor assembly compromising two or more detachable motor modules coupled together, wherein each motor module comprises a module housing with at least one stator and at least one rotor disposed therein with an axial gap therebetween, wherein at least one motor module comprises at least three stators and at least three rotors disposed within the corresponding module housing and having an axial gap therebetween, wherein each stator has a plurality of stator windings, wherein each rotor has a plurality of permanent magnets, wherein each rotor has a rotary shaft rotationally coupled together, and wherein the ESP system is configured to i) transport production fluids from the formation to the surface or ii) inject fluid from the surface to the formation; and
a heat exchanger system detachably coupled to the axial flux motor assembly to remove heat from the axial flux motor, wherein the heat exchanger system comprises an outer housing, an inner housing, and an oil pump, wherein the oil pump is configured to circulate a cooling fluid through the axial flux motor and between the outer housing and the inner housing to exchange heat with an ambient environment within the wellbore, wherein the heat exchanger system comprises first connection and a second connection, and wherein the first connection and second connection are each connectable to at least one of the two or more motor modules; and
wherein the module housing of each motor module is configured to detachably connect to the module housing of each other motor module of the two or more detachable motor modules, to jointly form a common housing of the axial flux motor assembly.