System and method for connecting load-bearing ESP power cables

Abstract

A pump system is configured to be deployed on a continuous armored cable in a well. The armored cable includes an outer layer structural wire, an inner layer structural wire, and a power cable within the inner layer structural wire. A cable adapter is connected between the pump system and the armored cable to transfer the weight of the pump system to the armored cable. The armored cable is connected to the pump system using a cable adapter that includes a compression cap, a collet cap, an upper collet, and a lower collet.

Description

Related Applications

[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 466,717, filed May 15, 2023, entitled “System and Method for Connecting Load Bearing ESP Power Cable,” the disclosure of which is incorporated herein by reference. TECHNICAL FIELD

[0002] The present invention relates generally to the use of electrical submersible pump systems to produce hydrocarbons from subterranean formations, and more particularly, but not exclusively, to systems and methods for deploying electrical submersible pump systems inside a wellbore. BACKGROUND

[0003] Submersible pump systems are commonly deployed into wells to extract oil fluids from subterranean reservoirs. Typically, a submersible pump system includes a plurality of components, including one or more electric motors coupled to one or more pumps. Each of the components and subcomponents in a submersible pump system are designed to withstand harsh downhole environments, including various temperatures, pressures, and corrosive well fluids.

[0004] Traditional submersible pump systems are connected to surface facilities and equipment through the interconnection of rigid production tubing. The pump system and tubing are typically laid inside a cased wellbore, and production fluids are pumped to the surface through the production tubing. Deployment and extraction of the pump system is a complex, expensive, and time-consuming operation because the downhole assembly is typically fixed to the lower joint of the production tubing, which requires an operator to assemble or disassemble the joint above the submersible pump system with a large workover rig. Workover rigs are typically expensive and difficult to procure.

[0005] As an alternative to the use of rigid production tubing, pump manufacturers have designed systems to install submersible pump systems inside a wellbore using coiled tubing systems. The TransCoil brand rigless deployment coiled tubing system developed by Baker Hughes is one such example. In these systems, coiled tubing can be used to provide power and support the weight of the submersible pump system. The submersible pump system can be configured to pump fluids to the surface through the annulus between the coiled tubing and the surrounding casing. In some cases, the use of a coiled tubing deployment system can reduce the installation time of a submersible pump system by more than 50%.

[0006] While these systems have achieved some commercial success, there remains a need for improved systems and methods for deploying an electric submersible pump system using coiled tubing. Specifically, there is a need for a system for quickly and securely connecting a pump system to coiled tubing that securely transfers the weight of the pump, motor, and other downhole equipment onto the armored cable. Embodiments of the present disclosure are directed precisely at this deficiency and others in the art. SUMMARY

[0007] In some embodiments, the present disclosure is directed to a pump system configured to be deployed in a well, where the pump system includes an armored cable, an electric motor, and a cable adapter. The armored cable includes an outer structural wire, an inner structural wire, and a power cable within the inner structural wire. The cable adapter is connected between the electric motor and the armored cable to transfer the weight of the electric motor onto the armored cable. In some embodiments, the cable adapter includes a compression cap, a collet cap, an upper collet, and a lower collet. The lower collet is directly or indirectly secured to the electric motor.

[0008] In other embodiments, the present disclosure is directed to a method for deploying a pump system into a well, where the pump system includes a pump connected to an electric motor. The method begins with the step of providing an armored cable having an outer structural wire, an inner structural wire, and a power cable within the inner structural wire. The method further includes the step of providing a cable adapter having a collet cap, a lower collet, an upper collet between the collet cap and the lower collet, and a compression cap. The method continues with the steps of extending the armored cable through the compression cap, threading the power cable through the lower collet to the electric motor, securing the outer structural wire between the collet cap and the upper collet, securing the inner structural wire between the upper collet and the lower collet, connecting the compression cap to the lower collet to apply a compression force between the lower collet and the collet cap, thereby constraining the outer structural wire and the inner structural wire within the cable adapter, and running the pump and motor into the well while transferring the weight of the pump and the motor onto the armored cable through the cable adapter.

[0009] In other embodiments, the present disclosure is directed to a method for connecting a power cable adapter to an armored power cable, the armored power cable comprising an outer structural wire, an inner structural wire, and a power cable within the inner structural wire. The method comprises the steps of: placing the outer structural wire between an upper collet and a collet cap; placing the inner structural wire between a lower collet and the upper collet; compressing the collet cap, the upper collet, and the lower collet using a tooling fixture; securing the upper collet to the collet cap using a first plurality of set pins; securing the lower collet to the upper collet using a second plurality of set pins; releasing the compression applied to the collet cap, the upper collet, and the lower collet by the tooling fixture; and installing a compression cap onto the lower collet and the collet cap to apply a compression force between the lower collet, the upper collet, and the collet cap. BRIEF DESCRIPTION OF DRAWINGS

[0010] Figure 1 A pump system constructed and installed in accordance with an exemplary embodiment is depicted.

[0011] Figure 2 is a cross-sectional view of an armored power cable for a pump system Figure 1 suspended from an electric motor and pump.

[0012] Figure 3A and Figure 3B A side view and exploded view of a power cable adapter and armored power cable are shown.

[0013] Figure 4A and Figure 4B A side view and cross-sectional view of a collet cap are shown.

[0014] Figure 5A and Figure 5B A side view and cross-sectional view of an upper collet are shown.

[0015] Figure 6A and Figure 6B A side view and cross-sectional view of a lower collet are shown.

[0016] Figure 7A and Figure 7B A side view and cross-sectional view of a compression cap are shown.

[0017] Figure 8 A perspective view of an armored power cable and power cable adapter in a first step of assembly is shown.

[0018] Figure 9 A perspective view of an armored power cable and power cable adapter in a second step of assembly is shown.

[0019] Figure 10 A perspective view of an armored power cable and power cable adapter in a third step of assembly is shown.

[0020] Figure 11A and Figure 11B A perspective view and a cross-sectional view of the armored power cable and the power cable adapter in a fourth step of assembly are provided.

[0021] Figure 12A and Figure 12B A perspective view and a cross-sectional view of the armored power cable and the power cable adapter in a fifth step of assembly are provided.

[0022] Figure 13A and Figure 13B A perspective view and a cross-sectional view of the armored power cable and the power cable adapter in a sixth step of assembly are provided.

[0023] Figure 14 is a perspective view of a crimping machine configured to assist in assembling a power cable adapter on an armored power cable.

[0024] Figure 15A and Figure 15B A perspective view and a cross-sectional view of the armored power cable and the power cable adapter in a sixth step of assembly are provided. Figure 14 A side view and a cross-sectional view of the crimping machine of DETAILED DESCRIPTION

[0025] According to exemplary embodiments of the present invention, Figure 1 A front view of a first embodiment of a pump system 100 installed in a well 102 within a reservoir 104 is shown. The well 102 includes a casing 106, a wellhead 108, and a lower completion 110. The pump system 100 is coupled to the lower completion 110, which can include a packer that forces reservoir fluid entering the well 102 through perforations 112 into the pump system 100.

[0026] In the embodiment shown, Figure 1 The pump system 100 includes a motor 114, a seal section 116, and a pump 118. The pump system 100 is configured in an "inverted" orientation, with the pump 118 positioned below the motor 114. The pump 118 includes a lower inlet 120 and an upper discharge 122 configured to produce fluid through an annular space 124 between the pump system 100 and the casing 106, where the fluid can be extracted through the wellhead 108. Although the pump system 100 is well suited for pumping oil fluids from the reservoir 104, it should be understood that the cable-supported pump system 100 can also be configured to produce fresh water, salt water, or other fluids from the reservoir 104. Additionally, it should be understood that the reservoir 104 and the well 102 can be located onshore or offshore.

[0027] The pump system 100 includes an armored cable 126, which can be a continuous piece of tubing. The armored cable 126 includes an outer structural casing 128 and an inner power cable 130.Figure 2 A cross-sectional view of the armored cable 126 is depicted. The inner power cable 130 includes one or more conductors 132 and one or more insulating layers 134 surrounding the conductors 132. In Figure 2 In the illustrated embodiment, the structural sleeve 128 includes an inner layer of structural wire 136 and an outer layer of structural wire 138, both of which are encased by an outer sheath 140. The outer sheath 140 can be composed of one or more polymers that protect the inner and outer layers of structural wire 136, 138 from abrasion or contact with wellbore fluids.

[0028] The inner and outer layers of structural wire 136, 138 each include a plurality of separable strands that are twisted or braided together. When the outer sheath 140 is removed, the free ends of the inner and outer layers of structural wire 136, 138 can be separated by bending the individual wires of the outer layer of structural wire 138 away from the inner layer of structural wire 136 and bending the individual wires of the inner layer of structural wire 136 away from the inner power cable 130. As used herein, the term “layer” refers to a collection of wires or strands in either the inner layer of structural wire 136 or the outer layer of structural wire 138.

[0029] The pump system 100 also includes a cable adapter 142 that is configured to connect the armored cable 126 to the motor 114 or other components within the pump system 100. As explained herein, the cable adapter 142 provides a secure connection between the pump system 100 and the structural sleeve 128 of the armored cable 126 that can be easily assembled on-site prior to deploying the pump system 100 and armored cable 126 into the well 102. During deployment, the weight of the pump system 100 is transferred through the cable adapter 142 onto the inner and outer layers of structural wire 136, 138 of the structural sleeve 128 of the armored cable 126.

[0030] Turning to Figure 3A and Figure 3B showing a side view and an exploded view of a portion of the armored cable 126 and the cable adapter 142, respectively. The cable adapter 142 includes a lower collet 144, an upper collet 146, a collet cap 148, and a compression cap 150. Generally, the outer layer of structural wire 136 is constrained between the collet cap 148 and the upper collet 146, while the inner layer of structural wire 138 is constrained between the upper collet 146 and the lower collet 144. Once installed, the compression cap 150 exerts a compression force between the collet cap 148 and the lower collet 144, thereby constraining the inner and outer layers of structural wire 136, 138 within the cable adapter 142.

[0031] Turning to Figure 4A and Figure 4BThe diagram shows a side view and a cross-sectional view of the chuck cap 148. The chuck cap 148 has a generally cylindrical chuck cap body 152, which includes a tapered internal channel 154, an upper surface 156, and a lower contact ring 158. The chuck cap 148 includes a plurality of alignment holes 160 extending through the lower contact ring 158. The chuck cap 148 also includes a plurality of locating pin holes 162 extending from the outer cylindrical surface of the chuck cap body 152 into the tapered internal channel 154. The tapered internal channel 154 may include grooves, channels, crosshairs, or other friction elements to improve contact with the outer structure line 138. In some embodiments, the locating pin holes 162 intersect with the alignment holes 160. As will be explained in more detail below, one or more alignment holes in alignment holes 160 are configured to receive corresponding alignment pins 164, and one or more locating pin holes in locating pin holes 162 are configured to receive corresponding locating pins 166.

[0032] Go to Figure 5A and Figure 5B The diagram shows a side view and a cross-sectional view of the upper chuck 146. The upper chuck 146 has a cylindrical base 168 and a tapered head 170 extending from the cylindrical base 168. The upper chuck 146 includes an upper circular channel 172 located at the junction between the tapered head 170 and the cylindrical base 168. The upper chuck 146 includes a lower contact ring 174 located at the bottom of the cylindrical base 168. An alignment hole 176 extends through the upper circular channel 172 and the lower contact ring 174 into the cylindrical base 168. The tapered head 170 may include grooves, channels, crosshairs, or other friction elements to improve contact with the outer structure line 138.

[0033] The cylindrical base 168 includes a tapered internal channel 178 that transitions into a cylindrical channel 180 within the tapered head 170. The upper chuck 146 includes an elliptical upper locating pin groove 182 and a lower locating pin hole 184, the upper locating pin groove extending through the tapered head 170 into the cylindrical channel 180, and the lower locating pin hole extending through the cylindrical base 168 into the tapered internal channel 178. The tapered internal channel 178 may include grooves, channels, crosshairs, or other friction elements to improve contact with the inner structure line 136.

[0034] When collet cap 148 is brought near upper collet 146, the tapered head 170 of upper collet 146 fits within the tapered interior channel 154 of collet cap 148. The wedge-shaped interface secures outer structural wire 138 between upper collet 146 and collet cap 148. The positioning pin hole 162 of collet cap 148 aligns with the upper positioning pin slot 182 of upper collet 146. Rotation or lateral position of collet cap 148 and upper collet 146 can be fixed by aligning the alignment hole 160 of collet cap 148 with the alignment hole 176 of upper collet 146. Alignment pin 164 extends into both alignment hole 160 and alignment hole 176 to maintain alignment between upper collet 146 and collet cap 148. In an example embodiment, the total length of alignment hole 160 and alignment hole 176 is greater than the length of corresponding alignment pin 164, which allows upper collet 146 and collet cap 148 to shift in the longitudinal (axial) direction when assembling cable adapter 142 without losing alignment.

[0035] Collet cap 148 can be locked into place on upper collet 146 by passing positioning pin 166 through positioning pin hole 162 of collet cap 148 and into the corresponding upper positioning pin slot 182 of upper collet 146. The oval shape of upper positioning pin slot 182 allows for some degree of longitudinal (axial) movement between upper collet 146 and collet cap 148. In this way, upper collet 146 and collet cap 148 are configured to cooperatively constrain the strands of outer structural wire 138 between tapered head 170 and tapered interior channel 154 and between lower contact ring 158 and upper circular channel 172.

[0036] Turning to Figure 6A and Figure 6B showing side and cross-sectional views of lower collet 144, respectively. Lower collet 144 has a cylindrical base 186 and a tapered head 188 extending from cylindrical base 186. Cylindrical base 186 includes an externally threaded portion 190. Lower collet 144 includes an upper circular channel 192 at the junction between tapered head 188 and cylindrical base 186. Lower collet 144 includes a central channel 194 extending through lower collet 144. Central channel 194 is sized to allow power cable 130 to pass through lower collet 144. As Figure 10 and Figure 12B depicted best in Figs. 16 and 17, alignment hole 196 extends through upper circular channel 192 into cylindrical base 186. Lower collet 144 can include additional threading or flanges to allow lower collet 144 to attach to motor 114 or other components within pump system 100. Tapered head 188 can include grooves, channels, cross-hatching, or other friction elements to improve contact with inner structural wire 136.

[0037] The lower collet 144 includes an oblong upper dowel slot 198 extending through the tapered head 188 to a central passage 194. When the upper collet 146 is brought close to the lower collet 144, the tapered head 188 of the lower collet 144 fits within the tapered interior passage 178 of the upper collet 146. The wedge-shaped engagement between the lower collet 144 and the upper collet 146 secures the inner layer structural wire 136. The lower dowel hole 184 of the upper collet 146 is aligned with the upper dowel slot 198 of the lower collet 144. The rotational or lateral position of the upper collet 146 and the lower collet 144 can be fixed by aligning the alignment hole 176 of the upper collet 146 with the alignment hole 196 of the lower collet 144. The alignment pin 164 extends into both the alignment hole 196 and the alignment hole 176 to maintain the alignment between the upper collet 146 and the lower collet 144. In an exemplary embodiment, the total length of the alignment hole 196 and the alignment hole 176 is greater than the length of the corresponding alignment pin 164, which allows the upper collet 146 and the lower collet 144 to be displaced in the longitudinal direction when assembling the cable adapter 142 without losing alignment.

[0038] The upper collet 146 can be locked onto the lower collet 144 by passing the dowel pin 166 through the lower dowel hole 184 of the upper collet 146 and inserting it into the corresponding upper dowel slot 198 of the lower collet 144. The larger oblong shape of the upper dowel slot 198 allows for a certain degree of longitudinal movement between the upper collet 146 and the lower collet 144. In this way, the upper collet 146 and the lower collet 144 are configured to cooperatively constrain the strands of the inner layer structural wire 136 between the tapered head 188 and the tapered interior passage 178 and between the lower contact ring 174 and the upper circular passage 192.

[0039] Turning to Figure 7A and Figure 7B showing side and cross-sectional views of the compression cap 150, respectively. The compression cap 150 has a cylindrical body 200 that includes an upper passage 202, an inner cavity 204, an inner abutment face 206, and an inner threaded portion 208. The upper passage 202 is sized to receive the outer jacket 140 of the armored cable 126. The inner cavity 204 is connected with the upper passage 202 and is sized to enclose the collet cap 148, the upper collet 146, and the lower collet 144.

[0040] When the lower collet 144, the upper collet 146, and the collet cap 148 have been assembled, the compression cap 150 is lowered onto the collet cap 148, the upper collet 146, and the lower collet 144 such that the inner abutment surface 206 is in contact with the upper surface 156 of the collet cap 148 and the internally threaded portion 208 is engaged with the externally threaded portion 190 of the lower collet 144. In this way, a compression force is exerted between the lower collet 144 and the collet cap 148 when the compression cap 150 is threaded onto the lower collet 144. This eliminates any axial play between the collet cap 148, the upper collet 146, and the lower collet 144, thereby securely constraining the inner layer of structural wires 136 and the outer layer of structural wires 138 within the cable adapter 142. In Figure 7A and Figure 7B In the embodiment shown, the compression cap 150 includes a tool flat 210 that can be used to properly tighten the compression cap 150 onto the lower collet 144 using a wrench or similar tool, thereby exerting an appropriate compression within the cable adapter 142. In some embodiments, properly tightening the compression cap 150 will crimp or sever the inner and outer layers of structural wires 136, 138 between the lower collet 144 and the upper collet 146 and between the upper collet 146 and the collet cap 148, respectively.

[0041] Turning to Figure 8 to Figure 1 3, an indication of the various steps in the process of assembling the cable adapter 142 and the armored cable 126 is shown. In Figure 8 , the armored cable 126 has been extended through the collet cap 148, and the strands of the outer layer of structural wires 138 have been separated from the inner layer of structural wires 136. The strands of the outer layer of structural wires 138 are separated and spread around the outside of the tapered head 170 of the upper collet 146. The inner layer of structural wires 136 and the power cable 130 are extended through the upper circular passage 192 of the lower collet 144, and the strands of the inner layer of structural wires 136 are separated and spread around the outside of the tapered head 188 of the lower collet 144. The alignment pin 164 is inserted into the alignment hole 176 of the upper collet 146, in preparation for the joining of the collet cap 148 and the lower collet 144.

[0042] In Figure 9 , Figure 10 , Figure 11A and Figure 11BIn the middle, collet cap 148, upper collet 146, and lower collet 144 have been compressed together and aligned so that alignment pins 164 extend between alignment holes 160, 176, and alignment holes 196. Positioning pins 166 have been inserted to maintain the longitudinal position of collet cap 148 on upper collet 146, and the longitudinal position of upper collet 146 on lower collet 144. Strands of outer layer structural wire 138 are constrained between collet cap 148 and upper collet 146, while strands of inner layer structural wire 136 are constrained between upper collet 146 and lower collet 144. The ends of the wires of inner layer structural wire 136 and outer layer structural wire 138 can be seen extending radially outward from cable adapter 142.

[0043] As shown in Figure 12A and Figure 12B the exposed ends of the strands of inner layer structural wire 136 and outer layer structural wire 138 are trimmed or trimmed prior to installation of compression cap 150. The ends of the strands of inner layer structural wire 136 and outer layer structural wire 138 can be trimmed using a wire cutter or saw. In some embodiments, lower contact ring 158 of collet cap 148 and upper circular channel 172 of upper collet 146 each have a beveled mating surface that together trim the ends of the strands of outer layer structural wire 138 when collet cap 148 is compressed into upper collet 146. Similarly, lower contact ring 174 of upper collet 146 and upper circular channel 192 of lower collet 144 can also be fitted with mating cutting surfaces that sever the ends of the strands of inner layer structural wire 136 when upper collet 146 and lower collet 144 are compressed together.

[0044] In Figure 13A and Figure 13B compression cap 150 has been lowered onto collet cap 148, upper collet 146, and lower collet 144. Compression cap 150 is then threaded onto lower collet 144 and tightened to the appropriate specification, thereby constraining the compression force applied to inner layer structural wire 136 and outer layer structural wire 138 by collet cap 148, upper collet 146, and lower collet 144. Cable adapter 142 is fully assembled and can be connected to motor 114 or another component of pump system 100.

[0045] In some embodiments, armored cable 126 includes a single layer of structural wire, and cable adapter 142 includes a single collet and collet cap. In other embodiments, armored cable 126 includes more than two layers of structural wire, and cable adapter includes a corresponding number of collets for securing each layer of structural wire.

[0046] While cable adapter 142 can be assembled using clamps, vise grips, or other hand tools, in certain applications it can be desirable to assemble using a hydraulic assembly tool. Turning to Figure 14wherein an assembly tool 300 is shown configured to apply a compression force to the cable adapter 142 during assembly. The assembly tool 300 is generally configured as a manual or electrically powered hydraulic crimping machine positionable around the cable adapter 142. The assembly tool 300 includes a lower plate 302, an upper plate 304, and a pair of tie rods 306 extending through the upper plate 302 and the lower plate 304. In some embodiments, the tie rods 306 are threaded and an adjustment nut 308 can be used to control the distance between the upper plate 302 and the lower plate 304.

[0047] The upper plate 304 includes two halves 304a, 304b connected by plate bolts 310. In the illustrated embodiment, the upper plate halves 304a, 304b each extend between two tie rods 306. This allows the upper plate 304 to be removed from the tie rods 306. The upper plate 304 includes an upper plate center hole 312. The lower plate 302 includes a lower plate center hole 314. The lower plate 302 can be configured as a single piece or multiple pieces connected together using lower plate bolts (not shown). Figure 14

[0048] The assembly tool 300 also includes a cylinder body 316 connected between the tie rods 306 and outside of the upper plate 304. In the illustrated embodiment of FIG. 16, the cylinder body 316 includes two halves 316a, 316b secured together using cylinder body bolts 318. Each cylinder plate half 316a, 316b includes one cylinder 320. The cylinder 320 can be a hydraulic cylinder including a coupler 322 and a plunger 324. When the two cylinder plate halves 316a, 316b are connected together, the cylinder body includes a cylinder body center hole 326 between the two cylinders 320. The cylinder body center hole 326 is axially aligned with the upper plate center hole 312 and the lower plate center hole 314.

[0049] When the cylinders 320 are connected through the couplers 322 to a hydraulic pump or generator producing a source of controllably pressurized hydraulic fluid, the plungers 324 extend out of the cylinders 320 and contact the upper plate 304. To ensure that both cylinders 320 apply substantially the same force, a flow divider or manifold (not shown) can be used to supply pressure-equalized hydraulic fluid. In some embodiments, the hydraulic cylinders 320 are double-acting and can be retracted by reversing the direction of the hydraulic fluid. In other embodiments, the hydraulic cylinders are single-acting cylinders that can be retracted by lowering the pressure of the cylinders 320 and pressing the upper plate 304 towards the cylinder body 316. Although the assembly tool 300 has been disclosed as a hydraulic driven crimping machine, it should be understood that in other embodiments, the upper plate 304 of the assembly tool 300 is driven by a pneumatic cylinder or a threaded telescoping rod that can be turned by hand or an electric motor.

[0050] Turning to Figure 15A and​Figure 15B wherein side and cross-sectional views of the cable adapter 142 and the armored cable 126 in the assembly tool 300 are shown. Initially, the compression cap 150 should be installed onto the armored cable 126. Then, a portion of the outer sheath 140 below the compression cap 150 is removed to expose the outer structural wires 138 and the inner structural wires 136. The un-sheathed armored cable 126 is inserted through the collet cap 148, and the outer structural wires 138 are separated and distributed around the outside of the tapered head 170 of the upper collet 146, while the inner structural wires 136 and the power cable 130 pass through the upper collet 146. Then, the inner structural wires 136 are separated and distributed around the outside of the tapered head 188 of the lower collet 144, while the power cable extends through the central passage 194 of the lower collet 144.

[0051] The compression cap 150, the collet cap 148, the upper collet 146, the lower collet 144, and the armored cable 126 can then be placed into the assembly tool 300 by separating the upper plate 304 and the cylinder body 316. The lower collet 144 remains within the lower plate central bore 314, the collet cap 148 is secured within the upper plate central bore 312, the armored power cable extends upward through the cylinder body central bore 326, and the compression cap 150 remains on the armored cable 126 above the assembly tool 300.

[0052] The assembly tool 300 can then be activated by supplying pressurized hydraulic fluid to the cylinder 320, thereby forcing the plunger 324 and the upper plate 304 to move downward toward the lower plate 302. The upper plate 304 moves downward, applying a compression force between the collet cap 148 and the lower collet 144 that compresses and constrains the inner structural wires 136 and the outer structural wires 138 within the cable adapter 142. Excess structural wires can be trimmed before, after, or during the application of compression force by the assembly tool 300.

[0053] Once the assembly tool 300 has properly compressed the collet cap 148, the upper collet 146, and the lower collet 144, the dowel pin 166 can be inserted, locking these components together in a compressed state. The cylinder 320 can then be depressurized and retracted. As explained above, because the upper dowel pin slot 198 and the upper dowel pin slot 182 are elongated, the collet cap 148, the upper collet 146, and the lower collet 144 can expand slightly in the longitudinal (axial) direction.

[0054] The armored cable 126 and cable adapter 142 can then be removed from the assembly tool 300 by separating the cylinder body 316 and the upper plate 304. The compression cap 150 can then be lowered over the collet cap 148, upper collet 146, and lower collet 144. Once the internal threaded portion 208 of the compression cap 150 engages the external threaded portion 190 of the lower collet 144, the compression cap 150 can be tightened onto the lower collet 144 to re-compress the collet cap 148, upper collet 146, and lower collet 144. In example embodiments, the assembly tool 300 is used to connect the cable adapter 142 with the armored cable 126 at a well site. In other embodiments, the assembly tool 300 is used to secure the cable adapter 142 onto the armored cable 126 during manufacturing.

[0055] It should be understood that although various features and advantages of the various embodiments of the present application have been set forth in the foregoing description, and various embodiments of the application have been described herein in the context of particular embodiments, but the application is not limited to these embodiments alone, and that details of the structure and function of the various embodiments of the application can be modified in various ways, and that other embodiments of the application will be apparent to those skilled in the art from the teachings herein, especially in light of the teachings from the appended claims. It should also be understood that where the claims recite "a," "an," or "the" preceding any plural element or elements, these terms are to be interpreted as excluding only the singular and not the plural. The disclosure is to be construed to cover all alternatives falling within the scope of the claims.

Claims

1. A pump system configured for deployment in a well, the pump system comprising: Armored cable, wherein the armored cable comprises: Outer structural lines; Inner structural lines; and Power cable, the power cable being located within the inner structure wire; Electric motor; and A cable adapter, which connects the motor and the armored cable to transfer the weight of the motor to the armored cable.

2. The pump system of claim 1, wherein the cable adapter comprises: Compression cap; Beanie; Upper clamp; and The lower chuck is capable of being fixed to the motor.

3. The pump system according to claim 2, wherein the upper clamp comprises: Conical head and upper circular channel; and Conical internal channel and lower contact ring.

4. The pump system of claim 3, wherein the chuck cap includes a tapered internal channel for engaging with the tapered head of the upper chuck, and a lower contact ring for engaging with the upper circular channel of the upper chuck.

5. The pump system of claim 4, wherein the outer structural line is constrained between the conical head of the upper clamp and the conical internal channel of the clamp cap.

6. The pump system of claim 4, wherein the outer structural line is constrained between the upper circular channel of the upper chuck and the lower contact ring of the chuck cap.

7. The pump system of claim 6, wherein the lower clamp comprises a conical head and an upper circular channel.

8. The pump system of claim 7, wherein the inner layer structure line is constrained between the tapered head of the lower clamp and the tapered internal channel of the upper clamp.

9. The pump system of claim 7, wherein the inner layer structure line is constrained between the lower contact ring of the upper clamp and the upper circular channel of the lower clamp.

10. The pump system of claim 2, wherein the compression cap is connected to the lower clamp to apply a compressive force between the lower clamp and the clamp cap.

11. The pump system of claim 10, wherein the lower collet further includes an external thread, and the compression cap further includes an internal thread, and wherein the compression cap is threadedly connected to the lower collet to apply a compressive force between the lower collet and the collet cap.

12. The pump system of claim 10, wherein the lower clamp includes a central channel, and the power cable extends through the central channel.

13. A method for deploying a pump system into a well, wherein the pump system includes a pump connected to an electric motor, the method comprising the steps of: An armored cable is provided, the armored cable comprising an outer structural wire, an inner structural wire, and a power cable within the inner structural wire; A cable adapter is provided, the cable adapter including a clamp cap, a lower clamp, an upper clamp between the clamp cap and the lower clamp, and a compression cap; The armored cable extends through the compression cap; The power cable is passed through the lower clamp and led to the motor; The outer structural line is fixed between the chuck cap and the upper chuck; The inner layer structure line is fixed between the upper clamp and the lower clamp; The compression cap is connected to the lower clamp to apply a compressive force between the lower clamp and the clamp cap, thereby constraining the outer layer structure line and the inner layer structure line within the cable adapter; The pump and motor are lowered into the well, and the weight of the pump and motor is transferred to the armored cable via the cable adapter.

14. The method of claim 13, wherein the step of fixing the outer structural line between the chuck cap and the upper chuck comprises: The outer structure line is unfolded around the conical head and upper circular channel of the upper clamp; as well as Bring the upper chuck close to the chuck cap, such that the outer structural line is constrained between the tapered head of the upper chuck and the tapered inner channel in the chuck cap, and between the upper circular channel of the upper chuck and the lower contact ring of the chuck cap.

15. The method of claim 13, wherein the step of fixing the inner layer structure line between the upper clamp and the lower clamp comprises: The inner structure lines are unfolded around the conical head and upper circular channel of the lower clamp; as well as The lower chuck is brought close to the upper chuck, such that the inner layer structure line is constrained between the tapered head of the lower chuck and the tapered internal channel in the upper chuck, and between the upper circular channel of the lower chuck and the lower contact ring of the upper chuck.

16. The method of claim 13, prior to the step of connecting the compression cap to the lower clamp to apply a compressive force between the lower clamp and the clamp cap, thereby constraining the outer layer structure wire and the inner layer structure wire within the cable adapter, the method further comprises the following steps: Insert multiple positioning pins between the chuck cap and the upper chuck.

17. The method of claim 13, prior to the step of connecting the compression cap to the lower clamp to apply a compressive force between the lower clamp and the clamp cap, thereby constraining the outer layer structure wire and the inner layer structure wire within the cable adapter, the method further comprises the following steps: Insert multiple locating pins between the upper clamp and the lower clamp.

18. The method of claim 13, prior to the step of connecting the compression cap to the lower clamp to apply a compressive force between the lower clamp and the clamp cap, thereby constraining the outer layer structure wire and the inner layer structure wire within the cable adapter, the method further comprises the following steps: Trim the excess length of the outer and inner structural lines.

19. A method for connecting a cable adapter to an armored cable, the armored cable comprising an outer structural wire, an inner structural wire, and a power cable within the inner structural wire, the method comprising the steps of: Place the outer structural line between the upper clamp and the clamp cap; The inner layer structure line is placed between the lower clamp and the upper clamp; The chuck cap, the upper chuck, and the lower chuck are compressed using an assembly tool; The upper clamp is secured to the clamp cap using a first plurality of locating pins; The lower clamp is secured to the upper clamp using a second plurality of locating pins; Release the compression applied to the chuck cap, the upper chuck, and the lower chuck by the assembly tool; as well as The compression cap is installed on the lower chuck and the chuck cap to apply a compressive force between the lower chuck, the upper chuck, and the chuck cap.

20. The method of claim 19, wherein the step of compressing the chuck cap, the upper chuck, and the lower chuck using an assembly tool comprises: The chuck cap, the upper chuck, and the lower chuck are placed between the upper and lower plates of the assembly tool; as well as One or more hydraulic cylinders are activated to push the upper plate toward the lower plate, thereby compressing the chuck cap, the upper chuck, and the lower chuck.

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