Integral penetrator tubing hanger

Abstract

An integrated penetrator tubing hanger, comprising a tubing hanger comprising a cylindrical body comprising a top end, a bottom end, an outside surface, and a bore defined therethrough forming an inside surface; a penetrator integrated within the bore of the tubing hanger, the penetrator comprising: a first conductor for receiving electrical power from and connecting to an electrical power source; an insulating body coupled to the first conductor, the insulating body having an electrical terminal that establishes electrical connections between the first conductor and a plurality of electrical terminal pins; a first seal coupled to the first conductor for protecting the first conductor; a second seal coupled to a downhole cable for protecting the electrical connection between the electrical terminal and the downhole cable, wherein the first and second seals and the insulating body are wholly disposed within a tubing hanger.

Description

CROSS-REFERENCE SECTION

[0001] This application is a U.S. Non-Provisional Application claiming priority to U.S. Provisional Application No. 63 / 708,868, filed on Oct. 18, 2024, which is incorporated by reference in its entirety.FIELD OF THE DISCLOSURE

[0002] This application relates to wellbore systems having hanger assemblies used in hydrocarbon recovery operations.BACKGROUND

[0003] Drilling operations continually occur at great depths, where the pressure is increased on the equipment used for drilling. One of the main reasons drilling equipment fails is the electrical connectors (sometimes referred to as “electrical penetrator” systems) are exposed to well fluid intrusion, heat, and poor insulation due to pressure and temperature. In addition to the effect of fluid intrusion, resulting in electric shorts between the connector's pins, the connector's geometry and materials also contribute to electric shorts occurring. The high voltages / currents, the short distance between the pins, and the presence of well fluids significantly increase the risk for shorts.

[0004] Conventional electrical penetrator systems also require that a separate penetrator component be disposed into the tubing hanger, thus requiring that penetrator components extend below the tubing hanger body.

[0005] A new approach to addressing these issues is presented herein.SUMMARY

[0006] According to one aspect of the subject matter described in this disclosure, an electrical connector is provided. The electrical connector includes a first conductor for receiving electrical power. A first seal is coupled to the first conductor for protecting the first conductor. An insulating body is coupled to the first conductor and includes an electrical terminal that establishes electrical connections between the first conductor and a plurality of electrical terminal pins. A downhole cable is coupled to a first electrical terminal pin of the plurality of electrical terminal pins. The first electrical terminal pin establishes an electrical connection between the electrical terminal and the downhole cable to provide the electric power to the downhole cable. A second seal is coupled to the downhole cable for protecting the electrical connection between the electrical terminal and the downhole cable.

[0007] According to another aspect of the subject matter described in this disclosure, a method of manufacturing an electrical connector is provided. The method includes providing a first conductor for receiving electrical power and coupling a first seal to the first conductor for protecting the first conductor. Also, the method includes positioning the first conductor in an insulating body. The insulating body includes an electrical terminal that establishes electrical connections between the first conductor and a plurality of electrical terminal pins. In addition, the method includes coupling a downhole cable to a first electrical terminal pin of the plurality of electrical terminal pins. Moreover, the method includes establishing an electrical connection between the first electrical terminal pin and the downhole cable to provide the electric power. Furthermore, the method includes protecting, using a second seal, the downhole cable. The second seal is coupled to the downhole cable.

[0008] According to another aspect of the subject matter described in this disclosure, an electrical connector is provided. The electrical connector may include a first conductor for receiving electrical power. An insulating body is coupled to the first conductor. Also, the insulating body includes an electrical terminal that establishes electrical connections between the first conductor and a plurality of electrical terminal pins. A downhole cable is coupled to a first electrical terminal pin of the plurality of electrical terminal pins. The first electrical terminal pin establishes an electrical connection between the electrical terminal and the downhole cable to provide the electric power. A plurality of sealing members are coupled to the first conductor and the downhole cable. The plurality of sealing members protect the electrical connections used to deliver the electrical power from the first conductor to the downhole cable.

[0009] Further, according to additional embodiments, the tubing hanger itself may function as an electrical penetrator system. In this regard, the penetrator system may be integrated directly into the wellhead tubing hanger. Specifically, the integration allows the seals and electrical contacts to remain within the envelope of the tubing hanger, thereby eliminating the need for penetrator components to extend below the hanger body.

[0010] According to some embodiments, the present disclosure relates to an integrated penetrator tubing hanger, including (a) a tubing hanger comprising a cylindrical body comprising a top end, a bottom end, an outside surface, and a bore defined therethrough forming an inside surface; (b) a penetrator integrated within the bore of the tubing hanger. The penetrator may include (i) a first conductor for receiving electrical power from and connecting to an electrical power source; (ii) an insulating body coupled to the first conductor, the insulating body having an electrical terminal that establishes electrical connections between the first conductor and a plurality of electrical terminal pins; (iii) a first seal coupled to the first conductor for protecting the first conductor; (iv) a downhole cable coupled to a first electrical terminal pin of the plurality of electrical terminal pins, the first electrical terminal pin establishing an electrical connection between the electrical terminal and the downhole cable to provide the electric power to the downhole cable; and (v) a second seal coupled to the downhole cable for protecting the electrical connection between the electrical terminal and the downhole cable. In some embodiments, the first and second seals and the insulating body are wholly disposed within a tubing hanger.

[0011] According to some embodiments, the present disclosure relates to an integrated penetrator tubing hanger including a tubing hanger having a cylindrical body with a top end, a bottom end, an outside surface, and a bore defined therethrough forming an inside surface. The penetrator is integrated within the bore of the tubing hanger. The penetrator may include a first seal having a substantially cylindrical body having a plurality of peripheral ridges, having a semi-circular profile, the peripheral ridges protruding outward from the substantially cylindrical body; an insulating body coupled to the first seal; a second seal coupled to the insulating body; and a downhole cable running through each of the second seal, the insulating body, and the first seal. The downhole cable is configured to connect to an LB junction box and to provide power downhole.

[0012] In some embodiments, the present disclosure relates to a method of manufacturing an integrated penetrator tubing hanger. The method may include manufacturing a penetrator by providing a first conductor for receiving electrical power, coupling a first seal to the first conductor for protecting the first conductor, positioning the first conductor in an insulating body, where the insulating body has an electrical terminal that establishes electrical connections between the first conductor and a plurality of electrical terminal pins, coupling a downhole cable to a first electrical terminal pin of the plurality of electrical terminal pins, establishing an electrical connection between the first electrical terminal pin and the downhole cable to provide the electric power, and protecting, using a second seal, the downhole cable, the second seal being coupled to the downhole cable. The method may include integrating the penetrator into a tubing hanger to form the integrated penetrator tubing hanger.

[0013] In some embodiments, a first seal and a second seal, may each include a substantially cylindrical body having a plurality of peripheral ridges, having a semi-circular profile, the peripheral ridges protruding outward from the substantially cylindrical body. An interior of the substantially cylindrical body may include two or more cylindrical sections connected to each other by a tapered cylindrical section tapering inward towards an axial center of the substantially cylindrical body. The first conductor may include a high temperature and / or high performance insulating material. The first seal may include a single-piece perfluoroalkoxy (PFA) seal, a polyvinyl chloride, a polyethylene, a silicone rubber, a neoprene, a fluoropolymer, a polyvinylidene fluoride, a rubber, a polytetrafluoroethylene, a polyurethane, a styrene butadiene rubber, a fluorinated ethylene propylene, a polyether ether ketone, a nitrile rubber, and copolymers thereof. The second seal may include a single-piece cable seal. The insulating body may be positioned within a main body. The main body may include carbon steel. The electrical terminal may be protected using a plurality of armor cables. The electrical terminal pins and the electrical terminal may be positioned within the insulating body. The tubing hanger may include at least one of a stainless steel and a galvanized steel.

[0014] Additional features and advantages of the present disclosure are described in, and will be apparent from, the detailed description of this disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The disclosure is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings in which like reference numerals are used to refer to similar elements. It is emphasized that various features may not be drawn to scale and the dimensions of various features may be arbitrarily increased or reduced for clarity of discussion.

[0016] FIG. 1 is a schematic diagram of an exemplary embodiment of a penetrator (electrical connector), in accordance with some embodiments.

[0017] FIG. 2A is a schematic diagram of a first single-piece seal, in accordance with some embodiments.

[0018] FIG. 2B is a schematic diagram of the cross-sectional view of the first single-piece seal, in accordance with some embodiments.

[0019] FIG. 3A is a schematic diagram of a second single-piece seal, in accordance with some embodiments.

[0020] FIG. 3B is a schematic diagram of the cross-sectional view of the second single-piece seal, in accordance with some embodiments.

[0021] FIG. 4 is a process flow for a method of manufacturing an electrical connector, in accordance with some embodiments.

[0022] FIG. 5 is a schematic diagram of a wellhead adapter connected to a tubing head while showing a disclosed integral penetrator tubing hanger, in accordance with some embodiments.

[0023] FIG. 6 is a zoomed in view of the schematic diagram of FIG. 5, in accordance with some embodiments.

[0024] FIG. 7 is another zoomed in view of the schematic diagram of FIG. 5 having the insulator tube hidden from view, in accordance with some embodiments.

[0025] FIG. 8 is a schematic diagram of a second single-piece seal, a cross-sectional view of the second single-piece seal, and a tapered compression nut configured to securely fit together with the second single-piece seal, in accordance with some embodiments.DETAILED DESCRIPTION

[0026] The figures and descriptions provided herein may have been simplified to illustrate aspects that are relevant for a clear understanding of the herein described devices, systems, and methods, while eliminating, for the purpose of clarity, other aspects that may be found in typical similar devices, systems, and methods. Those of ordinary skill may recognize that other elements and / or operations may be desirable and / or necessary to implement the devices, systems, and methods described herein. But because such elements and operations are well known in the art, and because they do not facilitate a better understanding of the present disclosure, a discussion of such elements and operations may not be provided herein. However, the present disclosure is deemed to inherently include all such elements, variations, and modifications to the described aspects that would be known to those of ordinary skill in the art.

[0027] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. For example, as used herein, the singular forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,”“comprising,”“including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

[0028] Although the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. That is, terms such as “first,”“second,” and other numerical terms, when used herein, do not imply a sequence or order unless clearly indicated by the context.

[0029] Reference in the specification to “one implementation” or “an implementation” means that a particular feature, structure, or characteristic described in connection with the implementation is included in at least one implementation of the disclosure. The appearances of the phrase “in one implementation,”“in some implementations,”“in one instance,”“in some instances,”“in one case,”“in some cases,”“in one embodiment,” or “in some embodiments” in various places in the specification are not necessarily all referring to the same implementation or embodiment.

[0030] The disclosure presents a novel design for an electrical connector requiring onshore or subsea connections and submersible pump connections. In particular, the disclosure describes an electrical connector that can handle the physical elements that deteriorate standard electrical connectors, such as high temperature, high pressure, and abrasive and / or corrosive fluids, including liquids and gases. Moreover, the compact design described in the disclosure allows the electrical connector to apply easily across multiple types of equipment, requiring onshore subsea connections and / or submersible pump connections.

[0031] Further, this disclosure presents a novel design of the tubing hanger where the penetrator (i.e., electrical penetrator) is integral with the tubing hanger as an integrated penetrator tubing hanger, thus removing the need to have portions of the penetrator system extend below the tubing hanger.

[0032] FIG. 1 illustrates an exemplary embodiment of a penetrator 100 (i.e., electrical connector), in accordance with some embodiments. In particular, the penetrator 100 may include a capillary tubing 102 that is connected to a fitting structure 104. The fitting structure 104 may be used to connect the capillary tubing 102 to a main body 108 of penetrator 100. Also, the fitting structure 104 may be designed to provide a leak-tight seal for pressures up to a suggested allowable pressure rating of the capillary tubing 102. A conductor 106 may be positioned within main body 108 and the fitting structure 104 and directly connected to the capillary tubing 102 at distal end 107 of electric conductor 106. A first single-piece seal 110 may be positioned on conductor 106 within main body 108 to protect conductor106. Also, the first single-piece seal 110 may provide a seal that is highly resistant to high temperatures, chemical, and steam.

[0033] The conductor 106 may be connected to a first electric terminal pin 114 in a PEEK or similar dielectric insulating body 112 at distal end 109 of electric conductor 106 to establish an electrical connection between first electric terminal pin 114 and capillary tubing 102. The diameter of conductor 106 at distal end 109 may be decreased relative to the diameter of conductor 106 at distal end 107. The first electric terminal pin 114 may be connected to an electrical terminal 116 to establish an electrical connection. The electrical terminal 116 may be connected to a second electrical terminal pin 118 to establish an electrical connection. A portion of the second electrical terminal pin 118 may extend horizontally (in the X-direction) into PEEK insulating body 112. A downhole cable 120 may extend horizontally (in the X-direction) into second electrical terminal pin 118. Also, the downhole cable 120 may extend horizontally (in the X-direction) outward of main body 108. An electrical connection may be established for downhole cable 120 via a conductor 117 that may be connected to terminal 116. The conductor 117 may extend horizontally (in the X-direction or any direction that has a non-zero angle) from electrical terminal 116 into electrical terminal pin 118. A second one piece seal 122 may be used to protect downhole cable 120 and provide a seal that is highly resistant to high temperatures, chemical, and steam. An adjustment nut 124 may be positioned beneath main body 108 to precisely adjust the position of main body 108 relative to downhole cable 120.

[0034] The penetrator 100 may establish an electrical connection between capillary tubing 102 and downhole cable 120, thus providing downhole cable 120 sufficient electrical power to perform downhole operations requiring subsea connections, submersible pump connections, or the like.

[0035] In some implementations, the electrical conductor 106 may include metallic materials. In some embodiments, the electrical conductor 106 may include plastic materials. In some embodiments, the electrical conductor 106 may include materials that sustain high pressure and / or fluid intrusion. In some implementations, the electrical conductor 106 may be a high temperature and / or high performance insulating material, such as a perfluoroalkoxy (PFA) insulated conductor.

[0036] In some implementations, the main body 108 may include metallic materials. In some embodiments, the main body 108 may include plastic materials. In some embodiments, the main body 108 may include materials that sustain high pressure and / or fluid intrusion. In some implementations, the main body 108 may include carbon steel.

[0037] In some implementations, the electrical terminal 116 may include metallic materials. In some embodiments, the electrical terminal 116 may include plastic materials. In some embodiments, the electrical conductor 116 may include materials that sustain high pressure and / or fluid intrusion. In some implementations, the electrical terminal 116 may be protected using a plurality of armor cables.

[0038] In some implementations, the electrical terminal pins 114 and 118 may include metallic materials. In some embodiments, the electrical terminal pins 114 and 118 may include plastic materials. In some embodiments, the electrical terminal pins 114 and 118 may include materials that sustain high pressure and / or fluid intrusion.

[0039] In some implementations, the downhole cable 120 may include metallic materials. In some embodiments, the downhole cable 120 may include plastic materials. In some embodiments, the downhole cable 120 may include materials that sustain high pressure and / or prevent fluid intrusion. In some implementations, the downhole cable 120 may include an Ethylene Propylene Diene Monomer (EPDM) insulated copper conductor. In some implementations, the downhole cable 120 may include a lead jacket for downhole operations.

[0040] In some embodiments, the adjustment nut 124 may include a hexagonal carbon steel nut.

[0041] In some embodiments, the first single-piece seal 110 may protect against fluids entering penetrator 100 and provide an additional barrier to prevent wellbore fluids and gas from entering the atmosphere at sustained overpressure, offset fracking events, or catastrophic failure. The first single-piece seal 110 may be an environmental protection seal.

[0042] FIG. 2A is a schematic diagram of a first single-piece seal 200, in accordance with some embodiments. The first single-piece seal 200 may be similar to the first single-piece seal 110 of FIG. 1. The first single-piece seal 200 may be a single-piece seal member used to protect the conductor 106 and provide a seal that is highly resistant to high temperatures, chemicals, and steam. The first single-piece seal 200 may be a cylindrical body having a number of peripheral ridges 202A-202D. Also, the first single-piece seal 200 may include a protruding cylindrical element 204 providing stability and rigidity to first single-piece seal 200.

[0043] FIG. 2B is a cross-sectional view of the first single-piece seal 200, in accordance with some embodiments. In particular, FIG. 2B shows four cylindrical sections 206A-206D. Each of the cylindrical sections 206A-206D are connected to tapered cylindrical sections 208A-208C. The cylindrical sections 206A-206D and 208A-208C may be arranged to allow a portion of electric conductor 106 to be fitted within the first single-piece seal 200 to form a seal.

[0044] FIG. 3A is a schematic diagram of a second single-piece seal 300, in accordance with some embodiments. The second single-piece seal 300 may be similar to the second single-piece seal 122 of FIG. 1. The second single-piece seal 300 may be a single-piece seal member used to protect the downhole cable 120. The second single-piece seal 300 may be a cylindrical body having a number of peripheral ridges 302A-302D. Also, the second single-piece seal 300 may include a protruding cylindrical element 304 to provide stability and rigidity to second single-piece seal 300.

[0045] FIG. 3B is a schematic diagram of the cross-sectional view of the second single-piece seal 300, in accordance with some embodiments. In particular, FIG. 3B shows four cylindrical sections 306A-306D. Each of the cylindrical sections 306A-306D are connected to tapered cylindrical sections 308A-308C. The cylindrical sections 306A-206D and 308A-308C may be arranged to allow a portion of downhole cable 120 to be fitted within the second single-piece seal 200 to form a seal. A sector of cylindrical section 306A may include a flap 310 to strengthen the seal when a portion of the downhole cable 120 settles in cylindrical section 306A.

[0046] FIG. 4 is a process flow 400 for a method of manufacturing an electrical connector, in accordance with some embodiments. Process flow 400 may be used to manufacture penetrator 100 including its respective components, as shown in FIGS. 1-3. The method includes providing a first conductor for receiving electrical power, as shown in step 402. The first conductor may be conductor 106, as shown in FIG. 1. Also, the method includes coupling a first seal to the first conductor for protecting the first conductor, as shown in step 404. The first seal may be the first single-piece seal 110 of FIG. 1 or first single-piece seal 200 of FIG. 2. At step 406, the method includes positioning the first conductor in an insulating body. The insulating body may include an electrical terminal that establishes electrical connections between the first conductor and a plurality of electrical terminal pins. The insulating body may be PEEK insulating body 112 of FIG. 1. The electrical terminal may be electrical terminal 110 of FIG. 1, and the electrical terminal pins may be electrical terminal pins 114 and 118 of FIG. 1.

[0047] Moreover, the method includes coupling a downhole cable to a first electrical terminal pin of the plurality of electrical terminal pins, as shown in step 408. The downhole cable may be downhole cable 120 of FIG. 1, and the first electrical terminal pin may be the electrical terminal pin 118 of FIG. 1. At step 410, the method includes establishing an electrical connection between the first electrical terminal pin and the downhole cable to provide the electric power. Furthermore, the method includes protecting the downhole cable using a second seal, as shown in step 412. The second seal is coupled to the downhole cable. The second seal may be the second single-piece seal 122 of FIG. 1 or second single-piece seal 300 of FIG. 3.

[0048] The disclosure presents a novel design for an electrical connector for use in downhole operations. In particular, the disclosure describes an electrical connector having a unique sealing arrangement that can provide electric power while handling the physical elements that deteriorate standard electrical connectors in downhole operations, such as high temperature, high pressure, and abrasive and / or corrosive fluids, including liquids and gases. Moreover, the compact design described in the disclosure allows the electrical connector to apply easily across multiple types of equipment, requiring subsea connections and / or submersible pump connections.

[0049] One particular advantage to the penetrators (electrical connectors) described herein is that it allows for the wellhead system to remain concentric and not eccentric as is the case in traditional systems where the three leads are in the same cylindrical body. Rather, the three individual bodies 102, 106, and 120 of the electrical connector described herein allow for production tubing to be centralized, which in turn, provides cost savings in the exploration and production aspects of oil and gas. By keeping the production string centered, this allows for use of the wellhead adapter and hanger (as part of the wellhead system) for plunger lift, gas lift and the like. In the present disclosure, the three individual connectors can be used for each phase as opposed to one cylindrical larger unit for three phases. Indeed, the electrical connector described herein offers a sealing method above the contacts, thus offering a dual sealing technology that not only protects the electrical system from fluid and gas ingress, but also provides an additional barrier to prevent any well fluid and gas from entering the atmosphere at sustained overpressure. In this regard, the top seal offers the additional advantage of providing environmental protection.

[0050] In further embodiments, as shown in FIG. 5, the penetrator according to the present disclosure may be integrated into the tubing hanger, as an integrated penetrator tubing hanger 506. FIG. 5 shows a schematic diagram of a wellhead adapter connected to a tubing head while showing the integrated penetrator tubing hanger 506. Disclosed integrated penetrator tubing hangers 506 are unlike conventional systems where a separate penetrator is installed into the hanger. An advantage of disclosed integrated penetrator tubing hangers 506 is that this design enables the tubing hanger itself to perform the function of the electrical penetrator system. Specifically, the integration allows the seals and electrical contacts to remain within the envelope of the tubing hanger, thereby eliminating the need for penetrator components to extend below the hanger body. As shown in FIG. 5, the integrated penetrator tubing hanger 506 may reside within a tubing head / recompletion spool 508, while connected to a wellhead adapter 502 and held in place with rotating flange 504. Additionally, the power cables are received from an upper connector 510, as shown in FIG. 5.

[0051] FIG. 6 is a zoomed in view of the schematic diagram of FIG. 5, showing an integrated penetrator tubing hanger 606 connecting to a capillary tube 602 that is secured with fittings 612 (⅜″ capillary tube fittings). The capillary tube 602 may have a diameter ranging from about 0.1 inches to about 10 inches, or even less than 0.1 inches. The capillary tube 602 may be secured with fittings 612 having a diameter ranging from about 0.1 inches to about 10 inches, or even less than 0.1 inches. The capillary tube 602 may have an insulated wire inside of any known size and material, including Perfluoroalkoxy (PFA) fluoropolymer, polyether ether ketone (PEEK), polyvinyl chloride, silicone rubber, polyethylene, polyvinylidene fluoride, Teflon, fluoropolymer, neoprene, and other known in the art. The integrated penetrator tubing hanger 606 may include a tubing hanger that includes a cylindrical body comprising a top end, a bottom end, an outside surface, and a bore defined therethrough forming an inside surface. The integrated penetrator tubing hanger 606 may include a penetrator integrated within the bore of the tubing hanger, the penetrator including a first conductor for receiving electrical power from and connecting to an electrical power source, such as providing through the capillary tube 602. The penetrator integrated within the bore may include an insulating body coupled to the first conductor, the insulating body having an electrical terminal that establishes electrical connections between the first conductor and a plurality of electrical terminal pins. The penetrator integrated within the bore may include a first seal 614 coupled to the first conductor for protecting the first conductor. The penetrator may include a downhole cable coupled to a first electrical terminal pin of the plurality of electrical terminal pins, the first electrical terminal pin establishing an electrical connection between the electrical terminal and the downhole cable to provide the electric power to the downhole cable. The penetrator integrated within the bore may include a second seal 618 coupled to the downhole cable for protecting the electrical connection between the electrical terminal and the downhole cable. As shown in FIG. 6, each of the first seal 614 and the second seal 618 may be tapered. According to some embodiments, each of the first seal 614, the second seal 618, and the insulating body 616 are wholly disposed within the tubing hanger, thus being integrated within. In some embodiments, as shown in FIG. 6, the second seal 616 may connect to ESP Cables 610 while being secured via tapered compression nuts 620 at a bottom end of the integrated penetrator tubing hanger 606. As shown in FIG. 6, the integrated penetrator tubing hanger 606 may include a hanger O-ring 604 and a dovetail hanger seal 608 for providing a seal between, the integrated penetrator tubing hanger 606 and the tubing head (see 508 from FIG. 5). In some embodiments, each of the first 614 and the second seal 618 may be made from a single-piece perfluoroalkoxy (PFA) seal, a polyvinyl chloride, a polyethylene, a silicone rubber, a neoprene, a fluoropolymer, a polyvinylidene fluoride, a rubber, a polytetrafluoroethylene, a polyurethane, a styrene butadiene rubber, a fluorinated ethylene propylene, a polyether ether ketone, a nitrile rubber, and copolymers thereof.

[0052] According to some embodiments, the integrated penetrator tubing hanger 606 (FIG. 6) may include a first seal 614 and a second seal 618, that each may include a substantially cylindrical body having a plurality of peripheral ridges, having a semi-circular profile, the peripheral ridges protruding outward from the substantially cylindrical body. Each of the first seal 614 and the second seal 618 may include two or more cylindrical sections connected to each other by a tapered cylindrical section tapering inward towards an axial center of the substantially cylindrical body. Each of the first seal 614 and the second seal 618 may be single-piece seals.

[0053] FIG. 7 is another zoomed in view of the schematic diagram of FIG. 5 that has the insulating body hidden from view, in accordance with some embodiments. As shown in FIG. 7, the first electric terminal pin 702 may be connected to an electrical terminal 704 to establish an electrical connection. The electrical terminal 704 may be connected to a second electrical terminal pin 708.

[0054] In some embodiments, a disclosed integrated penetrator tubing hanger may include a first seal, a second seal, and an insulating body, where a downhole cable may run through both seals without separation or cutting, thereby having a single conductor through both seals and the insulator. For example, a downhole cable, such as an ESP cable, may be routed through a disclosed integrated penetrator tubing hanger so that it could tie into a surface cable, such as through an LB junction box, essentially creating a continuous run. According to some embodiments, the present disclosure relates to an integrated penetrator tubing hanger including a tubing hanger having a cylindrical body with a top end, a bottom end, an outside surface, and a bore defined therethrough forming an inside surface; a penetrator integrated within the bore of the tubing hanger. The penetrator may include a first seal having a substantially cylindrical body having a plurality of peripheral ridges, having a semi-circular profile, the peripheral ridges protruding outward from the substantially cylindrical body; an insulating body coupled to the first seal; a second seal coupled to the insulating body; and a downhole cable running through each of the second seal, the insulating body, and the first seal. The downhole cable configured to connect to an LB junction box and to provide power downhole.

[0055] FIG. 8 shows a second seal 802 as a whole as well as from a cross-sectional view. In some embodiments, as shown in FIG. 8, the second seal 802 may connect to ESP Cables (not shown) while being secured via tapered compression nuts 820 at a bottom end of the integrated penetrator tubing hanger (not shown). Compression nuts 820 may advantageously secure the seal to a downhole cable while providing an additional seal to protect electrical components from damage during well operation.

[0056] According to some embodiments, the present disclosure relates to a method of manufacturing an integrated penetrator tubing hanger, as shown in FIGS. 5-7 and in part in FIGS. 1-3 (penetrator and seals). The method may include manufacturing a penetrator by providing a first conductor for receiving electrical power, coupling a first seal to the first conductor for protecting the first conductor, and positioning the first conductor in an insulating body, the insulating body having an electrical terminal that establishes electrical connections between the first conductor and a plurality of electrical terminal pins. The method may include coupling a downhole cable to a first electrical terminal pin of the plurality of electrical terminal pins, establishing an electrical connection between the first electrical terminal pin and the downhole cable to provide the electric power, and protecting, using a second seal, the downhole cable, the second seal being coupled to the downhole cable. The method may include integrating the penetrator into a tubing hanger to form the integrated penetrator tubing hanger.

[0057] According to some embodiments, there are several advantages of the disclosed integrated penetrator tubing hanger system and methods of manufacturing the same, including enhanced reliability during installation and a simplified assembly process. Furthermore, the design of disclosed integrated penetrator tubing hangers allow for the reduction of wellhead spool height, thus minimizing the quantity of steel required for manufacturing the tubing head or recompletion spool. The absence of a separate electrical penetrator body also eliminates the need for additional seals or O-rings, creating space to accommodate a three-lead system within the tubing hanger alongside a concentric production tubing port.

[0058] While depicted as being associated with the SCP10000 electrical penetrator, it is to be appreciated that the integral electrical penetrator tubing hanger may be incorporated as other electrical penetrator tubing hanger systems.

[0059] Additionally, the above descriptions of the implementations of the present disclosure have been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the present disclosure to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the present disclosure be limited not by this detailed description, but rather by the claims of this application. As will be understood by those familiar with the art, the present disclosure may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Accordingly, the present disclosure is intended to be illustrative, but not limiting, of the scope of the present disclosure, which is set forth in the following claims.

Claims

1. An integrated penetrator tubing hanger, comprising:(a) a tubing hanger comprising a cylindrical body comprising a top end, a bottom end, an outside surface, and a bore defined therethrough forming an inside surface;(b) a penetrator integrated within the bore of the tubing hanger, the penetrator comprising:(i) a first conductor for receiving electrical power from and connecting to an electrical power source;(ii) an insulating body coupled to the first conductor, the insulating body having an electrical terminal that establishes electrical connections between the first conductor and a plurality of electrical terminal pins;(iii) a first seal coupled to the first conductor for protecting the first conductor;(iv) a downhole cable coupled to a first electrical terminal pin of the plurality of electrical terminal pins, the first electrical terminal pin establishing an electrical connection between the electrical terminal and the downhole cable to provide the electric power to the downhole cable; and(v) a second seal coupled to the downhole cable for protecting the electrical connection between the electrical terminal and the downhole cable,wherein the first and second seals and the insulating body are wholly disposed within a tubing hanger.

2. The integrated penetrator tubing hanger according to claim 1, wherein the first seal and second seal, each comprise a substantially cylindrical body having a plurality of peripheral ridges, having a semi-circular profile, the peripheral ridges protruding outward from the substantially cylindrical body,wherein an interior of the substantially cylindrical body comprising two or more cylindrical sections connected to each other by a tapered cylindrical section tapering inward towards an axial center of the substantially cylindrical body.

3. The integrated penetrator tubing hanger according to claim 1, wherein the first conductor comprises a high temperature and / or high performance insulating material.

4. The integrated penetrator tubing hanger according to claim 1, wherein the first seal comprises a single-piece perfluoroalkoxy (PFA) seal, a polyvinyl chloride, a polyethylene, a silicone rubber, a neoprene, a fluoropolymer, a polyvinylidene fluoride, a rubber, a polytetrafluoroethylene, a polyurethane, a styrene butadiene rubber, a fluorinated ethylene propylene, a polyether ether ketone, a nitrile rubber, and copolymers thereof.

5. The integrated penetrator tubing hanger according to claim 1, wherein the second seal is a single-piece cable seal.

6. The integrated penetrator tubing hanger according to claim 1, wherein the insulating body is positioned within a main body.

7. The integrated penetrator tubing hanger according to claim 1, wherein the main body comprises carbon steel.

8. The integrated penetrator tubing hanger according to claim 1, wherein the electrical terminal is protected using a plurality of armor cables.

9. The integrated penetrator tubing hanger according to claim 1, wherein the electrical terminal pins and the electrical terminal are positioned within the insulating body.

10. The integrated penetrator tubing hanger according to claim 1, wherein the tubing hanger comprises at least one of a stainless steel and a galvanized steel.

11. A method of manufacturing an integrated penetrator tubing hanger, the method comprising:(a) manufacturing a penetrator by:(i) providing a first conductor for receiving electrical power;(ii) coupling a first seal to the first conductor for protecting the first conductor;(iii) positioning the first conductor in an insulating body, the insulating body having an electrical terminal that establishes electrical connections between the first conductor and a plurality of electrical terminal pins;(iv) coupling a downhole cable to a first electrical terminal pin of the plurality of electrical terminal pins;(v) establishing an electrical connection between the first electrical terminal pin and the downhole cable to provide the electric power; and(vi) protecting, using a second seal, the downhole cable, the second seal being coupled to the downhole cable;(b) integrating the penetrator into a tubing hanger to form the integrated penetrator tubing hanger.

12. The method of claim 11, wherein providing the first conductor includes providing the first conductor having a high temperature and / or high performance insulating material.

13. The method of claim 11, wherein the first seal comprises a single-piece perfluoroalkoxy (PFA) seal, a polyvinyl chloride, a polyethylene, a silicone rubber, a neoprene, a fluoropolymer, a polyvinylidene fluoride, a rubber, a polytetrafluoroethylene, a polyurethane, a styrene butadiene rubber, a fluorinated ethylene propylene, a polyether ether ketone, a nitrile rubber, and copolymers thereof.

14. The method of claim 11, wherein protecting, using the second seal, the downhole cable includes coupling a single-piece cable seal to the downhole cable.

15. The method of claim 11, wherein positioning the first conductor in the insulating body includes positioning the insulating body within a main body.

16. The method of claim 15, wherein the main body comprises carbon steel.

17. The method of claim 11, wherein positioning the first conductor in the insulating body includes protecting the electrical terminal using a plurality of armor cables.

18. The method of claim 11, wherein positioning the first conductor in the insulating body includes positioning the plurality of electrical terminal pins and the electrical terminal within the insulating body.

19. An integrated penetrator tubing hanger, comprising:(a) a tubing hanger comprising a cylindrical body comprising a top end, a bottom end, an outside surface, and a bore defined therethrough forming an inside surface;(b) a penetrator integrated within the bore of the tubing hanger, the penetrator comprising:(i) a first seal comprising a substantially cylindrical body having a plurality of peripheral ridges, having a semi-circular profile, the peripheral ridges protruding outward from the substantially cylindrical body;(ii) an insulating body coupled to the first seal;(iii) a second seal coupled to the insulating body; and(iv) a downhole cable running through each of the second seal, the insulating body, and the first seal, the downhole cable configured to connect to an LB junction box and to provide power downhole.

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