Pressure testable connector systems

The wellhead penetrator assembly with pressure testing ports and seals ensures reliable sealing by testing primary and auxiliary seals, addressing the challenges of high-pressure and explosion risks in wellhead connector systems, ensuring equipment integrity and reducing operational risks.

WO2026006084A1PCT designated stage Publication Date: 2026-01-02ITT MANUFACTURING ENTERPRISES LLC
View PDF 5 Cites 0 Cited by

Patent Information

Application Number
PCT/US2025/034266
Authority / Receiving Office
WO · WO
Patent Type
Applications
Current Assignee / Owner
Priority Date
2024-06-28
Filing Date
2025-06-18
Publication Date
2026-01-02

AI Technical Summary

Technical Problem

Existing wellhead connector systems in oil and gas extraction face challenges in testing sealing elements under high pressure and explosion-prone environments, leading to potential equipment loss and wellhead failure.

Method used

A wellhead penetrator assembly with a pressure block system and connector system, incorporating multiple seals and pressure testing ports, allows for comprehensive pressure testing of primary and auxiliary seals using conductive liquid injection to detect seal failures, ensuring proper sealing before deployment.

Benefits of technology

The system effectively tests both primary and auxiliary seals against surface and downhole pressures, preventing seal leakage and potential explosions, thereby safeguarding expensive wellhead equipment and reducing downtime.

✦ Generated by Eureka AI based on patent content.

Smart Images

  • Figure US2025034266_02012026_PF_FP_ABST
    Figure US2025034266_02012026_PF_FP_ABST
Patent Text Reader

Abstract

To test against risk of fire and explosions caused by pressurized gases and oil in wells, a wellhead penetrator assembly may include a pressure block system containing a surface cable, a first primary seal, and a first auxiliary seal; a connector system containing a downhole cable, a second primary seal, a low-end auxiliary seal, a second auxiliary seal, and a first pressure testing port to inject a conductive pressure testing liquid; and a coupling nut to affix the pressure block system and the connector system, the coupling nut containing a second pressure testing port. The surface and downhole cables may be spliced within the connector system; injection of the pressure testing liquid may enable testing of the first primary seal and the second primary seal against surface and downhole pressures, and injection of the pressure testing liquid further may enable testing of the first auxiliary seal against downhole pressures.
Need to check novelty before this filing date? Find Prior Art

Description

PRESSURE TESTABLE CONNECTOR SYSTEMSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 63 / 665,320 filed on June 28, 2024. The disclosures of the Provisional Application are hereby incorporated by reference in their entirety.BACKGROUND

[0002] Unless otherwise indicated herein, the materials described in this section are not prior art to the claims in this application and are not admitted as prior art by inclusion in this section.

[0003] Oil and gas underground extraction systems include electrical submersible pumps and other equipment that operate in a drill hole submerged in a fluid (e.g., oil, water, oil-water mixture, etc.). Such equipment, in addition to being submerged, are typically subject to high pressures and / or high temperatures. Power to the submersible equipment is provided through downhole and surface cables that are spliced above the wellhead or in the vicinity of the wellhead.SUMMARY

[0004] The present disclosure generally describes a method, system, and apparatus to provide testing ability of sealing elements within an electrical connector system of wellhead equipment and related cable assemblies.

[0005] The gases (and oil) in wells create an environment that includes high pressure and may be susceptible to fire and explosions. According to some examples, a wellhead penetrator assembly may include a pressure block system containing a surface cable, a first primary seal, and a first auxiliary seal; a connector system containing a downhole cable, a second primary seal, a low-end auxiliary seal, a second auxiliary seal, and a first pressure testing port to inject a pressure testing liquid; and a coupling nut to affix the pressure block system and the connector system, the coupling nut containing a second pressure testing port. The surface cable and the downhole cable may be spliced within the connector system; injection of the pressure testingliquid may enable testing of the first primary seal and the second primary seal against surface and downhole pressures, and injection of the pressure testing liquid further may enable testing of the first auxiliary seal against downhole pressures.

[0006] According to other examples, a wellhead penetrator pressure test system may include a wellhead penetrator assembly comprising a pressure block system containing a surface cable, a first primary seal, and a first auxiliary seal; a connector system containing a downhole cable, a second primary seal, a low-end auxiliary seal, a second auxiliary seal, and a first pressure testing port to inject a pressure testing liquid; a coupling nut to affix the pressure block system and the connector system, the coupling nut containing a second pressure testing port, where the surface cable and the downhole cable are spliced within the connector system; and a pressure testing liquid injection system. The pressure testing liquid injection system may be configured to inject the pressure testing liquid through the first pressure testing port and the second pressure testing port to test the first primary seal and the second primary seal against surface and downhole pressures, and inject the pressure testing liquid through the second pressure testing port to test the first auxiliary seal and the low-end auxiliary seal against downhole pressures.

[0007] According to further examples, a method to pressure test a wellhead penetrator assembly may include injecting a pressure testing liquid through one of a first pressure testing port and a second pressure testing port to test one of a first primary seal and a second primary seal against surface and downhole pressures, and detecting a seal failure through detection of a short circuit, wherein the pressure testing liquid is a conductive liquid. The wellhead penetrator assembly may include a pressure block system containing a surface cable, the first primary seal, and a first auxiliary seal; a connector system containing a downhole cable, the second primary seal, a low-end auxiliary seal, a second auxiliary seal, and the first pressure testing port; and a coupling nut to affix the pressure block system and the connector system, the coupling nut containing the second pressure testing port.

[0008] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The foregoing and other features of this disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several embodiments in accordance with the disclosure and are, therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings, in which:FIG. 1 illustrates a cross-sectional view of a well and wellhead with example equipment; FIG. 2 illustrates a combined penetrator-connector system in a mono-bore configuration; FIG. 3A and 3B illustrate a field pressure testable connector and various seals to enable pressure testing of the connector in a mono-bore configuration; andFIG. 4A and 4B illustrate another field pressure testable connector and various seals to enable pressure testing of the connector a tri-bore configuration, all arranged in accordance with at least some embodiments described herein.DETAILED DESCRIPTION

[0010] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. The aspects of the present disclosure, as generally described herein, and illustrated in the Figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein.

[0011] This disclosure is generally drawn, inter alia, to providing testing ability of sealing elements within an electrical connector system of wellhead equipment and related cable assemblies.

[0012] FIG. 1 illustrates a cross-sectional view of a well and wellhead with example equipment, arranged in accordance with at least some embodiments described herein.

[0013] As shown in FIG. 1, a wellhead 104 may be placed on a well 118, which is bored into ground 102. In-well equipment, such as downhole pump 108 and similar ones, may be submerged in fluid 106 (gas or liquid) and have one or more fluidic couplings 114 (e.g., via a fluid coupler such as a pipe, tube, channel or conduit) to surface mechanical equipment 110 such as pumps, filters, compressors, etc. In-well equipment may also have one or more electrical couplings 116 (e g., an electrical coupler or conductor such as a wire, cord, line, or cable) to surface electrical devices or systems 112 such as power supplies, controllers, amplifiers, switches, etc.

[0014] In some examples, a tube from a downhole penetrator may extend up into an enclosure (for example, as part of the surface electrical devices or systems 112 or prior to those). A tube may include an electrical cable to provide downhole equipment power and / or control signals. Because the oil and gases under high pressure may create an explosion-prone environment, some or all of the equipment may be designed to be explosion-proof. For example, explosion-proof enclosure(s), explosion-proof conduit(s), explosion-proof unions, high amperage restrictions, and similar approaches may be employed. A uni-directional pressure block may be used in a cable splice for each individual conductor of the electrical cable, in some examples. The cable splices (downhole cable and surface cable) may be inserted directly into wellhead hanger bores or may be assembled into housings that seal directly (via O-rings or pipe threads) to existing features in a wellhead.

[0015] As mentioned herein, a downhole cable providing power and / or control signals to downhole equipment may be spliced to a surface cable within the well. Each surface cable and corresponding downhole cable may be electrically coupled to one another through a splice using either a conductive crimp or a crimp-free contact. O-ring(s) and / or a rubber bootseal(s) may be used to prevent leakage of fluids or gases inside the tubings. For example, multiple O-rings may provide sealing at various locations (e.g., at or near couplings, between insulator and conduit, etc.).

[0016] One of the biggest risks to wellheads is explosion due to downhole pressure or explosion caused by the gases (and pressure) at the surface. In either scenario, splicing of the surface and downhole cables may be lost potentially causing loss of the wellhead. To mitigate pressure from the well, a seal is typically used around the splicing, for example in conjunction with a connector that contains the splicing. Some example implementations may include adownhole connector that can withstand explosions from surface equipment. The downhole connector can withstand pressure from well conditions as well as pressure seen in case of explosion within the enclosure on the surface. In case the explosive gases communicating through the inside space of the tubing, the downhole connector (splice tube in this case) may stop the propagation of the explosion into the well bore.

[0017] To protect extremely expensive wellhead equipment pressure testing is performed to ensure sealing before lowering connector / building wellhead / starting the well. Conventional approaches include vacuum testing. However, those approaches tend to test the connector in one direction (usually for pressure from the well).

[0018] According to some examples, the primary sealing element may be isolated on each side of the connector (uphole and downhole). By doing so, pressure may be applied directly to the primary seals to test / ensure they are seated properly and functioning. The isolation of the primary seal may be achieved with a combination of O-rings and custom shaped seals. These auxiliary seals may be used to remove any leak paths for the testing fluid so that the fluid only directly tests the primary sealing element. Ports may be installed into various positions of the connector to be able to fill and pressurize fluid to a stated pressure. The pressurized fluid may fill the area around the primary seal. Substantial loss of pressure can be attributed to the leaking of a seal.

[0019] FIG. 2 illustrates a combined penetrator-connector system in a mono-bore configuration, arranged according to at least some embodiments described herein.

[0020] Diagram 200 shows the pressure block system 234 and the connector system 202 combined with the right side corresponding to downhole direction and the left side corresponding to surface direction. At least two pressure testing ports 222, 224 are shown, one in the connector system 202 and one through the coupling nut 210 coupling both portions providing access to both sides of the second primary seal 204 (and the port through the coupling nut providing access to the first primary seal 214). The connector system 202 is arranged to receive the electrical submersible cable (ESP) 232 through the primary seal 206 at its left end.

[0021] As mentioned herein, providing testing ability of sealing elements within an electrical connector system may ensure sealing before lowering the connector, building the wellhead, and / or starting the well. A failure at this point may be costly in terms of labor, pulling the system and troubleshooting, operator costs (well downtime), etc. A pressure testing system asdescribed herein may allow testing of both primary seals 204, 214 and one or more auxiliary seals 206, 216, 208, 218 in-situ before the penetrator is lowered into the well.

[0022] The fittings in the system may have standard threads, for example 1 / 8-inch national pipe thread (NPT), or custom. In an example implementation, the surface cables may be #4 AWG Poly etheretherketone (PEEK) insulated pigtail cable in 3 / 8” metal tubing. The downhole cable may have a lead jacket. Of course, other types of insulators may be used for the surface and downhole cables.

[0023] FIG. 3A and 3B illustrate a field pressure testable connector and various seals to enable pressure testing of the connector in a mono-bore configuration; arranged in accordance with at least some embodiments described herein.

[0024] Diagram 300A shows a pressure block system 340 with surface cable 342, first primary seal 314, auxiliary seal 316, auxiliary seal 318, and pressure port 344. In a system according to examples, three seals may be tested, the first primary seal 314, a second primary seal (shown in diagram 300B), and the auxiliary seal 318 sealing the threaded joinder of the pressure block system 340 and the connector system 302 of the penetrator.

[0025] Diagram 300B shows the connector system 302 with low-end auxiliary seal 306, downhole cable 332, second primary seal 304, and auxiliary seal 308. Another pressure port 322 is also shown on the connector system 302.

[0026] In an implementation, a first pressure test may be performed by introducing a conductive liquid through pressure port 344 under pressure to the space between auxiliary seal 316 and auxiliary seal 318 testing the first primary seal 314 from downhole pressure. Auxiliary seals 316 and 318 isolate the first primary seal 314 ensuring that pressure is applied directly to the seal. A second test may include introduction of conductive liquid through pressure port 322 under pressure to test the space between low-end auxiliary seal 306 and auxiliary seal 308 testing the second primary seal 304 from downhole pressure. Low-end auxiliary seal 306 and auxiliary seal 308 isolate the bore so the second primary seal 304 has pressure directly applied to it. Thus, the system may be pressure tested against pressure entering from both sides of the connector before it is lowered into the well. Through the use of conductive liquid, pressure leakage may be detected by detecting a short circuit in the system (i.e., when the liquid leaks through the primary seal(s).

[0027] FIG. 4A and 4B illustrate another field pressure testable connector and various seals to enable pressure testing of the connector a tri -bore configuration, arranged according to at least some embodiments described herein.

[0028] In a mono-bore configuration, power for three phases (3 wires) are provided through a single bore (tubing or conduit). In the tri-bore configuration, individual splice tubes (conduits) are provided. In a system according to examples, pressure testing may be performed on both ends of the penetrator. Diagram 400A shows a conductive liquid based pressure testing system 402 injecting the conductive liquid into a space around the surface cable 404 through pressure testing port 406. In the tested space, a first primary seal 408 may be a metal seal. Auxiliary seals 410 and 412 provide an enclosed space for the conductive fluid while the first primary seal 408 is tested.

[0029] Diagram 400B shows the other end of the tri-bore configuration for pressure testing with second primary seal 414, auxiliary seals 418 and 420, and downhole cable 424. The second pressure testing port 416 allows injection of the conductive liquid from the pressure testing system 402 into the space below the second primary seal 414 to test the second primary seal against downhole pressure.

[0030] According to some examples, a wellhead penetrator assembly may include a pressure block system containing a surface cable, a first primary seal, and a first auxiliary seal; a connector system containing a downhole cable, a second primary seal, a low-end auxiliary seal, a second auxiliary seal, and a first pressure testing port to inject a pressure testing liquid; and a coupling nut to affix the pressure block system and the connector system, the coupling nut containing a second pressure testing port. The surface cable and the downhole cable may be spliced within the connector system; injection of the pressure testing liquid may enable testing of the first primary seal and the second primary seal against surface and downhole pressures, and injection of the pressure testing liquid further may enable testing of the first auxiliary seal against downhole pressures.

[0031] According to other examples, injection of the pressure testing liquid into the first pressure testing port may enable testing of the second primary seal and the low-end auxiliary seal. Injection of the pressure testing liquid into the second pressure testing port may enable testing of the first primary seal and the first auxiliary seal. The pressure block system may further contain a third auxiliary seal, and the connector system may further contain a fourthauxiliary seal. The pressure testing liquid may be a conductive liquid, and the pressure test may include a short circuit detection. The surface cable and the downhole cable may be spliced through a crimped or crimp-free connection.

[0032] According to further examples, a wellhead penetrator pressure test system may include a wellhead penetrator assembly comprising a pressure block system containing a surface cable, a first primary seal, and a first auxiliary seal; a connector system containing a downhole cable, a second primary seal, a low-end auxiliary seal, a second auxiliary seal, and a first pressure testing port to inject a pressure testing liquid; a coupling nut to affix the pressure block system and the connector system, the coupling nut containing a second pressure testing port, where the surface cable and the downhole cable are spliced within the connector system; and a pressure testing liquid injection system. The pressure testing liquid injection system may be configured to inject the pressure testing liquid through the first pressure testing port and the second pressure testing port to test the first primary seal and the second primary seal against surface and downhole pressures, and inject the pressure testing liquid through the second pressure testing port to test the first auxiliary seal and the low-end auxiliary seal against downhole pressures.

[0033] According to yet other examples, the pressure testing liquid injection system may be configured to inject the pressure testing liquid through the first pressure testing port to test the second primary seal and the low-end auxiliary seal. The pressure testing liquid injection system may also be configured to inject the pressure testing liquid through the second pressure testing port to test the first primary seal and the first auxiliary seal. The pressure block system may further contain a third auxiliary seal, and the connector system may further contain a fourth auxiliary seal. The pressure testing liquid may be a conductive liquid, and the wellhead penetrator pressure test system may be further configured to detect a short circuit to determine seal failure.

[0034] According to some examples, a method to pressure test a wellhead penetrator assembly may include injecting a pressure testing liquid through one of a first pressure testing port and a second pressure testing port to test one of a first primary seal and a second primary seal against surface and downhole pressures, and detecting a seal failure through detection of a short circuit, wherein the pressure testing liquid is a conductive liquid. The wellhead penetrator assembly may include a pressure block system containing a surface cable, the first primary seal,and a first auxiliary seal; a connector system containing a downhole cable, the second primary seal, a low-end auxiliary seal, a second auxiliary seal, and the first pressure testing port; and a coupling nut to affix the pressure block system and the connector system, the coupling nut containing the second pressure testing port.

[0035] According to other examples, the method may further include injecting the pressure testing liquid through the first pressure testing port to test the second primary seal and the low- end auxiliary seal. The method may also include injecting the pressure testing liquid through the second pressure testing port to test the first primary seal and the first auxiliary seal. The pressure block system may further contain a third auxiliary seal, and the connector system may further contain a fourth auxiliary seal.

[0036] The present disclosure is not to be limited in terms of the particular embodiments described in this application, which are intended as illustrations of various aspects. Many modifications and variations can be made without departing from its spirit and scope. Functionally equivalent methods and apparatuses within the scope of the disclosure, in addition to those enumerated herein, are possible from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the appended claims. The present disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

[0037] The herein described subject matter sometimes illustrates different components contained within, or connected with, different other components. Such depicted architectures are merely examples, and in fact, many other architectures may be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively "associated" such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality may be seen as "associated with" each other such that the desired functionality is achieved, irrespective of architectures or intermediate components. Likewise, any two components so associated may also be viewed as being "operably connected", or "operably coupled", to each other to achieve the desired functionality, and any two components capable of being so associated may also be viewed as being "operably couplable", to each other to achieve the desired functionality. Specific examples of operably couplable include but are not limited to physically connectable and / orphysically interacting components and / or wirelessly interactable and / or wirelessly interacting components and / or logically interacting and / or logically interactable components.

[0038] With respect to the use of substantially any plural and / or singular terms herein, those having skill in the art can translate from the plural to the singular and / or from the singular to the plural as is appropriate to the context and / or application. The various singular / plural permutations may be expressly set forth herein for sake of clarity.

[0039] In general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation, no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., “a” and / or “an” should be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, means at least two recitations, or two or more recitations).

[0040] Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general, such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and / or phrase presentingtwo or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”

[0041] For any and all purposes, such as in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art all language such as “up to,” “at least,” “greater than,” “less than,” and the like include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, a range includes each individual member. Thus, for example, a group having 1-3 cells refers to groups having 1, 2, or 3 cells. Similarly, a group having 1-5 cells refers to groups having 1, 2, 3, 4, or 5 cells, and so forth.

[0042] While various aspects and embodiments have been disclosed herein, other aspects and embodiments are possible. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

Claims

CLAIMSWHAT IS CLAIMED IS:

1. A wellhead penetrator assembly comprising: a pressure block system containing a surface cable, a first primary seal, and a first auxiliary seal; a connector system containing a downhole cable, a second primary seal, a low-end auxiliary seal, a second auxiliary seal, and a first pressure testing port to inject a pressure testing liquid; and a coupling nut to affix the pressure block system and the connector system, the coupling nut containing a second pressure testing port, wherein the surface cable and the downhole cable are spliced within the connector system, injection of the pressure testing liquid enables testing of the first primary seal and the second primary seal against surface and downhole pressures, and injection of the pressure testing liquid further enables testing of the first auxiliary seal against downhole pressures.

2. The wellhead penetrator assembly of claim 1, wherein injection of the pressure testing liquid into the first pressure testing port enables testing of the second primary seal and the low- end auxiliary seal.

3. The wellhead penetrator assembly of claim 1, wherein injection of the pressure testing liquid into the second pressure testing port enables testing of the first primary seal and the first auxiliary seal.

4. The wellhead penetrator assembly of claim 1, wherein the pressure block system further contains a third auxiliary seal, and the connector system further contains a fourth auxiliary seal.

5. The wellhead penetrator assembly of claim 1, wherein the pressure testing liquid is a conductive liquid, and the pressure test includes a short circuit detection.

6. The wellhead penetrator assembly of claim 1, wherein the surface cable and the downhole cable are spliced through a crimped or crimp-free connection.

7. A wellhead penetrator pressure test system comprising: a wellhead penetrator assembly comprising: a pressure block system containing a surface cable, a first primary seal, and a first auxiliary seal; a connector system containing a downhole cable, a second primary seal, a low- end auxiliary seal, a second auxiliary seal, and a first pressure testing port to inject a pressure testing liquid; a coupling nut to affix the pressure block system and the connector system, the coupling nut containing a second pressure testing port, wherein the surface cable and the downhole cable are spliced within the connector system; and a pressure testing liquid injection system configured to: inject the pressure testing liquid through the first pressure testing port and the second pressure testing port to test the first primary seal and the second primary seal against surface and downhole pressures, and inject the pressure testing liquid through the second pressure testing port to test the first auxiliary seal and the low-end auxiliary seal against downhole pressures.

8. The wellhead penetrator pressure test system of claim 7, wherein the pressure testing liquid injection system is configured to inject the pressure testing liquid through the first pressure testing port to test the second primary seal and the low-end auxiliary seal.

9. The wellhead penetrator pressure test system of claim 7, wherein the pressure testing liquid injection system is configured to inject the pressure testing liquid through the second pressure testing port to test the first primary seal and the first auxiliary seal.

10. The wellhead penetrator pressure test system of claim 7, wherein the pressure block system further contains a third auxiliary seal, and the connector system further contains a fourth auxiliary seal.

11. The wellhead penetrator pressure test system of claim 7, wherein the pressure testing liquid is a conductive liquid, and the wellhead penetrator pressure test system is further configured to detect a short circuit to determine seal failure.

12. A method to pressure test a wellhead penetrator assembly, the method comprising: injecting a pressure testing liquid through one of a first pressure testing port and a second pressure testing port to test one of a first primary seal and a second primary seal against surface and downhole pressures, wherein the wellhead penetrator assembly comprises: a pressure block system containing a surface cable, the first primary seal, and a first auxiliary seal; a connector system containing a downhole cable, the second primary seal, a low- end auxiliary seal, a second auxiliary seal, and the first pressure testing port; and a coupling nut to affix the pressure block system and the connector system, the coupling nut containing the second pressure testing port; and detecting a seal failure through detection of a short circuit, wherein the pressure testing liquid is a conductive liquid.

13. The method of claim 12, further comprising: injecting the pressure testing liquid through the first pressure testing port to test the second primary seal and the low-end auxiliary seal.

14. The method of claim 12, further comprising: injecting the pressure testing liquid through the second pressure testing port to test the first primary seal and the first auxiliary seal.

15. The method of claim 12, wherein the pressure block system further contains a third auxiliary seal, and the connector system further contains a fourth auxiliary seal.

Citation Information

Patent Citations

  • Wellhead assembly and test sealing architecture

    US20210189822A1

  • Connector assembly

    US20240030650A1

  • Electric feedthrough system

    US4583804A

  • Electric fed-thru connector assembly

    US4693534A

  • The testing of the integrity of a fluid coupling

    WO1999030124A1