3D-Printed Seals for Electric Submersible Pump Power Cables
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Solution Overview
Problem
The existing methods for sealing power cables to pothead connectors in electric submersible pumps are prone to human error, require significant training and time, and are ineffective in preventing fluid and gas ingress, especially in harsh environments.
Innovation Solution
3D-printed seals and connectors are used to create a fluid-impenetrable barrier between the power cable and the housing component of the pothead connector, eliminating the need for conventional metal-to-metal soldering or mechanical fasteners and providing a reliable seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional soldering or mechanical fastening methods are used to seal the power cable to the housing component, then the sealing can be achieved, but the process is vulnerable to human error, requires significant training and time, and the reliability is compromised
Solution Approach 1:
The patent replaces conventional mechanical sealing methods (soldering, mechanical fastening) with a 3D-printed seal component that integrates the sealing function directly into the housing structure. This eliminates the need for separate sealing operations and reduces human error while maintaining reliability.
Solution Approach 2:
The 3D-printed seal block merges multiple functions into a single integrated component: it provides the housing structure, the sealing barrier, and the cable retention features. This consolidation eliminates multiple manufacturing steps and reduces the complexity of assembly while improving sealing reliability.
2Reliability
If solder joints are used to create the fluid seal, then the seal can be formed, but the process requires significant space for torch operation and solder application, and the joints are weak and vulnerable to human error
Solution Approach 1:
The patent replaces the soldering process with a 3D-printed seal block that provides the sealing function through its geometric design and material properties. This eliminates the need for torch operation, solder application, and associated safety concerns while improving seal integrity.
Solution Approach 2:
The 3D-printed seal block acts as an intermediary component between the housing and the power cable, providing the sealing function without requiring direct metal-to-metal contact or soldering. This intermediary structure simplifies the sealing process while maintaining reliability.
3Ease of operation
If mechanical fasteners are used to secure the power cable, then the cable can be fastened, but the fasteners are ineffective with soft lead barriers and require skill to install
Solution Approach 1:
The 3D-printed seal block incorporates localized sealing features such as grooves, channels, and retention elements that are specifically designed to interface with the power cable's soft lead barriers. These localized features provide both mechanical retention and fluid sealing without requiring skillful installation.
Solution Approach 2:
The 3D-printed seal block is designed to self-retain the power cable through its geometric features, eliminating the need for separate mechanical fasteners. The cable is secured and sealed simply by inserting it into the pre-formed receptacle, making installation trivial while maintaining reliability.
4Reliability
If elastomeric seals are installed to prevent fluid ingress, then the seal can be formed, but the installation requires operator skill and the seals may not be effective in harsh environments
Solution Approach 1:
The 3D-printed seal block is manufactured from composite materials that combine the structural integrity of rigid plastics with the sealing properties of flexible polymers. This single material provides both the mechanical strength of a hard housing and the sealing effectiveness of elastomeric materials, eliminating the need for separate seal components and skilled installation.
Solution Approach 2:
The patent merges the functions of the rigid housing and the flexible seal into a single 3D-printed component. The seal block provides both structural support and fluid sealing through its integrated design, eliminating the need for separate elastomeric seal installation and reducing operator skill requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The 3D-printed seals offer a robust, reliable, and efficient sealing solution that reduces the risk of human error and permeability, ensuring effective prevention of fluid and gas ingress, even in severe service applications.
Implementation Method 1
at least a 3D-printed seal, printed between the power cable and the housing component
Implementation Method 2
a wrap layer at least in part deposited or bonded by a 3D printer during 3D-printing of a fluid impenetrable seal
Data Source
AI summary
An electrical connector assembly for electric submersible pumps (ESPs) has a fluid impenetrable seal 3D-printed between the power cable and an internal housing component of the electrical connector assembly. Electrical insulation or dielectric for a conductor of the power cable may also be 3D-printed integrally with the fluid seal. The housing component, such as an internal electrical housing, may also be 3D-printed integrally with the printed seal. Likewise, in an implementation, the 3D-printed seal, the internal housing component, and an outer pothead case may all be 3D-printed as a unit onto the power cable. The 3D-printed seal and associated pothead components may be composed of a variety of chemical-resistant materials, such as printed polyarylether-ketones, printed fluorinated polymers, and metal alloys. The 3D-printed seal may also include barrier materials or reinforcement fillers to enhance strength and chemical resistance to well fluids and gases.