Armored ESP Cable Adapter for Fast Secure Load Transfer

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Solution Overview

Problem

There is a need for improved systems and methods for quickly and securely connecting an electric submersible pumping system to coiled tubing, which securely transfers the weight of the pump, motor, and other downhole equipment to the armored cable, reducing the complexity and cost of deployment.

Innovation Solution

A pumping system comprising an armored cable with an outer and inner layer of structural wire and a power cable, connected via a cable adapter with collets and compression cap to transfer the weight of the electric motor to the armored cable, using a method that involves extending the armored cable through the compression cap, routing the power cable, securing the structural wires, and applying a compressive force to capture the wires within the cable adapter.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional rigid production tubing is used to connect the pumping system, then the connection is structurally strong, but the deployment is complicated, costly and time intensive

Engineering Contradiction:

Improveconnection strengthVSAvoiddeployment speed

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent replaces rigid production tubing with flexible coiled tubing and armored cable assembly. The coiled tubing can be deployed in a continuous flexible form through the wellbore, eliminating the need for rigid jointed sections and complex assembly operations at the surface.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The system divides the connection function into separate components: the coiled tubing provides structural support and fluid flow, while the armored cable (separately deployable) provides electrical power and weight support. This segmentation allows each component to be optimized independently and deployed more efficiently.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If rigid production tubing is used, then the system is stable, but assembly and disassembly require large workover rigs which are expensive and difficult to source

Engineering Contradiction:

Improvesystem stabilityVSAvoiddeployment equipment complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The flexible coiled tubing can be deployed and retrieved without requiring rigid joint connections, eliminating the need for large workover rigs with complex assembly equipment. The flexible nature allows deployment through smaller, simpler rigless equipment.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The coiled tubing serves multiple functions: providing structural support, enabling fluid flow, and serving as a deployment conduit for the armored cable. This multi-functionality reduces the overall system complexity and eliminates the need for specialized assembly equipment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If coiled tubing is used to support the pumping system, then installation time is reduced by more than 50%, but there is a need for improved connection systems to securely transfer weight to the armored cable

Engineering Contradiction:

Improveinstallation speedVSAvoidconnection reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The armored cable is nested within the coiled tubing during deployment, with the cable adapter providing a secure transition point. The collets and compression cap create a nested structure that securely captures the cable strands, ensuring reliable weight transfer while maintaining the space-efficient nested deployment configuration.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The cable adapter uses composite construction combining different materials and structures: the collet body, collets, and compression cap work together as a composite assembly to distribute and transfer the mechanical load from the cable to the coiled tubing, ensuring reliable connection while enabling rapid deployment.

Inventive Principle:

Principle #40Composite materials

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

Facilitates rapid and secure connection of the pumping system to coiled tubing, effectively transferring the weight of the pump and motor, thereby reducing deployment time and costs.

Implementation Method 1

The compression cap is connected to the lower collet to apply a compressive force between the lower collet and the collet cap to capture the outer layer of structural wire and inner layer of structural wire within the cable adapter

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS12540535B2System and method for connecting load bearing ESP power cable

Publication Date: 2026.02.03 BAKER HUGHES OILFIELD OPERATIONS LLC

AI summary

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