Deepwater Electrical Connector Ceramic Body Faraday Cage
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Solution Overview
Problem
Conventional electrical connection assemblies in deepwater applications, such as subsea oil or gas wells, fail to maintain integrity in harsh conditions of high temperature, high pressure, and corrosive environments, leading to potential electrical arcing and costly maintenance.
Innovation Solution
An electrical connector with a ceramic body and metallized inner surface, featuring a conductive contact and a sleeve that provides a gripping force, along with a complementary connector system to ensure a sealed and reliable electrical connection, utilizing a Faraday cage effect to prevent arcing and maintain electrical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical connection assemblies are used in deepwater applications, then electrical connections can be established, but they fail to maintain integrity in harsh conditions of high temperature, high pressure, and corrosive environments
Solution Approach 1:
The connector employs a composite structure combining ceramic body (for electrical insulation and corrosion resistance), metal components (for structural strength and conductivity), and elastomeric materials (for sealing). This multi-material approach allows the connector to simultaneously withstand high temperature, high pressure, and corrosive environments while maintaining electrical integrity.
Solution Approach 2:
The patent utilizes thermal expansion parameter changes by designing the connector with materials having different coefficients of thermal expansion. The elastomeric material is selected to have a higher coefficient of thermal expansion than the rigid components, allowing it to expand and fill gaps during thermal cycling, thereby maintaining sealed connections under temperature variations.
2Reliability
If conventional connectors are used, then connections can be made, but they are susceptible to electrical arcing in high temperature and high pressure environments
Solution Approach 1:
The connector design creates an inert environment by using ceramic materials with high dielectric strength and corrosion resistance. The ceramic body and metallized surfaces form a protective barrier that prevents electrical arcing by maintaining electrical isolation and resisting breakdown in high temperature and pressure conditions.
3Reliability
If sealed connections are formed to maintain integrity, then electrical connections remain sealed, but the complexity of the connector assembly increases
Solution Approach 1:
The connector integrates multiple functions into a single unified structure. The ceramic body simultaneously provides electrical insulation, structural support, and corrosion resistance. The elastomeric material combines sealing, thermal compensation, and mechanical cushioning functions, reducing the need for separate components and simplifying the overall assembly.
Solution Approach 2:
The connector is designed as a multi-functional component that can withstand high temperature, high pressure, corrosion, and thermal cycling while maintaining electrical isolation and sealed connections. This universal design allows a single connector type to handle multiple environmental challenges without requiring additional specialized components.
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 solution effectively maintains electrical integrity in extreme conditions, preventing arcing and ensuring long-term reliability of electrical connections in deepwater environments, even at temperatures up to 200°C and pressures of 10,000 psi.
Implementation Method 1
utilizing a Faraday cage effect to prevent arcing and maintain electrical integrity
Implementation Method 2
a sleeve disposed about an outer surface of the ceramic body to exert a gripping force on the ceramic body
Data Source
AI summary
A connector for a connection assembly for providing electrical power to a submersible electrical component in a deepwater environment, such as a subsea well, includes a ceramic body having a metallized inner passageway. A conductive contact extends through the passageway and has a contact end and a cable connecting end. A conductive sleeve is disposed about an outer surface of the ceramic body. The ceramic body is retained within a connector housing that has an interface chamber and a cable retaining chamber. The contact end of the connector contact is disposed within the interface chamber, and the cable connecting end of the contact is disposed within the cable retaining chamber. The sleeve is attached to the housing to provide a seal between the interface chamber and the cable retaining chamber. When the connector is engaged with a complementary connector, a Faraday cage is provided within the interface chamber to manage the electrical field about the connection interface between the connectors.