Downhole Splice for Submersible Pump Cable
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Solution Overview
Problem
Existing power cable splice arrangements for submersible pumping systems in well bores are complex, time-consuming to install, and prone to failure due to extreme pressure differentials, temperature conditions, and high voltage stress, leading to frequent repairs or replacements.
Innovation Solution
A sealed electrical splice arrangement using crimp splices between power cable segments, an insulating sleeve with internal passageways, and a protective housing with transition collars, which forms an impenetrable covering resistant to harsh well bore conditions, ensuring a durable and reliable electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional crimp splices with insulating tapes are used, then electrical connections can be established between cable segments, but the connections fail frequently under extreme pressure differential, temperature conditions and high voltage stress
Solution Approach 1:
The patent employs a nested structure where the insulating sleeve is positioned inside the protective housing, creating multiple layers of protection. The insulating sleeve provides electrical insulation and seals around the crimp splice, while the protective housing provides additional mechanical protection and sealing. This nested arrangement allows the connection to withstand extreme pressure differentials, temperature conditions, and high voltage stress by providing redundant protective barriers.
Solution Approach 2:
The patent uses composite material structures combining different materials with complementary properties. The insulating sleeve is made of electrically insulating material to prevent electrical breakdown under high voltage stress. The protective housing is made of mechanically strong material to resist pressure differential and physical damage. This composite approach allows the connection to simultaneously withstand multiple harsh environmental factors that would fail single-material solutions.
2Reliability
If traditional splice arrangements with multiple components are used, then electrical connections can be made, but the installation is complicated and time-consuming
Solution Approach 1:
The insulating sleeve and protective housing are pre-assembled into an integrated splice assembly before field installation. The insulating sleeve is positioned within the protective housing with transition collars at each end, creating a pre-configured unit. This preliminary assembly reduces field installation complexity and time, as the entire protective structure can be installed as a single unit rather than assembling multiple separate components in the field.
Solution Approach 2:
The patent merges the insulating sleeve, protective housing, and transition collars into an integrated splice assembly. The insulating sleeve provides electrical insulation, the protective housing provides mechanical protection, and the transition collars provide structural transition and sealing. By combining these functions into a single integrated assembly, the patent simplifies installation while maintaining the durability benefits of multiple protective layers.
3Ease of operation
If traditional splice arrangements are used, then electrical connections can be established, but frequent repair or replacement is required
Solution Approach 1:
The patent provides beforehand cushioning by pre-assembling the complete protective structure including the insulating sleeve, protective housing, and transition collars before field installation. This pre-cushioned assembly is designed to withstand the full range of expected environmental stresses (pressure differential, temperature extremes, high voltage stress) from the outset, preventing connection failure and eliminating the need for frequent repairs or replacements during the service life of the downhole equipment.
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 provides a simple, durable, and efficient power cable connection that withstands well bore environments, reducing the need for frequent repairs and ensuring reliable electricity transfer to down hole equipment, while being cost-effective and easier to install.
Implementation Method 1
an insulating sleeve with one or more internal passage ways, and a protective housing and transition collars such that the insulating sleeve is positioned to sealably cover the crimp splices and conductive wires
Implementation Method 2
The protective housing is positioned to cover the insulating sleeve
Implementation Method 3
crimp splices between the conductive wires of consecutive segments of the power cable
Implementation Method 4
The transition collars are positioned to cover each end of the protective housing
Data Source
AI summary
A splicing system that establishes an electrical union between two segments of power cable having internal conductor wires. The splicing system is resistant to electrical failures and the harsh environment existing in subterranean environments during all phases of the hydrocarbon extraction process. The splicing arrangements comprise a protective housing, insulating sleeve and crimp splice working in cooperation to create a sealed power cable connection.