ESP Cable Splice Enclosure for Fast, Reliable Well Assembly
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Solution Overview
Problem
Traditional methods for splicing electro submersible pump (ESP) cables in oil wells are labor-intensive, time-consuming, and prone to human error, leading to potential failures and increased costs due to the harsh conditions encountered in oil wells, which compromise the integrity and reliability of the electrical connections.
Innovation Solution
A splice connection system comprising a reinforced housing, seal members, splice connectors, and a protective case, which includes sealing rings, seal bands, and high-conductivity splice connectors made of copper, along with a potting insulation compound and epoxy sealant, to create a secure, efficient, and resilient splicing approach.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional splicing methods are used, then skilled technicians can execute proper connections, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The splicing system is divided into modular components including a housing assembly, seal assembly, connector assembly, and insulation assembly. Each component performs a specific function and can be independently manufactured and assembled, enabling faster installation while maintaining connection reliability through standardized interfaces and procedures
Solution Approach 2:
The splice connection system is designed to be self-aligning and self-sealing through integrated features such as tapered guides for automatic alignment, O-ring seals that automatically conform to mating surfaces, and spring-loaded connectors that self-adjust to contact pressure requirements, reducing dependency on highly skilled technicians
2Reliability
If traditional splicing methods with multiple components are used, then connections can be made, but the complexity increases and human error likelihood rises
Solution Approach 1:
Multiple protective functions are merged into integrated assemblies: the seal assembly combines sealing elements with positioning features, the connector assembly integrates electrical connection with mechanical securing, and the insulation assembly combines potting compound with protective housing. This reduces the number of separate components and assembly steps while maintaining comprehensive protection
Solution Approach 2:
The housing assembly serves multiple functions simultaneously: it provides structural support, environmental sealing, mechanical protection, and alignment guidance. The connector assembly provides both electrical connection and mechanical strain relief. This multi-functionality reduces the overall number of components needed in the system
3Reliability
If traditional splicing materials and procedures are used, then connections can be established, but installation time increases and labor costs rise
Solution Approach 1:
Critical protective elements are pre-assembled and pre-positioned during manufacturing: O-ring seals are pre-installed in grooves, connectors are pre-terminated with insulation, and the housing is pre-prepared with sealing surfaces and mounting features. This preliminary preparation eliminates time-consuming field assembly steps while ensuring proper installation for durable connections
Solution Approach 2:
The system transitions from manual, skill-dependent procedures to standardized, parameter-controlled assembly with specified torque values, insertion forces, and sealing pressures. This standardization enables faster installation by technicians with varying skill levels while maintaining consistent connection quality and durability
4Ease of manufacture
If conventional splicing techniques are used, then existing tools and materials can be utilized, but the system lacks protection against harsh well conditions
Solution Approach 1:
The system employs composite construction with multiple material layers: corrosion-resistant metal housing, elastomeric sealing materials, insulating polymers, and protective coatings. This composite structure provides comprehensive protection against corrosion, moisture, and mechanical damage while maintaining manufacturability through standard material fabrication processes
Solution Approach 2:
The design incorporates pre-positioned sealing elements, strain relief features, and protective barriers that are built into the structure before exposure to harsh conditions. O-rings are pre-installed in compressed positions to ensure immediate sealing, and the housing includes built-in corrosion barriers and insulation layers that protect against environmental degradation from the start
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 system enhances durability, reliability, and ease of assembly, reducing installation time and complexity while minimizing waste, ensuring efficient power transmission and protection against mechanical stress, corrosion, and fluid ingress, thereby improving the overall performance and longevity of ESP cable connections.
Implementation Method 1
one or more seal members, the plurality of seal members having plurality of holes configured to receive stripped conductor wires
Implementation Method 2
high-conductivity splice connectors made of copper
Implementation Method 3
potting insulation compound
Implementation Method 4
epoxy sealant
Data Source
AI summary
The present invention relates to a splice connection system for securely connecting electro submersible pump cables that transmit power from an external source to downhole equipment in an underground well for oil extraction applications, thereby ensuring enhanced durability, reliability, and ease of assembly in harsh well environments. The splice connection system comprises a pair of ESP cables and a spliced enclosure. The spliced enclosure comprises seal bands, sealing rings, seal members, splice connectors, a protective case, a potting insulation compound, an epoxy sealant and reinforced housing. The splice connection system significantly reduces installation time and complexity compared to traditional methods by providing a secure, efficient, and resilient splicing approach, thereby improving overall reliability of ESP systems. The splice connection system simplifies the splicing process, minimizes waste, and enhances performance and longevity of ESP cable connections.