Metal-Encapsulated ESP Cable Splice for Pressure and Gas Sealing
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Solution Overview
Problem
Existing electrical submersible pumping (ESP) systems face significant failures due to the power cable system, particularly at bulkheads and connectors, where high pressures and temperatures, along with gas penetration, compromise the integrity of the electrical connections.
Innovation Solution
The implementation of pre-assembled cable assemblies with a penetrator body and cable encapsulated in a low-temperature alloy like bismuth, eliminating the need for electrical connectors at bulkheads, and incorporating an electric heating element for a metal-to-metal seal, ensures reliable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connectors and bulkheads are used at cable penetration points, then the cable system can be assembled with standard components, but the electrical connections become vulnerable to high pressure, temperature, and gas penetration in harsh well conditions
Solution Approach 1:
The patent merges the cable conduit and electrical connector into a single integrated metal encapsulated penetrator assembly. The cable is directly encapsulated within the metal penetrator body, eliminating separate bulkheads and connectors. This unified structure provides continuous metal-to-metal sealing from the cable jacket through the penetrator to the motor housing, preventing gas and fluid migration while maintaining electrical connectivity in harsh well conditions.
Solution Approach 2:
The metal encapsulated penetrator acts as an intermediary barrier between the harsh external environment (high pressure, temperature, gas) and the electrical cable. The penetrator body with its metal-to-metal seal provides a protective interface that allows the cable to pass through bulkheads and into the motor while blocking harmful factors, thus protecting the electrical connection without requiring additional protective components.
2Ease of manufacture
If multiple separate components (bulkheads, connectors, cable jackets) are used to protect the cable, then the system can be assembled with standard parts, but the complexity of assembly and potential failure points increase
Solution Approach 1:
The patent combines multiple separate protective components (bulkhead, cable conduit, electrical connector, sealing elements) into a single pre-assembled metal encapsulated penetrator unit. This integration reduces the number of parts that need to be handled and assembled in the field, simplifying the installation process while reducing potential failure points associated with multiple connection interfaces.
Solution Approach 2:
The penetrator assembly is pre-assembled and pre-sealed at the factory with the cable encapsulated within the metal penetrator body before shipment to the well site. This preliminary assembly ensures proper sealing and alignment are achieved under controlled manufacturing conditions, eliminating the need for complex field assembly operations and reducing the skill level required for installation.
3Reliability
If traditional cable protection methods are used, then existing cable designs can be maintained, but gas can penetrate the cable jacket and migrate to connectors causing failures
Solution Approach 1:
The metal encapsulated penetrator serves as an intermediary barrier that blocks gas and fluid migration pathways. The penetrator body provides a metal-to-metal seal that prevents gas from penetrating the cable jacket and reaching the electrical connectors, thus protecting the electrical connection integrity in high-pressure gas environments without requiring changes to the cable design itself.
Solution Approach 2:
The metal penetrator creates a sealed, inert environment around the cable conductors within the bulkhead and motor connection area. This sealed metal enclosure prevents external gas and fluid from contacting the cable insulation and connectors, effectively isolating the electrical components from harmful atmospheric conditions in the well environment.
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
This solution significantly reduces the failure rate of ESP systems by providing a robust, reliable electrical connection that withstands harsh well conditions, as demonstrated by Saudi Aramco's reduction in failures attributed to the power cable system.
Implementation Method 1
the pot head is encapsulated in a low temperature alloy such as bismuth and includes an electric heating element which creates a metal-to-metal seal the housing of the motor
Implementation Method 2
allows the elimination of electrical connectors at bulk heads or other barriers which a cable has to pass through in order to supply a pump or other similar downhole device
Data Source
AI summary
A cable splice between a first electrical cable and a second first electrical cable together in a downhole environment, the first electrical cable including at least a first conductor, the second electrical cable including at least a second conductor bringing the first conductor into electrical contact with the second conductor forming a closed chamber around the first electrical cable and a second first electrical cable melting a low temperature metal or metal alloy and encapsulating the first electrical cable and a second first electrical cable in the penetrator body this metal or metal alloy.