ESP Motor Lead Protective Sleeve for Contamination Isolation

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Solution Overview

Problem

Conventional electric submersible pump (ESP) systems face issues with contamination and repair challenges due to the accumulation of debris and fluids at the pothead junction, leading to short-circuits and the impossibility of replacing or repairing flexible leads embedded in epoxy encapsulant.

Innovation Solution

The implementation of a protective sleeve made from ePTFE insulation around motor lead wires, sealing them from epoxy fixtures to the motor head, prevents fluid and debris contamination and allows for removable connections to the motor windings, enabling easier maintenance and repair.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If flexible leads are embedded in epoxy encapsulant for secure connection, then connection reliability is improved, but ease of repair deteriorates (becomes impossible to replace or repair)

Engineering Contradiction:

Improveconnection reliabilityVSAvoidease of repair

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The flexible lead assembly is segmented into modular components: a reusable connector portion that interfaces with the motor head and a replaceable lead portion embedded in epoxy. This segmentation allows the connector to be detached and reused while only the damaged lead portion needs replacement, resolving the contradiction between secure embedding and ease of repair.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A connector serves as an intermediary component between the flexible lead and the motor head. This intermediary allows the lead to be securely attached during operation while enabling easy detachment for replacement, thus maintaining both connection reliability and ease of repair.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If pothead connector is used to connect flexible leads to motor lead extension, then electrical connection is established, but susceptibility to contamination increases (debris accumulation causes short-circuits)

Engineering Contradiction:

Improveelectrical connectionVSAvoidcontamination susceptibility

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The vulnerable pothead connector junction is extracted from the motor interior environment. By routing the flexible lead through a sealed path and connecting to the motor head from the exterior side, the connection point is removed from the contaminated oil environment, eliminating debris accumulation while maintaining electrical connection.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

A sealed conduit or protective pathway acts as an intermediary between the flexible lead and the motor head connection. This intermediary barrier prevents contaminants from reaching the electrical junction while allowing electrical current to pass through, resolving the contradiction between establishing electrical connection and preventing contamination.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If motor interior is filled with dielectric oil for pressure equalization and insulation, then insulating properties are improved, but contamination accumulation worsens (water and debris accumulate at junctions)

Engineering Contradiction:

Improveinsulating propertiesVSAvoidcontamination accumulation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The electrical connection junctions are extracted from the oil-filled motor interior environment. By positioning connectors and connection points outside the oil cavity or in sealed compartments, the beneficial insulating properties of the oil are maintained while the harmful contamination accumulation at junctions is eliminated.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Sealed barriers or protective enclosures act as intermediaries between the dielectric oil and the electrical junctions. These intermediaries allow the oil to provide pressure equalization and insulation throughout the motor while preventing water and debris from accumulating at the electrical connections.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 effectively isolates electrical conductors from contaminants, preventing short-circuits and allowing for the replacement or repair of faulty connections, enhancing the reliability and longevity of ESP systems.

Implementation Method 1

This ePTFE insulation material is resistant to both water and chemicals that may be present in a well environment

Methodology Applied

Scientific EffectHydrophobic: Hydrophobe

Data Source

PatentUS10097060B2Systems and methods for preventing electrical faults associated with motor leads

Publication Date: 2018.10.09 BAKER HUGHES CO

AI summary

Systems and methods for protecting motor lead from debris and fluid contamination. In one embodiment, detachable, flexible lead wires within an ESP motor are covered by protective sleeves that are sealed against the end connectors of the leads. The end connectors are coupled to corresponding terminals in an epoxy fixture of the motor and a motor head in a manner that provides a seal between them. The sealed sleeve and end connectors prevent debris and contaminants in the fluid within the motor from reaching the conductive elements of the motor leads, thereby preventing accumulations of debris and contaminants that could otherwise cause electrical faults.