Heater Cable Connector for ESP Wellbore Installation
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Solution Overview
Problem
Manufacturing longer lengths of heater tubes for deep well applications is economically unfeasible, as current methods are not efficient for connecting heater cables to electrical submersible pump cables in high temperature and pressure well bores.
Innovation Solution
A connector is developed to join the cold lead of a heater cable with the individual wires of an ESP cable using a conductive sleeve, insulating boot, and protective outer sleeve, allowing for a combination of short heater cable and long ESP cable sections, which can be sealed and installed efficiently through the wellhead.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If longer lengths of heater tubes are manufactured for deep well applications, then the heating capability in deep well bores is improved, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
The heater cable system is divided into separate modular sections (heater cable section and ESP cable section) that can be manufactured independently and then connected through a connector assembly, enabling deep well applications without requiring single-piece manufacturing of extremely long heater tubes
2Adaptability or versatility
If heater cables are connected to ESP cables in deep well bores, then the electrical connection capability is improved, but the connection reliability in high temperature and pressure environments deteriorates
Solution Approach 1:
The connector assembly uses a nested structure where the inner sleeve containing conductors is positioned within an outer protective sleeve, with insulating boots and sealing elements nested between components, providing mechanical strength and environmental protection while maintaining electrical connection integrity in high temperature and pressure conditions
Solution Approach 2:
The connector assembly combines multiple materials with complementary properties including conductive metals for electrical connection, insulating materials for electrical isolation, and sealing materials for environmental protection, creating a composite structure that reliably withstands deep well conditions
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 provides an economical and efficient electrical connection in deep well bores, enhancing oil and gas production by allowing for the heating of specific zones without the need for lengthy heater tubes, reducing manufacturing costs and complexity.
Implementation Method 1
a conductive sleeve joining the heater cable cold lead and the pump cable lead
Implementation Method 2
a single electrical conductor wire of high resistance (such as ni-chrome wire) which is placed concentrically inside a stainless steel, or other alloy metal tube
Implementation Method 3
a single electrical conductor wire of high resistance (such as ni-chrome wire)
Data Source
AI summary
The connector arrangement attaches the electrical conductors of a standard electrical submersible pump (ESP) cable to a mineral insulated (MI) resistance heater cable for use in oil and gas wells by conductively joining one or more of the electrical conductors of the ESP cable to a cold lead of the MI heater cable within an insulated sleeve covered and sealed within a protective cover. The connector thereby allows the MI heater cable and ESP pump cable to be joined to production tubing and then lowered into the well bore to the desired location.