Pressure-Blocking Feedthru With Segmented Insulated Pins
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Solution Overview
Problem
Existing feedthrus for oil and gas well systems face challenges in withstanding varying pressures and temperatures while preventing fluid leakage and ensuring reliable electrical power transmission, especially in harsh environments.
Innovation Solution
A pressure-blocking feedthru design featuring insulated pin assemblies encased in pressure barrier shells, with a double-ended socket and air gap maintained at atmospheric pressure, and a metallic c-seal to create a reliable and pressure-balanced connection, coupled with a cable-connection assembly that includes a dielectric sleeve and shuttle for pressure balancing and fluid protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a feedthru is designed to withstand high pressures and temperatures in harsh well environments, then pressure blocking and temperature resistance are improved, but device complexity increases due to multiple seals and pressure-balanced assemblies
Solution Approach 1:
The feedthru is divided into separate pressure-blocking assemblies, each handling specific sealing functions. The first pressure-blocking assembly includes a first metallic c-seal positioned between the first insulated pin assembly and the first pressure barrier shell, while the second pressure-blocking assembly includes a second metallic c-seal positioned between the second insulated pin assembly and the second pressure barrier shell. This segmentation allows each assembly to be optimized for its specific pressure-blocking function.
Solution Approach 2:
An air gap is introduced as an intermediary element between the first sleeve and the first double-ended socket, maintained at atmospheric pressure. This air gap acts as a pressure-balancing intermediary that protects the electrical connection components from the harsh external pressure environment while allowing the feedthru to withstand high external pressures.
2Reliability
If metallic c-seals are used to ensure reliable sealing under high pressure, then sealing reliability is improved, but electrical conductivity increases creating potential interference
Solution Approach 1:
The metallic c-seals are positioned specifically at the interfaces between the insulated pin assemblies and the pressure barrier shells, where sealing is most critical. The first metallic c-seal is positioned between the first insulated pin assembly and the first pressure barrier shell, and the second metallic c-seal is positioned between the second insulated pin assembly and the second pressure barrier shell. This localized placement ensures sealing reliability at critical interfaces while minimizing the overall electrical interference in the system.
Solution Approach 2:
The air gap maintained at atmospheric pressure serves as an electrical insulating intermediary between the metallic sealing components and the external high-pressure environment. This air gap prevents electrical interference from propagating through the pressure barrier while allowing the metallic c-seals to provide reliable sealing at the component interfaces.
3Reliability
If pressure barrier shells encase the pin assemblies to block pressure, then pressure protection is improved, but thermal management becomes more difficult due to enclosed structure
Solution Approach 1:
The pressure barrier system is segmented into a first pressure barrier shell enclosing the first insulated pin assembly and a second pressure barrier shell enclosing the second insulated pin assembly. These shells are connected through the interface assembly with the air gap, creating separate thermal zones that can manage heat more effectively than a fully enclosed structure while maintaining pressure protection.
Solution Approach 2:
The air gap maintained at atmospheric pressure acts as a thermal intermediary between the enclosed pin assemblies and the external environment. This air gap provides thermal insulation while allowing the pressure barrier shells to withstand external pressures, effectively decoupling the thermal management requirements from the pressure containment function.
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 effectively blocks pressure, withstands extreme temperatures, and maintains a reliable electrical connection, with demonstrated temperature ratings exceeding 260°C and pressure ratings up to 1378 bar, while allowing easy modification for varying lengths and accommodating different cable sizes and materials.
Implementation Method 1
an air gap separates an inner surface of the first sleeve and an outer surface of the first doubled ended socket, wherein the air gap is maintained at atmospheric pressure
Implementation Method 2
a first metallic c-seal positioned between the first insulated pin assembly and the first pressure barrier shell
Data Source
Figure 1A~1B
Figure 2~4
AI summary
A pressure-blocking feedthru that is exposable to varying temperatures and pressures includes various components. For example, the pressure-blocking feedthru might include pressure-blocking assemblies that each include a respective pressure-barrier shell and insulated pin assembly. The pressure-blocking feedthru also includes an interface assembly that couples the pressure-blocking assemblies to one another. The interface assembly includes a double-ended socket for coupling the insulated pin assemblies and a sleeve that circumscribes the doubled ended socket and at least part of the first and the second ceramic pin assemblies. In addition, the pressure-blocking assemblies might each be connected to a cable-connection assembly that employs a pressure-balanced cable termination.