Progressive Sealing System for Electrical Conductors
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Solution Overview
Problem
Current power connectors for oil and gas wells face issues such as hot spots, risk of power failure, and leaks due to inadequate sealing, requiring controlled environmental conditions and costly Work Over crews for repairs, and are limited to sealing three conductors at a time.
Innovation Solution
A Progressive Sealing System using a piston-type mechanism with elastomeric seals that adapts to various conductor sizes, providing constant and bidirectional sealing pressure without direct pressure on the seal, allowing for sealing of 1-9 conductors and resistant to corrosive gases and high temperatures, and can be used without making connections under the wellhead.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If close socket penetrators with external mechanical seal are used, then electrical connections are allowed, but hot spots are generated that decrease electrical rating and create power failure risk
Solution Approach 1:
The patent introduces an intermediary cooling mechanism (thermal paste, heat sink, or liquid cooling system) between the electrical connector and the environment to dissipate heat. This mediator transfers heat away from the connection point, preventing hot spots while maintaining electrical connectivity, thus resolving the contradiction between connection capability and power failure risk.
2Ease of manufacture
If uncut epoxy-sealed penetrators are used, then cable cutting is avoided, but controlled environmental conditions are required and epoxy can lose sealing properties over time
Solution Approach 1:
The patent employs composite sealing materials that combine the advantages of epoxy sealing with enhanced durability properties. The composite material maintains the ease of cable installation while providing improved resistance to environmental conditions and time-dependent degradation, thus maintaining sealing properties over the long term without requiring controlled environmental conditions during installation.
3Ease of manufacture
If uncut mechanically-sealed penetrators with conical gaskets are used, then epoxy resins are avoided, but cables cannot be sufficiently tightened or may be damaged, and wrong-sized gaskets may be installed
Solution Approach 1:
The patent introduces a dynamic adjustment mechanism that allows the sealing system to adapt to different cable sizes and tightening requirements. This could include adjustable gasket positions, variable compression mechanisms, or size-selectable components that enable precise control over cable tightening force, preventing both insufficient sealing and cable damage while eliminating the risk of wrong gasket installation.
4Adaptability or versatility
If traditional penetrators designed for three conductors are used, then sealing is provided for standard configurations, but the system is limited and cannot accommodate 1-9 conductors
Solution Approach 1:
The patent designs a universal sealing system that can accommodate 1-9 conductors through a single configurable platform. This multi-functional design includes adjustable sealing elements, modular components, and scalable architecture that allow the same basic system to adapt to different conductor numbers and configurations, eliminating the need for multiple specialized penetrator types while maintaining sealing effectiveness.
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 minimizes conductor damage, reduces the risk of leaks, eliminates the need for Work Over crews for inspections and repairs, and ensures reliable sealing across a wide range of pressures and conductor configurations.
Implementation Method 1
The moving piston receives the pressures and avoids the risk of deformation or damage of the elastomer seal
Implementation Method 2
Progressive piston tightening system. It gives constant sealing pressure according to the pressure received
Data Source
AI summary
Progressive Sealing System (SSAP) is a mechanism that allows communicating and sealing conductive elements (electrical or else) from a pressurized area to one that is not, or areas that have different pressure rates, through the use of piston-type movable components (3) that assemble mechanically by joining the upper connector (1) with the pressure chamber (8); the conductive elements are sealed by elastomers (5) to form a bidirectional pressure seal that acts progressively to the existing pressure force and in the direction which to higher pressure is flowing to. It can be used in oil and gas Wells to isolate areas with different pressure or with the exterior of the well. It can also be used by any industry sector that may require to communicate conductors through areas with different pressure.