Multi-Piece Pump Connector Housing for H2S-Resistant Sealing

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Solution Overview

Problem

Existing power cable connectors for electrical submersible well pumps face challenges in providing reliable and durable connections that can withstand harsh well environments, particularly in resisting hydrogen sulfide production and maintaining electrical insulation under varying pressure conditions.

Innovation Solution

The electrical connector features a multi-piece housing with upward protruding bosses and isolation boots made of lead tape, which securely clamp around the electrical lines and armor strip, providing a frictional engagement and self-sealing mechanism to prevent hydrogen sulfide ingress and mitigate explosive expansion risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a single-piece housing is used for the electrical connector, then the manufacturing process is simpler, but the sealing effectiveness against hydrogen sulfide is reduced

Engineering Contradiction:

Improvehousing manufacturing simplicityVSAvoidhydrogen sulfide ingress

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The housing is divided into multiple segments including an outer housing, inner housing, and isolation boots that can be assembled together. This segmentation allows each component to be optimized for its specific function, particularly the isolation boots which provide enhanced sealing against hydrogen sulfide by conforming to the electrical lines and bosses.

Inventive Principle:

Principle #1Segmentation

2Object-affected harmful factors

If isolation boots are added to seal around electrical lines and bosses, then the resistance to hydrogen sulfide is improved, but the device complexity increases

Engineering Contradiction:

Improvehydrogen sulfide resistanceVSAvoidconnector structure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The isolation boots are nested within the housing structure, with each boot fitting around an electrical line and securing to a boss. The boots are further nested within the inner and outer housing layers, creating a compact multi-layered sealing system that provides enhanced protection without excessive external complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Reliability

If the upper housing clamps around electrical lines, then the electrical integrity is improved, but the risk of insulation damage increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidinsulation integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The clamping force is distributed locally through multiple contact points along the electrical lines rather than concentrated at single points. The isolation boots provide localized cushioning at critical sealing points, while the housing provides distributed support, ensuring reliable electrical connection without damaging the insulation.

Inventive Principle:

Principle #3Local quality

4Reliability

If a multi-piece housing with isolation boots is used, then the seal tightness is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improveseal tightnessVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The isolation boots are pre-formed with their sealing surfaces and are designed to snap into place during assembly. The housing components are pre-assembled with alignment features including ribs and grooves that guide the isolation boots into their correct positions, reducing the complexity of the final assembly process while maintaining seal tightness.

Inventive Principle:

Principle #10Preliminary action

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 design enhances the reliability and durability of power connections by ensuring a tight seal and resistance to hydrogen sulfide, while also preventing insulation damage and maintaining electrical integrity under changing pressure conditions.

Implementation Method 1

isolation boots made of lead tape, which securely clamp around the electrical lines and armor strip, providing a frictional engagement and self-sealing mechanism to prevent hydrogen sulfide ingress

Methodology Applied

Scientific EffectSelf-sealing:

Implementation Method 2

securely clamp around the electrical lines and armor strip, providing a frictional engagement

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentEP3724952B1Multi-piece housing for submersible pump electrical connector

Publication Date: 2023.09.06 BAKER HUGHES CO

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AI summary

An electrical connector (33) for a submersible well pump motor (17) has a lower housing (39) with upward protruding bosses (71). The bosses have parallel axes (79) and a passage (73). An electrical line (47) extends through each of the passages, each of the electrical lines having a lead sheath (69). A lead tape wrap (83) is wrapped around an external side wall (81) of each of the bosses and a portion of the lead sheath of one of the electrical lines. An upper housing (45) has first and second members (45a, 45b) that fit on opposite sides of the electrical lines and lower ends (97) that connect to the lower housing. The first and second members have recesses (87) that mate to define cavities, each of the cavities receiving one of the lead tape wraps. A fastener (101) clamps the first and second members of the upper housing together.