Segmented Decompression Resistant Cable Splice
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Solution Overview
Problem
Existing electrical cable splices in underground wells are prone to decompression failure due to rapid gas expansion, leading to arcing and cable damage, especially when the well pressure changes, requiring a solution that prevents gas entrapment and provides a reliable, rapid installation method.
Innovation Solution
A decompression-resistant electrical conductor splice featuring three crimp sockets with elastomeric insulating sleeves and transition collars, coated with dielectric grease and encapsulated in epoxy putty, which allows for rapid assembly and resistance to pressure changes by preventing excessive movement and gas escape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional cable splicing methods are used with extensive wrapping and armor rewinding, then the splice is protected from mechanical damage, but the splice width becomes too large for well bore insertion and installation time increases
Solution Approach 1:
The splice assembly is divided into modular components: individual conductor splices, insulating boots, transition collars, and armor sections. Each conductor is spliced and insulated separately, then assembled into a compact configuration that fits within the well bore diameter while maintaining protection and electrical isolation.
2Reliability
If the splice is tightly sealed to prevent gas leakage, then electrical insulation is maintained, but decompression causes gas expansion that tears the splice and causes arcing
Solution Approach 1:
Elastomeric insulating boots with circumferential ridges are used to encapsulate each conductor splice. These flexible boots can expand and contract during pressure cycling, accommodating gas expansion without tearing. The boots maintain electrical insulation while allowing controlled deformation during decompression events.
Solution Approach 2:
The elastomeric boots are pre-installed on each conductor before the splicing operation, creating a protective cushion that will accommodate future decompression events. The boots are positioned and secured with transition collars before the well experiences pressure changes, ensuring protection is already in place when decompression occurs.
3Productivity
If the splice assembly is made compact for well bore insertion, then installation efficiency improves, but the splice may not adequately contain or manage decompression forces
Solution Approach 1:
The compact assembly is achieved through segmentation of the splice into discrete, pre-configured units (individual conductor-boot-collar assemblies) that can be quickly installed in a standardized sequence, maintaining both compactness and decompression resistance.
Solution Approach 2:
The splice assembly uses a nested structure where conductors are inserted into insulating boots, which are then secured by transition collars, which are in turn protected by armor sections. Each layer is nested within the previous one, creating a compact multi-layered assembly that maintains strength while minimizing overall dimensions for well bore insertion.
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 prevents arcing and cable failure by containing gases and providing a durable, compact splice assembly that can withstand rapid decompression, facilitating efficient installation and extended cable life in high-pressure environments.
Implementation Method 1
three elastomeric insulating/sealing segmented sleeves or boots
Implementation Method 2
providing a circumferential ridge engaging said detent or groove on said electrical crimp socket
Implementation Method 3
having an epoxy sealant between each end of the three elastomeric insulating sealing segmented sleeves and each power cable spliced ends to sealingly engage the three elastomeric segmented sleeves within the conjoined first and second transition collars
Implementation Method 4
restraining the segmented sleeves from excessive circumferential movement
Implementation Method 5
a layer of dielectric grease which is applied to the conductor to coat between elastomeric segmented sleeve and the outer surface of the electrical crimp socket facilitating longitudinal placement
Implementation Method 6
providing a circumferential ridge engaging said detent or groove on said electrical crimp socket
Implementation Method 7
resist decompression because the interior of the splice is restrained from excessive circumferential movement by the protective sleeve or transition collars and from longitudinal movement by the affixation of the epoxy putty
Data Source
Figure 1~3
Figure 4A~4C
Figure 5~6B
AI summary
An electrical splice, resistant to decompression failure for use in gassy hydrocarbon wells, is segmented thereby permitting the installation of the splice quickly and efficiently. The segmented cable splice provides a passage into which is inserted an electrical crimping union which provides a detent to engage a ridge on the interior passage of the segmented sleeve. When each sleeve is complete, the exterior surface of the complete splice is either cylindrical or flat; and covered by protective transition covers having epoxy encapsulating each contained conductor line back to the armored cover, thereby providing mechanical protection and inhibiting movement of the spliced conductors within the splice connection.