Side-exit Motor Cable Connections for ESPs
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Solution Overview
Problem
Conventional pothead connectors for electric submersible pumps (ESP) face issues such as difficult alignment due to stiff motor lead extensions, potential damage to insulation blocks, and inadequate sealing, leading to short circuits and increased risk of equipment failure during installation in narrow well annuli.
Innovation Solution
The implementation of side-exit (radial) connections for power cables, where terminals are oriented perpendicularly to the cable, allowing for axial orientation of the power cable and reduced annular space requirements, along with complementary sealing surfaces and multiple fasteners for improved sealing and reduced deflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the motor lead extension is curved inward to connect the pothead connector to the motor head, then the connection can be made at an angle to facilitate installation, but the stiffness of the motor lead extension makes it difficult to accurately position the pothead and increases the risk of misalignment
Solution Approach 1:
Instead of curving the motor lead extension inward to achieve angular connection, the patent inverts the approach by extending the motor lead extension outward axially and connecting the pothead connector at the end. This allows the connection to be made without curving the stiff conductor, eliminating positioning difficulties while achieving the same facilitation of installation through a different geometric arrangement
Solution Approach 2:
The patent transitions from angular connection in a radial direction to axial connection in the longitudinal dimension. By extending the motor lead extension axially outward from the motor housing and making the connection in this extended dimension, the system avoids the positioning problems associated with curving stiff conductors while maintaining installation ease
2Ease of operation
If the pothead connector is angled with respect to the motor axis to accommodate the curved motor lead extension, then the connection can be made, but the connector and motor lead extension extend outward beyond the motor outer diameter into the narrow annulus, increasing risk of damage
Solution Approach 1:
Instead of angling the connector radially outward to facilitate connection, the patent inverts the geometry by extending the motor lead extension axially outward and making the connection in this direction. This eliminates the radial extension into the narrow annulus while maintaining connection facilitation through the axial extension approach
Solution Approach 2:
The patent creates an asymmetric arrangement where the motor lead extension exits axially from one side of the motor housing rather than symmetrically angling outward. This asymmetric axial extension allows the connection to be made without the pothead and conductor extending into the constrained annular space, reducing damage risk
3Ease of manufacture
If the pothead connector is secured with only two bolts on opposite sides, then the connection can be made, but the connector housing deflects under its own weight, reducing contact pressure on the sealing surface and compromising the seal
Solution Approach 1:
The patent segments the fastening system from two bolts to four or more bolts distributed around the connector housing. This segmentation of the fastening function into multiple attachment points prevents excessive deflection of the connector housing under its own weight, maintains adequate contact pressure on the sealing surface, and ensures reliable sealing while preserving assembly simplicity through the use of standard multiple-bolt fastening
Data Source
AI summary
Systems and methods for connecting power cables to downhole equipment such as ESPs using side-exit (radial) connections. In one embodiment, a system includes an electric drive coupled by a power cable to an ESP. The electric drive is positioned at the surface of a well with the power cable coupled to it. The power cable extends into the well bore and is coupled to the downhole equipment which is positioned in the well bore. The power cable has a connector with a first set of radially oriented terminals (the terminals are perpendicular to the conductors of the power cable). These terminals engage a second set of terminals that are installed in the downhole equipment. The radial orientation of the terminals of the connector and downhole equipment allow the power cable to remain axially oriented, thereby facilitating engagement of the terminals and requiring less annular space in the well bore.