Spring-Energized Connector Assembly for Reliable ESP Motor Leads
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Solution Overview
Problem
The reliability of motor lead connections in electric submersible pump systems is compromised by improper assembly, leading to ingress of corrosive wellbore fluids and loss of conductivity due to the dependence on assembly skills of service personnel.
Innovation Solution
A connector assembly comprising a pin connector, socket connector, and insulating member, with energizing springs to enhance contact stress and reduce resistance, ensuring a reliable electrical connection and protection against wellbore fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pin connector assembly is used for splicing motor lead to power cable, then electrical connection can be established, but reliability is compromised due to improper assembly by service personnel
Solution Approach 1:
The connector assembly is designed to be self-aligning and self-securing. The pin connector automatically engages with the socket connector through tapered surfaces that guide proper alignment, and the insulating member self-adjusts to provide adequate insulation without requiring precise assembly by service personnel.
Solution Approach 2:
The insulating member is pre-installed on the pin connector assembly before field installation. This preliminary action ensures that insulation is already in place and properly positioned, eliminating the need for service personnel to apply insulation material during assembly and reducing the risk of improper insulation application.
2Reliability
If insulation material is applied to pin connector assembly, then electrical insulation is provided, but corrosive wellbore fluids can ingress when improperly applied causing loss of conductivity
Solution Approach 1:
The insulating member is designed as a self-contained component that automatically provides adequate insulation coverage when the connector is properly assembled. The tapered engagement surfaces ensure the insulating member is pushed into the correct position, self-adjusting to provide complete coverage without requiring precise manual application.
Solution Approach 2:
The insulating member functions as a flexible protective shell that conforms to the shape of the pin connector assembly. This flexible insulating barrier effectively seals the connection interface, preventing corrosive wellbore fluids from ingress while maintaining electrical insulation properties.
3Adaptability or versatility
If connector assembly is designed for field assembly, then installation flexibility is improved, but assembly precision may be compromised
Solution Approach 1:
The insulating member is pre-installed on the pin connector assembly at the manufacturing stage with precise positioning. This preliminary action ensures that when the connector is assembled in the field, the insulation is already in the correct position and orientation, eliminating precision requirements for insulation application during field assembly.
Solution Approach 2:
The connector assembly incorporates asymmetric tapered engagement surfaces that guide the pin connector into a single correct orientation within the socket connector. This asymmetric design provides mechanical guidance that ensures proper alignment and precise engagement even when assembled by service personnel in the field, eliminating the need for high assembly precision.
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 connector assembly provides a reliable and durable electrical connection by increasing contact stress and reducing resistance, thereby enhancing the long-term performance and integrity of motor lead connections in ESP systems.
Implementation Method 1
energizing springs to enhance contact stress and reduce resistance
Data Source
AI summary
A connector assembly comprising a pin connector assembly, a socket connector assembly, and an insulating member. The pin connector assembly comprises a generally cylindrical shape with an outer surface, an inner spring, and mechanically coupled to an electrical cable. The socket connector assembly comprises a generally cylindrical in shape with an inner surface, an outer spring, and mechanically coupled to an electrical cable. The contact surface stress between the pin connector and socket connector can be increased by the inner spring, the outer spring, or both. The contact resistance of the connectors is reduced by the increase in contact surface stress via the spring force. The insulating member can be threadingly coupled to the mated connectors.