Subsea Pump Electrical Feedthrough Insulation

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Solution Overview

Problem

Electrical connections in subsea electrical submersible pumps (ESP) are prone to failures due to exposure to well fluid, leading to reliability issues and potential system downtime.

Innovation Solution

The implementation of a subsea pump assembly with a motor assembly housing that includes an electrical insulator and dielectric liquid, where the power conductor is immersed in the dielectric liquid and sealed within the motor assembly housing, preventing exposure to well fluid and enhancing electrical insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the power conductor is exposed to well fluid in the conduit, then the installation is simpler, but electrical connection failures occur due to fluid exposure

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmotor assembly housing structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The motor assembly housing is segmented into distinct functional zones: an electrical connector housing containing the electrical connector, and a motor housing containing the motor. This segmentation allows the electrical components to be isolated and protected from well fluid while maintaining structural integrity and simplifying the overall assembly process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A dielectric liquid is introduced as an intermediary substance between the power conductor and the well fluid environment. The dielectric liquid fills the electrical connector housing and provides electrical insulation, preventing fluid-induced failures while allowing the conductor to remain accessible for connection.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If the electrical connector is sealed within the motor assembly housing, then protection from well fluid is improved, but access for connection becomes more difficult

Engineering Contradiction:

Improveprotection from well fluidVSAvoidelectrical connection access

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The electrical connector is nested within the electrical connector housing, which is itself integrated into the motor assembly housing. This nested structure provides multiple layers of protection against well fluid while maintaining a compact design that allows for accessible connection points through the housing structure.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The electrical connector housing acts as a protective shell that seals the electrical connector from well fluid. The housing design includes sealed openings and gaskets that maintain protection while allowing controlled access for electrical connections during installation and maintenance.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If the dielectric liquid is used to immerse the power conductor, then electrical insulation is enhanced, but the risk of dielectric liquid leakage increases

Engineering Contradiction:

Improveelectrical insulationVSAvoiddielectric liquid leakage

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The dielectric liquid is combined with the electrical connector housing to create an integrated sealed environment. The housing is designed as a closed container that holds the dielectric liquid and immerses the power conductor, eliminating leakage risks while maintaining enhanced electrical insulation throughout the electrical connection assembly.

Inventive Principle:

Principle #5Merging (Combining)

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 solution effectively prevents electrical failures by isolating the power conductor from the well fluid, ensuring reliable operation and reducing maintenance needs for subsea ESP systems.

Implementation Method 1

A dielectric liquid is located in the motor assembly housing. A dielectric liquid passage extends from the upstream end of the motor assembly housing into the power cable opening, immersing the power conductor in the dielectric liquid.

Methodology Applied

Scientific EffectDielectric: Dielectric

Data Source

PatentUS10447105B2Electrical feedthrough for subsea submersible well pump in canister

Publication Date: 2019.10.15 BAKER HUGHES CO

AI summary

A subsea pump assembly includes a tubular conduit that has an upstream end plate and an inlet for flowing well fluid into an interior of the conduit. A power cable opening extends through the upstream end plate. An electrical submersible pump and motor are in the interior of the conduit. The motor has a motor assembly housing with an upstream end having an electrical insulator opening. An end connection secures the upstream end to an interior side of the upstream end plate with the insulator opening registering with the power cable opening. An insulated electrical connector is mounted in the insulator opening. A motor wire in the motor assembly housing joins to an inner end of the electrical connector. A power conductor extends from exterior of the conduit through the power cable opening and joins to an outer end of the electrical connector.