Tubing Encapsulated Cable Splice for ESP Pressure Sealing

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Solution Overview

Problem

Existing cable splice systems for electric submersible pumps in oil and gas wells are complex and costly due to the use of multiple insulators and expensive shells, which increase the diameter and complexity of the splicing process, while also requiring cable-specific sized seals for optimal performance.

Innovation Solution

A method and apparatus that utilize a tubing encapsulated cable and an electric submersible downhole cable, tape-spliced through contacts, with a thermoplastic insulator and multiple layers of sealant tape to create a pressure-blocking seal inside a shell, reducing the need for expensive components and allowing for a thinner, more cost-effective splice assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple insulators and expensive shells are used in cable splice systems, then the sealing and insulation performance is improved, but the device complexity and cost increase

Engineering Contradiction:

Improvesealing and insulation performanceVSAvoidcomplexity of splicing process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple insulators and shells into a single integrated shell structure that provides both sealing and insulation functions simultaneously. This merger eliminates the need for separate insulator components while maintaining the required protective performance, thereby reducing device complexity without compromising reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The shell is designed to perform multiple functions: it provides mechanical protection, electrical insulation, and pressure sealing simultaneously. This multi-functional design replaces what would traditionally require separate dedicated components for each function, simplifying the overall splice assembly while maintaining all necessary performance characteristics.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple insulators and large shells are used, then the sealing performance is improved, but the overall diameter of the splice assembly increases

Engineering Contradiction:

Improvesealing performanceVSAvoiddiameter of splice assembly

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent employs a thin-film sealant tape wrapped around the cable assembly to create an effective pressure seal. This flexible sealing approach provides reliable sealing performance without requiring a large-diameter rigid shell, thereby maintaining compact overall dimensions while ensuring adequate sealing against pressure differential.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If cable-specific sized seals are used, then the sealing performance is optimized, but the adaptability to different cable sizes decreases

Engineering Contradiction:

Improvesealing performanceVSAvoidadaptability to different cable sizes

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The sealant tape is designed with flexible wrapping capability that allows it to adapt dynamically to different cable diameters. Rather than using fixed-size rigid seals, the tape can be wrapped in appropriate layers around cables of varying sizes, maintaining effective sealing contact while providing versatility across different cable specifications.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The sealing approach changes from fixed geometric seals to a variable-parameter system where the number of tape layers and wrap tension can be adjusted based on cable size. This parameter-based adaptation allows the same sealing mechanism to effectively seal around cables of different diameters while maintaining optimal sealing performance.

Inventive Principle:

Principle #35Parameter changes

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 provides a reliable, pressure-blocking seal with minimal components, reducing the overall diameter and cost of the splice assembly, while maintaining well pressure and insulating the connection between surface and downhole cables, and can be easily adapted to different cable sizes.

Implementation Method 1

multiple layers of sealant tape wrapped around at least the tubing encapsulated cable and the thermoplastic insulator inside the shell, where a number of layers of the sealant tape is selected to create a pressure blocking seal inside the shell

Methodology Applied

Scientific EffectPressure blocking seal: Pressure Gradient

Implementation Method 2

a thermoplastic insulator to seal the tubing encapsulated cable

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS11721957B2Electric submersible pump cable tubing encapsulated cable splice

Publication Date: 2023.08.08 ITT MANUFACTURING ENTERPRISES LLC

AI summary

A cable splice assembly includes a tubing encapsulated cable, an electric submersible downhole cable, where the tubing encapsulated cable and the electric submersible downhole cable are tape-spliced through a pair of respective contacts, and a thermoplastic insulator to seal the tubing encapsulated cable. A shell contains the tape-spliced tubing encapsulated cable and the electric submersible downhole cable and multiple layers of sealant tape are wrapped around at least the tubing encapsulated cable and the thermoplastic insulator inside the shell, where a number of layers of the sealant tape is selected to create a pressure blocking seal inside the shell.