Wellhead Cable Penetrator Compression Sealing for High Pressure
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Solution Overview
Problem
Existing penetrator systems for electrical submersible pumps (ESPs) in the oil and gas industry fail to provide effective sealing and pressure resistance for cables passing through wellheads, requiring inconvenient epoxy packing and unable to withstand high wellbore pressures.
Innovation Solution
A wellhead penetrator system with a polymer insulator, compression seals, and a compression plate that compresses seals without epoxy, allowing cables to pass through without splicing, featuring a cavity devoid of filling material and capable of withstanding high pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If epoxy is packed at the seal around the cable, then sealing is provided, but the operation becomes inconvenient and pressure resistance is insufficient
Solution Approach 1:
The patent removes the epoxy packing step from the sealing process, extracting the problematic material application step while maintaining sealing effectiveness through the compression seal mechanism alone
Solution Approach 2:
The patent replaces the chemical/manual epoxy packing system with a mechanical compression seal system that uses a compression plate and spring to apply continuous radial pressure on the cable, providing both sealing and pressure resistance without manual intervention
2Ease of manufacture
If cables are cut or spliced at the seal, then electrical connections are made, but the process becomes more complex and time-consuming
Solution Approach 1:
The patent enables continuous cable passage through the penetrator body without interruption for cutting or splicing, maintaining the cable's electrical continuity and mechanical integrity throughout the installation process
Solution Approach 2:
The compression seal and compression plate assembly serves multiple functions simultaneously: it provides sealing around the cable, maintains electrical continuity, and enables pressure resistance, eliminating the need for separate cable cutting and splicing operations
3Strength
If penetrator systems are designed for high pressure resistance, then they can withstand wellbore pressure, but cable passage becomes more difficult
Solution Approach 1:
The patent uses a dynamic compression seal system with a spring-loaded compression plate that can adapt to different cable diameters and provide variable compression force, allowing easy cable insertion while maintaining high pressure resistance once installed
Solution Approach 2:
The patent applies compression seals at specific locations where cables pass through the penetrator body, providing localized sealing and pressure resistance only where needed, rather than requiring the entire penetrator structure to be overly complex
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
Enhances sealing, stability, and pressure resistance, ensuring safe and reliable power delivery to ESPs by preventing fluid and gas escape while allowing cables to pass through wellheads without splicing, thus improving safety and reliability.
Implementation Method 1
A compression plate is coupled to the upper end of the polymer insulator and against the compression seals to thereby compress the compression seals about the electrical cables
Data Source
AI summary
The present disclosure relates to a wellhead penetrator system comprising a penetrator body comprising a hollowed cylindrical frame connecting a top end to a bottom end; a cable seal located within the penetrator body, comprising: a cylindrical core made of a polymer having three cylinder-shaped port holes configured to each provide a path for of the three insulated electrical wires; a top side, wherein the port holes extend upward from the top side of the cable seal; and a bottom side facing into the cavity located in the bottom end of the penetrator body, wherein the port holes extend downward from the bottom side of the cable seal; and a follower comprising a cylindrical metal body and cylindrical holes, wherein the follower seats against the bottom side of the cable seal so that port holes of the cable seal protrude through the cylindrical holes of the follower.