Wet Mate Connector for ESP Pumping System Cable Wear
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Solution Overview
Problem
Submersible pumping systems in hydrocarbon wells face mechanical wear and damage during periodic retrieval due to the mechanical handling of power cables, which are often secured alongside the production tubing.
Innovation Solution
A wet mate connector system is deployed within the production tubing, allowing for electrical connection between the pump motor and power supply through conductive pins and receptacles, eliminating the need for external power cables and reducing mechanical stress on the electrical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power cable is strapped to tubing or lowered along with pump and tubing, then electrical power can be supplied to pump motor, but mechanical wear and damage occurs during periodic retrieval
Solution Approach 1:
The power cable system is segmented into a permanent cable attached to the tubing and a removable connector assembly attached to the pump. This allows the pump to be retrieved and reconnected without handling the entire power cable, reducing mechanical wear on the cable itself.
Solution Approach 2:
The connector is extracted as a separate removable component from the power cable system. The connector with receptacles is permanently installed on the tubing, while the corresponding pins are attached to the pump. This separation allows the pump to be disconnected and reconnected without disturbing the main power cable.
2Ease of repair
If power cable is mechanically handled during retrieval, then pump can be serviced, but cable wear and damage increases
Solution Approach 1:
The system is divided into a stationary cable-receptacle assembly on the tubing and a movable pump-connector assembly. During maintenance, only the pump and its connector are handled and disconnected, while the cable remains permanently installed and undisturbed, preventing cable wear during retrieval operations.
Solution Approach 2:
The connector acts as an intermediary between the power cable and pump motor. It provides a standardized interface that allows the pump to be connected and disconnected without directly handling the power cable, thus protecting the cable from mechanical damage while enabling easy pump maintenance.
3Reliability
If wet mate connector is used for electrical connection, then mechanical wear on cable is reduced, but connection complexity increases
Solution Approach 1:
The electrical connector integrates multiple functions into a single component: mechanical attachment, electrical connection, and alignment features are combined in the wet mate connector assembly. This reduces the number of separate components needed while providing robust electrical connection that protects against cable wear.
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 wet mate connector system provides reliable and durable electrical power to the pump motor within the wellbore, reducing mechanical wear and enabling efficient maintenance by allowing in-situ power supply without the need for external cable handling.
Implementation Method 1
a wet mate connector in electrical communication with the pump motor and the electrical power supply having receptacles and pins configured for insertion into the receptacles. Inserting the pins into the receptacles provides electrical communication between the pump motor and the electrical power supply.
Data Source
AI summary
A submersible pumping system for use downhole, wherein the system includes tubing disposed in a wellbore having a wet connection formed for coupling with a pumping system disposable in the tubing. An electrical power cable connects to the wet connection through the tubing. The wet connection comprises receptacles configured to mate with electrically conducting pins, the receptacles and the pins are oriented substantially parallel with the tubing axis. The receptacles are formed to receive the pins therein and form an electrical connection for connecting electrical power from the cable to the pumping system.