Abstract: A gas resistant pothead system and method for electric submersible motors. A gas resistant pothead system includes a lead foil wrapped motor lead cable (MLE) extending through a pothead, a sleeve of an insulator block inside the pothead, the sleeve including gold plating and lead-foil wrapping over the gold plating, and a lead-to-gold seal formed between the gold plating of the sleeve and the lead foil wrapping over the gold plating. A method of creating a seal to gas around a power cable connection to a downhole electric submersible motor includes wrapping lead foil around a MLE extending through a pothead, continuing the lead foil wrapping around a gold-plated sleeve of an insulating block inside the pothead, mechanically reinforcing the lead foil with an encapsulant, and bonding the lead foil to the gold plating of the insulating block.

Abstract: An apparatus, system and method for treatment of an electric submersible pump (ESP) power cable is described. A method of treating an ESP power cable includes wrapping an ESP power cable around a reel as the cable is removed from a production well to form cable layers, supporting the cable-wrapped reel horizontally above a tank, the reel supported on a shaft extending between actuatable support members, pumping treatment fluid into the tank, lowering the cable-wrapped reel partially into the tank by activating the actuatable support members such that a lower portion of the reel is submerged in the treatment fluid and an inner diameter of the cable-wrapped reel is fluidly coupled to the treatment fluid, rotating the reel around its central axis such that each portion of an outermost layer of the cable is submerged in the treatment fluid at least once to coat the ESP power cable.

Abstract: A gas resistant pothead system and method for electric submersible motors. A gas resistant pothead system includes a lead foil wrapped motor lead cable (MLE) extending through a pothead, a sleeve of an insulator block inside the pothead, the sleeve including gold plating and lead-foil wrapping over the gold plating, and a lead-to-gold seal formed between the gold plating of the sleeve and the lead foil wrapping over the gold plating. A method of creating a seal to gas around a power cable connection to a downhole electric submersible motor includes wrapping lead foil around a MLE extending through a pothead, continuing the lead foil wrapping around a gold-plated sleeve of an insulating block inside the pothead, mechanically reinforcing the lead foil with an encapsulant, and bonding the lead foil to the gold plating of the insulating block.

Abstract: A gas resistant pothead system and method for electric submersible motors. A gas resistant pothead system includes a lead foil wrapped motor lead cable (MLE) extending through a pothead, a sleeve of an insulator block inside the pothead, the sleeve including gold plating and lead-foil wrapping over the gold plating, and a lead-to-gold seal formed between the gold plating of the sleeve and the lead foil wrapping over the gold plating. A method of creating a seal to gas around a power cable connection to a downhole electric submersible motor includes wrapping lead foil around a MLE extending through a pothead, continuing the lead foil wrapping around a gold-plated sleeve of an insulating block inside the pothead, mechanically reinforcing the lead foil with an encapsulant, and bonding the lead foil to the gold plating of the insulating block.

Abstract: A gas resistant pothead system and method for electric submersible motors. A gas resistant pothead system includes a lead foil wrapped motor lead cable (MLE) extending through a pothead, a sleeve of an insulator block inside the pothead, the sleeve including gold plating and lead-foil wrapping over the gold plating, and a lead-to-gold seal formed between the gold plating of the sleeve and the lead foil wrapping over the gold plating. A method of creating a seal to gas around a power cable connection to a downhole electric submersible motor includes wrapping lead foil around a MLE extending through a pothead, continuing the lead foil wrapping around a gold-plated sleeve of an insulating block inside the pothead, mechanically reinforcing the lead foil with an encapsulant, and bonding the lead foil to the gold plating of the insulating block.

Abstract: An apparatus, system and method for treatment of an electric submersible pump (ESP) power cable is described. A method of treating an ESP power cable includes wrapping an ESP power cable around a reel as the cable is removed from a production well to form cable layers, supporting the cable-wrapped reel horizontally above a tank, the reel supported on a shaft extending between actuatable support members, pumping treatment fluid into the tank, lowering the cable-wrapped reel partially into the tank by activating the actuatable support members such that a lower portion of the reel is submerged in the treatment fluid and an inner diameter of the cable-wrapped reel is fluidly coupled to the treatment fluid, rotating the reel around its central axis such that each portion of an outermost layer of the cable is submerged in the treatment fluid at least once to coat the ESP power cable.

Abstract: Systems and methods for maintaining a desired compressive force on seals in an electrical junction such as a pothead connector for an ESP motor. In one embodiment, insulated conductors of a power cable extend into a housing of a connector. The insulated conductors pass through an upper insulator, a set of elastomeric boot seals, and a lower insulator. O-rings are positioned between the upper insulator and the housing of the pothead connector. The lower insulator is secured to the upper insulator by a set of bolts and springs that urge the lower insulator toward the upper insulator, compressing the boot seals. The bolts are threaded into the upper insulator and are tightened to compress the springs against the lower insulator. The compression of the boot seals between the insulators maintains a desired range of contact pressure against the seals despite changes in the seal dimensions.

Abstract: Systems and methods for maintaining a desired compressive force on seals in an electrical junction such as a pothead connector for an ESP motor. In one embodiment, insulated conductors of a power cable extend into a housing of a connector. The insulated conductors pass through an upper insulator, a set of elastomeric boot seals, and a lower insulator. O-rings are positioned between the upper insulator and the housing of the pothead connector. The lower insulator is secured to the upper insulator by a set of bolts and springs that urge the lower insulator toward the upper insulator, compressing the boot seals. The bolts are threaded into the upper insulator and are tightened to compress the springs against the lower insulator. The compression of the boot seals between the insulators maintains a desired range of contact pressure against the seals despite changes in the seal dimensions.

Abstract: Systems and methods for cooling a pothead connector that couples a power cable to the motor of an ESP system, wherein a heat dissipation structure is provided on the connector to increase the transfer of heat from the connector to the surrounding well fluid. In one embodiment, the connector has a housing through which conductors from the power cable extend to a set of terminals which are configured to mate with complementary terminals of the motor. Heat dissipation structures such as fins are provided on the connector housing to facilitate the transfer of heat from the connector to the surrounding well fluid. Baffles or flow diverters may be positioned near the fins to cause turbulence or increased fluid flow near the fins, thereby increasing the heat transfer and improving the cooling of the pothead connector.

Abstract: An electrical power assembly comprises a motor lead with individual metal sheathed conductors, a power cable with individual metal sheathed conductors and a splice connector for connecting each of the conductors. Each splice connector has a tubular metal fastener body with an upward facing shoulder at an upper end and a downward facing shoulder at a lower end. A metal nut assembly is fixed to one of the power cable conductors with a downward facing shoulder in metal-to-metal sealing engagement with the upward facing shoulder of the fastener body. A metal coupler fixed to one of the motor lead conductors with an upward facing shoulder in metal-to-metal sealing engagement with the downward facing shoulder of the fastener body. Contacts electrically connect one of the motor lead conductors to one of the power cable conductors within the fastener body.

Abstract: An electrical power assembly comprises a motor lead with individual metal sheathed conductors, a power cable with individual metal sheathed conductors and a splice connector for connecting each of the conductors. Each splice connector has a tubular metal fastener body with an upward facing shoulder at an upper end and a downward facing shoulder at a lower end. A metal nut assembly is fixed to one of the power cable conductors with a downward facing shoulder in metal-to-metal sealing engagement with the upward facing shoulder of the fastener body. A metal coupler fixed to one of the motor lead conductors with an upward facing shoulder in metal-to-metal sealing engagement with the downward facing shoulder of the fastener body. Contacts electrically connect one of the motor lead conductors to one of the power cable conductors within the fastener body.

Abstract: A pothead assembly for use under severe operating conditions. The pothead assembly includes a plurality of ferrules, a compression plate, a pothead housing, and a threaded collar. When the collar and a base portion of a pothead housing are engaged, the pothead assembly is operable to form a metal to metal seal on metal tubing that surrounds insulated wiring without the use of a solder joint or weld joint. The resulting pothead assembly has a lower profile than conventional potheads, does not require the use of tube connectors and is operable to form the seal in close proximity to the motor.

Abstract: A pothead assembly for use under severe operating conditions. The pothead assembly includes a plurality of ferrules, a compression plate, a pothead housing, and a threaded collar. When the collar and a base portion of a pothead housing are engaged, the pothead assembly is operable to form a metal to metal seal on metal tubing that surrounds insulated wiring without the use of a solder joint or weld joint. The resulting pothead assembly has a lower profile than conventional potheads, does not require the use of tube connectors and is operable to form the seal in close proximity to the motor.