Abstract:
An electrical coupling particularly for submersible pumps serves as a barrier between high and low pressure zones and allows electrical cables to be connected through it. The coupling includes a jacket mounted in a housing. The jacket has at least one tapered hole extending through it. A conductor rod is bonded to a dielectric sheath and inserted into the hole. The sheath is compressed in the hole to provide sealing. The sheath is preferably of glass bonded mica.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates in general to submersible pumps, and in particular to an electrical coupling that provides a boundary between high and low pressure zones and also provides an electrical connection between electrical cables in the low and high pressure zones. 
     In a typical large volume submersible pump installation, an electrical motor will be located downhole for rotating a centrifugal pump. Electrical conductors extend from the surface to the motor. If the wellhead is under pressure, the conductors must feed through a barrier separating high wellhead pressure from low surface pressure. Also, in certain installations using downhole packers, the conductor must extend from a high pressure zone into a low pressure zone. 
     Feed-through mandrels are available for providing a barrier between different pressure zones and for connecting electrical cable from the two separate zones. These mandrels usually have a thermoset insulation material molded around copper conductors. In general, these types will withstand up to about 3,000 psi (pounds per square inch) pressure differential. One disadvantage is that if gas is present in the wellhead, the gas may enter the thermoset material under pressure. When pressure is relieved, the gas will expand, possibly destroying the insulation material. 
     It is known that glass based materials, such as glass bonded mica, can be compressed against a rigid surface such as metal to very high pressures to form a seal. Also, these glass bonded mica materials are dielectric, thus provide good insulators. Feed-through mandrels for submersible pump installations, to applicant&#39;s knowledge, however, do not utilize glass based materials. 
     SUMMARY OF THE INVENTION 
     In this invention, a feed-through mandrel is provided that utilizes a rigid jacket located within a housing. The jacket has a hole for each conductor. The holes are conical and receive conductor rods which protrude past the ends of the jacket for connecting to electrical cable. The conductor rods are bonded within conical sheaths that fit tightly in the holes in the jacket. The sheaths are of a glass based material and are pressed tightly by compression means against the jacket to form a tight seal as well as a good insulator. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a partially sectioned view of part of an adapter showing a feed-through mandrel constructed in accordance with this invention. 
     FIG. 2 is an enlarged cross-sectional view of the feed-through mandrel of FIG. 1. 
     FIG. 3 is an end view of the lower end of the feed-through mandrel of FIG. 2, with the lower connector removed. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIG. 1, an adapter 11 includes a threaded member 13 for bolting to a portion of the wellhead. Member 13 is tubular and has a tubing hanger 15 adapted to be sealed within its bore. Tubing hanger 15 is held in place by means of a cap or threaded ring 17. Tubing hanger 15 has two passages 19 and 21. Passage 21 has threads for retaining tubing 23, through which fluid from one of the zones in the well will be produced. A pipe 25 is secured in the exit end of passage 21 and leads to separation and storage equipment. A feed-through mandrel 27 is located in passage 19. Feed-through mandrel 27 seals any pressure within the wellhead and interior of connection member 13. Feed-through mandrel 27 also enables the connection of a connector 29 for a cable leading to the pump motor (not shown) with a connector 31, which connects a cable leading to the power supply and control equipment on the surface (not shown). 
     Feed through mandrel 27 includes a tubular housing 33 that is secured within passage 19 by threads 35. O-rings 37 seal the housing 33 within passage 19. The upper and lower ends of housing 33 are threaded for receiving the connectors 29 and 31. Referring to FIG. 2, housing 33 has a cylindrical bore 40 that closely receives a rigid, preferably metal, jacket 39. O-rings 42 seal jacket 39 within bore 40. Jacket 39 is a solid plug but for a frusto-conical hole 41 extending through it for each of the conductors of the electrical cable. Normally there will be three holes 41. Each hole 41 has a larger diameter on the high pressure side or end 43 and tapers gradually to a smaller diameter on the lower pressure end 45. The three holes 41 are equally spaced 120 degrees apart about the axis of jacket 39. Referring again to FIG. 2, the low pressure end 45 of jacket 39 is retained by a stop means comprising a snap ring 46 retained within a groove formed in the bore 40 of housing 33. Snap ring 46 prevents further movement of jacket 39 in the low pressure direction. 
     Three conductor rods 47, each of a conducting material such as copper, are bonded concentrically within a sheath or insulator 49. Rod 47 protrudes beyond the ends of sheath 49 and beyond the ends 43 and 45 of jacket 39. Sheath 49 has an exterior that is frusto-conical and of the same taper and cross-sectional dimensions as the holes 41. Sheath 49 has a high pressure end 51 that has an annular face perpendicular to rod 47. High pressure end 51 protrudes beyond the high pressure end 43 of jacket 39 a short distance. Sheath 49 has low pressure end 53 that has an annular face that is perpendicular to the axis of rod 47 and flush with the low pressure end 45 of jacket 39. Sheath 49 is a dielectric material for forming good insulation, and is also a glass based material such as ceramic, aluminum oxide or glass bonded mica. Extreme pressures can be mechanically exerted between the sheath 49 and jacket 39, to provide a high pressure isolator while retaining electrical insulation. 
     A circular plate 55 is used to serve as compression means for compressing the sheaths 49 into the holes 41 and retaining them under compression. Plate 55, as shown also in FIG. 3, has three apertures 57 spaced 120 degrees apart. Apertures 57 are adapted to be received over the ends of the three conductor rods 47. Apertures 57 are smaller in diameter than the high pressure ends 51 of the sheaths 49. This causes the plate 55 to bear against the high pressure ends 51. During assembly, a hydraulic press (not shown) will be used to press plate 55 against the sheaths 49, with the retaining ring 46 serving as a backup. While under tight compression, a retaining or snap ring 59 is inserted into a groove formed in the bore 40 of housing 33 to retain the plate 55 in compression. The high compression causes the sheaths 49 to form a tight seal against jacket 39. Plate 55 and retaining ring 59 thus serve as compression means for compressing sheaths 49 in jacket 39. 
     The connectors 29 and 31 are conventional, with only a portion of the connector 29 being shown in detail, and connector 31 not being shown in detail. Referring to FIG. 2, connector 29 has three sockets 61 spaced 120 degrees apart for close reception over the protruding ends of the conductor rods 47 to make electrical connection. Each socket 61 is connected to one of the conductors 63 leading to the pump motor. A thermoset insulation material 65 is molded around the sockets 61. A threaded sleeve 67 engages threads on the high pressure end of housing 33 to secure the sockets 61 over the conductor rods 47. The insulation material 65 has an annular band 69 that provides sealing when compressed between the end of housing 33 and an interior band 71 located in threaded sleeve 67. A steel wire 73 holds the sleeve 67 in place. 
     To install the system, the submersible pump (not shown) will be lowered into the well and anchored by a suitable means. The three conductors 63 leading to the motor of the pump will be conducted to connecting member 29. Housing 33 will be secured in tubing hanger 15 before the tubing hanger is sealed in adapter member 13. Connecting member 31, which leads to the power supply and control equipment for the submersible pump motor, will be connected to the upper end of housing 33. Connecting member 29 will be connected to the lower end of housing 33, with its sockets 61 engaging the conductor rods 47 as shown in FIG. 2. Conduit 23 is secured to tubing hanger 15. Then tubing hanger 15 will be lowered into adapter member 13 and secured tightly by cap 17. Tubing 23 is supported by tubing hanger 15. Conduit 25 leads to separation and storage equipment for the fluid being produced from the well. 
     In operation, electrical energy is provided through connector 31, conductor rods 47, connector 29 and conductors 63 to the pump motor. Any pressure below tubing hanger 15 will be sealed by the sheaths 49, jacket 39, and housing 33. Sheaths 49 also insulate the conductor rods 47. 
     The invention has significant advantages. The feed-through mandrel provide a pressure barrier that will seal against very high pressure differential, yet allow electrical continuity through the barrier. The glass bonded mica insulators provide good insulation and withstand high pressures. The insulators are not subject to deterioration by high pressure gas from the well. 
     While the invention has been shown in only one of its forms, it should be apparent to those skilled in the art that it not so limited but is susceptible to various changes and modifications without departing from the spirit of the invention.