Background

1. Field of the Invention

[01] The present invention relates generally to electrical penetrator assemblies for feed through of electrical power through the wall of a pressurized vessel or the like, and is particularly concerned with an electrical penetrator assembly for subsea use.

2. Related Art

[02] Electrical penetrators are used to power subsea electric submersible pump (ESP) equipment and the like which pump hydrocarbons in oil well installations, and also in other applications such as high pressure downhole electrical penetrations and other penetrations to provide power to various types of subsea equipment. The penetrator extends through the wall or bulkhead of the vessel in which the equipment is located, and is normally connected to power cables at one end for connecting the equipment to an external power source. In an ESP application, the connection or penetrator cannot be isolated from the pumping pressure for practical reasons. This creates an extreme environment for the connector or penetrator in terms of pressure, temperature, and high voltage. The penetrator must transfer power to the motor as well as maintaining a pressure barrier for both internal pressure created by the ESP and external pressure caused by the depth in seawater. The temperatures are increased due to fluid temperatures as well as resistive heating of the electrical elements.

[03] In a typical electrical penetrator or feed through arrangement, a one-piece conductor such as a conductive connector pin extends through a bore in an insulating sleeve or body, with appropriate seals brazed or bonded between the outer body and pin at each end of the penetrator assembly. This causes problems in manufacture and in subsequent use of the penetrator, due to the different coefficients of expansion of the different materials used in the penetrator assembly. In one known arrangement, the seals comprise metal sealing sleeves which seal the insulating sleeve of ceramic or the like to the conductive connector pin body. Due to the heat involved during the brazing or bonding process, the parts expand by different amounts. Once the penetrator assembly is allowed to cool, the different rates of shrinkage of the different material parts causes stress on the ceramic housing material, brittle bonds, or both, and may lead to failure of the seal. Additionally, most existing penetrators are designed for high pressure on one side only, and application of pressure on the other side may cause additional stress on the seal arrangement and the ceramic housing.

Summary

[04] Embodiments described herein provide for an electrical penetrator assembly which is particularly suitable for high pressure, high temperature, and high voltage applications such as subsea use.

[05] According to one embodiment, an electrical penetrator assembly is provided which comprises a ceramic housing having a through bore, a first electrical conductor extending through a first end of the bore and terminating short of a second end of the bore and having an outer end engageable with a first cable, a second electrical conductor extending through a second end of the bore and terminating short of the first end of the bore, the second conductor having an outer end engageable with a second cable, the conductors having slidably or telescopically engaging inner ends. First and second seals extend between the ceramic housing and first and second conductor, respectively, at each end of the assembly. In one embodiment, a conductive layer or coating is provided on the inner diameter of the ceramic housing, between the housing and telescopically engaged conductors.

[06] In one embodiment, the inner end of one conductor has a bore and the inner end of the other conductor is slidably engaged in the bore. An internal sliding contact band may be provided between the opposing faces of the bore and conducter inner end, to maintain electrical contact between the conductors as they move inwardly and outwardly.

[07] In another embodiment, an electrical penetrator assembly comprises a ceramic housing having a through bore with opposite first and second ends, a rigid conductor extending into the first end of the bore and terminating short of the second end, and a flexible conductor secured to the inner end of the conductor and extending out of the second end of the bore, with a suitable seal arrangement between the conductor and bore at one end, and between the flexible conductor and bore at the other end of the assembly. In this arrangement, the flexible conductor moves to compensate for different rates of thermal expansion and contraction of the rigid conductor, ceramic housing, and seals, reducing stress between the sealing sleeves and ceramic or insulating housing. [08] Other features and advantages of the present invention will become more readily apparent to those of ordinary skill in the art after reviewing the following detailed description and accompanying drawings.

Brief Description of the Drawings

[09] The details of the present invention, both as to its structure and operation, may be gleaned in part by study of the accompanying drawings, in which like reference numerals refer to like parts, and in which:

[10] FIG. 1 is a cross sectional view of a first embodiment of an electrical penetrator pin assembly;

[11] FIG. 2 is an enlarged cross-sectional view of the circled sliding contact area of the dual contact pins of FIG. 1;

[12] FIG. 3 is an enlarged view of the circled end seal area of FIG. 1, illustrating the metal end seal at one end of the assembly;

[13] FIG. 4 is a broken away perspective view of one end of the assembly of FIG. 1

[14] FIG. 5 is a broken away perspective view of a modified penetrator pin assembly with a different end seal arrangement;

[15] FIG. 6 is a cross-sectional view of a complete electrical penetrator unit including the penetrator pin assembly of FIGS. 1 to 4;

[16] FIG. 7 is an enlarged cross-sectional view of the pin assembly seating area of FIG.

6, illustrating a modification;

[17] FIG. 8 is a cross-sectional view of the dielectric housing of the pin assembly of

FIG. 5, illustrating an optional internal conductive coating;

[18] FIG. 9 is an enlarged cross-sectional view of the circled area of FIG. 8, illustrating extension of the internal conductive coating up to the metal end seal;

[19] FIG. 10 is a broken away perspective view illustrating another embodiment of an electrical penetrator pin assembly;

[20] FIG. 11 is an enlarged view of the circled area of FIG. 10; and

[21] FIG. 12 is a longitudinal cross-sectional view of the penetrator pin assembly of

FIGS. 10 and 11. Detailed Description

[22] Certain embodiments as disclosed herein provide for an electrical penetrator assembly suitable for use in high pressure applications, such as in providing power for subsea equipment.

[23] After reading this description it will become apparent to one skilled in the art how to implement the invention in various alternative embodiments and alternative applications. However, although various embodiments of the present invention will be described herein, it is understood that these embodiments are presented by way of example only, and not limitation. As such, this detailed description of various alternative embodiments should not be construed to limit the scope or breadth of the present invention.

[24] FIGS. 1 to 4 illustrate a first embodiment of an electrical penetrator pin assembly or subassembly 10, while FIG. 6 illustrates the assembly 10 mounted in an outer penetrator housing 12 for extending through a wall or bulkhead of a subsea vessel or container. The pin subassembly 10 includes an outer body or housing 14 of ceramic or other dielectric material, the housing 14 having a through bore 15. First and second conductor portions or pins 16, 18 having slidably engaged inner ends extend through the housing, with the first pin 16 extending through a first end 20 of the housing bore 15 and terminating short of the second end 22 of the bore, and the second pin 18 extending through the second end 22 of the bore and terminating short of the first end 20. The pins are of suitable rigid conductive material such as copper or the like. The inner ends of the two pins are telescopically engaged, as illustrated in more detail in FIG. 2, with the inner end of the first pin 16 having an inwardly extending bore 24 and inner end of the second pin 18 slidably or telescopically engaged in the bore, so that the overall length of the conductive pin assembly can vary. An internal sliding contact band 25 mounted in an annular recess in bore 24 provides a sliding electrical engagement or contact interface between the pins 16 and 18 while permitting the pins to telescope inwardly and outwardly to compensate for various types of stress, as discussed in more detail below. Band 25 provides a clearance between the opposing inner surface of bore 24 and outer surface of pin 18, while still providing electrical contact between the two pins or conductor halves at all times. The contact band may alternatively be mounted on the outer surface of the portion of pin 18 which engages in bore 24 in other embodiments. [25] A cable connector 26 is provided at the outer end of the first pin for connection to a first cable on one side of the penetrator assembly, while cable connector 28 at the outer end of the second pin 18 is designed for connection to a second cable on the opposite side of the penetrator assembly. One of the cable connectors 28 is formed integrally with the pin, while the other cable connector 26 is formed separately and has a reduced diameter post 29 which is in threaded engagement in a bore 31 at the outer end of pin 16. Either or both ends of the penetrator may have a two part cable connector or integral cable connector.

[26] Metal sealing sleeves 30, 32 at each end of the outer body 14 hermetically seal the outer ceramic body to the respective conductors or pins 16, 18. Each metal sleeve 30, 32 is generally J- shaped in cross-section, as illustrated in FIG. 3, and the outer ends of the body 14 have annular recesses 34 in which the hooked ends of the respective J-shaped seals 30, 32 are brazed or bonded, as illustrated for sleeve 32 in FIG. 3. The stem of the J-shaped sleeve is welded or brazed to the adjacent outer surface of the respective pin 16, 18. The J-shaped sleeve design is such that the braze joint is tightened by thermal expansion during the brazing process, and also has the advantage that a longer tracking distance is produced for the same penetrator length, as compared to a standard Z-shaped sealing sleeve as used in some prior art single pin penetrators.

[27] The outer dielectric housing 14 has a central portion 35 of enlarged outer diameter and an inclined shoulder or step 36 at each end of the central portion forming a transition to the smaller diameter end portions 38. The angle of shoulders or steps 36 may be in the range from 40 to 75 degrees, and in one embodiment each step had an angle of 60 degrees to the central axis of the pin assembly, as shown in FIG. 2. The through bore 15 is of stepped diameter to accommodate the slightly different outer diameters of the pins 16, 18, with the first end portion which receives the larger pin 16 having a correspondingly larger diameter than the second end portion which receives pin 18, and an angled step 40 between the two end portions. An external conductive coating 42 extends over the larger diameter portion 35 and part of each smaller diameter portion 38 of the body, with an exposed ceramic portion between each sealing sleeve 30, 32 and the adjacent end of coating 42. The conductive coating 42 provides a uniform or substantially uniform ground plane for controlling electrical stress imparted to the ceramic dielectric material, as discussed in more detail below in connection with FIG. 6. [28] A conductive coating or intermediate conductive or semi-conductive layer 45 may also be provided on the inner diameter of the ceramic body 14 between the ceramic body and the conductors or pins. Layer 45 extends the entire length of bore 15 and also around the end faces 43 of the body, as indicated in FIG. 3. In one embodiment, the coating may comprise a moly-manganese sintered coating, followed by nickel plating, although any semi-conductive or conductive coating may be used for this purpose. The purpose of coating 45 is to provide a bonded high or medium voltage interface at the inner surface of the ceramic or dielectric body 14, allowing a clearance between the conductor pins 16, 18 and the ceramic body. The coating may help to reduce the occurrence and severity of electrical discharges which may degrade the ceramic insulation and ultimately result in component failure. By providing a clearance between the ceramic body and the conductive pins, a high conductivity material such as copper or the like may be used for the pins while not causing issues such as thermal expansion mismatch and induced mechanical stress on the ceramic insulation and the brazed metal seals or sleeves 30, 32. Inner coating layer 45 may be extended over the end faces 43 of the ceramic body, facing the enlarged shoulders of the pins outside the body. This helps to ensure contact between the coating and the conductive pins when opposite ends of the penetrator assembly are exposed to high pressures. The coating on the end faces may or may not terminate short of the conductive metal sealing sleeves 30, 32.

[29] FIG. 5 illustrates a modified end seal arrangement for the dual pin assembly of FIGS. 1 to 4. In FIG. 5, the J-shaped end seals 30, 32 of FIGS. 1 to 4 are replaced by Z- shaped seals or metal sleeves 46 of Z-shaped cross-section (only one of which is seen in FIG. 5). The embodiment of FIG. 5 is otherwise identical to that of FIGS. 1 to 4, and like reference numbers are used for like parts as appropriate. As illustrated in FIG. 5, each sleeve 46 has a first end portion brazed or bonded to the outer surface and part of the end face of body 14, and a second end portion welded or brazed to the outer surface of conductive metal pin 18 adjacent the end face of the ceramic body, forming hermetic seals. In both the embodiments of FIGS. 1 to 4 and that of FIG. 5, the brazed and welded sealing sleeves are designed to increase their sealing contact pressure and effectiveness as a result of applied external pressure on opposite ends of the penetrator pin assembly, so that applied pressure does not stress the braze/weld joint. In the J-sleeve arrangement of FIGS. 1 to 4, the braze joint is tightened by thermal expansion during the brazing process. As in the embodiment of FIGS. 1 to 4, the ceramic body 14 in FIG. 5 has an internal conductive coating layer 45 which extends along the entire length of through bore 15 and over the opposite end faces 48 of the body 14, as best illustrated in FIGS. 8 and 9. In both embodiments, the inner coating extends around opposite end faces of the body as seen in FIG. 9, and contacts the opposing face of the respective contact pin under pressure. The inner coating may terminate short of the metal end sleeves, or extend under the metal end sleeve up to end face 43 of FIG. 1.

[30] FIG. 6 illustrates the penetrator assembly 10 of FIGS. 1 to 4 assembled in an outer feedthrough or penetrator housing 12, which may be of metal or other conductive material such as stainless steel. When the penetrator assembly is assembled in the outer housing as illustrated in FIG. 6, the outer conductive coating 42 is in direct physical contact with the metal outer housing, providing a ground plane continuation. The ground plane may be continued or terminated by a conductive portion of a separate boot seal component (not illustrated) on either end of the assembly 10, 12.

[31] Outer housing 12 has a through bore 70 of stepped diameter, with successive portions of progressively increasing diameter from a first end 72 to a second, larger end 74 of the bore. The penetrator pin assembly is installed via the larger diameter end 74 and suitably secured in place by a seal retainer housing or plate 75 and retainer nut 78. When the assembly 10 is installed, the inclined shoulder 36 at one end of the enlarged portion 35 of the ceramic body 14 abuts a correspondingly shaped shoulder or seat 80 in through bore 70 close to the smaller, first end of the bore. Retainer housing or plate 75 has a through bore 82 with a correspondingly shaped shoulder or seat 84 which abuts the angled shoulder 36 at the opposite end of the enlarged portion 35. Thus, body 14 is held firmly between the opposing shoulders or seats 80 and 84. Rigid housing or plate 75, which may be of metal such as stainless steel, has one or more outer annular or O-ring seals 85 in sealing engagement with an opposing inner surface portion of housing through bore 70, and an inner annular seal or O-ring seal 86 in through bore 82 which seals against the outer surface of the enlarged portion 35 of the dielectric body 14. A gland seal 88 is located at the end of an enlarged portion 90 of bore 70 surrounding the enlarged portion 35 of body 14 between seats or shoulders 80 and 84.

[32] In one embodiment, the penetrator unit of FIG. 6 may be used to supply power from a cable on the seawater side 195 of the bulkhead to a pump on the pump side 196 of the bulkhead, and thus is exposed to high pump pressure on the pump side and to high seawater pressure on the seawater side. The penetrator housing 12, retainer nut 78, and retainer sleeve or plate 75 may be of any suitable rigid material such as stainless steel or other metallic material.

[33] The design of the pin subassembly 10 and the outer housing 12 and retainer components containing the pin subassembly is configured to reduce tensile stress on the insulating or dielectric body 14, while using the compressive strength of the body 14. Ceramic material in particular has much higher compressive than tensile strength. The angle of the inclined shoulders 36 and the corresponding angled faces or seats 80, 84 of the outer housing bore 70 and the bore in retainer sleeve or plate 75, respectively, are designed to improve or optimize mechanical strength. Because of the angled interface, increased pressure at one end of the penetrator assembly results in compressive rather than tensile stress on the ceramic body at the angled interface. This reduces stress on the ceramic material and on the bonds between the ceramic and sealing sleeves, since ceramic material has much higher compressive strength than tensile strength. Any practical angle less than ninety degrees may be used for the angled faces 36 and the mating faces or seating surfaces of the outer housing and retainer ring. As noted above, this angle may be in the range of 40 to 75 degrees, and in one embodiment an angle of 60 degrees was used. Additionally, an intermediate layer 95 of softer material may be used in the seating area between the inclined shoulder and the opposing face of the housing or retainer ring 75, as illustrated in FIG. 7. This creates a conformal load area to further minimize stress concentrations. The softer material may be copper, nickel, elastomeric material, or the like.

[34] The dual sliding pin arrangement of FIGS. 1 to 4 reduces the problems in manufacture of the penetrator assembly which result from the large differences in coefficients of thermal expansion of the conductive pin, ceramic body, and metal sealing sleeves. In prior art single pin arrangements, the high temperatures which arise during brazing of the metal seals to the ceramic body and the conductive pin, which is typically of copper or the like, cause expansion of the copper pin. Subsequent cooling causes the copper pin to shrink, pulling and causing stress on the ceramic body at the bond between the metal sleeve and the body. This may make the bond brittle or cause it to break. This problem is avoided with the two part, telescopically engaging pin assembly of FIG. 1 to 4, since the contacts can be assembled after metal seal brazing to the ceramic, and the telescoping ends of the pins can slide relative to one another to accommodate thermal expansion and contraction without producing stress on the seal bonds to the ceramic body.

[35] Typical penetrators are designed to have high pressure acting on one end only. The arrangement of FIGS. 1 to 4 is designed to accommodate high pressure at both ends of the penetrator. The different stiffness or elastic modulus of the materials of the conductive pin, ceramic body, and metal sealing sleeves can potentially create relative movement and stress on the seals in a typical penetrator when under pressure. The slidable arrangement of the above embodiment avoids such problems, lowering the stress between the conductors and the ceramic body. The brazed and welded sealing sleeves which are secured to the respective conductor halves or pins are configured so as to increase their sealing contact pressure or effectiveness with increased pressure.

[36] Another embodiment of a penetrator pin assembly or subassembly 100 which may be assembled in housing 12 in place of assembly 10 is illustrated in FIGS. 10 to 12. In this embodiment, the outer ceramic body is identical to that of the previous embodiments, and like reference numbers are used for like parts as appropriate. However, the dual conductor arrangement is different. In this embodiment, a solid conductor pin 102 extends into one end of bore 15 which extends through dielectric outer body or housing 14, and has an inner end attached to a flexible cable or flexible conductor 105 which extends up to the opposite end of bore 15. Opposite ends of flexible cable 105 are crimped or soldered in a bore 106 at the inner end of pin 102 and to an end cap 108, respectively. End cap 108 is welded or otherwise secured to a cable connector 110, and an outer, conductive sealing sleeve 112 extends between connector 110 and an opposing recessed end face 113 of the ceramic body 14. Metallic J-shaped sealing sleeves 114, 115 are brazed at opposite ends of the ceramic body 14, as in the first embodiment, with sleeve 114 brazed to the first end of ceramic body 14 and sleeve 115 brazed to the second end. Sleeve 114 is welded to the adjacent outer surface of conductor pin 102, while sleeve 115 is welded to the outer surface of sleeve 112. A second cable connector 116 is secured to the outer end of pin 102. With this arrangement, the flexible conductor 105 moves or flexes inwardly and outwardly to accommodate variations in thermal expansion. This design also lowers the stress between the conductor and the ceramic outer body during changes in temperature and during temperature and pressure extremes. [37] In each of the above embodiments, a hermetic electrical penetrator assembly is provided which is suitable for use in high temperature, high pressure, high voltage, and high current application, such as powering of subsea electrical submersible (ESP) pump equipment which is used to pump hydrocarbons in oil rig installations and the like. Other applications for the penetrator assemblies in the above embodiments include high temperature, high pressure downhole electrical penetrations and other electrical penetrations used in subsea equipment of various types. The penetrator assemblies are scalable for a variety of current and voltage requirements. The penetrator assemblies of the above embodiments each include a two part conductor extending through the ceramic body which can move to accommodate different rates of thermal expansion and contraction as a result of extreme temperature changes The above designs lower stress under pressure extremes, and higher pressure on either side of the dual conductor assembly does not appreciably impact the conductor opposite the higher pressure side. This is an improvement over standard penetrator assemblies designed to have high pressure at one end only.

[38] The above description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles described herein can be applied to other embodiments without departing from the spirit or scope of the invention. Thus, it is to be understood that the description and drawings presented herein represent a presently preferred embodiment of the invention and are therefore representative of the subject matter which is broadly contemplated by the present invention. It is further understood that the scope of the present invention fully encompasses other embodiments that may become obvious to those skilled in the art and that the scope of the present invention is accordingly limited by nothing other than the appended claims.