Pressure-Balanced k-PaC™ Technology

 

Artificial lift technologies such as ESPs, downhole electrical cable and cable penetrator systems are expected to operate reliably in the harshest and most demanding environments including high temperature (HPHT) wells, wells containing corrosive gases, steam or thermal assisted gravity drainage wells (SAGD/TAGD), and ultra-high pressure deep offshore wells, among many others.

But most legacy ESP electrical cable penetrator systems are not designed to last in these extreme conditions, contributing to increased product failure rates, inefficiencies in production, and ultimately, lost time and revenue.

Our pressure-balanced k-PaC Technology changes all of that.

BIW Connector Systems' groundbreaking k-PaC Technology answers the growing demand for increased product lifetimes and reliability in the upstream artificial lift market. The result of years of research, development and extensive lab and field testing, k-PaC™ Technology dramatically improves ESP system performance, reliability and ease of use in harsh environments. Extensive testing was performed using our new, ultra-harsh regime for new products based on:

• k-PaC Technology - we found these products are capable of performing for extended periods in well conditions of greater than 15,000 psi and 500 ºF / 260ºC.
• k-PaC Technology is more resistant to rapid decompression and repetitive pressure cycles and protects the conductor against corrosive gases
• k-PaC Technology meets an urgent need for increased ESP system lifetimes
• k-PaC Technology is designed to perform for an extended lifetime in conditions in excess of 500ºF (260ºC) and 20,000 psi
• k-PaC Technology requires minimal technical expertise to use and install, taking less than 30 minutes for a downhole connector and  < 90 minutes for a deep offshore splice

Conventional industry ESP cable terminations protect electrical connections by literally sealing out conductive well fluids. However, as pressure and temperature conditions harshen, elastomers over time can no longer be solely relied upon for this seal. 

Our new patented k-PaC Technology changes the traditional approach to this problem by balancing the pressure of the electrically conductive well-fluid outside the device with a benign viscous dielectric medium inside the device. k-PaC Technology does not depend on any elastomer as a primary seal.

Prototypes of the new design have passed unprecedented levels of environmental testing, demonstrating that they can perform in >15,000 psi environments at >500^oF temperatures, while also being subjected to rapid decompressions.
 

k-PaC Technology: How it Works As external pressure and thermal expansion increase, movable shuttles enabled by a viscous dielectric medium serve to balance the internal and external pressures, eliminating unwanted destructive ingress forces.