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BIW Connector Systems

Electrical Feedthru Systems for Oil and Gas WellsElectrical Feedthru Systems for Oil and Gas Wells

BIW Connector Systems

BIW Connector Systems

BIW Connector Systems, a part of ITT since 2001, is the pioneer supplier of electrical connector systems used by the petroleum industry in applications that include electrical submersible pumps, oil and gas reservoir monitoring instruments and downhole heaters. These pressure and safety barrier products have been supplied since 1973.

State-of-the-art engineering and production capability combined with high performance elastomeric and thermoplastic technology provide customers with robust products that perform reliably in harsh environments. BIW Connector Systems supplies the industry with the widest range of products manufactured under ISO 9001-2008 and ATEX certified quality and manufacturing systems, setting the standard for quality, reliability and ease of installation. A culture of forward-looking innovation and resourcefulness promotes continual process and product improvement and new system development.

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Surface Connectors 4

Wellhead Feedthrus 6

Downhole Connectors 8

Packer Feedthrus 10

Smart Well Connector Systems 12

Field Support 14

Testing and Analysis Capability 15

Submersible Pump and Smart Well Connector Equipment and Support Services

Surface ConnectorsSafe, long-lasting, separable surface power connectors are available in a variety of shapes to fit any wellhead and cable installation space requirement.

Factory rubber molded connector with 90 stainless steel housing,approved for hazardous locations.

Factory rubber molded connector with 60 stainless steel housing approved for hazardous locations.

Factory rubber molded connector with 45 stainless steel housing approved for hazardous locations.

Features and Benefits Standard power system ratings for ESP applications up to 5kV, 215A.

Temperature ratings from -55 to 300 F. Special designs rated up to 450 F.

Surface equipment for downhole heaters rated to 2.4kV, 215A.

Nickel aluminum bronze coupling nuts with knurled exteriors allow firm grip.

Copper socket contacts with louvered spring contact bands provide highly efficient and durable electrical connections.

Advanced proprietary elastomeric compounds perform insulation and sealing functions reliably in oil and water environments.

Some systems feature designs composed of PEEK or molded rubber construction that permit fast assembly in the field.

Heavy-duty metal housings help protect connectors and extend run life.

Numerous angle options allow fitting to a variety of wellhead and christmas tree configurations.

CAPTOR design is available for power connectors. This design features a metal-to- metal keying system. This eliminates damage associated with over-tightening when connector is mated to the feedthru or from extreme bends in the cable.

Third-party-approved 5kV explosion proof connectors are available with National Electric Code (NEC) compliant, UL approved, three conductor MV 105 metal clad hazardous location cable with shielded conductors.

Surface cable length can be modified to suit location of junction box or power supply.

The available Lipseal is an integrally molded peripheral seal in the connector that seals on a smooth shoulder on the feedthru shell.

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AccessoriesRubber boots are available to protect engagement threads from corrosion, allowing easy un-mating of connector.

Locking mechanisms are available to prevent unauthorized or accidental un-mating of energized connectors.

Test connectors are available to safely mate to the feedthru to be tested. Use of this connector prevents flash-over across the feedthru pins. These units include a factory molded, customer specified length of cable prepared for connection to test leads.

Field Attachable rubber molded power connector with 90 stainless steel housing. Approved for hazard-ous locations

Tri-Lok rubber molded, connectors with surface break-out housing. Suitable for hazardous locations.

Factory molded power connector with rubber molded body at 30 angle.

Thermoplastic connector with 30 angle and factory or field installed cable.

Surface connectors for downhole heater connectors are available factory molded up to 2/0 cable.

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LEFT TO RIGHT:

Cold shrink rubber boot seal ready for installation onto the surface connector coupling nut.

Boot seal installed on coupling nut, just prior to mating to feedthru.

Surface connector fully mated. Boot seal ready to be rolled onto remaining exposed metal surfaces.

Boot installed on mated system.

Surface Connectors

Surface Test Connector

Wellhead Feedthrus The feedthru portion of the system provides a fluid block at the wellhead permitting electrical power to pass safely and reliably through the wells pressure barrier. BIW Connector Systems works with the wellhead manufacturer to assure proper fit and material compatibility. New configurations are continually being developed to meet specific customer requirements.

E-Zee Feed

Feedthru stabs into tubing hanger from lower side and is held with bolts from the bottom and an upper retaining nut. This feedthru can be supplied as a field attachable kit, eliminating a downhole splice.

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Safe-T-Lok

Feedthru is molded to cable at both ends.

Tri-Lok

In situations where the tubing in the wellhead must be centralized, the Tri-Lok system can be used. Shown is the version where separate single pin feedthrus are used to provide pressure barriers for each of the three power conductors. Note that with this one-piece factory molded cable breakout assembly, installation is quick and the surface connector system (see page 5) can be prepared for easy installation before the blow-out preventer (BOP) is removed. Also available is a version using three, 3/8" Duplex tubes through the wellhead.

High Temperature ApplicationFeedthru is terminated onto downhole cable in the field and is then installed in a stand-off adapter used for cooling the feedthru (F/T) in steam injection applications. The F/T assembly is then locked with a retaining nut.

Kwik-LokRemovable surface connector interface allows narrow metal shell with lower molded cable to be stabbed through the tubing hanger from the bottom and retained with a threaded nut on the top side. This can be used when 312" tubing is used with 7" casing.

Drop-N-Lok DesignDownhole cable is factory molded to lower end of feedthru. This feedthru is stabbed in from the top and is held in place with a retaining nut using the Drop-N-Lok design.

Coiled Tubing ApplicationFeedthru is installed onto flexible cable in the field for coiled tubing applications.

Drop-N-Lok DesignFeedthru uses metal-to-metal seals backed up with O-rings and is held in place with a retaining nut pulling against a machined shoulder on the metal shell using the Drop-N-Lok design.

Thread-in DesignFeedthru seals in the tubing hanger and the adapter flange with O-rings and is held in place with threads on the metal shell.

Features and Benefits Standard power system ratings for Electrical Submersible Pump (ESP) applications up to 5kV, 215A.

Feedthrus for downhole heaters rated to 2.4kV, 215A.

Temperature rating from -55 to 300 F. Special designs rated up to 450 F.

Pressure ratings to 5,000 psi. Designs are type tested to 13,500 psi.

Heavy-duty metal shells prevent collapse from high pressure well conditions and are a key element in maintaining a fluid barrier at the wellhead. The final assembly assures safe, reliable delivery of electrical power to downhole applications.

Internal construction features solid copper conductors, state-of-the-art insulation and strong pressure barrier materials that combine to deliver reliable performance. The feedthru face design features extended dielectric protection.

O-ring materials are available in Viton*, AFLAS** or other compounds upon request to assure reliable sealing in a variety of conditions.

Standard shell material is 4130/4140 alloy steel that meets NACE MR 0175 and API specifications for strength and resistance to sulfide stress cracking. All feedthru shells are also available in corrosion-resistant materials as required.

The available CAPTOR metal keying system results in a very strong feedthru/ connector interface.

Drop-N-Lok feedthru shell designs are available that allow the tubing hanger to be manufactured without threads to hold the feedthru in place. Use of this design reduces costs and eliminates damaged threads.

AccessoriesDummy mandrels with identical profiles as the actual feedthrus are available in solid metal for stack-up and pressure tests of wellheads. They are also used to seal the feedthru bore prior to installation of the ESP.

Pressure and thread protector caps are available for use on the upper end of feedthrus during installation and BOP pressure tests.

ThepressurecapsealsoutfluidsduringBOPtests,keeping the feedthru face clean.

ThebullnosecapinNI/ALbronzeguidestheadapterflange safely over the feedthru during its installation.

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Wellhead Feedthrus

Pressure Cap Bullnose Protective Cap

CAPTOR Interface

Feedthru Face Configurationwith Dielectric Cone and Skirt

Hundreds of feedthru options are available.

*VITON is a registered trademark of DuPont.**AFLAS is a registered trademark of Asahi Glass Co.

Downhole Connectors The downhole