Analysis of electrical connector performance requirement in the Downhole Applications

Sunkye High Pressure and High-Temperature Connectors Provide High Performance and High Reliability for Downhole Equipments.

In the "World Oil Outlook 2022” report, OPEC raised the world oil demand in 2023 to 103 million barrels per day, an increase of 2.7 million barrels per day compared with 2022. Rising demand drives global oil and gas exploration and development to re-enter the acceleration stage.

In recent years, the difficulty of global oil and gas exploration and development has gradually increased. Oil and gas exploration has extended from land to ocean, oil and gas discovery has expanded from medium-deep layers to deep and ultra-deep layers, and from medium-shallow water to deep water and ultra-Deepwater. With the continuous development of oil and gas exploration to deeper, wider, and more challenging areas, there are higher requirements for petroleum equipment. Offshore exploration needs to consider various effects of seawater, tides, water pressure, depth, etc. High-pressure and high-temperature connectors that can realize downhole signals and current transmission of oil drilling equipment are essential.

The extreme functionality of a connector can be tested more in the deep-down harsh environment of an oil or gas well. Demanding requirements for downhole applications start with high pressures and high temperatures (HPHT), and many other factors include electrical properties (insulation resistance, dielectric-withstanding voltage, current-carrying capacity), and corrosion resistance.

Pressure. In downhole applications, typical pressures range from 20kPSI to 35kPSI, and super-high-strength alloys are utilized in drilling and logging tools to maintain structural integrity.

Temperature. As the pressure requirement increases, so does the temperature. The temperature in a downhole application will typically range from +300°F to +500°F.

Electrical Performance. Under high temperatures and high-pressure conditions, the internal sealing design of the connector is very important, metal sealing materials usually have better sealing performance.

Corrosion Resistance. As if all of this was not enough to overcome, the downhole tool also has to add in the formidable task of resisting corrosion in the well. Indispensable in the oil and gas industry, PEEK provides excellent insulation and corrosion resistance in connectors.

Sunkye connector oil and gas connector is made of high-temperature resistant alloy materials, such as beryllium bronze, corrosion-resistant material PEEK, glass, and ceramics, with stable power transmission capability. Provides reliable performance in harsh environments such as high temperature, high pressure, and high corrosion.

■ Random vibration: 10Hz-2000Hz, 0.3G2/Hz, acceleration 20G, 175℃~200℃

■ Shock:490m2/s, 11ms

■ Dielectric withstanding voltage: 1000VDC, 60s, leak current≤ 5mA

■ High temperature insulate resistance: ≥500MΩ (500VDC, 175℃~200℃)

■ Rated current: 1A continuous current

■ Temperature range: -55 ℃ to +175℃/200℃

■ Operating pressure: 0 MPa to 140 MPa /172.5 MPa

■ High temperature life: 175℃/200 ℃ ,600h

■ Temperature shock: -55℃ to +200℃, 15 cycles, the temperature switching time is ≤ 15 min

■ Salt spray: 24h / 48h

■ Air leak: helium leak test ≤ 1×10-3Pa.cm3/s

Sunkye Connection Technologies provides a wide product portfolio with a complete interconnect solutions offering. Sunkye connectors and cables assemblies are complementary with Sunkye backshells and conduits.