Connector assembly

Abstract

A penetrator connector assembly is suitable for connecting two parts of an electrical conductor across a pressure barrier in an oil or gas well. The assembly includes a body with a bore for an electrical conductor, a sealing boot that seals an annular space between the conductor and the bore, and a port that transmits a pressure differential between the exterior of the body and the annular space, so that the pressure differential acts on one side of the sealing boot to apply a compressive force and enhance the seal. The assembly also has a spring that can be resiliently energised to apply a compressive force to the sealing boot independently of fluid pressure differentials.

Claims

1. A penetrator assembly for connecting electrical conductors on opposite sides of a pressure barrier in an oil or gas well, the assembly comprising a body having a bore adapted to receive an electrical conductor within the bore, a sealing device adapted to seal an annular space between the electrical conductor and the bore, the sealing device being resilient, and a fluid pathway adapted to allow fluid communication between an external surface of the body and the annular space, wherein the fluid pathway comprises at least one port passing through the body into the bore, and wherein the port is adapted to transmit a pressure differential between the external surface of the body and the annular space to act on one side of the sealing device, wherein the resilient sealing device comprises an extended sheath portion configured to surround at least a portion of an outer surface of an electrical conductor, wherein the extended sheath portion of the sealing device extends from a body of the sealing device on said one side of the sealing device, wherein the extended sheath portion of the sealing device is in fluid communication with the annular space, whereby the pressure differential communicated to the annular area via the fluid pathway applies pressure to the extended sheath portion of the sealing device and forces the extended sheath portion of the sealing device radially against the outer surface of the electrical conductor, thereby creating or enhancing a seal between the extended sheath portion of the sealing device and the electrical conductor.

2. A penetrator assembly as claimed in claim 1, wherein the fluid pathway is adapted to transmit wellbore pressure on one side of the pressure barrier to a surface of the sealing device on the same side of the pressure barrier.

3. A penetrator assembly as claimed in claim 1, wherein the bore of the body is adapted to receive the sealing device, and wherein a resilient compression device is adapted to compress the sealing device against the outer surface of the conductor and against an inner surface of the bore.

4. A penetrator assembly as claimed in claim 3, wherein the resilient compression device surrounds at least a portion of the conductor.

5. A penetrator assembly as claimed in claim 3, wherein the resilient compression device comprises at least one bearing device arranged to reduce friction during rotational movement of one part of the assembly relative to another part of the assembly.

6. A penetrator assembly as claimed in claim 1, wherein the body is adapted to receive a plurality of electrical conductors within the body, wherein the sealing device comprises a respective extended sheath portion for each of the plurality of electrical conductors, wherein each extended portion of the sealing device extends from the lower end of the body of the sealing device.

7. A penetrator assembly as claimed in claim 3, wherein the bore tapers inwards towards the longitudinal central axis of the bore as the bore extends through the body, at least in a portion of the bore which receives the sealing device, and wherein axial movement of the sealing device under the force applied by the resilient compression device causes the sealing device to be compressed radially by the tapered bore and compressed axially as a result of the force applied by the compression device.

8. A penetrator assembly as claimed in claim 3, wherein the body comprises first and second portions connectable by a threaded arrangement, wherein said threaded arrangement is adjustable in order to vary the force energising the resilient compression device.

9. A penetrator assembly as claimed in claim 1, wherein the sealing device comprises a resilient boot having a bore to receive the conductor.

10. A penetrator assembly as claimed in claim 3, including a spring sleeve urged by a resilient compression device towards the sealing device, wherein the spring sleeve has a bore adapted to receive each conductor in the bore.

11. A penetrator assembly as claimed in claim 10, wherein the bore in the spring sleeve has a first portion and a second portion having a narrower diameter than the first portion, and wherein the spring sleeve is configured to move axially over the extended sheath portion of the sealing device, and wherein the extended sheath portion of the sealing device is adapted to be compressed radially between the inner surface of the narrow portion of the bore of the spring sleeve and the outer surface of the conductor received in the bore of the spring sleeve.

12. A method of connecting first and second limbs of an electrical conductor on opposite sides of a pressure barrier in an oil or gas well, the method comprising passing the first limb of the conduit into a body of a penetrator assembly, said body having a bore adapted to receive the first limb of the electrical conductor within the bore, wherein the method includes the steps of sealing an annular space between the first limb of the electrical conductor and the bore with a sealing device, the sealing device being resilient; communicating fluid between an external surface of the body and the annular space through a fluid pathway, wherein the fluid pathway comprises at least one port passing through the body into the bore; and transmitting a pressure differential through the port between the external surface of the body and the annular space to act on one side of the sealing device, wherein the resilient sealing device comprises an extended sheath portion configured to surround at least a portion of an outer surface of an electrical conductor, wherein the extended sheath portion of the sealing device extends from a body of the sealing device on said one side of the sealing device, wherein the extended sheath portion of the sealing device is in fluid communication with the annular space, and wherein the method includes creating or enhancing a seal between the extended sheath portion of the sealing device and the electrical conductor forcing the extended sheath portion of the sealing device radially against the outer surface of the electrical conductor using a pressure differential communicated to the annular area via the fluid pathway to apply pressure to the extended sheath portion of the sealing device.

13. A method as claimed in claim 12, including terminating the electrical conductor by crimping an electrical terminal onto the electrical conductor.

14. A method as claimed in claim 13, wherein the electrical terminal is crimped onto the electrical conductor at the oil or gas well.

15. A method as claimed in claim 12, the method including terminating the or each conductor at the oil or gas well by crimping an electrical terminal onto the or each electrical conductor to form at least one terminated conductor, inserting the or each terminated conductor into a pre-formed aperture within the assembly body, said aperture being adapted to mate with a connector assembly on the other side of the pressure barrier for transfer of electrical power or signals across the pressure barrier.

16. A method as claimed in claim 12, including resiliently energising a resilient compression device, and applying a compressive force from the resilient compression device to the sealing device within the annular space.

17. A method as claimed in claim 12, including accommodating expansion, contraction and movement of the components in the bore of the penetrator assembly by compression and expansion of the resilient compression device.

18. A penetrator assembly for connecting electrical conductors on opposite sides of a pressure barrier in an oil or gas well, the penetrator assembly having a body, the body having a bore with an axis, adapted to receive a plurality of electrical conductors within the bore, each electrical conductor having a terminal attached thereto, the penetrator assembly including a sealing device adapted to seal an annular space between the plurality of electrical conductors and the bore, and a fluid pathway adapted to allow fluid communication between an external surface of the body and the annular space, wherein the sealing device is resilient, wherein the fluid pathway comprises at least one port passing through the body into the bore, and wherein the port is adapted to transmit a pressure differential between the external surface of the body and the annular space to act on one side of the sealing device, wherein the sealing device comprises a respective extended sheath portion for each electrical conductor, each extended sheath portion being configured to surround at least a portion of an outer surface of an electrical conductor, wherein the extended sheath portions of the sealing device extend axially parallel to the axis from a body of the sealing device on said one side of the sealing device, wherein the extended sheath portions of the sealing device are in fluid communication with the annular space, whereby the pressure differential communicated to the annular area via the fluid pathway applies pressure to the extended sheath portions of the sealing device and forces the extended sheath portions of the sealing device radially against the outer surfaces of the electrical conductors, thereby creating or enhancing a seal between the extended sheath portions of the sealing device and the electrical conductors.

19. A penetrator assembly as claimed in claim 18, wherein each extended sheath portion of the sealing device has a bore to receive a respective electrical conductor, and wherein each extended sheath portion and conductor is received in a tapered bore in a sleeve abutting the sealing device, and wherein the sleeve is axially slidable relative to the sealing device, and wherein the bore of the sleeve is tapered, wherein the extended sheath portion of the sealing device is adapted to be compressed radially between the inner surface of the narrow portion of the bore of the sleeve and the outer surface of the conductor received in the bore of the sleeve.

20. A penetrator assembly as claimed in claim 18, wherein each conductor is terminated by a crimped end terminal, each crimped end terminal having a screw thread, and wherein the penetrator assembly comprises a conductor retaining nut for each crimped end terminal, each conductor retaining nut having a screw thread adapted to cooperate with the screw thread on the crimped end terminal on each conductor, to secure each conductor nut to its respective crimped end terminal.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the accompanying drawings:

(2) FIG. 1 shows a side view of an example of the invention, where the electrical conductor is an armour-covered cable, with a cross-sectional view of an end cap;

(3) FIG. 2 shows a side view of the cable of FIG. 1 sequentially stripped and ready for termination;

(4) FIG. 3 shows a side view of the terminated cable of FIG. 2 with terminals crimped onto the conductors;

(5) FIG. 4 shows a cross-sectional view of the connector assembly;

(6) FIG. 5 shows a cross-sectional view of the connector assembly of FIG. 4 installed on the cable;

(7) FIG. 6 shows the installed connector assembly of FIG. 5 secured to the cable by retaining nuts;

(8) FIG. 7 shows the connector assembly of FIG. 6 with the rear portion of the assembly having been partially tightened to energise the sealing device;

(9) FIG. 8 is a close-up view of the section A of FIG. 5, prior to energising the sealing device;

(10) FIG. 9 is a close-up view of the section B of FIG. 7, showing the sealing device partially energised;

(11) FIG. 10 shows the connector assembly of FIG. 6 with the rear portion of the assembly fully tightened, with the resilient compression device engaged and the sealing device energised;

(12) FIG. 11 shows the connector assembly of FIG. 10, with the end cap of FIG. 1 in position;

(13) FIG. 12 is a close-up view of the section D of FIG. 10;

(14) FIG. 13 is a three dimensional view of the assembly as shown in FIG. 11; and

(15) FIG. 14 is an alternative cross-sectional view of the connector assembly of FIG. 11.

DETAILED DESCRIPTION

(16) According to a first example, a connector assembly 1 comprises a body 30 having a bore 30b to receive an electrical conductor within the bore 30b. In this example the conductor comprises a three phase electrical cable 5 having three separate internal electrical conductors 5c for transfer of power or signals in a downhole environment. In other examples, the conductor can have a single phase, two phases, or more than three.

(17) The assembly 1 in this example also comprises a resilient sealing device in the form of a sleeve that seals an annular space between the outer surface of the cable 5 and the inner surface of the bore 30b of the body 30 when the sealing device is compressed within the annular space by a resiliently energised compression device, here shown as a wave spring 70, which is held in compression to exert the compressive force on the internal components of the assembly 1 as will be described in more detail below.

(18) FIG. 1 shows the cable 5 with an end cap positioned on the cable 5 ready for making up the cable 5 into the connector assembly 1. In this example, the end cap incorporates a clamping device such as a cable gland 20 which surrounds the outer surface of the cable 5 and retains it in a central aperture. In this example, the cable 5 is a multi-phase (3 phase in this example) flat cable and the gland 20 has a non-circular aperture to allow the cable 5 to pass through the aperture. The cable 5 has an armoured outer layer and the gland 20 is slid over the armoured outer layer prior to installation of the connector assembly 1. The gland 20 comprises a seal 23 in the form of a rubber bung, through which the non-circular aperture passes. The gland 20 seals around the armoured outer sheath of the cable 5 and reduces or restricts ingress of well fluids and debris into the body 30 through the gland. The seal 23 can be made of any suitable material that is resistant to well fluids and can withstand the relevant operating temperature. By way of example, suitable materials could include nitrile rubber or a member of the fluoropolymer family with appropriate chemical properties. The gland 20 also comprises a low friction ring 26 comprising PEEK or another low friction material to reduce friction between the cable clamp seal 23 and the rear of the body 30; a metal ring 28 on the other side of the seal 23 which pressed on the rear of the seal 23 to compress the seal 23 into the armoured sheath of the cable 5; and a lock ring 29, which holds all of the gland components in place and comprises a threaded portion 25, by which the gland 20 attaches to a rear end of the body 30.

(19) The cable 5 must be stripped in order to expose the conductor core for termination prior to installation of the connector assembly 1. FIG. 2 shows the cable with the armoured outer layer stripped back to expose the conductors 5c with their sheaths covering the conductor cores. An outer sheath 6 on each conductor 5c provides a chemical barrier to well or other fluids. In this example the outer sheath 6 comprises lead. Within the outer sheath 6 is an inner sheath 7, which in this example comprises an electrical insulator, in this case EPDM. Finally the conductive central core 8 (in this example comprising copper) is exposed and can then be terminated.

(20) FIG. 3 shows terminals 10 being crimped onto the free ends of the exposed copper cores 8 to terminate the conductors 5c and permit a suitable connection between separate limbs of conductor 5c above and below a pressure barrier, for example, a packer or wellhead. This is suitably performed at the well site and allows a factory-made terminal 10 to be crimped onto different lengths of conductor to suit the local circumstances. Therefore, the cable does not need to be cut to length before deployment, and can be deployed, cut and then terminated all at the well site, saving on time, materials and transport costs. The crimped end terminals 10 each have a contact pin 11 at the free end of the terminal and a thread 13 on its outer surface for attaching a lock ring 15 described in further detail below.

(21) The connector assembly body is shown pre-installation in FIG. 4. The body 30 comprises first 31 and second 32 portions connected by a threaded connection 34. The threaded connection 34 is adjustable and can be tightened or loosened, which can change the energisation of the spring 70. The first portion 31 comprises a cylindrical sleeve that contains a resilient sealing device in the form of a resilient rubber sealing boot 40 which in this example comprises a sleeve with at least one bore 40b formed around the outer surface of the conductor 5c (e.g. the sheath 7 or 6 or the core 8), an electrical insulator in the form of an insulating boot 50 also in this example comprising a sleeve with at least one bore 50b formed around the outer surface of the conductor 5c (e.g. the sheath 7 or 6 or the core 8), and an insulating sleeve 60. The insulating sleeve 60 is disposed within the bore 30b of the upper body portion 31 of the assembly 1, being fixed in position below a narrow throat at the upper end of the body with a screw thread arrangement 60t, and secured therein against rotation by a set screw 60s and has at least one inner bore 60b adapted to receive the or each terminating apparatus of at least one core cable 8. The set screw 60s holds the insulating sleeve 60 in alignment with the body 30 and resists relative rotation. The screw thread arrangement 60t and the narrow throat limit upward axial movement of the boots 50, 40 within the bore 30b. The bores 40b, 50b, and 60b are maintained in alignment with one another within the body 30. In this example, each of the boots 40 and 50 and the insulating sleeve 60 has three bores (visible in FIG. 13), held in alignment within the body 30.

(22) A spring sleeve 73 is also rotationally connected to the first (upper) body portion 31 by a cap screw 75, which maintains alignment of the two components and stops the spring sleeve 73 from turning relative to the first (upper) body portion 31 during rotation of the two body portions 31, 32 when the connector assembly is being made up. The spring sleeve 73 is adapted to slide axially within the bore of the body portion 32, but cannot rotate therein.

(23) In the FIG. 4 configuration, the body portions 31, 32 have not yet been screwed together, and the spring 70 is only slightly energised (perhaps about 10-20% energised) in axial compression between a circlip 72 at the lower end of the second portion the spring sleeve 73 above the spring, which transmits the spring force to the component in the bore (e.g. the boots 40, 50 and the insulating sleeve 60) above the spring sleeve 73 when the body 30 is fully made up. The spring sleeve 73 has a lower portion with a single central bore 73b, and an upper portion with three separate bores 73c aligned with the bores 40b, 50b and 60b, for accommodating the conductors 5c of the separate phases. Each of the separate bores 73c terminate at their lower ends in apertures into the central bore 73b, and are held in the same rotational position within the bore of the body 32 by the cap screw 75, which slides axially within a slot in the body 32.

(24) The spring 70 is separated from the circlip 72 and the spring sleeve 73 by two low friction (e.g. PEEK) discs 71a,b, with each disc 71a,b disposed on axially opposite sides of the spring 70, in line with the bore 30b of the body of the assembly 30. The discs 71a,b act as bearings to reduce and ideally eliminate friction and transfer of torque to the spring sleeve 73 during rotational movement of the assembly 1, for example when the portions 31, 32 of the body 30 of the assembly 1 are screwed together at the threaded connection 34. The spring sleeve 73, the discs 71, the circlip 72 and the spring 70 all contain bores to receive a portion of the cable 5 when the assembly body 30 is installed on the cable 5.

(25) In the configuration shown in FIG. 4, the two body portions 31, 32 have not been fully screwed together, and the spring sleeve 73 is therefore not yet engaged with the resilient sealing boot 40, as a radially outwardly extending shoulder 73s on the lower end of the spring sleeve 73 has engaged against a radially inwardly extending shoulder 32s on the inner surface of the body portion 32. The spring 70 is slightly (but not fully) energised between the circlip 72 and the lower end of the spring sleeve 73, which helps to maintain the spring sleeve 73 in the upper position with the shoulders 73s and 32s engaged. The bore of the body 30b receives the spring sleeve 73 between the first and second portions 31, 32 of the body 30.

(26) Above the lower end of the first body portion 31, a snap ring 38 is held in a circumferential groove in the inner wall of the body portion 31 and above the snap ring 38, the walls of the bore 30b taper inwards at 33 towards the central axis of the bore 30b as the bore 30b extends through the body 30. The snap ring 38 extends radially a short distance into the bore 30b. The snap ring 38 acts to hold the boots 40, 50 in position during removal of the conductor from the connector assembly 1. The snap ring 38 also prevents the boot 40 re-engaging with the spring sleeve 73 after removal of the conductor, by retaining the boot sleeve 40 in its axial position, thus preventing the two components contacting and engaging each other. The snap ring 38 optionally sets the upper limit for the permitted axial movement of the spring sleeve 73 within the bore.

(27) The spring sleeve 73 has an upper portion 74 with a reduced outer diameter which can fit inside the snap ring 38. The upper end of the upper portion 74 is also tapered radially inwards towards the central axis of the bore 30b, and has a flat upper face at its upper axial end.

(28) At the upper narrow end of the tapered wall 33 of the first body portion 31, there is a metal plate 39, which is not secured to the body 30 and is free to slide axially within the bore 30b, and which transmits the mechanical loading applied by the spring 70 via the spring sleeve 73 and distributes the load across the rear face of the resilient sealing boot 40 when the connector assembly is fully made up. At the lower widest end of the tapered wall 33, the PEEK snap ring 38 is held in the circumferential groove.

(29) The insulating boot 50 above the sealing boot 40 is electrically insulated and provides an insulating bridge between the insulating sleeve 60 and the inner electrically insulating sheath 7 of the core 8. The upper insulating boot 50 is axially compressed between the lower sealing boot 40 and the insulating sleeve 60. The upper insulating boot 50 has upper and lower protrusions surrounding each bore 50b, which extend axially in opposite directions, and which are tapered radially inwards towards their outer ends, which are received within correspondingly tapered recesses in the lower sealing boot 40 and the insulating sleeve 60 as is best shown in FIG. 4. Because of the tapered upper and lower protrusions and their respective recesses in the adjacent components, the axial compression of the upper insulating boot 50 by the force of the spring 70 also compresses the upper insulating boot 50 radially inwards onto the inner sheath 7 of the conductor. Thermal expansion and contraction of the upper insulating boot 50 after the connector is made up is accommodated by the spring 70, which unloads in the event of thermal contraction of the insulating boot 50, and is compressed (energised) in the event of thermal expansion of the insulating boot 50.

(30) The lower sealing boot 40 includes at least one, but in this case, three axially extended tubular extensions in the form of a sheath 45. One sheath 45 is shown in FIG. 4, arranged as a continuous extension from the boot 40 and extending downwards over a part of the outer sheath 6 of each conductor 5c (while only one is visible in section in FIG. 4, the other sheaths 45 are the same) and forming a chemical barrier to well fluid entry along the outer surfaces of the conductor 5c and into the bores 40b, 50b, 60b, mitigating against the potential catastrophic damage fluid ingress could cause to an electrical system. The extended sheath 45 is received in a bore 73c of the upper end of the spring sleeve 73 as it engages with the body 30. Each bore 73c has a generally wide mouth at its upper end and a narrowing tapered throat 73t as is best seen in FIG. 8, which tapers to a narrower section below the tapered throat 73t. As the spring sleeve 73 is forced axially upwards in the body 30 relative to the sealing boot 40, the sheath 45 extending from the lower end of the boot 40 into the bore 73c moves further down the bore 73c. The sheath 45 can be received within the upper wide mouth 73m of the bore above the narrow throat 73t, but the lower end of the throat and the lower section of the bore 73c below it is narrower than the mouth 73m and narrower than the uncompressed outer diameter of the sheath 45, so as the sheath 45 moves down into the throat it is gradually radially compressed between the inner surface of the narrow throat 73t and the outer surface of the conductor 5c in the bore 73c (see the transition between FIGS. 8 and 9).

(31) The sealing boot 40 also has a sealing ring 42 on its outer surface, which acts as a secondary, back up seal to reduce or restrict fluid ingress around the outside of the sealing boot 40. The sealing boot 40 is moulded around the sealing ring 42, as best seen in FIG. 4, which is arranged in a recess in the outer surface of the sealing boot 40. The sealing ring 42 comprises an O-ring 42a, and a backup seal 42b with a square cross section. The backup seal 42b prevents extrusion of the O-ring 42a when the O-ring 42a is exposed to pressure differentials during operational use of the connector assembly. By resisting extrusion of the O-ring 42a from the groove, the backup seal 42b thus also assists with maintaining continuous compression of the O-ring 42a. As the sealing boot 40 is axially compressed by the spring 70, the outer surfaces of the sealing boot 40 are forced radially outwards, thereby enhancing the seal.

(32) The bore of the upper body portion 31 also has a radial port 30p (seen in section in FIG. 5) forming part of a fluid pathway which passes radially through the wall of the body portion 31 and connects the annular area between the spring sleeve 73 and the inner surface of the body portion 31 with the outer surface of the body 30. The port 30p is located in a region of the body portion 31 that is just below the snap ring 38. The port 30p allows fluid communication between the outer surface of the body 30, and the annular space in the bore 30b below the seal created by the sealing boot 40. The upper end of the spring sleeve 73 also has a port 77, which acts as a compensation channel (see FIG. 4) to allow pressure equalisation between the outer and inner surfaces of the spring sleeve 73.

(33) The pressure differential between the external surface of the body 30 and the inner surface of the bore 30b below the seal of the spring sleeve 73 is therefore communicated to the lower side of the sealing boot 40, and thus also applies a force to the sealing boot 40, acting to compress the sealing boot 40 axially. Axial movement of the boot 40 within the bore 30b is limited by the insulation sleeve 60 being secured in the bore above the boots 50, 40, so axial upward force from the pressure differential across the sealing boot 40 and the expansion of the spring 70 below it results in axial compression of the sealing boot 40 leading also to radial expansion of the boot 40 as a result of the tapered inter-engaging section of the boots 40, 50, forcing the outer surface of the sealing boot 40 radially outwards against the inner surface of the internal bore 30b of the body 30. The axial compression of the boot 40 also forces the inner surface of the bore 40b of the boot 40 radially inwards, compressing it radially against the outer surface of the conductor 5c, thereby enhancing the seal between the boot 40 and the conductor 5c, and resisting transmission of wellbore fluids through the bore 40b past the conductor 5c.

(34) As the spring sleeve 73 is urged axially upwards in the bore 30b relative to the stationary sealing boot 40, the lower end of the sheath 45 is received within the narrow throat 73t of the spring sleeve, which is narrower than the outer diameter of the sheath 45, and so compresses the lower end of the sheath 45 radially inwards onto the outer surface of the conductor 5c. The wellbore fluid pressure applied via the port 30p also acts on the sheath 45, the outer surface of which is in fluid communication with the annular space in the bore 30b, and enhances the radial compression of the sheath 45 onto the conductor 5c. This in turn creates or enhances the seal between the boot 40 and the conductor 5c. Fluid pressure outside the spring sleeve 73 and below the spring sleeve 73 in the bore 30b of the body also equalises across the spring sleeve 73 via the port 77, and so enhances the force acting to seal the sheath 45 onto the outer surface of the conductor 5c.

(35) The spring 70 applies a force on the spring sleeve 73, and therefore the boot 40, independently of the fluid pressure within the annular space in the bore 30b. At low fluid pressure, below a given pressure threshold, the force that the spring 70 applies to the spring sleeve 73 and thus to the boot 40 exceeds the force applied by the fluid pressure differential across the ports 30p and 77. As the fluid pressure increases and exceeds the pressure threshold, the force applied to the spring sleeve 73 and the boot 40 by the fluid pressure differential then exceeds the force applied by the spring 70. The fluid pressure enhances the radial compression of the sheath 45 against the conductor 5c. The pressure of the fluid within the annular space also acts on the face of the boot 40 in an axial direction, compressing the boot 40 axially and driving the radial expansion of the boot 40 as described above.

(36) FIG. 5 shows the connector assembly 1 installed onto the terminated conductor 5. The internal conductors 5c (only one is visible in FIG. 5) complete with copper end terminals 10 crimped in place on the cores 8 are inserted into apertures (60b in FIG. 4) within the insulating sleeve 60 once the insulating sleeve 60 is fixed in place. The spring sleeve 73 is disengaged from the sealing boot 40 as can be seen in the close-up view of FIG. 8. The gland 20 has not yet been connected and remains loose on the conductor 5.

(37) The crimped terminal 10 that connects the core 8 with the electrical contact pins 11 for making an electrical connection to an adjacent conductor on the other side of the pressure barrier is at least partially surrounded by a bearing ring 16 when the connector assembly 1 is installed. The outer surface of the bearing ring 16 is tapered radially inwards towards the terminal 10 to form an external shoulder, which then engages with an internal shoulder of the insulating sleeve 60 having a corresponding taper.

(38) Once the bearing ring 16 is shouldered out on the insulating sleeve, a retaining device in the form of a lock ring 15 is screwed onto the threads 13 on the outer surface of the terminal 10 as shown in FIG. 5. The electrical contacts 11 on the end of the crimped terminal 11 extend through the lock ring 15. The lock ring 15 helps to hold the crimped terminal 10 in place within the connector assembly 1, as the insulating sleeve 60 is effectively clamped between the outer surface of the bearing ring 16 and the inner surface of the lock ring 15. The lock ring 15 is threaded onto the threaded portions 13 of the contact pin 11 and surrounds part of the contact pin 11. FIG. 6 shows the connector assembly with the lock ring 15 in place on the contact pin 11. When the shoulders of the bearing ring 16 and the insulating sleeve 60 are engaged, any tensile loads applied to the conductor 5c are transferred from the crimped terminal 10 to the insulating sleeve 60. The body portion 31 has on its upper end an alignment slot 31s (best seen in FIG. 13) to control alignment of the mating connector on the other side of the pressure barrier. The insulating sleeve 60 electrically insulates the end terminal from the body 30.

(39) The conductor 5c can be offered up to its respective bore in the body 30 and secured in place in the connector assembly 1 by the lock ring 15 as shown in FIG. 6 before or after the second portion 32 of the body 30 is partially tightened onto the first portion 31 by threading the second portion 32 along the thread 34 a short distance as shown in the transition between FIG. 6 and FIG. 7. At this stage, as shown in the detailed view of FIG. 8, which is a close up of FIG. 6, the upper end of the spring sleeve 73 has not yet engaged with the metal plate 39, and the lower end of the sheath 45 has not yet entered the narrowing throat 73t of the bore of the spring sleeve 73, and hence is not at this stage compressed radially against the outer surface of the conductor 5c. Hence at this stage, the conductors 5c can be removed or inserted into the bores in the assembly if desired.

(40) The spring sleeve 73 is restrained within the second portion 32 by the inter-engaging shoulders 32s, 73s, and moves axially upwards within the bore 30b of the body 30 as the body portions 31 and 32 are screwed together, until the upper face of the upper section 74 of the spring sleeve 73 engages with the lower face of the metal plate 39 below the resilient sealing boot 40 as shown in FIG. 7. The front face of the spring sleeve 73 is then seated against the underside of the metal plate 38. At this stage, the spring 70 is still held in moderate compression between the circlip 72 and the spring sleeve 73, but the spring sleeve 73 is still held in its fully extended configuration with the shoulders 73s and 32s fully engaged. Hence, no further compression of the spring 70 has taken place at this stage. However, as is shown in FIG. 7, the lower end of the sheath 45 has passed through the narrowed throat 73t of the bore 73c in the spring sleeve 73 into the narrower diameter section of the bore 73c, and the axial relative movement between the sheath 45 and the spring sleeve 73 is radially compressing the sheath 45 between the inner surface of the bore 73c and the outer surface of the conductor 5c, and firmly clamping the sheath 45 against the outer surface of the conductor 5c. Repositioning of the conductor 5c within the bores at this stage is therefore restricted by the radial compression of the sheath 45.

(41) Further relative movement of the body portions 31, 32 as they are screwed together beyond the FIG. 7 point starts to move the spring sleeve 73 into the bore of the lower body portion 31, until the assembly reaches the configuration shown in FIGS. 10 and 11, in which the spring 70 has been about 60-80% compressed by the downward axial translation of the spring sleeve 73 in the lower body portion 32. At this stage, the energised spring 70 is urging the spring sleeve 73 upwards in the bore 30b against the underside of the metal plate 39, which is transmitting the axial force to all of the internal components of the assembly above it in the bore 30b, thereby compressing the resilient sealing boot 40, the insulation boot 50, and the insulation sleeve 60. The axial compression applied by the compressed spring 70 accommodates expansion and contraction of the internal components in the bore 30b, and maintains the seal, thereby reducing or restricting well bore fluids below the connector assembly 1 from tracking through the annulus between the body 30 and the conductors 5c. It is desirable that the spring 70 is not completely compressed at this stage, to allow for additional compression of the spring 70 in order to accommodate thermal expansion of the components in the bore.

(42) Well bore pressure outside the body can be communicated through the fluid pathway comprising the port 30p between the outer surface of the body 30 and the bore 30b, exposing the bore below the sealing boot 40 to the well bore pressure outside the body 30. The pressure differential between the external surface of the body 30 and the inside of the bore 30b thus applies additional force to the internal components, increasing the sealing force applied to the sealing boot 40.

(43) The axial force urging the spring sleeve 73 compresses the sheath 45 of the sealing boot 40 within the bore 73c between the inner surface of the bore 73c and the outer surface of the conductor 5c in the bore 73c, and hence improves the resistance of the spring sleeve 73 to passage of fluids through the bore 30b or along the conductor 5c.

(44) Once the two body parts 31, 32 have been connected and fully screwed together, the gland 20 can be made up with the lower end of the lower body portion 32 to at least partially seal off the bore 30b at the lower end of the assembly 1. The lock ring 29 on the gland 20 is threaded onto the (lower) second portion 32 of the body along the threaded connection 25. The low friction PEEK ring 26 is pressed against the end of the body portion 32 when the lock ring 29 is in position, and the ring 26 reduces friction between the rubber bung 23 and the body during relative rotation to make up the gland 20. At the outer end of the gland 20 is a metal ring 28, which presses against the rubber bung 23 when the assembly is threaded in place. This compresses the rubber bung 23 and presses the rubber bung 23 into the conductor 5 for at least partial sealing against fluid ingress.

(45) FIG. 13 shows a three-dimensional partial cut-away view of the installed assembly 1. The spring 70 is maintaining compression on the internal components in the bore of the body 30, and the arrangement also increases radial compression of various internal components, e.g. the sealing boot 40, radially inwards against the outer surface of the conductors 5c, which increases the sealing effectiveness. The spring 70 is optionally still able to compress in the event of expansion of any of the internal components in the bore, and this prevents thermal expansion events from damaging the conductor, as well as maintaining the optimum compression necessary to contain the well bore fluids in the bore of the connector.

(46) FIG. 14 shows the assembly body 30 with an optional end cap 80 threaded into place and installed onto the end of the body 30, but before the conductors 5c have been inserted into the bore of the body 30. The body 30 is optionally delivered to the well site in this partially made up configuration, with the spring sleeve 73 not engaging the internal components as it is axially spaced from the metal ring 39, and the sheath 45 is only received in the wide mouth 73m of the bore 73 and has not been compressed by the narrow throat 73t. At this stage, therefore, the end cap 20 can be easily removed and the conductors 5c can be passed through the body as all bores 73c, 40b, 50b, and 60b are aligned, and the terminals 10 can be crimped in place on the ends of the conductors 5c, after which the body portions 30, 31 can be screwed together, which drives the spring sleeve 73 upwards in the bore as the spring 70 is compressed which axially urges the boots 40, 50 and the sleeve 60 and radially compresses the sheath 45 in the narrow throat 73t of the bores 73c. After assembly as indicated above, the assembly 30 is installed in a penetrator bore passing through a pressure barrier ready for connection to a mating connector assembly on the other side of the pressure barrier. When the assembly 30 is subjected to fluid pressure differentials from one side of the pressure barrier to the other, for example, most often the pressure of wellbore fluids at high pressure below the pressure barrier, which would be the case in a wellhead for example, the high pressure of the wellbore fluids below the pressure barrier is communicated to the sealing boot 40 via the fluid pathway comprising the ports 30p and 77. The pressure in the bore 30b below the sealing boot 40 is optionally equalised throughout the lower section of the bore 32b, and flows around the spring sleeve 73, spring 70 and other internal components within the bore, so there is a reduced risk of pressure differentials building up within the bore 32b below the sealing boot 40, hence, the pressure differential across the sealing boot 40 acts to compress the boot 40 axially upwards in the bore 30b, and compresses the sheath 45 radially inwards onto the conductor 5c. Higher pressure differentials across the sealing boot 40 therefore augment the seal.