CL20 Motor Lead Extension Pothead

A Pothead at the end of the Motor Lead Extension (MLE) serves as the plug-in for the cable and motor. Pins in the pothead securely engage the motor terminal block, and a rubber boot seals the connection to prevent any well fluid ingress.

The Additive Manufacturing (AM) team received an urgent request from the OFSE – Artificial Lift Services in July 2023. The Operations team in Indonesia was awarded a multimillion contract taken from our competitors with over 50 wells installations. These wells became in imminent risk with potential stop work for customer in Indonesia and loss of revenue for Baker Hughes due to the Motor Lead Extension (MLE) shortages; this risk materialized because of supply chain disruption for Pothead parts, which was caused by a significant delay on orders due to quality issues of the standard supplier.

The Baker Hughes Additive Manufacturing and Artificial Lift Services teams qualified 3D printing of Potheads as a solution to supply the parts for emergency service requests by reducing lead time from 16+ weeks to less than 6 weeks.

Existing Design

The conventionally manufactured CentriLink MLE Pothead is a machined casted geometry that is designed to house connector components sealed with epoxy potting. The Pothead portfolio offers design features that deliver higher temperature, voltage, and amperage ratings as well as improved motor connection electrical properties to withstand ever-growing downhole challenges. The MLE’s unique low-profile design prevents installation damage and delays, allowing to get the well into production sooner.

Validated Technology

The immediate task was to produce an equivalent part number to cover the required demand in less than 6 weeks for the first batch of 48 parts, with total demand of 299 parts for initial request. The parts were printed with a qualified Solution-Annealed and Single Aged Ni718 material, which was accepted as a suitable substitution to the original Monel 400. Since the initial request, AM team has delivered more than 650 parts, constantly improving on manufacturing efficiency and lead-time. With print time of only 20+ hrs for the batch of 16+ parts, AM team may accommodate continuous printing of hundreds of parts on a quarterly basis, utilizing multiple printers at the same time. Next is to look for expansion of AM to a wider range of designs within the Pothead product family.

Challenges

• Supply chain interrupted by the quality of parts and unreliable supply from the conventional manufacturer.
• Long lead-times of casted parts.
• Machining complexity of casted parts.

Results

• Avoided rig down condition and potential loss of contract.
• Qualified AM first articles printed in Ni718 material and heat-treated to single aged state.
• 650+ parts produced to date.
• 60%+ in lead-time reduction.
• Continuous and uninterrupted supply of high-demand critical parts on short notice.

Benefits

• Wells impacted: 50+
• Lead-time reduction: 16+ to less than 6 weeks
• Total AM parts produced: 650+