Products and Services

Advanced Products
BIW Connector Systems supplies the oil and gas industry with a breadth
and depth of innovative products and breakthrough solutions. Our
For more than four decades, BIW Connector Systems has been the industry-leading supplier state-of-the-art engineering, testing and production capabilities,
of electrical penetrator systems used by the petroleum industry. Applications include safety combined with high-performance elastomeric, thermoplastic and
barriers for electric submersible pump (ESP) systems, oil reservoir monitoring instruments, pressure-balanced technology, allow us to deliver robust products that
downhole heaters and ESP isolation systems. We operate on a global basis serving customers perform continuously and reliably in the harshest environments.
in every major oil center in the world.
Reliability
At BIW Connector Systems, our commitment to designing and delivering quality products,
Product reliability is critical in the upstream oil and gas production
solutions and services is unwavering. We also certify our products through recognized test
market. If any part of the production string fails, the well goes down
laboratories to worldwide specifications for hazardous location environments, including the
and valuable revenue opportunity is lost. BIW Connector Systems invests
National Electric Codes of the USA and Canada, ATEX and IEC, among others. BIW Connector
significant resources in design and testing to ensure our products
Systems is certified to ISO9001:2008.
withstand the extreme, harsh environment of a production well.
In 2011, BIW Connector Systems became part of ITT Interconnect Solutions, a world leader
in the design and manufacture of highly engineered connector solutions for harsh conditions Responsive Partner
and ruggedized environments. Together, ITT and BIW Connector Systems foster a culture of Our customers need partners and suppliers that move at the speed
innovation, resourcefulness and continuous improvement that helps us solve our customers’ most of their business. That’s where BIW Connector Systems comes in.
pressing business challenges today and in the future. When an oil well is down, we help you quickly get it back into service.
When deliveries need to arrive sooner, our infrastructure is nimble and
flexible enough to accommodate. And when there are last minute
design changes, we have both the expertise and production facilities
to execute. At BIW Connector Systems, we move at the speed of
business—and then some.

Innovation
When quality design and engineering are at the core of your DNA,
innovation, performance and reliability become the standard. At BIW
Connector Systems, we carefully balance the development of new
solutions and technology with improvements to existing products,
ensuring that our customers receive value at every touch point.

Looking for a specific product? Not sure what product you need?
See our Product Index on pp 22-23.

3
 Wellhead Applications

Electrical Penetrators for Wellheads Wellheads with Bonnet

A wellhead provides the most critical safety barrier between the A bonnet or adapter flange is used in high pressure applications.
oil well and the surrounding environment. The electrical wellhead These applications are rated for 5000 psi or greater and all
penetrator is designed to safely deliver electrical energy through off-shore installations will include a bonnet. BIW's penetrator
this critical barrier to operate electric submersible pumps deep systems for this application are designed to work in the harshest
in the well. Requirements for relatively high voltage and current, environments, and in most cases, the system is made up of
together with wide variation in operational temperatures of three pieces: surface connector, penetrator/mandrel and lower
wellhead systems, add significant challenges. connector. These three pieces provide the complete pressure block
Length variations and physical characteristics of the wellhead insuring the integrity of the wellhead.
penetrator are the result of differences in wellhead designs and
the need to seal against wellhead sealing structures, the tubing
hanger and the top flange or “bonnet.” General configurations
of wellhead penetrators can be divided into three groups. The
shortest penetrators are used in wellheads that do not employ Wellheads without Bonnet
a top flange. Medium sized penetrators are used in wellheads Wellheads that do not have a bonnet are typically used in lower
that have top flanges, and the longest penetrators are used pressure applications and are sometimes referred to as non-API
in wellhead with long tubing hangers and/or large top flange or independent wellheads. These wellheads are typically rated for
structures. 3000 psi or lower. BIW has designed 1, 2, and 3 piece penetrator
systems and all provide a complete safety block while delivering
BIW’s wellhead penetrator systems have provided important
reliable power. These systems are a safe and reliable replacement
sealing protection for the oil and gas industry over the last four
for cable packoffs.
decades. Our products are installed in thousands of wellheads
around the globe and have a proven track record in meeting the
requirements of each application.

Wellheads with Long Hanger

Long hangers are typically used when the wellhead has extended
length. These wellheads usually require special penetrator systems
that have a small penetrator bore profile. BIW’s solutions to these
types of wellheads are 2 piece systems that consist of a surface
connector and mandrel/lower connector made up as one piece.
These systems are easy to install and provide the same safety and
BIW Connector Systems’ wellhead penetrators deliver high power through the reliable power as all of BIW’s other systems.
critical safety barrier between the oil well and its surrounding environment.

4 5
 Wellhead Penetrator Systems
Metal-Lok™ High Temperature Metal-Lok™ Slimline

The Metal-Lok High Temperature Wellhead Penetrator System is rated 450°F

(232°C) and 3000 psi and is suitable for some of the most challenging downhole
conditions. This product has been subjected to BIW Connector Systems’
qualification regimen proving its robustness and reliability. This product is
provided with a field attachable lower, which eliminates the need for a rig splice,
making installation both quick and easy. It is designed to be used in higher
temperature well applications on wellheads with bonnets.
The Metal-Lok Slimline is a versatile new product in the BIW line. It is designed
Specifications to fit into a smaller sealing bore, as small as 2.25”, and is suitable for 300°F,
5000 psi service. The system comes with BIW’s innovative crimp-free contact,
Environmental 450°F (232°C), 3000 psi
Electrical 5000 VAC, 20 to 120Hz, 140 Amperes
completely eliminating the need for crimp tools. This new contact withstands a
Approvals CSA approved for Class 1, Division 1, T-Code T4A, Groups C and D Hazardous Locations. minimum of 1000 pounds of pull force, making it stronger than most crimped
ATEX & IEC Ex d IIBT4 Gb
contacts. The crimp-free contacts will reduce the installation complexity
Features saving precious rig time. The product also includes a new sealing design
Decompression-Resistant Increased product lifetime and reliability downhole that requires just one kit for each cable size eliminating the need for cable-
Field Attachable Eliminates need for a rig splice and is highly adaptable to your ESP cables specific sealing elements and reduces stocking inventory and confusion. You
High Temperature Materials Suitable for use in applications with a maximum conductor temperature of can rely on Metal-Lok Slimline, like you do all BIW products, as it has passed
4500F (2320C)
Metal-Lok™ Keying Prevents damage that could results from inadvertent turning or
rigorous qualification testing at temperature, pressure and decompression in
mishandling of the surface connector environmental well fluids and gas while under electrical monitoring.
Metal-Lok Ultra in
wellhead with bonnet.

Metal-Lok™
This is the workhorse of the Metal-Lok family. Rated and tested to 300°F
Specifications
(149°C) and 5000 psi, it covers the majority of ESP well applications and is
designed and tested to handle harsh environments. The use of PEEK and Environmental 300°F (149°C), 5000 psi

the minimal use of elastomers make it highly resistant to downhole pressure Electrical 5000 VAC, 20 to 120Hz, 140 or 160 Amperes

decompression. This product has been subjected to BIW’s qualification Approvals CSA approved for Class 1, Division 1, Groups C and D Hazardous Locations

regimen proving its robustness and reliability. This system is designed to work
in wellheads with or without bonnets. Features
Slim profile Fits in tight annular spaces and in smaller bore tubing hangers (2.25”
Specifications Metal-Lok Slimline with
diameter)
BIW’s Quick-Thread™
Environmental 300°F (149°C), 5000 psi Technology Field Attachable Field attachable design eliminates a downhole splice and is highly
adaptable to all ESP cables
Electrical 5000 VAC, 20 to 120Hz, 160 Amperes
Quick and Easy Assembly/ Connector is preassembled making it the quickest installation offered by
Approvals CSA approved for Class 1, Division 1, Groups C and D Hazardous Locations. IEC and ATEX Installation BIW
Certification Exd IIB T4 G.
Metal-Lok™ Keying Prevents damage that could result from inadvertent rotation or mishandling
of the surface connector
Features
Decompression-Resistant Decompression-resistant
Field Attachable Lower Eliminates need for a rig splice and is highly adaptable to your ESP cables
Metal-Lok™ Keying Prevents damage that could results from inadvertent turning or mishan-
dling of the surface connector

6 7
 Wellhead Penetrator Systems

Metal-Lok™ Ultra with k-PaC™ Technology

This system features a new high temperature feedthru and lower connector Rubber Molded 3-Piece and
design that is suitable for use to 500°F (260°C) and pressures of up to 3000
psi. The downhole field attachable connector features BIW Connector Systems’ Rubber Molded 2-Piece (FTLM)
groundbreaking k-PaC Technology, a pressure-balanced design that compensates BIW Connector Systems’ Vulcanized Elastomer Electric Penetrator designs
for normally destructive thermal expansion pressure variation and operates over have long been recognized for superior performance. These products are
a wide temperature range. Metal-Lok Ultra was designed to withstand extended manufactured using a variety of metallurgies. Internal pressure blocking
exposure to steam and multiple temperature cycles. This product is the solution
elements are made from high performance epoxy resins and include vulcanized
to your SAGD wells.
elastomer seals. Throughout the years, these products have been meticulously
Specifications improved. Modern epoxy resins retain their mechanical properties at very high
Environmental 500°F (260°C), 3000 psi temperatures and elastomers offer superb electrical and sealing characteristics.
Electrical 5000 VAC, 140 Amperes
Today’s products are optimized for long life and utmost safety, with approvals
Approvals CSA Approval for Hazardous Location Installation, Class 1, Division 1 Groups C and D
for use in hazardous locations from ATEX, IEC, CSA and Factory Mutual. We
Features offer more than 2,000 part numbers, a product range unmatched by all other
Decompression-Resistant Increased product lifetime and reliability downhole suppliers combined. Our vulcanized elastomer solutions are just one of several
Field Attachable Field attachable lower requires no splice and is highly adaptable to your ESP technologies that meet your needs for safe, reliable, and easy-to-use penetrator
cables
High Temperature Innovative k-PaC Technology enables applications with an ambient
systems.
temperature of up to 5000 F (2600C)
Most Surface Connectors are supplied with coupling rings retained by ball
Metal-Lok™ Keying Metal-Lok Keying positively prevents damage that could results from
inadvertent turning or mishandling of the surface connector bearings. This retention method ensures longer life, better resistance to
corrosion, and easier engagement.
Many connectors are also supplied with replaceable sealing
EFT ®
elements. These new seals consist of O-rings that are easily
EFT penetrator products have been safely sealing and passing power through replaced with a special tool.  
5000 psi-rated wellheads for over 20 years. With over 10,000 installations,
the EFT Wellhead Penetrator System has proven that it is a mainstay in the ESP
market. The surface and lower connector can be provided in a field attachable Specifications
kit and configured to your cable preference, making it a quick, flexible and cost-
Environmental 300°F (149°C), 5000 psi
effective option. These systems can also be provided with cable pigtails and are
Electrical 5000 VAC, 20 to 120Hz up to 215 Amperes
designed to work in systems with or without bonnets.
Approvals CSA and FM for Class 1, Division 1 Hazardous Locations; ATEX for Hazardous Locations;
Specifications IEC for Hazardous Locations

Environmental 300°F (149°C), 5000 psi

Electrical 5000 VAC, 20 to 120Hz 180 Amperes Features
Approvals CSA Approval for, Class I, Division 1, Groups C and D, Hazardous Locations
2- and 3-Piece Penetrator Systems Separable Surface Connectors allow for fast and easy installation
Ball Bearing Coupling Ring on Ball Bearing Coupling Ring on Surface Connectors provide the same
Features Surface Connectors reliability, and makes installation easier
Metal-Lok Ultra
Thousands Installed Making it one of the most proven penetrator systems on the market 3-Piece Rubber Molded Field Attachable, Factory Molded Field Attachable and Factory Molded Lower Connectors provide flexibility to
Penetrator System with
Feedthru System meet your installation needs
k-PaC Technology Field Attachable Field attachable lower connector eliminates downhole splice and streamlines
installation Lip Seal Design The Lip Seal Design to provides a secondary seal from ingress, increasing
Standard Sizes Enables quick lead-time and repeatable performance reliability

Three-Piece Versatility Versatile 3-piece system makes installation and work-overs a breeze, saving Replaceable Sealing Elements on Replaceable sealing elements on surface connectors allow for re-use on
rig time Surface Connectors used connectors, saving both time and money

8 9
 Wellhead Penetrator Systems
E-ZEE Feed® Kwik-Lok™
The E-ZEE Feed Wellhead Penetrator System is designed
for easy conversion from cable pack-off with minimal wellhead modifications.
It is supplied as a field attachable kit. This two-piece, “stab-in” design, reduces
IMAGE ?
The Kwik-Lok Wellhead Penetrator System offers a safe, explosion-proof option
cable handling issues by permitting fast coupling of the surface cable to the
to a cable pack-off wellhead penetration. This robust design and construction
penetrator, making it is easy to install or to pull during workovers. The E-ZEE
ensures reliable performance and long run life. The slim feedthru OD needs
Feed comes in both 3000 psi and 5000 psi versions to accommodate most
only a small penetrator bore. The bottom fed, stab-in feedthru design with
wellhead pressure ratings. The E-ZEE Feed is available for applications requiring
downhole molded cable makes it fast and easy to install.
certification for hazardous locations and for applications where this is not
required. Specifications
Specifications Environmental 300°F (149°C), 3000 psi

Environmental 300°F (149°C), 3000 or 5000 psi Electrical 5000 VAC, 20 to 120Hz 140 Amperes

Electrical 5000 VAC, 20 to 120Hz 140 or160 Amperes Approvals CSA approved for Class I, Division 1, Groups C and D Hazardous Location installation

Approvals CSA approved for Class 1, Division 1, Groups C and D Hazardous Locations
Features
Features Reliable Wellhead Sealing Complete cable termination below the wellhead, which results in a reliable
wellhead seal. Well fluids stay downhole, no need to vent
E-ZEE Feed Field Atttachable Bottom-fed Installation Bottom-fed installation, coupled with field attachable design, provide the
Wellhead Feedtrhu System easiest, quickest and most reliable installation Slim Design Slim design is great for use in small well casings. Requires seal bore of only
now aviable in 3000 or 1.75” diameter.
Field Attachable Field attachable design eliminates a downhole splice
5000 psi
Full Qualification Proven reliability by passing BIW’s rigorous qualification testing and
numerous successful field installations
Geothermal Wells Suitable for geothermal wells
High Performance Materials High strength, high temperature insulators provide safety and reliability

Uni-Lok™ Wellhead Penetrator

The Uni-Lok Wellhead Penetrator system is designed to provide the quickest
and easiest pass-through of ESP power at a very competitive price. Unlike other
Safe-T-Lok®
products, the Uni-Lok system offers a complete verified pressure block inside The Safe-T-Lok Wellhead Penetrator System is a one-piece design that is a safe, reliable
and an inexpensive replacement for cable packoffs. Unlike packoffs, the Safe-T-Lok
the tubing hanger ensuring that downhole gases stay downhole. This field
provides a complete pressure block. This is done through a mandrel design with factory
attachable system is designed as a single plug-and-play pressure barrier that
cable molded on both ends. The Safe-T-Lok requires splicing below the tubing hanger
fits into sealing bores as small as 1.75” and to have the flexibility to fit/re-
and is intended for use with independent wellheads, suitable for 3000 psi service.
use any existing surface cable infrastructure. It has passed BIW’s rigorous
testing protocol and is available for applications requiring certification
for hazardous locations and for applications where this is not required. Specifications
Specifications Environmental 300°F (149°C), 3000 psi
Electrical 5000 VAC, 20 to 120Hz 140 Amperes
Environmental 300°F (149°C), 3000 psi
Electrical 5000 VAC, 20 to 120Hz 140 Amperes
Uni-Lok Wellhead Features
Penetrator System Approvals Pending CSA Class 1, Division 1 Hazardous Locations and ATEX Hazardous locations
Safe-T-Lok Feedthrus & Tubing Safe-T-Lok feedthrus are suitable for use with “independent wellheads”
Hangers if they are equipped with tubing hangers. Alternative configurations are
Features available for different tubing hangers.
Slim profile Fits in tight annular spaces and in smaller bore tubing hanger (1.75”) that Compatible with most ESP Cable Sizes Compatible ESP Cable Sizes: AWG4 Flat; AWG2 Round, AWG4 Round
fits nearly all tubing hangers
Slim Design Fits into wellheads too small for any other type of feedthru systems
Field Attachable Field attachable design eliminates a downhole splice and is highly adaptable
to all ESP cables

Well Control Provides a complete pressure block in the wellhead, guaranteeing that well
fluids and gases stay downhole
Versatility Designed to re-use existing surface installation or be installed onto existing
surface cable
10 11
 Wellhead Penetrator Systems Packer Applications
Tri-Lok® 3-Bore Packer Penetrator Systems
The Tri-Lok 3-Bore Wellhead Penetrator Systems are designed to provide safe and reliable BIW Connector Systems offers electrical power penetrator solutions for all types of
ESP power transfer through wellheads with minimal space. The design of these systems downhole pressure barriers, including mudline packers, deep-set packers and electric
are ideal for concentric wellheads, with or without bonnets, where there is not enough submersible pump pods. Packer penetrators are specifically engineered to withstand
room for a standard mandrel system. The Tri-Lok system also provides the ultimate safety pressure from both sides. All packer penetrator systems are designed to withstand
providing a complete pressure block and cable termination in the wellhead. The Tri-Lok repeated pressure cycles, and qualification testing for these devices includes a severe
3-Bore Wellhead Penetrator System now comes with an improved surface connector regimen of pressure cycling.
making it the most flexible and easiest to install 3-Bore product on the market. The
new BIW Quick-Thread™ Technology connection does away with tedious wrench turns Packer Penetrators for Dual-String Retrievable
and the flexible leads make installation easy even in the tightest of locations and can be Packers
retrofitted to the surface cable in place. The new higher rating of 160 Amperes enables
When used with dual-string retrievable packers, penetrators are installed directly into
the user to use this product with larger motors. The surface connector is available in
the packer. Field attachable connectors or downhole connectors with cables are used to
field attachable or cable-molded configurations and is ATEX approved for hazardous
make the electrical connection between ESP cable above and below the packer.
locations.

Packer Penetrator Systems with Cross-over

Adapters
In many wells, there is not sufficient space for a twin-seal packer. Often, cross-over
adapter solutions are used to provide reliable sealing at the packer, but with the
pressure barrier device (“penetrator”) actually located below or above the packer itself.

Tri-Lok Wellhead Penetrator with BIW’s Quick-Thread™ Technology Field Attachable Packer Penetrator Systems
Using PEEK technology, we offer field attachable packer systems. These systems can be
easily installed above or below the packer, without requiring a cable splice. Systems are
Specifications exceptionally robust, and they are suitable for temperatures up to 450ºF.
Environmental 300°F (149°C), 5000 psi
Electrical
Approvals
5000 VAC, 20 to 120Hz 160 Amperes
ATEX approved for Hazardous Locations
3-Bore Packer Penetrator Systems
With enhanced production methods, it may be desirable to use a packer in wells with
Features just 7-inch casings – or even smaller. In those cases, BIW Connector Systems can offer a
Flexible Surface Connector Multiple surface mounting configurations, which provides the flexibility to fit Tri-Lok 3-Bore packer feedthru, where steel-encased power conductors pass through the
most wellheads, even those where space is limited wellhead with positive seals to ESP cables located above and below the packers.
Field Attachable, Cable Molded Flexibility to meet your specific installation
Wellhead Pressure Block & Seal The complete pressure block and seal at wellhead keeps the well fluids in the
well, which provides the ultimate safety and peace of mind without requiring
a vent
High Performance Packer Penetrator Systems
Quick and Easy Installation New patent pending quick-connection/disconnection technology that greatly Most packer penetrator systems are intended for 5000 psi maximum pressure,
reduces the installation time
at a temperature of 300ºF. However, there are installations which require higher
performance. Downhole conditions with temperatures in excess of 300ºF, sour wells
with high concentrations of corrosive gases and production techniques that result in
high numbers of pressure decompression cycles are examples. BIW’s k-PaC Technology
was developed specifically for these harsh conditions.

12 13
 Packer and POD Penetrator Systems

Tri-Lok® 3-Bore
Molded Cable Packer installations can boost ESP performance in many wells, including those with casing
Molded Cable Packer Penetrator Systems are widely used in both mudline applications and deep-set diameters of 7-inches or less. For these wells, it is necessary to use the smallest possible diameters
applications. Molded Cable Penetrators are supplied with cable factory installed both above and for electrical penetrations in the packer. The Tri-Lok 3-Bore Packer Penetrator System meets this
below the penetrator. Cable splicing is a widely available skill, and penetrators with cable may be need. High performance electrical conductors are encased in 3/8-inch Duplex tubing and the three
preferred for remote installations that may not have technical support available for field attachable tubes penetrate the packer. Below the packer, three mechanical splice tubes are used to connect the
solutions. Duplex-encased conductors to the Motor Lead Extension cable. Similar splice tubes are used above
the packer to connect the ESP cable above.
When used with deep-set packers, these penetrators are often supplied with motor lead extension
cables and pothead connectors. In these cases, the penetrators are mounted below the packer, and Specifications
there is no need for a field splice to the MLE below the packer. Environmental 300°F (149°C), 5000 psi
Electrical 5000VAC, up to 140A
Specifications
Insulators PEEK
Environmental 300°F (149°C), 5000 psi Metallurgy Tubing – Duplex 2205; Hardware-316 Corrosion Resistant Steel
Electrical 5000VAC, up to 160A
Maximum Length Penetrator - 28-inches
Features
Metallurgy 4130 Alloy Steel, 316 Corrosion Resistant Steel, 410 Corrosion Resistant Steel, Monel 400 Tubing Encased Cable 3/8-inch Duplex Tubing fits into all ESP packers, even when bores in the packer are not
straight
Features 75-inch Duplex Tubes For use with a variety of packers. Tubing is trimmed to the required size at time of
installation.
Cross-over Adapters Ease of installation - not necessary to rotate penetrators during installation
Metal-to-metal seals Reliable sealing to the packer
Test Ports Permits hydraulic testing of O-ring Seals
Splice Tube Technology Easy, reliable sealing to ESP cable above and below the Packer
Adjustment Slot Ease of installation — helps to manage cable slack
Wide thread selection Cross-over Adapters are supplied with both pin and box threads in the following sizes:
1.90NU-10RD • 2 3/8 EU 8 RD and 2 3/8 EU10 RD • 2 7/8 EU 8 RD • 2 7/8 EU10 RD

Tri-Lok® Ultra
The Tri-Lok Ultra Packer Penetrator System is designed for high performance applications where
long life is a requirement. Pressure blocking is achieved using redundant electrical power contacts
HEZF Field Attachable brazed into ceramic blocks. Connections to cables are made using patented pressure-balanced
The HEZF Field Attachable Packer Penetrator System is intended for convenient installation above technology. This unique system applies virtually no mechanical stress on ESP cable insulation and
or below the packer. The systems consists of three major components: Packer Penetrator, Field barriers over a wide range of pressure and temperature.
Attachable; 2) Downhole Power Connector, Field Attachable; and 3) Cross-over Adapter. Tri-Lok Ultra Penetrators are designed for 400ºF (204ºC) service at pressures up to 7500 psi
(absolute or differential). The system is designed to withstand harsh and repetitive pressure cycles.
Installation consists of separately installing the ESP cable end and the Motor Lead Extension cable
end to the Packer Penetrator assembly and to the Field Attachable Power Connector, respectively. The system is delivered pre-assembled. On-site work requires minimal cable preparation and
The system can be ordered for installation above or below the packer, depending on local inserting cable ends into the packer penetrator.
preference. Specifications
Specifications Environmental 400°F (204°C), 7500 psi
Electrical 5000VAC, up to 180A
Environmental 350°F (177°C), 5000 psi
Insulators Ceramic, PEK and VDM-1000
Electrical 5000VAC, up to 140A
Metallurgy 17-4 Corrosion Resistant Steel, 410 Corrosion Resistant Steel, 316 Corrosion Resistant Steel
Metallurgy 4130 Alloy Steel, 316 Corrosion Resistant Steel, 410 Corrosion Resistant Steel, Monel 400
Features
Features
Ceramic Pressure Block Withstands extremely high pressures, with no harmful effects from high temperature
Cross-over Adapters Ease of installation Left: exposure
Adjustment Nut Ease of installation — helps to manage cable slack Tri-Lok 3-Bore Packer Penetrator Metal-to-metal seals Reliable sealing to the packer with pressure test ports
Right:
Wide thread selection Cross-over Adapters are supplied with both pin and box threads in the following sizes: Pressure Balanced Cable Pressure cycling and the presence of gas do not harm the cable termination. Suitable for
Tri-Lok Ultra Packer Penetrator
1.90NU-10RD • 2 3/8 EU 8 RD and 2 3/8 EU10 RD • 2 7/8 EU 8 RD Termination round cables, flat cables, lead-sheathed cables and tube encapsulated MLEs

14 15
 Mechanical Splices Instrumentation Feedthru Systems
Products for permanent downhole gauges.
Presta™ GS Splice Permanent downhole gauges (PDG) have an important role for optimizing oil
The Presta Global Service Mechanical Splice is designed to make uniform,
production. PDGs are always installed using metal-tubing encased cable, using
reliable splices quickly and with minimal training. Using the Presta splice
both the conventional 1-conductor, and the newer 7-conductor cable types. BIW
requires only easy cable preparation. The prepared cable ends are then
Connector Systems offers a variety of products to make the installation of these
inserted into the Presta splice, where they are permanently retained. Presta 7-Pin I-Wire
Penetrator systems safer and easier. The safest installations of PDG cables require the use
replaces taped splices, and allows splices to be made up in 45-60 minutes.
System of a pressure-proof electrical penetration system. If an accidental breach of the
PDG cable should occur downhole, the tubing encapsulated cable could provide
Specifications
a conduit for hazardous gases and fluids. When a penetrator is used, this risk is
Environmental 300°F (149°C), 5000 psi averted.
Electrical 5000VAC, up to 160A
PDG Penetrators for 7-conductor cables and 1-conductor cables.
Dielectric Leakage Current Less than 1 micro-ampere at 24KVDC
These penetrators are designed to be installed either atop the wellhead bonnet or
Features on the side of the wellhead bowl. Pressure proof sealing is provided by electrical
Plug & Play Assembly Field Attachable. Requires only that cable ends must be prepared and contacts in a glass-to-metal sealed barrier. These systems have removable surface
inserted into the pre-fabricated device.
connectors for easy work-over. Our products have ATEX approvals for installation
Boot Seal Technology Reliable sealing with minimal cable preparation.
in hazardous locations.
PDG Penetrators for 1-conductor cables for tubing hanger installations.
These penetrators are long electrical connectors, designed to seal both to the
Easy strip-and-click tubing hanger and the top flange. Pressure-proof sealing is provided either with
assembly
glass-to-metal barriers or by elastomer/epoxy resin barriers. Surface connectors
are removable, and may be either 1- or 2-conductor. Connection to the PDG
cable is by field attachable lower connectors, with verifiable metal-to-metal
sealing. The feedthru and surface connectors of these systems have Class 1
Division 1 approvals for installation in Hazardous Locations.
Presta™ Splice with k-PaC™ Technology
Splices for 1-conductor PDG cables.
The Presta® Splice with k-PaC Technology is designed to allow difficult splices to be made easily,
Splices are used to join single conductor PDG cables downhole. Splices attach to
quickly, and uniformly by rig personnel with minimal training. Using the Presta splice requires only
easy cable preparation. The prepared cable ends are then inserted into the Presta splice, where they cable ends using verifiable metal-to-metal seals. Each splice includes a pressure
are permanently retained. Presta replaces complex taped splices, and allows severe service splices to block element within the splice, to prevent fluid migration past the splice
be made up in 60 to 90 minutes. junction, should the PDG cables become breached.

The Presta Splice with k-PaC Technology are designed for Deep Water Offshore applications rated PDG Instrument Penetrations for 1-conductor Cables.
for 350°F and 7500 psi and for Extreme Service applications rated for 400°F and 5000 psi. Both Instrument Penetrations are used to protect costly instruments from fluid ingress
have performance headroom for even more severe applications. should the PDG cables become breached. The instrument penetrator has a glass-
Specifications to-metal sealed electrical contact that is designed for welding to the instrument.
Single Pin I-Wire
Connection to the PDG cable is made using Field Attachable downhole
Environmental 400°F (204°C), 7500 psi Penetrator
Test Temperature 500°F (260°C)
System connectors with verifiable metal-to-metal seals.
Test Pressures 20,000 psi at 200°F (93°C), 5500 psi at 550°F (288°C)
Electrical 5000VAC, up to 160A
Electrical Test Value 30KVAC for 4 hours Specifications for Penetrator Products
Dielectric Leakage Current Less than 1 micro-ampere at 24KVDC
7-Wire Wellhead 1-Wire Wellhead 1-Wire Tubing Hanger 1-Wire Instrument 1-Wire PDG Cable
Penetrator Penetrator Penetrator Penetrator Splice
Features
Pressure Rating 5000 psi Up to 10,000 psi 5000 psi Up to 10,000 psi 5000 psi
Plug & Play Assembly Field Attachable. Requires only that cable ends must be prepared and inserted into the Temperature Rating 350°F (177°C) 300°F (149°C) 300°F (149°C) 392°F (200°C) 300°F (149°C)
pre-fabricated device.
Voltage/Current 240VAC / 1A 600VAC / 15A 600VAC / 15A 600VAC / 15A 600VAC / 15A
Pressure Balanced Cable Termination Pressure cycling and the presence of gas do not harm the cable termination. Suitable for
round cables, flat cables, lead-sheathed cables and tube encapsulated MLEs. Verifiable Seal Yes No No No Yes

16 17
 Design Approach
Product reliability is critical in the upstream oil and gas production market. If any part of Forensic Analysis
the production string fails, the well is down and valuable revenue opportunity is lost. BIW We analyze every returned product to root cause.
Connector Systems invests heavily in design and test to ensure our products can withstand the
This information is then fully documented and
extreme, harsh environment of a production well.
uploaded to our Knowledge Database.

Test Chamber #2
19,000 psi
180°F

Test Chamber #3
10,000 psi
600°F Test Chamber #1
6,500 psi
500°F

The BIW Connector Systems Engineering Knowledge

Database systematically captures all test, qualification and
in-service field return data into a single searchable storehouse
of information which informs each new design.

Informed Design
We have experienced oilfield product designers with
the best tools and technology. In addition, we have
Test invested in a significant material science lab and
Environmental testing that closely replicates the created a common electronic Knowledge Database
downhole conditions are essential to prove product that is mined for information from past designs,
reliability. BIW Connector Systems has multiple test engineering tests and forensic analysis.
chambers capable of up to 600ºF/10,000 psi with We apply all this learning to each and every design.
temperature and pressure cycling and electrically
monitors every qualification test to ensure operation
in all conditions.

Every product qualification

is continuously monitored
for electrical performance
throughout the test”

BIW Connector Systems’ reliability and long product lifetimes are realized via a three-fold engineering strategy. The first
is to test exhaustively. The second is to conduct extensive forensic analysis on all field returns to identify root cause.
Finally, we maintain an electronic Knowledge Database of all technical data to practice “Informed Design.”

18 19
 Specialized Application Products

BIW Connector Systems produces many products to support specialized Coiled Tubing Penetrators
requirements in the energy industry. The following are examples of these ESP installation with coiled tubing have specialized requirements. ESP cable is
products: protected inside of the coiled tubing, and production flows either through the
well bore annulus or through a second coiled tube. At the wellhead, the tubing is
suspended in a coiled tubing hanger, and a short length of ESP cable is available
above the hanger. BIW penetrators are supplied with lengths of extra flexible 5KV
Side Entry Feedthru Systems. insulated cable conductors. These conductors are easily terminated to the ESP
Side entry penetrator systems are designed to enter the wellhead on the side cable conductors. Penetrators are installed in the wellhead wall above the hanger.
instead of through the bonnet. This configuration has many advantages,
including shorter work-over times and the ability to easily test an ESP while
a BOP is still in place during work-over. Our side entry systems have three
components – (1) Horizontal Feedthru, which enters through the side of the
wellhead and tubing hanger and engages with (2) the Vertical Feedthru. (3) Cross-overs Adapters and Y-Adapters
A conventional downhole connector is used to connect the Vertical Feedthru Dual ESP completions often require specialized packer feedthru methods. Using a
to the ESP cable. Y-Adapter, an operator can supply power to two ESPs using a convention packer
design, with two packer feedthrus installed using a Y-adapter system.

When there is a need for multiple injection and control lines to the ESP, the design
of a specialized cross-over adapter will allow these lines to pass through the bore
Pothead Connectors and Motor Housing Penetrators.
together with ESP cable.
Large geothermal ESPs and specialized ESPs for gas wells may require
specialized motor lead systems. BIW Connector Systems supplies connectors
for these applications.

Penetration Systems for Cable Deployed ESP and Electro-

thermic Heating.
8KV Power Feedthru Systems. These systems often have unique wellhead designs and special considerations
With ever-longer cable runs and high power motors, BIW meets the need for for delivering power. BIW Connector Systems supplies field installable feedthru
8KV Power Penetrator Systems. systems and penetrators with flexible high voltage power conductors to make
installation easy.

Penetration Systems for Geothermal Wells.

Electric submersible pumps in geothermal wells have many special BIW also makes specialized field attachable connectors and penetrators which
requirements. BIW supplies equipment specifically designed to fit are installed in hardware which attaches the tubing to the ESP at the bottom
geothermal wells. =of the well.

20 21
 Product Index
Quickly find your product by application.

Pressure Voltage Number Cable

Product Application Rating (PSI) Temp Rating /Amperage of Pieces Bores Termination Type Page

Metal-Lok Wellhead Penetrator 5000 psi 300ºF (149ºC) 5000VAC /160A 3 1 Field Attachable 6

Metal-Lok HT Wellhead Penetrator 3000/5000 psi 450ºF (232ºC) 5000VAC /160A 3 1 Field Attachable 6

Metal-Lok Slimline Wellhead Penetrator 5000 psi 300ºF (149ºC) 5000VAC /160A 3 1 Field Attachable 7

EFT Wellhead Penetrator 5000 psi 300ºF (149ºC) 5000VAC /180A 3 1 Field Attachable or Factory Build 8

Metal-Lok Ultra Wellhead Penetrator 3000 psi 500ºF (260ºC) 5000VAC /140A 3 1 Field Attachable 8

Rubber Molded Wellhead Penetrator 5000 psi 300ºF (149ºC) 5000VAC /215A 2 or 3 1 Field Attachable or Factory Molded 9

E-ZEE Feed Wellhead Penetrator 5000 psi 300ºF (149ºC) 5000VAC /160A 2 1 Field Attachable 10

Uni-Lok Wellhead Penetrator 3000 psi 300ºF (149ºC) 5000VAC /140A 2 1 Field Attachable 10

Kwik-Lok Wellhead Penetrator 5000 psi 300ºF (149ºC) 5000VAC /160A 2 1 Factory Molded 11

Safe-T-Lok Wellhead Penetrator 3000 psi 300ºF (149ºC) 5000VAC /140A 1 1 Factory Molded 11

Tri-Lok Wellhead Penetrator 5000 psi 300ºF (149ºC) 5000VAC /160A 2 3 Field Attachable or Factory Molded 12

Rubber Molded Packer Penetrator 5000 psi 300ºF (149ºC) 5000VAC /215A 1, 2, or 3 1 Factory Molded 14
HEZF Packer Penetrator 5000 psi 350ºF (177ºC) 5000VAC /140A 2 1 Field Attachable 14
Tri-Lok Packer Penetrator 5000 psi 300ºF (149ºC) 5000VAC /180A 1 3 Field Attachable 15
Tri-Lok Ultra Packer Penetrator 7500 psi 400ºF (204ºC) 5000VAC /180A 1 3 Field Attachable 15

Presta GS Mechanical Splice 5000 psi 350ºF (177ºC) 5000VAC /160 A 1 N/A Field Attachable 16
Presta Deep Water Mechanical Splice 7500 psi 400ºF (204ºC) 5000VAC /160 A 1 N/A Field Attachable 16
Offshore/Extreme
Service

I-Wire Instrumentation Penetrator 5000 psi 300ºF (149ºC) 600VAC /15A 3 1 Field Attachable 17
Heaters Instrumentation Penetrator 5000 psi 300ºF (149ºC) 5000VAC /250A 3 1 Factory Molded 17

22 23
Connect with your ITT BIW Connector Systems’ representative today
or visit us at www.ittbiw.com

Why ITT
ITT is a focused multi-industrial company that designs and manufactures highly engineered critical components and customized
technology solutions. Our customers in the energy, transportation and industrial markets depend on us to solve their most
critical problems, and we focus on partnering with them to find solutions to their unique challenges. Founded in 1920, ITT is
headquartered in White Plains, NY, with employees in more than 35 countries. For more information, visit www.itt.com.

About BIW Connector Systems

BIW Connector Systems supplies the industry with the widest range of electrical feedthru products, with more than 3,000 available
active part numbers. BIW Connector Systems has set the standard for quality, reliability and ease of installation. BIW Connector
Systems has a strong culture of forward-looking innovation. With a foundation of quality engineering and focus on reliability, BIW
Connector Systems’ legacy of continuous improvement drives the development of its products. These systems help deliver power
to the submersible pumps in wells on frozen tundras, in sun-bleached deserts and at the bottom of oceans, keeping workers and
environments safe and global economies running 24-hours a day. For more information, visit www.ittbiw.com.

BIW Connector Systems Headquarters Sales Offices

500 Tesconi Circle Beirut Jakarta
Santa Rosa, CA 95401 USA Dubai Rome
Phone: +1 707-523-2300 Edmonton Shreveport
Fax: +1 707-523-3567 Houston Singapore
Toll Free US: +1 800-437-2248
[email protected]
www.ittbiw.com

© 2017 ITT Corporation. The “ITT Engineered Blocks” symbol, “Engineered for life,” “ITT” and “BIW Products & Services Brochure 20170407
Connector Systems” are registered trademarks of ITT Corporation. Specification and other data are
based on information available at the time of printing, and are subject to change without notice.