Inductive coupler connector

Abstract

An inductive coupler connection for an electrical downhole tool, which can be made up offline. A male inductive coupler can be coupled to a permanent downhole cable, and a female inductive coupler can be coupled to the electrical downhole tool. The couplers are pre-installed on the cable and tool offline, thereby improving deployment efficiency.

Description

IS24.1941INDUCTIVE COUPLER CONNECTORCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57. The present application claims priority benefit of U.S. Provisional Application No. 63 / 729,707, filed December 9, 2024, the entirety of which is incorporated by reference herein and should be considered part of this specification.BACKGROUNDField

[0002] The present disclosure generally relates to downhole electrical completions, and more particularly to inductive couplers and inductive coupler connectors.Description of the Related Art

[0003] For downhole electrical completions tools, a permanent cable is used to power the tool(s) and provide communication between the downhole tool(s) and surface unit. The downhole electrical tool connects to the permanent cable through a connector.SUMMARY

[0004] In some configurations, a downhole assembly includes a first inductive coupler component coupled to a permanent downhole cable and a second inductive coupler component coupled to an electrical downhole tool. During deployment, the first inductive coupler component contactlessly couples with the second inductive coupler component. The first inductive coupler component can be a male component, and the second inductive coupler component can be a female component. The first inductive coupler component can be directly coupled to the permanent downhole cable. The first inductive coupler component can be coupled, e.g., directly coupled, to the permanent downhole cable offline. The second inductive coupler component can be coupled to the electrical downhole tool offline.

[0005] In some configurations, a Y-block assembly includes a Y-block, a first segment of a permanent downhole cable connected to the Y-block (e g., an uphole end of the Y-block), a second segment of the permanent downhole cable connected to the Y-block (e.g., a downhole endof the Y-block), and a first inductive coupler component connected to the Y-block (e.g., the downhole end of the Y-block). The first inductive coupler component is configured to couple (contactlessly couple) to a second inductive coupler component coupled to a downhole electrical tool during deployment.

[0006] In some configurations, a well completion architecture includes a plurality of Y- block assemblies and a plurality of downhole electrical tools. Each downhole tool has a second (e.g., female) inductive coupler component coupled thereto. During deployment, the first (e.g., male) inductive coupler component of each of the plurality of Y-block assemblies contactlessly couples with a corresponding second (e.g., female) inductive coupler component of one of the plurality of downhole electrical tools.

[0007] In some configurations, a method includes coupling a first inductive coupler component to a permanent downhole cable, coupling a second inductive coupler component to an electrical downhole tool offline, contactlessly coupling the first inductive coupler component to the second inductive coupler component online, and deploying the permanent downhole cable and electrical downhole tool in a borehole.

[0008] Coupling the first inductive coupler component to the permanent downhole cable can mean coupling the first inductive coupler directly to the permanent downhole cable offline. In some configurations, the first inductive coupler component is coupled to the permanent downhole cable via a Y-block. The first inductive coupler component can be a first male inductive coupler component, and the second inductive coupler component can be a first female inductive coupler component. The method can further include coupling a plurality of male inductive coupler components along the permanent downhole cable, coupling a female inductive coupler component to each of a plurality of electrical downhole tools, and contactlessly coupling each of the plurality of male inductive coupler components to a corresponding female inductive coupler component of one of the plurality of electrical downhole tools. In some configurations, the method further includes retrieving the electrical downhole tool (or one or more of the plurality of electrical downhole tools) via well intervention.

[0009] In some configurations, a downhole assembly includes a first inductive coupler component coupled to an electrical downhole tool and a second inductive coupler component coupled to or integrated into a side pocket mandrel, wherein during deployment, the first inductive coupler component contactlessly couples with the second inductive coupler component. The firstinductive coupler component can be a male component, and the second inductive coupler component can be a female component. The tool can be retrievable and / or replaceable via well intervention.BRIEF DESCRIPTION OF THE FIGURES

[0010] Certain embodiments, features, aspects, and advantages of the disclosure will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It should be understood that the accompanying figures illustrate the various implementations described herein and are not meant to limit the scope of various technologies described herein.

[0011] Figure 1 schematically shows an example wetmate connection according to the present disclosure.

[0012] Figure 2 schematically shows a well completion architecture including multiple wetmate connections as shown in Figure 1.

[0013] Figure 3 schematically shows a Y-block arrangement.DETAILED DESCRIPTION

[0014] In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the disclosure. These are, of course, merely examples and are not intended to be limiting. However, it will be understood by those of ordinary skill in the art that the system and / or methodology may be practiced without these details and that numerous variations or modifications from the described embodiments are possible. This description is not to be taken in a limiting sense, but rather made merely for the purpose of describing general principles of the implementations. The scope of the described implementations should be ascertained with reference to the issued claims.

[0015] As used herein, the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via one or more elements”; and the term “set” is used to mean “one element” or “more than oneelement”. Further, the terms “couple”, “coupling”, “coupled”, “coupled together”, and “coupled with” are used to mean “directly coupled together” or “coupled together via one or more elements”. As used herein, the terms "up" and "down"; "upper" and "lower"; "top" and "bottom"; and other like terms indicating relative positions to a given point or element are utilized to more clearly describe some elements. Commonly, these terms relate to a reference point at the surface from which drilling operations are initiated as being the top point and the total depth being the lowest point, wherein the well (e.g., wellbore, borehole) is vertical, horizontal or slanted relative to the surface.

[0016] In addition, as used herein, the terms “real time”, “real-time”, or “substantially real time” may be used interchangeably and are intended to described operations (e.g., computing operations) that are performed without any human-perceivable interruption between operations. For example, as used herein, data relating to the systems described herein may be collected, transmitted, and / or used in control computations in “substantially real time” such that data readings, data transfers, and / or data processing steps occur once every second, once every 0.1 second, once every 0.01 second, or even more frequent, during operations of the systems (e.g., while the systems are operating). In addition, as used herein, the terms “automatic” and “automated” are intended to describe operations that are performed are caused to be performed, for example, by a control system (i.e., solely by the control system, without human intervention).

[0017] Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and / or within less than 0.01% of the stated amount. As another example, in certain embodiments, the terms “generally parallel” and “substantially parallel” or “generally perpendicular” and “substantially perpendicular” refer to a value, amount, or characteristic that departs from exactly parallel or perpendicular, respectively, by less than or equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, or 0.1 degree.

[0018] For downhole electrical completions tools, a permanent cable (permanent downhole cable or PDC) is used to power the tool(s) and / or provide communication between the downhole tool(s) and surface unit. The downhole electrical tool connects to the permanent cablethrough a connector. Traditional connectors, such as dry mate electrical connectors, typically provide metal to metal sealing to guarantee electrical integrity and the reliability of the electrical system. The connector has to be made up online, which reduces the electrical system deployment efficiency.

[0019] The present disclosure generally relates to well systems and methodology involving wellbore operations and equipment. For example, the systems and methodology may be used to facilitate deployment and / or intervention operations in many types of wells including horizontal, multi-zone wells. The present disclosure provides a contactless connector, components of which can be made up offline. Inductive couplers provide a wet mate electrical downhole connection. The connector includes a male connector or coupler and a female connector or coupler, which can be connected and / or disconnected in downhole conditions.

[0020] In some configurations according to the present disclosure, for example as shown in Figure 1, a first coupler or connector 100 of an inductive coupler or mini inductive coupler pair is coupled to (e.g., coupled directly to) a permanent downhole cable 150, and a second corresponding coupler or connector 200 is coupled (e.g., welded) to an electrical downhole tool 250. In the illustrated configuration, the first coupler or connector 100 is a male coupler or connector, and the second coupler or connector 200 is a female connector or coupler. The electrical downhole tool 250 can be, for example, an electric flow control valve (or interval control valve, FCV, ICV), an electric ICD (inflow control device), a sensor, a gauge, or any other appropriate and desired electrical downhole tool.

[0021] Typically, a PDC 150 is coupled to an electrical downhole tool 250 online (e.g., on the rig) via a dry mate connection. In contrast, in systems and methods of the present disclosure, the first (e.g., male) component 100 can be coupled to or made on the cable 150 offline, for example, during manufacturing or assembly. The second (e.g., female) component 200 can be integrated with or coupled to the downhole tool 250 offline, for example, during manufacturing or assembly. During deployment or run-in-hole, the first (e.g., male) component 100 can couple to, e.g., sting into, the second (e.g., female) component 200. The inductive coupler pair therefore allows for transmission of power and / or telemetry to / from the downhole tool(s) 250 and the surface via the PDC.

[0022] Systems and methods of the present disclosure therefore advantageously reduce or eliminate connector make-up time on the rig and allow for more efficient deployment. Further, asthe coupler forms a contactless connection, and electrical integrity is achieved by induction, a pressure test is not required for the connection. Additionally, coupling the downhole tool(s) 250 to the PDC 150 via a contactless connection such as inductive coupler, as opposed to the traditional dry mate connection, can advantageously allow the downhole tool(s) 250 to be retrievable (e.g., via well intervention, such as wireline and / or kickover tool), for example, for repair or replacement.

[0023] In some configurations, a well completion architecture may include multiple electrical downhole tools 250, for example as shown in Figure 2. As shown, a second (e.g., female) coupler component 200 can be integrated with or coupled to (e.g., offline) each tool 250. Multiple first (e.g., male) coupler components 100 are coupled to or made on the cable 150 (e.g., offline), for example at different positions, lengths, or depths along the cable 150, with each of the first coupler components 100 corresponding to and configured to be coupled to a respective second coupler component 200 during deployment.

[0024] In some configurations, an architecture including multiple electrical downhole tools 250 can include one or more Y-blocks 300. As shown in Figure 3, the PDC 150 can be connected to the top or uphole end of the Y-block 300 at point A. The PDC 150 continuing downhole can be connected to the bottom or downhole end of the Y-block 300 at point B. One of the downhole tools 250 can be connected to the bottom or downhole end of the Y-block 300 at point C. Each of the connections A, B, and C can be dry mate connections in some configurations, with connection C and possibly connection A being able to be made up offline. Alternatively, to reduce the dry mate connections and improve efficiency of deployment, a first (e.g., male) inductive coupler component 100 can be coupled to the Y-block 300 at connection C. This enables multiple first (e.g., male) coupler components 100 to be coupled to or made on the cable 150, as shown in Figure 2.

[0025] In some configurations, the second (e.g., female) coupler 200 is coupled to or integrated into a side pocket mandrel, and the first (e.g., male) coupler 100 is integrated with or coupled to a downhole electrical tool, which can be installed in the side pocket. Such a configuration allows the electrical tool to be retrievable and / or replaceable via well intervention.

[0026] Although a few embodiments of the disclosure have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, suchmodifications are intended to be included within the scope of this disclosure as defined in the claims. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments described may be made and still fall within the scope of the disclosure. It should be understood that various features and aspects of the disclosed embodiments can be combined with, or substituted for, one another in order to form varying modes of the embodiments of the disclosure. Thus, it is intended that the scope of the disclosure herein should not be limited by the particular embodiments described above.

Claims

CLAIMSWhat is claimed is:

1. A downhole assembly comprising: a first inductive coupler component coupled to a permanent downhole cable; and a second inductive coupler component coupled to an electrical downhole tool, wherein during deployment, the first inductive coupler component contactlessly couples with the second inductive coupler component.

2. The assembly of Claim 1, wherein the first inductive coupler component is a male component, and the second inductive coupler component is a female component.

3. The assembly of Claim 1, wherein the first inductive coupler component is directly coupled to the permanent downhole cable.

4. The assembly of Claim 1, wherein the first inductive coupler is coupled to the permanent downhole cable offline and the second inductive coupler component is coupled to the electrical downhole tool offline.

5. A Y-block assembly comprising: a Y-block; a first segment of a permanent downhole cable connected to an uphole end of the Y-block; a second segment of the permanent downhole cable connected to a downhole end of the Y-block; and a first inductive coupler component connected to the downhole end of the Y-block; the first inductive coupler configured to couple to a second inductive coupler component coupled to a downhole electrical tool during deployment.

6. A well completion architecture, comprising: a plurality of Y-block assemblies of Claim 5; and a plurality of downhole electrical tools, each comprising a second inductive coupler component; wherein during deployment, the first inductive coupler component of each of the plurality of Y-block assemblies contactlessly couples with a respective second inductive coupler component of one of the plurality of downhole electrical tools.

7. A method comprising:coupling a first inductive coupler component to a permanent downhole cable; coupling a second inductive coupler component to an electrical downhole tool offline; contactlessly coupling the first inductive coupler component to the second inductive coupler component online; and deploying the permanent downhole cable and electrical downhole tool in a borehole.

8. The method of Claim 7, wherein coupling the first inductive coupler component to the permanent downhole cable comprises coupling the first inductive coupler directly to the permanent downhole cable offline.

9. The method of Claim 7, wherein the first inductive coupler component is coupled to the permanent downhole cable via a Y-block.

10. The method of Claim 7, wherein the first inductive coupler component is a first male inductive coupler component, and the second inductive coupler component is a first female inductive coupler component.

11. The method of Claim 10, further comprising coupling a plurality male inductive coupler components along the permanent downhole cable, coupling a female inductive coupler component to each of a plurality of electrical downhole tools, and contactlessly coupling each of the plurality of male inductive coupler components to a corresponding female inductive coupler component of one of the plurality of electrical downhole tools.

12. The method of Claim 7, further comprising retrieving the electrical downhole tool via well intervention.

13. A downhole assembly comprising: a first inductive coupler component coupled to an electrical downhole tool; and a second inductive coupler component coupled to or integrated into a side pocket mandrel, wherein during deployment, the first inductive coupler component contactlessly couples with the second inductive coupler component.

14. The assembly of Claim 13, wherein the first inductive coupler component is a male component, and the second inductive coupler component is a female component.

15. The assembly of Claim 13, wherein the electrical tool is configured to be retrieved and / or replaced via well intervention.

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