Annular Wet Connector for Downhole Signal Isolation Under Pressure
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Solution Overview
Problem
Existing downhole tool connections face challenges in providing reliable electrical and fluid communication within space-limited wellhead environments, where traditional electrical connections can be compromised by fluid pressure and lack precise orientation, leading to potential short circuits and inefficient signal transmission.
Innovation Solution
The development of an annular electrical wet connector that combines signal leads into a bus system, featuring curved radial surfaces and insulating tabs to prevent electrical isolation between adjacent components, ensuring secure and isolated signal transmission across the tool string while allowing for fluid circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connections are used between adjacent tools, then the connection structure is simple, but the reliability deteriorates due to fluid pressure compromising electrical connections and potential short circuits
Solution Approach 1:
The connector is divided into separate plug and socket assemblies, each with distinct electrical contact elements. The plug assembly contains male electrical contacts while the socket assembly contains female electrical contacts, allowing independent design and optimization of each component's electrical connection features.
Solution Approach 2:
An insulator ring is introduced as an intermediary element between adjacent electrical contacts. This insulator ring prevents fluid from compromising electrical connections by providing electrical isolation and physical protection, thereby improving reliability without requiring complex sealing mechanisms around each contact point.
2Manufacturing precision
If electrical connections are made between adjacent tools in space-limited wellhead environments, then the connection can be formed, but precise orientation becomes difficult leading to misalignment and potential short circuits
Solution Approach 1:
The plug and socket assemblies incorporate asymmetric alignment features including alignment pins and corresponding alignment holes. These asymmetric features guide the tools into proper orientation during assembly, ensuring precise alignment of electrical contacts without requiring complex alignment procedures.
Solution Approach 2:
The alignment features are pre-configured on the tool ends before assembly. The alignment pins and holes are positioned in advance to automatically guide the tools into correct orientation when brought together, eliminating the need for precise manual alignment during the connection process.
3Reliability
If multiple signal leads are provided for communication across tools, then signal communication avenues are established, but the risk of short circuits and electrical isolation increases
Solution Approach 1:
An insulator ring is positioned between adjacent electrical contacts to act as an intermediary barrier. This insulator ring prevents fluid from causing short circuits between multiple signal leads while allowing each lead to maintain its electrical connection, thereby enabling reliable multi-signal communication without increasing short circuit risk.
4Reliability
If traditional electrical connections are used, then the connector design is straightforward, but fluid pressure can compromise the electrical connections leading to potential short circuits
Solution Approach 1:
The insulator ring serves as a protective intermediary element that shields electrical contacts from fluid pressure. By positioning the insulator ring between electrical contacts and the external fluid environment, it prevents fluid from compromising electrical connections without requiring complex pressure sealing mechanisms around each contact point.
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A connector assembly attaches downhole tools to one another to form a tool string. The connector assembly includes male and female subs, each with latch ends that selectively latch to one another. Ends of the subs distal from their latch ends are configured for attachment to the downhole tools. A plug assembly is in one of the subs and a socket assembly is disposed in the other sub; the plug and socket assemblies mate with one another when the subs attach. Mating the plug and socket assemblies forms a signal communication path through the connector assembly so that adjacent tools are in signal communication. The plug and socket assemblies and male and female subs are annular and circumscribe a bore that extends axially through the connector assembly. Downhole tools that attach to opposing ends of the connector assembly are in communication through the bore in the connector assembly.