Coated Electrical Connector Bands for Downhole Disconnect Tools
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Solution Overview
Problem
Conventional Electro-Hydraulic Disconnect Tools (EHDTs) face issues with pressure compensation, where PEEK materials crack due to low strength, leading to electrical shorts, and O-ring seals can deform, causing sealability loss, increasing complexity and cost.
Innovation Solution
The use of metallic connector bands with electrically insulating coatings eliminates the need for pressure compensation assemblies by providing sufficient strength and corrosion resistance, ensuring reliable electrical insulation and seal integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PEEK materials are used for connector bands, then electrical insulation is provided, but the low strength causes cracking and tool failure under pressure
Solution Approach 1:
The connector band is constructed as a composite structure with a metallic core (Stainless Steel or alloy steel) providing mechanical strength and pressure resistance, overlaid with an electrically insulating coating material (such as polymeric coating, ceramic coating, or composite coating) that provides electrical insulation. This composite design combines the advantages of both materials to eliminate the weaknesses of using PEEK alone.
2Reliability
If O-ring seals are added to prevent PEEK part separation, then sealability is improved, but the O-rings can take compression set and lose sealability
Solution Approach 1:
The patent eliminates the need for O-ring seals by removing the glued assembly structure entirely. The connector band is manufactured as a single integrated piece where the metallic core and insulating coating are bonded through metallurgical or chemical bonding processes, eliminating separate components that would require sealing.
Solution Approach 2:
The insulating coating acts as an intermediary layer that not only provides electrical insulation but also serves as the bonding interface between the metallic core and any external components, eliminating the need for separate glue and O-ring sealing systems.
3Ease of manufacture
If glued assembly is used for PEEK parts, then manufacturing is simplified, but the glue fails under heat and pressure causing part separation
Solution Approach 1:
The connector band is manufactured as a composite structure where the metallic core and insulating coating are bonded through metallurgical or chemical bonding processes during coating application, creating a permanent bond that withstands downhole heat and pressure conditions without degrading.
4Reliability
If pressure compensation assemblies are added to prevent PEEK cracking, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The connector band is constructed as a composite structure with a metallic core providing inherent pressure resistance and strength, eliminating the need for external pressure compensation assemblies. The metallic material naturally withstands downhole pressure conditions without requiring additional compensating mechanisms.
Solution Approach 2:
The patent removes the pressure compensation assembly from the system by using a metallic connector band that inherently resists pressure without requiring separate compensation mechanisms, thereby simplifying the overall device structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces the complexity, cost, and lead time of EHDTs, enhancing reliability and market share by eliminating the need for additional pressure compensation systems and maintaining electrical connectivity and seal integrity in harsh wellbore environments.
Implementation Method 1
a metallic receptacle connector band having a first coated section overlaid with electrically insulating material
Implementation Method 2
metallic connector bands with electrically insulating coatings eliminates the need for pressure compensation assemblies by providing sufficient strength and corrosion resistance
Data Source
AI summary
Electrically insulated connector bands for Downhole Electrical Disconnect Tools provide power and/or data communication downhole are made from metal having sufficient strength and corrosion resistance to eliminate the need of any vacuum and sealed pressure compensation assembly while being exposed to wellbore fluids. The electrical insulation is achieved by having portions of the connector bands coated with electrically insulating material. An uncoated section of each connector band will provide the electrical path between the male and female mandrels.