Completion Stinger for Wellbore Control Line Connections
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Solution Overview
Problem
Existing multi-stage well completion systems face challenges in forming dependable and repeatable control line connections between upper and lower completion assemblies due to susceptibility to debris and contaminants, unfavorable geometry, and complexity in debris removal and flushing, which limits the integration of control lines and compromises the design and functionality of the completion equipment.
Innovation Solution
The system includes a lower completion stage with a receptacle and a first communication line connector, and an upper completion stage with a stinger and a second communication line connector, featuring alignment and anti-rotation mechanisms, along with displaceable sleeves for debris protection and flushing fluid paths, allowing for efficient alignment and sealing of communication line connectors below a packer, enabling reliable coupling of fiber optic, electrical, and fluid control lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wet-mate connections are made between upper and lower completion assemblies, then communication lines can be transmitted, but debris and contaminants compromise connection reliability
Solution Approach 1:
The system performs preliminary flushing and debris removal actions before the actual connector mating occurs. The stinger extends through the packer to position connectors for engagement, and flushing fluid is directed through the stinger and receptacle area to clean debris away in advance of the connection, ensuring reliable mating despite the wet-mate environment
Solution Approach 2:
The stinger acts as an intermediary component that extends through the packer to bridge the upper and lower completion assemblies. It provides a protected pathway for communication lines and positioning features that enable accurate connector alignment, mediating the connection process between the two completion stages while protecting against debris
2Object-affected harmful factors
If communication line connectors are positioned below the packer, then debris protection is improved, but alignment and connection complexity increases
Solution Approach 1:
The system employs asymmetric positioning where the stinger extends through the packer at a specific angle or position that is not symmetric with respect to the wellbore centerline. This asymmetric configuration allows the connectors to be positioned below the packer in a debris-protected zone while maintaining alignment through the asymmetric geometry of the stinger and receptacle interfaces
Solution Approach 2:
The alignment feature utilizes dimensional relationships by extending the stinger through the packer in the axial dimension, positioning connectors in a different spatial dimension (below the packer) while maintaining connection capability through the extended stinger geometry. This dimensional approach simplifies alignment by using the packer thickness as a positioning reference
3Adaptability or versatility
If multi-stage completion assemblies are connected, then wellbore coverage is improved, but control line integration becomes complex
Solution Approach 1:
The stinger serves multiple functions: it acts as a mechanical connector between completion stages, provides a pathway for communication lines (fiber optic, electrical, hydraulic), enables alignment through its geometry, and extends through the packer to position connectors. This multi-functionality reduces overall system complexity by consolidating multiple requirements into a single component
Solution Approach 2:
The completion system is segmented into modular upper and lower completion assemblies that can be independently deployed and then connected. The stinger and receptacle provide the interface for this segmentation, allowing each module to be optimized independently while maintaining simple integration through standardized connection features
Data Source
AI summary
Systems and methods are provided to facilitate connection of multiple stage completions. A first completion stage is deployed at a wellbore location. Subsequently, the next completion stage is moved downhole into engagement with the first completion stage. The completion stages each have communication lines that are coupled together downhole via movement of the completion stages into engagement.