Concentric Disconnect Tool with Segmented Conductive Bands
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Solution Overview
Problem
Conventional disconnect tools in wellbore strings typically allow only one electrical line to be bypassed, limiting the ability to connect multiple control systems to downhole devices, which is inadequate for complex well operations.
Innovation Solution
A disconnect tool with a male connector band having multiple electrically conductive sections and a female connector band, both with insulating materials, allowing for multiple hydraulic and electrical connections to be established and broken, enabling the removal and reinsertion of upper production string portions while maintaining connections to downhole devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional disconnect tools with single electrical line are used, then the structure is simple, but the ability to connect multiple control systems to downhole devices is limited
Solution Approach 1:
The connector band is segmented into multiple electrically conductive sections separated by insulating material. Each conductive section can independently connect to corresponding downhole devices, enabling multiple control systems to be connected simultaneously while maintaining a relatively simple overall connector structure
Solution Approach 2:
The disconnect tool is designed with universal multi-functionality by incorporating multiple electrically conductive sections that can connect to different downhole devices (such as packers, valves, and sensors) simultaneously. This allows a single disconnect tool to serve multiple control and monitoring functions rather than requiring separate tools for each function
2Adaptability or versatility
If multiple electrical conductors are added to disconnect tool, then the control capability to downhole devices is enhanced, but the manufacturing complexity increases
Solution Approach 1:
The manufacturing process is simplified through segmentation by dividing the connector band into modular conductive sections separated by insulating material. Each section can be manufactured and positioned independently, making the assembly process more manageable despite the increased number of conductors
Solution Approach 2:
Multiple electrical conductors and hydraulic conduits are merged into a single integrated disconnect tool assembly. The conductive sections are combined with the mechanical disconnect mechanism and hydraulic sealing elements into one unified device, reducing the number of separate components that need to be manufactured and assembled
3Ease of repair
If upper production string portion is removed and reinserted, then maintenance and replacement operations are enabled, but the electrical connections may be disrupted
Solution Approach 1:
The electrical conductors are pre-configured within the disconnect tool assembly with connection points that remain active during the disconnect and reconnect operations. The conductive sections are positioned and insulated in advance so that when the upper production string portion is removed and reinserted, the electrical connections are automatically re-established without disruption to the downhole device signals or power supply
Data Source
AI summary
A disconnect tool can be part of a production string in a wellbore. The disconnect tool can include a disconnect sub and a disconnect receptacle. The disconnect sub can be inserted into the disconnect receptacle such that the disconnect sub is concentric with the disconnect receptacle. The disconnect sub and the disconnect receptacle can include bands having multiple electrically conductive sections separated by an electrically insulating material. Insertion of the disconnect sub into the disconnect receptacle cause the electrically conductive sections of the disconnect sub to contact the electrically conductive sections of the disconnect receptacle, thereby completing multiple electrical connections between a control system uphole of the disconnect tool and one or more devices downhole from the disconnect tool along the lower portion of the production string. The disconnect tool allows the upper portion of the production string to be removed leaving devices in the lower production string undisturbed.