Downhole Wet Connector Testing During ESP Completion Installation
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Solution Overview
Problem
Conventional ESP systems struggle to monitor the condition of the ESP cable and downhole equipment during the installation of permanent completions, particularly in retrievable ESP systems where the retrievable assembly is not installed in the string.
Innovation Solution
The development of methods and equipment for testing ESP cable integrity and monitoring the condition of permanent downhole wet connectors and motors during permanent completion installation, including the use of custom test plug arm assemblies, built-in star-points in permanent downhole wet mate connectors, and fusible links within the permanent downhole connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ESP systems are used without built-in testing capabilities, then the system structure remains simple, but the ability to monitor cable and equipment condition during installation is lost
Solution Approach 1:
The patent combines the testing functionality with the permanent downhole connector by integrating a built-in star-point (common connection point) and fusible links directly into the connector structure. This merging allows the connector to serve dual purposes: electrical connection and continuity testing, eliminating the need for separate testing equipment while ensuring reliable monitoring of cable and equipment condition during installation.
Solution Approach 2:
The patent introduces an intermediary testing mechanism using fusible links and star-points that act as mediators between the cable conductors and the monitoring system. These intermediaries enable indirect testing of cable integrity and equipment condition by providing measurable electrical pathways that reveal system status without requiring direct access to all components.
2Adaptability or versatility
If retrievable assembly is not installed in the string during permanent completion installation, then the installation flexibility is improved, but the ability to test cable integrity and monitor equipment condition is reduced
Solution Approach 1:
The patent implements preliminary testing capabilities by installing the built-in star-point and fusible links into the permanent downhole connector before the retrievable assembly is deployed. This preliminary configuration ensures that cable integrity and equipment condition can be tested and monitored during permanent completion installation, even though the retrievable assembly is not yet in place, thereby maintaining reliability without compromising installation flexibility.
3Ease of manufacture
If manual plug and socket connections are used, then the connector design is simple, but the electrical system cannot be tested during installation
Solution Approach 1:
The patent merges the manual plug and socket connection design with built-in testing features by integrating the star-point and fusible links directly into the connector housing. This combination maintains the simplicity and ease of manufacture of manual connections while adding the capability to test electrical system integrity during installation, thereby achieving both manufacturing simplicity and measurement precision.
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
These solutions enable continuous monitoring of ESP cable conductor continuity, resistance, and insulation integrity, as well as the condition of permanent downhole connectors, during and after the installation of permanent completions, improving the reliability and efficiency of ESP systems.
Implementation Method 1
a fusible link (256) connected between two phases, such that the fusible link provides a common connection point (star-point) for all phases... the fusible link is configured for an amount of current flowing through the permanent downhole connector wire conductor that will melt the fusible link when a motor is operated
Implementation Method 2
Electrical measurements are collected during run in hole (RIH), whenever a pre-determined interval is reached. One or more of a condition of a motor winding, a condition of permanent downhole connector and motor insulation integrity are monitored, through the collected electrical measurement
Data Source
AI summary
Disclosed are methods and devices for testing downhole connector electrical systems and cable integrity during installation of a permanent completion, including a customized retrievable plug arm assembly connectable to the completion during RIH, the tool mimicking a retrievable ESP, but without motor, and can be employed with or without pressure isolation. Another method employs a slidable starpoint located within the downhole wet mate connector of the completion to provide continuous electrical contact between the phases when no retrievable assembly is in place. When a retrievable assembly is later put in place, the slidable starpoint is moved into a second position that no longer provides electrical contact between the phases. Another method uses fusible links installed between two conductors within the downhole electrical connector system of the completion to provide similar electrical contact between phases, the fusible link configured to melt away once motor current is sent through the conductors.