Downhole Wet-Mate Connector for Electrically Powered Wellbore Valves
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Solution Overview
Problem
Current wellbore operations face challenges in supplying power to electrical safety valves and insert valves due to mechanical incompatibilities and harsh wellbore conditions, leading to complex maintenance requirements and potential hazards from hydraulic systems.
Innovation Solution
A wet mate connection system using insulated male and female connectors with latching profiles to facilitate electrical power transmission to downhole tools, including pressure compensation and insulation to withstand wellbore conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic systems are used to control downhole valves, then valve operation is achieved, but maintenance complexity increases and safety hazards arise from fluid leaks
Solution Approach 1:
The patent replaces hydraulic control systems with electrically actuated valves. The downhole safety valve and insert valve are controlled through electrical signals transmitted via the wet mate connection system, eliminating hydraulic fluid reservoirs, pumps, and control lines. This substitution reduces maintenance complexity by removing hydraulic system components that require fluid management while maintaining reliable valve operation through electrical actuation mechanisms.
Solution Approach 2:
The patent eliminates the need for hydraulic systems by using electrical power transmission through the wet mate connection. Instead of relying on hydraulic fluid to operate valves downhole, the system uses electrical conductors within the connector assembly to deliver power and control signals directly to the valve actuators, thereby eliminating hazards associated with hydraulic fluid leaks and reducing maintenance requirements.
2Speed
If electrical valves are used in harsh wellbore conditions, then response time improves, but power supply difficulty increases due to mechanical incompatibilities
Solution Approach 1:
The wet mate connection system serves multiple functions simultaneously: it provides mechanical coupling between surface equipment and downhole tools, transmits electrical power to the electrical valves, and enables control signal communication. This multi-functional connector design eliminates the need for separate hydraulic lines and electrical conduits, simplifying the overall power supply system while enabling fast-responding electrical valves to operate in harsh wellbore conditions.
Solution Approach 2:
The wet mate connector acts as an intermediary component that bridges the surface power source and the downhole electrical valves. It contains integrated electrical conductors and sealing elements that facilitate reliable power transmission through the wellbore environment, solving the mechanical incompatibility problem by providing a standardized interface that accommodates both power delivery and environmental protection requirements.
3Ease of repair
If wet mate connectors are used to transmit power downhole, then ease of replacement improves, but connection reliability must be maintained under pressure differentials
Solution Approach 1:
The wet mate connector incorporates a dynamic sealing mechanism that automatically adjusts to pressure differentials between the wellbore environment and the connector interior. The sealing elements are designed to deform and conform to the mating surfaces under varying pressure conditions, ensuring reliable electrical and mechanical connections. This dynamic adaptation allows the connector to be easily assembled and disconnected while maintaining connection integrity during operation, facilitating tool replacement without compromising reliability.
Data Source
AI summary
A wet mate connection system can be provided for suppling power to a wellbore tool. For example, the wet mate connection system can be positioned downhole in the wellbore. The wet mate connection system can further be electrically coupled with a valve. The wet mate connection system can include a first wet mate connector and a second wet mate connector. The second wet mate connector can be coupled with the first wet mate connector and with the valve. Additionally, the wet mate connection system can include one or more electrical contacts between the first wet mate connector and the second wet mate connector.