Fiber Optic Wet-Mate Coupling for Reliable Downhole Control Lines
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Solution Overview
Problem
Existing technologies face challenges in establishing dependable and repeatable control line connections, particularly electrical and optical connections, between upper and lower completion assemblies in multi-stage well completions, which are often unreliable and time-consuming.
Innovation Solution
A system utilizing a fiber optic connection and an inductive coupler to establish electrical and optical communication between upper and lower completion assemblies, eliminating the need for unreliable electrical wetmate connectors and allowing for quick deployment and installation of fiber optic sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical wetmate connectors are used to establish control line connections between upper and lower completion assemblies, then electrical signal transmission is enabled, but the connections are unreliable and time-consuming
Solution Approach 1:
The patent replaces mechanical electrical wetmate connectors with a fiber optic connection system combined with an inductive coupler. The fiber optic connector provides a reliable mechanical interface for optical signals, while the inductive coupler establishes electrical connections through electromagnetic induction without direct mechanical contact, eliminating the unreliability and time-consuming nature of traditional electrical wetmate connectors.
Solution Approach 2:
The patent introduces an inductive coupler as an intermediary device that enables electrical signal transmission through electromagnetic fields without requiring direct mechanical contact between connectors. This intermediary approach allows electrical connections to be established rapidly and reliably between the upper and lower completion assemblies while the fiber optic connector handles optical signal transmission.
2Productivity
If traditional electrical wetmate connectors are used for control line connections, then electrical communication is established, but the deployment and installation process becomes complex and time-consuming
Solution Approach 1:
The patent segments the control line connection system into two independent components: a fiber optic connector for optical signals and an inductive coupler for electrical signals. This segmentation allows each component to be optimized independently and simplifies the overall deployment process, as the fiber optic and electrical connections can be established separately without the complexity of integrating multiple electrical contacts in a single wetmate connector.
Solution Approach 2:
The patent replaces the complex mechanical system of electrical wetmate connectors with a simplified system combining fiber optic connectors and inductive coupling. The inductive coupler uses electromagnetic fields to establish electrical connections without mechanical contact, dramatically reducing the complexity of the connection system and enabling faster deployment while maintaining full electrical communication capability.
3Reliability
If fiber optic cables are routed through inductive coupler mandrels, then optical signal transmission is enabled, but the cable management becomes challenging
Solution Approach 1:
The patent implements a nested cable management system where the fiber optic cable is routed through the hollow mandrel of the inductive coupler. The mandrel acts as a protective conduit that guides and protects the fiber optic cable from damage and interference, while the cable can be easily installed and removed through the mandrel's passageway. This nested arrangement simplifies cable management by providing a dedicated, protected pathway for the fiber optic cable within the existing inductive coupler 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
Enables reliable and efficient electrical and optical signal transmission, facilitating rapid connection and disconnection of control lines, including fiber optics, electrical lines, and hydraulic conduits, in multi-stage well completions, particularly in subsea environments.
Implementation Method 1
a first inductive coupler and a second inductive coupler to establish electrical communication
Data Source
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AI summary
Systems and methods for monitoring and control in downhole well applications are provided. The system and methodology may be combined with a variety of completions or other types of well equipment deployed downhole to enable both electrical and fiber optic communication with downhole components. For example, the system enables both electrical and fiber optic communication for operating and monitoring of downhole completion systems or other systems.