SMA Dry Mate Connectors for Downhole Sealing Under Tensile Load
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Solution Overview
Problem
Existing connectors in downhole environments face challenges in forming a sealed connection that can withstand tensile loading and maintain integrity under high vibration, compression, and temperature conditions, requiring a solution that simplifies installation and enhances reliability.
Innovation Solution
A dry mate connector system utilizing shape memory alloy (SMA) materials for both sealing and retention, activated via heat to form a secure seal and grip, comprising a ring clamp with internal sealing teeth and retainer rings with internal and external gripping surfaces, integrated into an external housing with coupler ends secured via weldments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connectors are used in downhole environments, then installation time is reduced, but the connection reliability and sealing capability under tensile loading deteriorate
Solution Approach 1:
The patent utilizes shape memory alloy (SMA) materials that change their physical properties (shape, stiffness) in response to temperature changes. The SMA components are activated by heating to transform from an austenite phase (high strength, rigid) to a martensite phase (more flexible), enabling them to expand and form secure seals and grips on the control lines, thereby achieving reliable connections under tensile loading while maintaining installation efficiency
2Strength
If conventional sealing and retention systems are used, then device complexity is reduced, but the ability to withstand tensile loading and maintain seal integrity deteriorates
Solution Approach 1:
The patent integrates multiple functions into the SMA components: the same shape memory alloy elements serve both as sealing mechanisms (forming radial seals against control lines) and as retention systems (gripping and securing the control lines under tensile load). This multi-functionality eliminates the need for separate sealing and retention systems, reducing overall device complexity while enhancing tensile loading capacity
Solution Approach 2:
The connector employs composite construction combining shape memory alloy materials with traditional connector components (housing, coupler ends). The SMA material provides the active sealing and retention functions, while the traditional components provide structural support and housing, creating a hybrid system that achieves high strength under tensile loading without excessive complexity
3Reliability
If simplified connector designs are used, then ease of operation is improved, but the ability to remain sealed under harsh downhole conditions deteriorates
Solution Approach 1:
The SMA components exhibit self-activating behavior where the actuation process is simplified: the connector is installed in the martensite phase (flexible state), allowing easy placement over the control lines, and then automatically transforms to the austenite phase (expanded state) upon heating, self-sealing and self-gripping without requiring additional manual operations. This maintains seal integrity under harsh conditions while preserving installation simplicity
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
The SMA-based connector system provides a rapid and reliable sealed connection capable of withstanding substantial tensile loading, reducing installation time from 4-6 hours to 1.5-2 hours, enhancing rig efficiency and reducing costs while maintaining integrity under harsh conditions.
Implementation Method 1
the sealing system and the retainer system each being formed at least in part of a shape memory alloy material selectively activatable to seal against and grip the pair of hydraulic control line sections
Implementation Method 2
The shape memory alloy material can be a metal alloy material that is activatable via application of heat
Data Source
AI summary
A technique facilitates formation of secure connections for use in downhole environments. According to an embodiment, a connector may be constructed as a dry mate connector which provides both a sealed connection and a connection able to withstand a predetermined tensile loading. The connector can include a shape memory alloy sealing system which may be activated to form a secure seal with a corresponding cable or other component feature.