Conformal Soft-Shell Electrical Connection for Corrosive Downhole Wells
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Solution Overview
Problem
Establishing a strong electrical connection in hydrocarbon wells with complex geometries and corrosive environments is challenging due to electrical losses and navigation issues, particularly in deep wells and high hydrogen sulfide environments.
Innovation Solution
A conformal multilayer soft shell apparatus with an innermost conductive layer and multiple outer layers, which allows for a stable electrical connection through a stabbing mechanism that minimizes mechanical wear and electrical losses, using materials like self-healing polymers and conductive materials resistant to corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional metal-to-metal electrical connections are used in downhole environments, then electrical connection can be established, but electrical losses occur due to corrosion and complicated well geometries
Solution Approach 1:
The patent introduces a soft shell matrix as an intermediary material between the conductor and the wellbore environment. This soft shell acts as a protective mediator that prevents direct contact between corrosive wellbore fluids and the electrical conductor, thereby reducing electrical losses while maintaining connection integrity through the conformal multilayer structure.
Solution Approach 2:
The patent employs a conformal multilayer soft shell matrix composed of multiple materials with different properties. This composite structure combines the electrical conductivity of the inner layer with the protective and conformal properties of outer layers, creating a material system that simultaneously enables electrical connection and resists corrosion from wellbore fluids.
2Adaptability or versatility
If rigid electrical connection structures are used, then connection strength can be maintained, but adaptability to complicated well geometries is reduced
Solution Approach 1:
The patent utilizes a soft shell matrix that is both flexible and conformal, allowing it to adapt to complicated well geometries while maintaining electrical connection strength. The soft shell can deform to match the contours of the wellbore and surrounding structures, providing versatility without sacrificing connection integrity.
Solution Approach 2:
The soft shell matrix provides dynamic adaptability to the wellbore environment, allowing the electrical connection structure to change its shape and configuration in response to the specific geometry of the well. This dynamic property enables the system to maintain optimal electrical connection across varying well conditions.
3Reliability
If metal connectors are used for electrical connection, then electrical conductivity is achieved, but mechanical wear and corrosion occur
Solution Approach 1:
The soft shell matrix serves as a protective intermediary layer between the metal connector and the corrosive wellbore environment. This intermediary structure prevents direct exposure of the metal connector to corrosive fluids, thereby reducing corrosion and extending connection durability while allowing electrical conductivity to be maintained through the inner conductive layer.
4Ease of operation
If conventional electrical connection methods are used, then connection can be established, but sensitivity to tool orientation and bore centralization increases
Solution Approach 1:
The conformal multilayer soft shell matrix is designed with asymmetric properties that allow it to adapt to different orientations and positions within the wellbore. The soft, conformal nature of the matrix enables it to maintain electrical connection regardless of tool orientation or bore centralization, providing ease of operation without requiring precise alignment.
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 solution provides a reliable high-voltage electrical connection that maintains integrity in harsh well environments, reducing electrical losses and mechanical wear, and is suitable for deep wells and high hydrogen sulfide conditions.
Implementation Method 1
The conformal multilayer soft shell apparatus includes at least an innermost layer which includes an electrically conductive material or materials
Implementation Method 2
using a soft shell matrix that prevents mechanical wear and optimizes electrical conductivity
Data Source
AI summary
Embodiments disclosed herein relate to a conformal multilayer soft shell apparatus and a system to make a downhole connection between an electric power supply, a conformal multilayer soft shell apparatus, and a downhole system requiring power. The conformal multilayer soft shell apparatus may include an innermost layer with one or more electrically conductive materials, a number of middle layers, and a protective outermost layer.