Two-Stage In-Well Wet-Mate Connection for Connector Protection

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Solution Overview

Problem

The installation of completion systems with electronic components in boreholes requires two trips due to the inefficiency of Blow Out Preventers (BOP) when collars, clamps, and flatpacks are present, leading to potential hazards and risks of damaging delicate connectors during wet-mate connections.

Innovation Solution

A wet-mate connection system with actuators controlled by a wireless electronic controller that allows for precise and remote mating and unmating of connectors, separating mechanical and sealing processes to minimize damage and vibration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a wet-mate connection is used to install the upper portion of the completion system, then the cable can connect to electronic components and provide power and control, but high forces and vibrations during landing can damage the delicate electric and fiber optic connectors

Engineering Contradiction:

Improvecable connection capabilityVSAvoidconnector damage from vibration and force

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The connection system is divided into two separate stages: a mechanical connection stage that handles high forces and vibrations, and an electrical/fiber optic connection stage that occurs after the mechanical connection is established. This segmentation allows the delicate connectors to be protected from the harmful forces during the initial landing phase.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mechanical connection is established first as a preliminary action before the delicate electric and fiber optic connectors are engaged. This preliminary mechanical connection provides a stable base that protects the subsequent electrical connections from vibration and force damage.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the upper portion of the completion system is pulled and reset to refresh the mating of connectors, then electrical contact can be maintained, but this requires physical manipulation that increases the risk of connector damage

Engineering Contradiction:

Improveelectrical contact continuityVSAvoidconnector damage from physical manipulation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical approach of pulling and resetting the upper portion with a controlled mechanical actuator that can refresh the connector mating without requiring physical manipulation of the entire completion system. The actuator provides precise, localized movement that maintains electrical contact without the harmful forces of full system manipulation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses its own actuator mechanism to refresh the connector mating, eliminating the need for external physical manipulation. The actuator serves the system's own need to maintain electrical contact by providing controlled movement of the connectors.

Inventive Principle:

Principle #25Self-service

3Reliability

If vibration is induced in the wet-mate connection to keep electrical contact fresh, then electrical connectors can be maintained, but this is not acceptable for fiber optic connectors

Engineering Contradiction:

Improveelectrical contact freshnessVSAvoidfiber optic connector damage from vibration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The system provides dynamic control over the connector mating process through the actuator, allowing independent control of electrical and fiber optic connectors. The actuator can provide controlled movement to electrical connectors to maintain contact without applying vibration to fiber optic connectors, enabling different treatment modes for different connector types.

Inventive Principle:

Principle #15Dynamics

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 safe and precise connection of electronic components in a single trip, reducing the risk of connector damage and ensuring continuous operation by eliminating the need for physical manipulation during the mating process.

Implementation Method 1

The actuator can be disposed on the second connection assembly and can be configured to move the at least one second connector at least from the retracted condition to the extended condition

Methodology Applied

Scientific EffectMechanical actuation: Mechanical Force

Data Source

PatentUS20250207465A1Two-Stage In-Well Wet Mate Connection

Publication Date: 2025.06.26 WEATHERFORD TECHNOLOGY HOLDINGS LLC

AI summary

A wet-mate connection is used in a well and comprises first and second connection assemblies and an actuator. The first connection assembly includes at least one first connector for at least one first control line. The second connection assembly is configured to connect with the first connection assembly and includes at least one second connector for at least one second control line. The second connector is movable on the second connection assembly between a retracted condition and an extended condition. In the extended condition, the second connector can mate with the first connector to communicate the first and second control lines with one another. The actuator is disposed on the second connection assembly and is configured to move the second connector at least from the retracted condition to the extended condition.