Nested Well Completion Pipe for Fluid-Isolated Conductive Paths

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Solution Overview

Problem

Existing well completion pipes with insulated electrical conductors are not suitable for long-term fluid flow and elevated temperatures, leading to potential failure and unsuitability for hydraulic or pneumatic control lines.

Innovation Solution

A well completion pipe design featuring a pressure isolated conductive path with insulated electrical conductors or hydraulic/pneumatic control lines, using a nested structure with inner and outer pipes and an intermediate layer, forming metal-to-metal seals and insulated electrical contacts to maintain isolation from well fluids.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If an insulated electrical conductor is inserted into the pipe with industry standard drill pipe sections, then electrical power and signal communication channels are provided during drilling, but the pipe structure is not suitable for long-term fluid flow and elevated temperatures in well completion

Engineering Contradiction:

Improveelectrical power and signal communicationVSAvoidresistance to long-term fluid exposure and elevated temperatures

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The pipe structure is divided into separate functional components: an outer pipe for structural integrity and fluid containment, and an inner pipe for housing the electrical conductor. This segmentation allows each component to be optimized for its specific function while maintaining overall reliability in harsh well completion environments.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The inner pipe containing the electrical conductor is nested within the outer pipe, creating a protected conductive path. This nested structure isolates the electrical conductor from direct exposure to well fluids and temperatures, while the outer pipe provides structural support and environmental protection.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Strength

If the electrical conductor is radially expanded and bonded to the insulation layer, then the conductor is secured during drilling operations, but the structure may fail under prolonged exposure to well fluids and heat

Engineering Contradiction:

Improveconductor bonding strengthVSAvoidlong-term durability in fluid and temperature exposure

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

An intermediate layer is introduced between the inner pipe and outer pipe to provide chemical and thermal resistance. This intermediary layer protects the bonded electrical conductor assembly from direct contact with aggressive well fluids and extreme temperatures, preventing degradation over time.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The pipe structure utilizes composite material construction with the outer pipe, inner pipe, and intermediate layer made from materials selected for their specific properties: structural strength, electrical insulation, and chemical/thermal resistance. This composite approach enhances overall reliability in harsh environments.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If threaded connections are made between pipe joints for assembly, then the pipe can be assembled in sections, but the threaded connections may compromise the fluid isolation of the conductive path

Engineering Contradiction:

Improveassembly of pipe sectionsVSAvoidfluid isolation at connections

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The intermediate layer extends through the threaded connections between pipe joints, acting as a continuous barrier that maintains fluid isolation across connection points. This ensures the conductive path remains protected from well fluids even at assembly joints.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The intermediate layer functions as a flexible protective film that can accommodate the geometry of threaded connections while maintaining continuous fluid isolation. This thin film barrier ensures reliability at connection points without compromising assembly ease.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS12366122B2Well completion pipe having fluid isolated conductive path

Publication Date: 2025.07.22 REELWELL AS

AI summary

A well completion pipe has a plurality of pipe joints, each comprising an outer pipe, an intermediate layer disposed inside the outer pipe and an inner pipe disposed inside the layer. The inner pipe extends longitudinally beyond a respective longitudinal end of the outer pipe or the outer pipe extends longitudinally beyond a respective longitudinal end of the inner pipe. The inner pipe and the outer pipe comprise respective threaded connections at each longitudinal end. The respective threaded connections form a metal to metal seal when engaged to corresponding mating threads. A pressure isolated passageway extends through the intermediate layer. In some embodiments, the inner pipe comprises well casing. In some embodiments, the outer pipe comprises a well completion tubular.