Wet-Mate Connector Assembly With Grease Retainer for Wellbore Reconnection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Wet-mate connectors in wellbores face challenges with fluid ingress and corrosion due to dielectric grease extrusion during connections and disconnections, leading to reduced electrical resistance and shortened lifespan, especially under varying pressure and temperature conditions.
Innovation Solution
Incorporation of a dielectric grease retainer and a stiffening material within the wet-mate connector assembly, where the dielectric grease retainer prevents extrusion of dielectric grease and the stiffening material increases contact pressure to maintain electrical resistance and prevent fluid ingress, using materials like ceramic, PEEK, and steel to enhance sealing and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wet-mate connectors are used in wellbores with varying pressure and temperature conditions, then the connector can operate in harsh environments, but dielectric grease extrusion occurs during connections and disconnections leading to fluid ingress and reduced electrical resistance
Solution Approach 1:
The dielectric grease retainer is pre-filled with dielectric grease before deployment. When the connector is assembled, the grease is already in position to prevent fluid ingress and maintain electrical resistance, addressing the reliability issue before it occurs during field operations
Solution Approach 2:
Dielectric grease acts as an intermediary substance between the male and female connector portions. It fills the contact chamber and prevents wellbore fluids from ingressing into the electrical connection interface, thereby maintaining electrical resistance while allowing the connector to operate in harsh environments
2Ease of operation
If wet-mate connectors allow multiple connections and disconnections, then the connector can be serviced and redressed, but dielectric grease extrusion occurs leading to corrosion and shortened lifespan
Solution Approach 1:
The dielectric grease retainer is pre-filled with sufficient dielectric grease before deployment. This preliminary action ensures that even after multiple connections and disconnections, there remains enough grease to prevent corrosion and maintain sealing, thereby extending connector lifespan while preserving reconnectability
Solution Approach 2:
The dielectric grease serves as a protective cushion that is already in place before the connector undergoes multiple mating cycles. It prevents corrosion during each connection/disconnection event, protecting the connector components and extending their operational life
3Reliability
If dielectric grease is used to prevent fluid ingress, then electrical resistance is maintained, but the grease can extrude during connection and disconnection processes
Solution Approach 1:
The dielectric grease retainer extracts and contains the dielectric grease within a dedicated containment structure. This separation prevents the grease from being lost during connector assembly and disassembly, while still allowing it to perform its fluid sealing function in the contact chamber
Solution Approach 2:
The dielectric grease is nested within the dielectric grease retainer, which itself is contained within the overall connector assembly. This nested structure allows the grease to be retained and protected while still being positioned to perform its sealing function when needed
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 effectively maintains electrical resistance and prevents fluid ingress, allowing for multiple connections and disconnections while protecting components from corrosion, thereby extending the lifespan of the wet-mate connector assembly.
Implementation Method 1
The wet-mate connector assembly can include a dielectric grease for repelling fluid from the contact chamber
Implementation Method 2
The insulating material may provide the wet-mate connector assembly with an electrical resistance and protect electrical wiring from exposure to fluids
Data Source
AI summary
Systems and methods are provided for a wet-mate connector assembly that can include a stiffening material and a dielectric grease retainer for preventing the extrusion of dielectric grease during a wet connect. The wet-mate connector assembly can include a male portion and a female portion that can receive the male portion to form an electrical connection with the male portion. The wet-mate connector assembly can also include a dielectric grease retainer that can be positioned near the male portion and the female portion for retaining dielectric grease extruded from a contact chamber when the female portion receives the male portion. The dielectric grease retainer can seal and insulate the contact chamber. The contact chamber can be defined by an outer diameter of the male portion and an inner diameter of the female portion. The male portion and the female portion can include a stiffening material and an insulating material.