Downhole Wet Connector Ferrule Mating Mechanism
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Solution Overview
Problem
Existing techniques fail to effectively connect downhole devices to the surface for power or signal transmission when they are already installed in a well, limiting the ability to deliver power or signals to sensors and equipment already in place.
Innovation Solution
A wet connector system that allows a cable with a pre-connected lower portion to be installed in an auxiliary conduit, enabling connection to downhole sensors or equipment, with a ferrule mechanism for secure mating and fluid circulation to deliver power or signals from the surface, and a bypass port for fluid exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If fiber optic cable is pumped through a conduit to a downhole location and back to the surface, then the cable can reach downhole sensors, but the delivery technique does not allow connection to downhole equipment that is already in place
Solution Approach 1:
The connection system is divided into two separate hubs: a first hub with a female component that remains downhole with the sensors, and a second hub with a male component that is run in from the surface. This segmentation allows the downhole equipment to be connected to the cable before being deployed, while the surface-delivered hub completes the connection afterward, resolving the contradiction between ease of connection and system complexity.
Solution Approach 2:
The cable is pre-connected to the downhole sensors and equipment before they are deployed into the well. The first hub with the female component is installed downhole along with the sensors, preparing the connection interface in advance. This preliminary action enables seamless connection when the second hub is later run in from the surface, eliminating the need for complex downhole connection operations.
2Reliability
If a wet connector system is used to connect cables downhole, then power and signals can be transmitted to downhole devices, but rotational alignment is required which complicates the connection process
Solution Approach 1:
The male and female connector components have asymmetric, non-circular cross-sections with complementary shapes. The male component features a D-shaped or rectangular profile that precisely matches the corresponding female component, eliminating rotational symmetry. This asymmetric design ensures that only one rotational orientation allows the components to mate, automatically providing alignment without requiring manual rotational adjustment, thus improving both reliability and ease of operation.
3Manufacturing precision
If ferrules are used to connect cable ends, then precise alignment is achieved, but the connection requires complex positioning mechanisms
Solution Approach 1:
The ferrule connection system is designed to be self-aligning through the asymmetric geometry of the male and female components. When the hubs are pushed together, the complementary asymmetric shapes guide the ferrules into precise alignment automatically, without requiring external positioning mechanisms or complex adjustment devices. The connection structure itself provides the alignment function, reducing overall system complexity while maintaining high precision.
Data Source
AI summary
A cable that delivers power, signals, or information is wet connected downhole. The lower portion of the cable can be in an auxiliary conduit to a main tubular and be installed already connected to sensors, instruments or other downhole equipment. The connection is made up downhole to connect a string with its auxiliary conduit to the portion of the string and its auxiliary conduit that are below. The cable already in the hole has an upper end ferrule for connection to a ferrule on the lower end of a cable delivered into the upper auxiliary conduit after the wet connect is made up. When the ferrules connect they are held together and a signal goes to the surface that they have connected. The auxiliary connected conduits have a lateral conduit in fluid communication for use in delivery of the cable with circulating fluid.