Downhole Wet-Mate Connector Testing for ESP Cable Integrity
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Solution Overview
Problem
Conventional ESP systems lack effective methods for monitoring the integrity of ESP cables and the condition of downhole equipment, particularly during the installation of permanent completions, especially in retrievable ESP systems where cable continuity and motor insulation resistance cannot be reliably measured.
Innovation Solution
The development of methods and equipment for testing downhole electrical cable installations, including the use of retrievable assemblies, custom test plug arm assemblies, built-in star-points, fusible links, and wet mate electrical connectors, which allow for continuous electrical contact and measurement of conductor resistance and insulation resistance during and after installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional plug and socket electrical connectors are used in ESP systems, then the electrical connection can be established, but the cable integrity and downhole equipment condition cannot be monitored during installation
Solution Approach 1:
The patent combines the electrical connector functions with built-in testing capabilities by integrating star-point contacts and fusible links directly into the connector assembly. This merging eliminates the need for separate testing equipment while enabling continuous monitoring of cable integrity and equipment condition during installation.
Solution Approach 2:
The electrical connector system performs self-testing through built-in star-point contacts that automatically measure insulation resistance and continuity during installation. The fusible links provide automatic protection and indication of cable faults without requiring external monitoring equipment, allowing the system to monitor its own integrity.
2Adaptability or versatility
If retrievable assembly is used in permanent completion, then the ESP system becomes retrievable, but the cable continuity and motor insulation resistance cannot be reliably measured
Solution Approach 1:
The patent incorporates testing capabilities into the permanent completion before the retrievable assembly is installed. The star-point contacts and measurement circuits are pre-configured in the permanent completion, enabling insulation resistance and continuity measurements to be taken before, during, and after the retrievable assembly installation, ensuring reliable measurement capability is maintained throughout the process.
3Ease of manufacture
If manual assembly of electrical connectors is performed, then the connection can be made, but the installation time and labor requirements increase
Solution Approach 1:
The electrical connector system is divided into modular components including the permanent completion with built-in star-points, the retrievable assembly with corresponding contacts, and integrated fusible links. This segmentation allows for pre-assembly and testing of individual modules, reducing on-site installation time and manual assembly requirements while maintaining connection reliability.
Data Source
AI summary
Disclosed are methods and devices for testing downhole connector electrical systems and cable integrity during installation of a permanent completion, including a customized retrievable plug arm assembly connectable to the completion during RIH, the tool mimicking a retrievable ESP, but without motor, and can be employed with or without pressure isolation. Another method employs a slidable starpoint located within the downhole wet mate connector of the completion to provide continuous electrical contact between the phases when no retrievable assembly is in place. When a retrievable assembly is later put in place, the slidable starpoint is moved into a second position that no longer provides electrical contact between the phases. Another method uses fusible links installed between two conductors within the downhole electrical connector system of the completion to provide similar electrical contact between phases, the fusible link configured to melt away once motor current is sent through the conductors.