Wet-Mate Connector Grease Retention for Wellbore Fluid Isolation
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Solution Overview
Problem
Wet-mate connector assemblies in wellbores face challenges with fluid ingress and corrosion due to dielectric grease extrusion and insulating material deformation under varying pressure and temperature conditions, leading to reduced electrical resistance and shortened lifespan.
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, typically made of steel or ceramic, increases contact pressure and stiffness of insulating materials like PEEK or ceramic, maintaining electrical resistance and preventing fluid ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dielectric grease is used to prevent fluid ingress, then electrical resistance is maintained, but dielectric grease extrudes under pressure causing fluid intake and reduced electrical resistance
Solution Approach 1:
A dielectric grease retainer is introduced as an intermediary component between the dielectric grease and the external environment. This retainer holds the dielectric grease in place while allowing it to perform its insulating function, preventing extrusion under pressure while maintaining electrical resistance.
Solution Approach 2:
The dielectric grease retainer is installed beforehand to cushion and contain the dielectric grease against pressure changes. This pre-positioned protective structure prevents the grease from extruding before pressure conditions can cause failure.
2Reliability
If insulating material is used to provide electrical resistance, then electrical connection is protected, but insulating material deforms under varying pressure and temperature reducing effectiveness
Solution Approach 1:
The insulating material is combined with a stiffening material to create a composite structure. This composite maintains the electrical insulating properties while gaining dimensional stability and resistance to deformation under varying pressure and temperature conditions.
Solution Approach 2:
The stiffening material is strategically positioned within or alongside the insulating material to provide localized reinforcement. This creates areas of enhanced rigidity where needed while preserving the overall insulating function of the material.
3Adaptability or versatility
If connector assembly is designed for wet-mate operation, then connection capability in fluid is achieved, but fluid ingress and corrosion occur reducing lifespan
Solution Approach 1:
The dielectric grease retainer acts as an intermediary barrier that allows the connector to maintain wet-mate capability while protecting internal components from fluid ingress. This mediator enables the beneficial wet-mate function while blocking the harmful fluid contact.
Solution Approach 2:
The design converts the potential harm of fluid exposure into a benefit by using dielectric grease as both the sealing medium and the protective barrier. The grease that could potentially extrude is instead contained and used to actively prevent corrosion, turning a potential failure mode into a protective mechanism.
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 reduces 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
A stiffening material may be a hard material that can be placed within portions of the wet-mate connector assembly to stiffen an insulating material
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.