Wellbore Wet Mate Orientation for Debris-Free Connections

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Solution Overview

Problem

During well completion, stimulation, and production operations, debris such as frac sand can prevent energy transfer mechanisms like wet mate connections from achieving a reliable and sealed connection, especially when oriented on the low side of the wellbore, leading to interference and coupling issues.

Innovation Solution

The energy transfer mechanisms are oriented to the high side of the wellbore, above 3 o'clock or 9 o'clock relative to gravity, to prevent debris from settling and interfering with the coupling, using an orientation tool and communication devices to ensure proper alignment and orientation, such as Halliburton's Workstring Orientation Tool with Mud Pulse Telemetry.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If wet mate connections are oriented on the low side of the wellbore, then installation is simpler, but debris such as frac sand settles and interferes with the coupling, preventing reliable connection

Engineering Contradiction:

Improveease of wet mate connection installationVSAvoidreliability of wet mate connection

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent inverts the conventional orientation by positioning wet mate connections on the high side of the wellbore rather than the low side. This inversion prevents debris accumulation on the connection surfaces, as gravity causes debris to settle away from the high-side oriented connections, thereby maintaining connection reliability while requiring minimal operational changes.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent converts the harmful effect of gravity (which causes debris to settle) into a beneficial force. By orienting wet mate connections to the high side, gravity actually works in favor of the connection reliability by continuously pushing debris away from the connection interfaces, preventing interference and ensuring consistent coupling performance.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Reliability

If orientation tools and communication devices are added to ensure proper alignment, then connection reliability is improved, but device complexity increases

Engineering Contradiction:

Improvereliability of wet mate connectionVSAvoidcomplexity of orientation and communication system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements self-service through passive orientation features that automatically align wet mate connections without requiring active control systems. The high-side orientation is achieved through gravity-dependent positioning and simple mechanical alignment features, eliminating the need for complex active orientation tools while maintaining connection reliability.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent extracts and eliminates complex active orientation and communication systems from the well completion operation. By using passive high-side orientation based on gravity and simple mechanical features, the solution removes the need for sophisticated orientation tools and continuous communication devices, reducing device complexity while maintaining reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

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

This solution reliably connects Fiber Optic Couplers and other Wet Mates without debris interference, ensuring a risk-free gravel-pack completion system, outperforming competitors, and applicable in deep water and Carbon Capture, Utilization and Storage (CCUS) projects.

Implementation Method 1

Halliburton's Workstring Orientation Tool with Mud Pulse Telemetry

Methodology Applied

Scientific EffectAcoustic pulse transmission: Sound

Implementation Method 2

debris such as frac sand can prevent energy transfer mechanisms like wet mate connections from achieving a reliable and sealed connection, especially when oriented on the low side of the wellbore

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS20240318539A1Well system including a lower completion string having one or more sensors positioned there along and coupled to a service string

Publication Date: 2024.09.26 HALLIBURTON ENERGY SERVICES INC

AI summary

Provided is a well system and a method. The well system, in one aspect, includes a wellbore extending through one or more subterranean formations, and a lower completion string located within the wellbore, the lower completion string having a downhole energy transfer mechanism coupled to one or more sensors positioned along the lower completion string. The well system, according to one aspect, further includes a service string coupled with the lower completion string, the service string having an uphole energy transfer mechanism coupled with the downhole energy transfer mechanism of the lower completion string, the downhole energy transfer mechanism and the uphole energy transfer mechanism configured to transfer sensor information obtained by the one or more sensors uphole as the service string is coupled with the lower completion string.