HARNESS FOR INTELLIGENT COMPLETIONS

Inventors: Robert J. TURNER

Brett W. BOULDIN

BACKGROUND

1. Field

[0001] The present disclosure relates to establishing communication between components on a downhole string and surface. More specifically, the disclosure relates to providing a harness made up of an umbilical with prefabricated connectors; and mating the connectors with connectors that are attached to the components.

2. Related Art

[0002] Hydrocarbon producing wellbores often have tubular completion strings disposed within that are equipped with electric completion items at various depths along the string. Common examples of electric completion items are electrically actuated valves for controlling flow through the string; and sensors for monitoring conditions downhole. Umbilicals are sometimes deployed with the completion strings having electric completion items. The umbilicals typically contain one or more electrically conducting members for communicating signals, power, or both, to the electric completion items. Real time well monitoring and control of devices in the completion string is usually available by transmitting electricity along an umbilical, signals along the umbilical, or both electricity and signals along the umbilical, which is a feature commonly used in what are referred to as intelligent completions.

[0003] Connecting an electric umbilical to electric completion items in an intelligent completion currently requires the electric umbilical to be cut and connected to the electric completion items. Currently cutting and connecting operations are performed at the rig site (typically on the rig floor); to space-out the correct length of electric umbilical to the electric completion items. Performing these operations at the rig-site is expensive due to the significant rig-time required to build and test the connections. Connection of the metallic tubing of an umbilical is generally formed by welding or with a ferrule based compression fitting. Because hot work permit requirements must be fulfilled while welding at a rig site, most umbilical connections are made with ferrule compression fittings. Ferrule-based compression fittings used to join metallic tubulars are sometimes referred to as a“dry mate” or“splice” connection. Rig site assembly exposes the connections to wind, rain, sand, and contamination; which reduces connection quality and reliability to below that of connections made in a controlled workshop environment.

SUMMARY OF THE INVENTION

[0004] Disclosed is an example method of completing a wellbore by providing an umbilical harness having an umbilical and an umbilical connector mounted to the umbilical that is in communication with lines in the umbilical, transporting the umbilical harness to the wellbore, providing a downhole string that includes a component, and providing communication between the component and the umbilical by connecting the umbilical connector to the component. In an example, the method further includes disposing the umbilical harness on a spool, and unspooling the umbilical harness at the wellbore. The downhole string and umbilical are optionally disposed into the wellbore. In one embodiment, electrically connecting the umbilical connector to the component involves mating a plug on an end of the umbilical connector with a receptacle that is electrically connected to the component. In an alternative, the method further includes, installing additional umbilical connectors to the umbilical harness so that each umbilical connector is in communication with a line in the umbilical, and installing additional components. The method further optionally includes identifying a location on the umbilical harness for placement of each of the umbilical connectors that corresponds with a location of a corresponding component, installing the umbilical connectors at those locations, and connecting each umbilical connector with the corresponding component. The umbilical connectors alternatively have lengths that vary, and wherein the downhole string is adjusted in accordance with the lengths of the umbilical connectors. Examples of the component include a sensor, a control valve, a component in a side pocket mandrel, and a safety valve. In an example, the component is powered with electricity in the umbilical harness. Signal data is optionally transmitted through the umbilical harness that is in communication with the component.

[0005] Another method of completing a wellbore involves connecting a plurality of umbilical connectors to an umbilical to form an umbilical harness, transporting the umbilical harness to the wellbore, forming a completion by mating the umbilical connectors with corresponding component connectors that connect to components disposed in a downhole string, and disposing the completion into the wellbore. The method optionally further includes, communicating with a one of the components through the umbilical harness. The method optionally includes adjusting a length of the downhole string to reduce a distance between a one of the umbilical connectors and a component connector that corresponds to the one of the umbilical connectors. In an example, the umbilical connectors are added to the umbilical at points along the distance of the umbilical, so that when the umbilical harness and downhole string are positioned next to and parallel with one another, each umbilical connector is in contactable distance with a corresponding component connector. A jumper is optionally added to a one of the component connectors and mated with an umbilical connector that corresponds to the a one of the component connectors when the corresponding umbilical connector is outside of a connectable distance.

[0006] An alternative method of completing a wellbore contains the steps of receiving an umbilical harness at a wellsite, the umbilical harness made up of an umbilical, conducting elements in the umbilical, and a plurality of umbilical connectors disposed along a length of the umbilical that are in communication with the conducting elements. Further included in the alternative method are the steps of receiving a downhole string at the wellsite, the downhole string having components, and component connectors that are in communication with the components; and engaging the umbilical connectors and corresponding component connectors. In an example, the method further includes, controlling a flow through the completion by transmitting electrical power and electrical signals along the umbilical harness and to a one of the components and via a connection that couples the a one of the components with a corresponding umbilical connector. One alternative step of the method is inserting the downhole string and umbilical harness into the wellbore at the same time. In one alternative, each umbilical connector is coupled to the umbilical harness at a designated point that is within a connectable distance with a corresponding component connector, and is connected to designated conducting elements in the umbilical, so that electrical power and signals is transmitted to a corresponding component according to a predefined design.

BRIEF DESCRIPTION OF DRAWINGS

[0007] Some of the features and benefits of that in the present disclosure having been stated, and others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:

[0008] Figure 1 is a partial sectional view of an example of a completion being formed in a wellbore by mating component connectors on a downhole string with umbilical connectors on an umbilical harness.

[0009] Figure 2 is a partial sectional view of an embodiment of the completion of Figure 1 installed in the wellbore.

[0010] Figure 3 is a schematic view of an example of portions of the downhole string and umbilical harness of Figure 1.

[0011] Figure 4 is a schematic view of umbilical connectors attached to conducting elements in the umbilical.

DETAILED DESCRIPTION OF THE INVENTION

[0012] The method and system of the present disclosure will now be described more fully after with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout. In an embodiment, usage of the term“about” includes +/- 5% of the cited magnitude. In an embodiment, usage of the term “substantially” includes +/- 5% of the cited magnitude.

[0013] It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, materials, or embodiments shown and described. Modifications and equivalents will be apparent to one skilled in the art. Illustrative examples have been disclosed in the drawings and specification. Although specific terms are employed they are used in a generic and descriptive sense only and not for the purpose of limitation.

[0014] Illustrated in a side partial sectional view in Figure 1 is an example of an elongated downhole string 10 disposed in a wellbore 12, where the downhole string 10 includes a number of components 14i _n+i disposed at various locations along a length of the downhole string 10; where“1 - n + 1” means“1 to n + 1”, such as“1, 2, 3, ... n, n + 1”. Also schematically illustrated are components 14 _h+2 , 14 _h+3 , 14 _h+4 , that in an example are to be added in the downhole string 10 at a later time. For the purposes of convenience, components 14i _h+ i, 14 _h+2 , 14 _h+3 , l4 _n+4 , are identified as 14i _ _n+ 4. Tubing 16 is included with the downhole string 10, and which is generally coaxially mounted between adjacent ones of the components 14 _1-h . Examples of the components 14i _{- n} +4 include devices deployed for use in the wellbore 12, such as valves, sensors, and actuators. Further in the example of Figure 1, an embodiment of an umbilical harness 18 is shown being coupled with the downhole string 10 and being inserted into the wellbore 12 along with the downhole string 10. In the illustrated example, umbilical harness 18 is wound around a spool 20 and is shown having a number of umbilical connectors 22i _ _n+ 4; where“1 - n+4” means “1 to n+4”, such as“1, 2, 3, ...n+3, n+4”. Umbilical harness 18 of Figure 1 includes an umbilical 23 with the umbilical connectors 22i _ _n +4 attached at various locations along a length of the umbilical 23. Attached to each of the components 14i _ _n +4 are component connectors 241 -„+4 that are in communication with the components 14i _ _n+ 4. In an example, communicating with or connecting to a particular one of the component connectors 241 _ _n+ 4 _, provides communication to one of the components 14i _ _n +4 to which the particular component connector 24i _ _n +4 is attached. In the example illustrated, the umbilical harness 18 is unwound or unspooled from the spool 20 and drawn adjacent the downhole string 10. As illustrated, the umbilical connectors 22i_ _n+i are connected to corresponding component connectors 241 _ _n+i while on surface and prior to being deployed inside the wellbore 12. Connections 26i _+n are formed by mating umbilical connectors 22i _ _n+i with component connectors 24i _ _n+i . The connections 26 _n+i provide communication, such as electrical and signal, between umbilical harness 18 and components 14i _ _n+i . As noted previously, the remaining component connectors 24 _n+2 , 24 _n+3 , 24 _n+4 , are optionally mated with the remaining umbilical connectors 22 _n+2 , 22 _n+3 , 22 _n+4 at a later time Described in more detail in the following text, in an alternative mating connectors 22, 24 provides communication between the umbilical 23 and devices (including intelligent electrically powered devices) provided within the components 141 _n+ 4.

[0015] In the illustrated example of Figure 1, umbilical harness 18 is equipped with the umbilical connectors 22i _„+4 while mounted on the spool 20. In an example of use, the umbilical connectors 22i _ _n +4 are installed on the umbilical 23 at a location remote from the wellsite W to form the umbilical harness 18. The umbilical harness 18 is then wound onto the spool 20 and transported to the wellsite W. In an alternative, the umbilical connectors 22i _„+4 are configured such that they do not impede the umbilical harness 18 from passing over a sheave 28 shown proximate a drilling rig 30. A wellhead assembly 32, which alternatively provides pressure control of the wellbore 12, is schematically depicted at the base of drilling rig 30 and over wellbore 12. Axial passages (not shown) are formed in blowout preventer (“BOP”) 32; and through which the string 10 and umbilical harness 18 are routed when being installed in the wellbore 12. Further included in the example of Figure 1 is casing 34 shown lining the wellbore 12, and isolating wellbore 12 from a formation 36 surrounding wellbore 12. In one example, the downhole string 10 functions as a production string, and while inserted within casing 34 directs fluids produced from the formation 36 to surface. An advantage of the umbilical harness 18 having preinstalled umbilical connectors 22i _„+4 is the step of cutting and splicing connectors onto the umbilical harness 18 at the wellsite W is eliminated, thereby reducing rig time and expense. An additional advantage of installing umbilical connectors 22i _n +4 in a controlled environment is increased quality and reliability over that of the currently practiced method of cutting and connecting at the wellsite.

[0016] Referring now to Figure 2, shown in a side partial sectional view is an example of an intelligent completion 38 disposed in wellbore 12; and which includes tubing 16, umbilical harness 18, components l4 _l-m , and connections 26i _-m ; where“1 - m” means“1 to m”, such as“1, 2, 3, ... m”. In the example of Figure 2, intelligent completion 38 is formed by coupling together the umbilical and connectors 22 _l-m , 24 _l-m of Figure 1. In this embodiment, there are m number of umbilical and component connectors ultimately engaged with one another; thus connections 261- _m are formed that provide electrical and signal communication between umbilical harness 18 and intelligent completion 38, including components 14 _1-h in intelligent completion 38, and any intelligent devices in intelligent completion 38. Additionally shown in Figure 2 are optional clamps 40 securing the umbilical harness 18 to the string 10 to prevent unwanted movement that could uncouple one of the connections 26i _-m . In one embodiment, components l4 _l-m each include a housing to cover and protect components 48 i _-m , 50i _-m , 52 _l-m from harsh downhole environments. The housings each alternatively include means for attachment (such as a threaded or flanged fitting) to the segments of tubing 16 between the adjacent components l4 _l-m . As set forth in more detail in the following text, the umbilical harness 18 is assembled in accordance with an expected design of the downhole string 10 and so that a one of the umbilical connectors 22i- _m is provided for each component connector 24 _l-m . In a specific example, each umbilical connector 22 _l-m is installed at a designated point on the umbilical harness 18 in accordance with a design of the intelligent completion 38 to mate with a particular one of the intelligent connector harnesses 26i _-m . In a non-limiting example, a particular one of the intelligent connector harnesses 26i _-m designated per design to mate with a particular umbilical connector 22 _l-m is referred to as a“corresponding” intelligent connector harness 26i _-m and vice versa. For purposes of discussion, in an example an umbilical connector 22 _l-m is also referred to as corresponding to a particular component l4 _l-m on which its corresponding intelligent connector harness 26i _-m is attached.

[0017] Further illustrated in the example of Figure 2 is a terminal 42 disposed outside of wellbore 12 and which couples to an end of umbilical harness 18 disposed outside of wellbore 12. Umbilical harness 18 is in communication with controller 44 via a communication means 46, accordingly intelligent completion 38 and all devices (such as components 14 _1-h ) within intelligent completion 38 are in communication with controller 44 via connections 26i _-m , umbilical harness 18, terminal 42, and communication means 46. In an example controller 44 includes an information handling system (“IHS”) employed for controlling electrical signals and power along umbilical harness 18. The IHS optionally stores recorded data as well as processing the data into a readable format. Embodiments exist where the IHS includes a processor, memory accessible by the processor, nonvolatile storage area accessible by the processor, and logics for performing each of the steps described. Illustrative communication means 46 include those that employ a conducting medium, fiber optic media, receive and transmit electromagnetic waves, and combinations thereof. In one non limiting example of operation, information obtained by electrical devices within string 10 are transmitted via umbilical harness 18 to terminal 42 and via communication means 46 to controller 44. Alternatively, control commands are selectively issued by controller 44 that transmit through umbilical harness 18 to one or more of the components l4 _l-m , and electrical power for operating the various intelligent devices within string 10 is transmitted along the umbilical harness 18. In an example, a power source (not shown), that optionally includes a variable frequency drive, is provided on surface that provides electrical power, such as electricity; and which is conducted by umbilical harness 18 into the wellbore 12.

[0018] Referring now to Figure 3, schematically illustrated is an example of coupling downhole string 10A with umbilical harness 18A to form intelligent completion 38A. In the illustrated example, downhole string 10A includes components 14A _1-5 disposed in tubing 16A, and where components 14A _1-5 have a different assortment of devices. Examples exist where at least some of the devices are electrically powered. Alternatively, at least some of the devices handle electrical signals, such as by transmitting, receiving, or both. More specifically, component 14Ai includes component 48Ai, component 50Ai and component 52Ai. Components 48Ai, 50Ai are schematically illustrated to represent valves, examples of which include a control valve, an on/off valve, and a safety valve. Component 52Ai is schematically represented to illustrate a sensor, such as for measuring pressure or temperature within the wellbore 12 (Figure 2). Further in this example, the component connectors 24Ai-s include lines 54Ai-s that provide electrical communication between the devices in the components 14A _1-5 and plugs 56Ai-s shown mounted respectively on ends of the lines 54Ai-s distal from the components 14A _1-5 . Junctions 58Ai-s are optionally provided in each of the components 14A _1-5 , which in an example provide a connection point for each of the lines 54A _l-5 . In an alternate embodiment, leads 60Ai, 62Ai and 64Ai are pro vided in component 14Ai and that provide electrical communication respectively between junction 58Ai and components 48Ai, 50Ai, and 52Ai. Receptacles 66A _1-5 are included in the illustrated embodiment, and which are shown mounted on ends of umbilical connectors 22Ai-s distal from umbilical 23A. As illustrated by the dashed lines L _l-5 , plugs 56Ai-s collectively engage and mate with receptacles 66 A _1-5 to provide electrical and signal communication from and between umbilical connectors 22Ai-s and component connectors 24A _l-5 . Lines 68A _1-5 electrically connect the umbilical receptacles 66A _1-5 with electrically conducting members within umbilical harness 18A. Examples of the junctions 58Ai-s include pigtail type connections between electrically conducting members (not shown) in lines 54Ai-s and those in components 14A _I-5 . Optionally, junctions 58Ai-s are made up of receptacle and plug like connections similar to plugs 56A _I-5 and receptacles 66A _1-5 .

[0019] In one alternative, the different components 14A _1-5 illustrated in Figure 3 are equipped with a different type and number of devices. For example, while components 14Ai and 14A ₂ include each of the components 48Ai _{, 2} , 50Ai _{, 2} , and 52Ai _{, 2} , the remaining components l4A _2-5 include a single one of the completion devices. More specifically component 14A ₃ of Figure 3 is shown having component 52A ₃ , component 14A ₄ is shown including completion device 50A ₄ , and component 14A ₅ includes component device 48A ₅ . The components are not limited to the embodiments illustrated, but can include any number of other combinations.

[0020] Still referring to Figure 3, the embodiment of the line 54 A ₁ shown has a length greater than that of lines 54A _2-5 , and in an example takes the form of what is referred to as a length extension or jumper. An advantage of a line 54Ai having an increased length is realized if the receptacle 66A ₁ to be engaged by the plug 56Ai on the end of the line 54Ai is vertically offset from the corresponding component 14Ai a distance that is greater than that which a harness line typically spans. Optionally, jumper includes readymade connectors on its opposing ends, such as a plug (the same or similar to one of plugs 56A _l-5 ) on one end of its length of electrically conducting members, and a receptacle (the same or similar to one of receptacles 66A _1-5 ) on an opposing end of the conducting members. In this example of jumper, its plug and receptacle (not shown) engage one of receptacles 66A _1-5 and its corresponding one of the plugs 56A _l-5 , which readily provides communication between one of components 14A _1-5 and a corresponding umbilical connector 22A _l-5 . In another alternative, an optional pup joint 70A is added to string 10A to adjust the vertical position of a one or more of the components 14A _1-5 into close enough alignment with a corresponding one of the receptacles 66Ai_ _n so that a one of the plugs 56Ai_ _n mates with a corresponding one of the receptacles 66Ai_ _n by normal extension of corresponding ones of the lines 54Ai_ _n and lines 68A _l-n .

[0021] Schematically illustrated in a partial sectional view in Figure 4 is an example of a portion of the intelligent completion 38B where the completion string 10B is electrically coupled with umbilical harness 18B via connections 26Bi- ₄ . Here, the connections 26B I_ ₄ provide electrical communication between the components 14 B i - ₄ and the umbilical harness 18B, and formed by mating umbilical connectors 22B I_ ₄ with component connectors 24B _l-4 . In this example, umbilical harness 18B includes an outer sheath 72B encasing a number of elongated conducting elements 74B _l-n . Example materials for the sheath 72B include metal or metallic substances, and alternatively formed into a tubular shape. Further shown is line 68Bi in electrical communication with conducting element 74Bi, thus component 14Bi is in communication with the conducting element 74Bi via component connector 24Bi and connection 26Bi. Similarly, umbilical harness line 68B ₂ is shown connected to conducting element 74B ₃ which thereby puts the component 14B ₂ in communication with conducting element 74B ₃ . Conducting element 74B ₂ is in electrical communication with component 14B ₃ via communication between line 68B ₃ and component connector 24B ₃ via connection 26B ₃ . Further, also connected to conducting element 74Bi is line 68B ₄ , to in turn provide electrical communication with component 14B ₄ and conducting element 74Bi. Accordingly, examples exist where different ones of the components 14B I_ ₄ are in electrical communication with the same one of the conducting elements 74B _l-n . Examples exist where embodiments of the umbilical harness 18, 18A, 18B include umbilical 23, 23A, 23B having media that communicates multiple types of energy, such as electric, fiber-optic, acoustic, pressure, and combinations thereof.

[0022] In one non-limiting example of operation, an umbilical harness is formed having a number of elongated conducting elements disposed within a sheath (such as that described above). A design of an intelligent completion is obtained, and which includes the types and respective positions of completion assemblies included on intelligent completion. Knowing the arrangement and type of the completion assemblies in the intelligent completion, locations on the umbilical harness are identified where to install umbilical connectors. The configurations and placements of component connectors as expected from the design of the intelligent completion are taken into account when identifying the locations of where the umbilical connectors are to be installed on the umbilical to form the umbilical harness. Also identified are the conducting elements on which to connect the umbilical harness lines. In an example as discussed in the foregoing, the umbilical connectors are mounted to the umbilical at the identified points while at a location remote from the wellsite, and which is sheltered from environmental elements capable of degrading connections between the umbilical connectors and the umbilical harness.

[0023] Further in the example of operation, the umbilical harness is strategically located to position umbilical connectors sufficiently close to corresponding component connectors. In one example, umbilical connectors are sufficiently close to corresponding component connectors when they are connectable without repositioning either of the umbilical harness or downhole string, or altering the lines of either of the umbilical connectors or the component connectors. An example of an umbilical connector being connectable to a corresponding component connector is that plug of component connectors engages with receptacle of umbilical connector to form a connection. Explained another way, the umbilical and component connectors are sufficiently close to one another, or are within a connectable distance, when lines of the umbilical and component connectors have a combined length that exceeds a distance between where the component connector and umbilical connector connect to the downhole string and umbilical harness respectively.

[0024] Additional alternate steps of this non-limiting example include winding the umbilical harness with attached umbilical connectors onto a spool, and transporting the umbilical harness to the wellsite. At the wellsite, completion assemblies and sections of tubing are assembled to form the string, which is inserted into the wellbore. In an alternate embodiment, prior to inserting each of the completion assemblies into the wellbore, attached component connectors are mated with corresponding umbilical connectors to form connections. Mating connectors to one another places controller into communication with one or more of the completion devices in the intelligent completion. In an example, the communication occurs along the umbilical harness. Communication includes electricity and signals that are transmitted along the umbilical harness. Example signals include instruction for operating devices in the completion or otherwise disposed in wellbore. The types of signals communicated include electrical signals, acoustic signals, and electro-magnetic signals. Electricity is available for energizing such devices, such as for powering a motor that drives a valve member to a designated position. [0025] The present disclosure therefore is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent. While embodiments of the disclosure have been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present disclosure and the scope of the appended claims.