CROSS REFERENCE TO RELATED APPLICATION

[0001] The present document is based on and claims priority to US Provisional Application Serial No: 63/368,394, filed July 14, 2022, which is incorporated herein by reference in its entirety.

BACKGROUND

Field

[0002] The present disclosure generally relates to multi-stage completions and downhole connectors for use in oil and gas wells, and more particularly, to systems and methods for connecting multi-stage completions, for example, including, but not limited to, multi-stage completions including optical fibers.

Description of the Related Art

[0003] Many types of wells, e.g., oil and gas wells, are completed in multiple stages. For example, a lower stage of the completion, or lower completion assembly, is moved downhole on a running string. After deployment of the lower completion assembly at a desired location in the wellbore, an upper stage of the completion, or upper completion assembly, is deployed downhole and engaged with the lower completion assembly.

[0004] In many applications, it is desirable to instrument the lower completion with electrical or optical sensors or to provide for transmission of fluids to devices in the lower completion. For example, a fiber optic cable can be placed in the annulus between a screen of the lower completion and the open or cased hole. To enable communication of signals between the sensor in the lower completion and the surface or seabed, a wetmate connection is needed between the upper and lower completion equipment.

SUMMARY

[0005] In some configurations, a downhole completion system includes a lower completion comprising a receptacle and two or more of a lower fiber optic wetmate connector, a first component of an inductive coupler pair, a lower hydraulic wetmate connector, and a lower control line connector. An upper completion may comprise a stinger and two or more of an upper fiber optic wetmate connector, a second component of an inductive coupler pair, an upper hydraulic wetmate connector, and an upper control line connector. The stinger is configured to engage the receptacle. Similarly, the upper fiber optic wetmate connector may be configured to couple to the lower fiber optic wetmate connector, and the first component of the inductive coupler pair may be configured to inductively couple to the second component of the inductive coupler pair.

BRIEF DESCRIPTION OF THE FIGURES

[0006] Certain embodiments, features, aspects, and advantages of the disclosure will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It should be understood that the accompanying figures illustrate the various implementations described herein and are not meant to limit the scope of various technologies described herein.

[0007] Figure 1 illustrates an example of a completion having a fiber optic and electric downhole wetmate system, according to an embodiment of the disclosure.

[0008] Figure 2 illustrates an example of a lower completion of a two-stage completion including the wetmate system of Figure 1, according to an embodiment of the disclosure.

[0009] Figure 3 illustrates an example of an upper completion of the two-stage completion including the wetmate system of Figure 1, according to an embodiment of the disclosure.

[0010] Figure 4 illustrates another example of a completion having a fiber optic and electric downhole wetmate system, according to an embodiment of the disclosure.

[0011] Figure 5 illustrates an example of a lower completion downhole wetmate system, according to an embodiment of the disclosure.

[0012] Figure 6 illustrates an example of an upper completion downhole wetmate system, according to an embodiment of the disclosure.

[0013] Figure 7 illustrates an example of a downhole wetmate system including a hydraulic flow path, according to an embodiment of the disclosure.

[0014] Figure 8 illustrates an example downhole wemate system including control line wetmate connectors and functionality, according to an embodiment of the disclosure. [0015] Figure 9 illustrates an example of a stinger component of the wetmate system of Figure 8, according to an embodiment of the disclosure.

[0016] Figure 10 illustrates an example of a receptacle component of the wetmate system of Figure 8, according to an embodiment of the disclosure.

[0017] Figure 11 illustrates transverse cross sectional views of the stinger and receptacle of Figures 9 and 10, according to an embodiment of the disclosure.

[0018] Figure 12 schematically illustrates an example of a flushing fluid flow path of the wetmate system of Figure 8, according to an embodiment of the disclosure.

[0019] Figure 13 illustrates an example of an upper completion downhole wetmate system including fiber optic, hydraulic, and electric connectors and functionality, according to an embodiment of the disclosure.

[0020] Figure 14 illustrates an example of a lower completion downhole wetmate system including fiber optic, hydraulic, and electric connectors and functionality, according to an embodiment of the disclosure.

[0021] Figure 15 illustrates an example configuration of the hydraulic and electric connectors of Figure 13, according to an embodiment of the disclosure.

[0022] Figure 16 illustrates a cross-sectional partial view of the hydraulic connections of Figure 13, according to an embodiment of the disclosure.

[0023] Figure 17 illustrates a close-up partial view of the hydraulic connections of Figure 16, according to an embodiment of the disclosure.

DETAILED DESCRIPTION

[0024] In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the disclosure. These are, of course, merely examples and are not intended to be limiting. However, it will be understood by those of ordinary skill in the art that the system and/or methodology may be practiced without these details and that numerous variations or modifications from the described embodiments are possible. This description is not to be taken in a limiting sense, but rather made merely for the purpose of describing general principles of the implementations. The scope of the described implementations should be ascertained with reference to the issued claims.

[00251 As used herein, the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via one or more elements”; and the term “set” is used to mean “one element” or “more than one element”. Further, the terms “couple”, “coupling”, “coupled”, “coupled together”, and “coupled with” are used to mean “directly coupled together” or “coupled together via one or more elements”. As used herein, the terms "up" and "down"; "upper" and "lower"; "top" and "bottom"; and other like terms indicating relative positions to a given point or element are utilized to more clearly describe some elements. Commonly, these terms relate to a reference point at the surface from which drilling operations are initiated as being the top point and the total depth being the lowest point, wherein the well (e.g., wellbore, borehole) is vertical, horizontal or slanted relative to the surface.

[0026] Many types of wells, e.g., oil and gas wells, are completed in multiple stages. For example, a lower stage of the completion, or lower completion assembly, is moved downhole on a running string. After deployment of the lower completion assembly at a desired location in the wellbore, an upper stage of the completion, or upper completion assembly, is deployed downhole and engaged with the lower completion assembly. As used herein, “lower” can refer to a first or lead equipment/assembly moved downhole. “Upper” can refer to a second or later equipment/assembly moved downhole into engagement with the lower unit. In a horizontal wellbore, for example, the lower equipment/assembly is run downhole first prior to the upper equipment/assembly.

[0027] Many well completions incorporate one or more control lines, such as optical, electrical, and/or hydraulic control lines, to carry signals and/or fluids to or from components of the downhole completion. For example, in many applications, it is desirable to instrument the lower completion with electrical or optical sensors or to provide for transmission of fluids to devices in the lower completion. A downhole wetmate connector system enables communication (e.g., electrical, fiber optic, and/or hydraulic communication) between the lower completion and the upper completion. Electrical connections can be utilized to power downhole sensors and equipment, as well as to send and receive data. Hydraulic connections can be utilized to actuate or move downhole systems or pump chemicals into or past the lower completion. Fiber optic connections can be utilized for various downhole measurements or for data transmission from downhole equipment and sensors. The completion of wells in two or more stages, however, can create difficulties in forming dependable and repeatable control line connections between adjacent completion assemblies.

[0028] The present disclosure provides systems and methods for connecting and providing communication between an upper completion and a lower completion. More specifically, the present disclosure provides wetmate systems and methods including a fiber optic connection, inductive coupler pair or connection, a hydraulic connection, and/or a control line connection. Wetmate systems and methods according to the present disclosure advantageously establish a fiber optic connection, electrical, hydraulic, and/or control line connection, and allow for fiber optic signal communication, electrical signal communication, hydraulic communication, and/or control line communication. The use of an inductive coupler, e.g. an inductive coupler pair, to establish an electrical connection and allow for electrical signal communication advantageously removes the need for an electrical wetmate connector. Whereas electrical wetmate connectors can be unreliable, the inductive coupler provides a more reliable and preferred method of transmitted electrical signals. By way of example, the first component of the inductive coupler pair may be a female inductive coupler, and the second component of the inductive coupler pair can be a male inductive coupler.

[0029] In some configurations, a method includes engaging an upper completion with a lower completion; and establishing two or more of electrical, fiber optic, hydraulic, and control line communication between the upper and lower completions. The method can include establishing control line communication between the upper and lower completions. The method also can include pumping a fiber cable through the upper completion and lower completion. In some configurations, a downhole completion system includes a lower completion comprising a receptacle, a lower fiber optic wetmate connector, and a lower control line connector. An upper completion may comprise a stinger, an upper fiber optic wetmate connector, and an upper control line connector. In this example, the stinger is configured to engage the receptacle, the upper fiber optic wetmate connector is configured to couple to the lower fiber optic wetmate connector, and the upper control line connector is configured to couple to the lower control line connector. The lower completion can further include a first component of an inductive coupler pair and the upper completion can further include a second component of the inductive coupler pair. [0030] In some embodiments, systems and methods according to the present disclosure allow for deploying and connecting a fiber optic sensor network in a two-stage completion. In some configurations, the present disclosure provides systems and methods for coupling control lines, such as hydraulic lines, of the upper and lower completions. Fiber can then be pumped from the surface, with water or another fluid, through the entire length of the coupled control lines to reach the lower completion.

[0031] According to some embodiments, an optical fiber can be pre-deployed. The lower completion can be run with fiber, then the upper completion can be run with fiber, and the fiber of the upper completion and fiber of the lower completion can be mated via a connector. This can advantageously save time during deployment and installation as the fiber does not need to be pumped from the surface once a wetmate connection has been established. Once the connection is established, a continuous optical path is provided from a surface location to the bottom of an open hole formation. In some configurations, systems and methods according to the present disclosure also allow for connecting other types of control lines and/or connectors, such as electrical control lines or connectors and/or fluid control lines or connectors. Different types of control lines and/or connectors, including fiber optic, electrical, and/or hydraulic control lines and/or connections, can be included in various combinations. The connections may be established, broken, and reestablished repeatedly.

[0032] Connection systems and methods according to the present disclosure may be used for land applications, offshore platform applications, or subsea deployments in a variety of environments and with a variety of downhole components. The systems and methods can be used to connect a variety of downhole control lines, including communication lines, power lines, electrical lines, fiber optic lines, hydraulic conduits, fluid communication lines, and other control lines. The connections can allow for the deployment of sensors, e.g., fiber optic sensors, in sand control components, perforating components, formation fracturing components, flow control components, or other components used in various well operations including well drilling operations, completion operations, maintenance operations, and/or production operations.

[0033] The upper and lower completion assemblies can include a variety of components and assemblies for multistage well operations, including completion assemblies, drilling assemblies, well testing assemblies, well intervention assemblies, production assemblies, and other assemblies used in various well operations. The upper and lower assemblies can include a variety of components depending on the application, including tubing, casing, liner hangers, formation isolation valves, safety valves, other well flow/control valves, perforating and other formation fracturing tools, well sealing elements, e.g., packers, polished bore receptacles, sand control components, e.g., sand screens and gravel packing tools, artificial lift mechanisms, e.g., electric submersible pumps or other pumps/gas lift valves and related accessories, drilling tools, bottom hole assemblies, diverter tools, running tools and other downhole components.

[0034] By way of example, a two-stage completion may include an upper completion and a lower completion. The upper completion can include a stinger, and the lower completion can include a receptacle. In use, the upper completion is run inside the lower completion, and the stinger engages the receptacle to complete a downhole connection.

[0035] Figure 1 shows an example of a downhole completion 30 having a wetmate system 32. The completion 30 may comprise a two-stage completion having a lower completion 34 (see Figure 2) and an upper completion 36 (see Figure 3). The upper completion 36 may comprise a stinger 38 and may include one or more upper fiber optic wetmate connectors 40, as also shown in Figure 3. The lower completion 34 may comprise a receptacle 42 and may include one or more lower fiber optic wetmate connectors 44, as also shown in Figure 2. As illustrated, the upper completion 36 also may include a first (male in the illustrated configuration) inductive component 46 of an inductive coupler pair, and the lower completion 34 may include a second (female in the illustrated configuration) inductive component 48 of the inductive coupler pair.

[0036] In an operational example, as the upper completion 36 is run in hole, the stinger 38 is lowered until a stinger key 50 on the stinger 38 contacts or engages an alignment sleeve 52 of the receptacle 42. The alignment sleeve 52 has a generally helical or curved profile. The stinger key 50 rotates along the helix of the alignment sleeve 52 until the stinger key 50 is clocked or aligned with a slot in the alignment sleeve 52. The upper completion 36 is then further lowered as the stinger key moves into and along the slot until the stringer 38 fully engages the receptacle 42. The upper fiber optic wetmate connectors 40 are then mated with the lower fiber optic wetmate connectors 44, as shown in Figure 1. When the upper completion 36 (e.g., stinger 38) is engaged with the lower completion 34 (e.g., the receptacle 42), the first and second components 46, 48 of the inductive coupler pair are also aligned and inductively coupled.

[0037] The lower completion 34 may include communication lines 54 in the form of fiber optic and electrical lines extending from the lower fiber optic wetmate connector(s) 44 and second component 48 of the inductive coupler pair, respectively, downhole to associated sensors, receivers, equipment and/or another downhole wetmate system. The upper completion 36 may also include communication lines 54, e.g. fiber optic and electrical lines, extending from the upper fiber optic wetmate connector(s) 40 and first component 46 of the inductive coupler pair, respectively, uphole to or towards the surface. The wetmate system 32, including fiber optic connectors 40, 44 and the inductive coupler pair 46, 48, allows the transmission of fiber optic and electrical signals, respectively, through the upper and lower completions 36, 34, for example, to, from, or between the surface and downhole sensors, receivers, and/or equipment.

[0038] In the configuration of Figures 1-3, the second component 48 of the inductive coupler pair is positioned below or downhole of the receptacle 42, as shown in Figure 2. The fiber optic cable portion of communication lines 54 extending along the lower completion 34 therefore bypasses the inductive coupler 48 to continue downhole. In the illustrated configuration, the first component 46 of the inductive coupler pair is positioned below the stinger 38 and upper fiber optic wetmate connector(s) 40, as shown in Figure 3. The electrical cable portion of communication lines 54 extending from the first component 46 therefore bypasses the stinger 38 to continue uphole. When the upper completion 36 is engaged with the lower completion 34, the inductive coupler pair 46, 48 is positioned below or downhole of the fiber optic wetmate connection 40, 44, as shown in Figure 1. Figure 4 illustrates an alternative configuration in which the inductive coupler pair 46, 48 is positioned above or uphole of the fiber optic wetmate connection 40, 44. In this configuration, the electric cable portion of communication lines 54 bypasses the fiber optic receptacle in the lower completion 34, and the fiber optic cable portion of communication lines 54 bypasses the inductive coupler in the upper completion 36.

[0039] In some configurations, the fiber optic connection between the upper fiber optic wetmate connector 40 and the lower fiber optic wetmate connector 44 is made above or uphole of a packer. This configuration may be implemented in the embodiment shown in Figures 1-3 (see also Figure 14). Also, the fiber optic connection between the upper fiber optic wetmate connector 40 and the lower fiber optic wetmate connector 44 may be made below or downhole of the packer as shown, for example, in the embodiments of Figures 4-11. In such configurations, when the upper completion 36 and lower completion 34 are engaged, a portion of the upper completion 36, e.g., the stinger 38, may extend through the packer to engage the lower completion 34, e.g., the receptacle 42, below the packer. An example regarding below the packer wetmate connections can be found in WO 2021/247726, the entirety of which is hereby incorporated by reference herein.

[00401 Figures 5 and 6 show another example of downhole wetmate system 32 that can be included in the two-stage completion 30 having lower completion 34 (Figure 5) constructed for receiving upper completion 36 (Figure 6). The wetmate system 32 can include various combinations of one or more fiber optic wetmate connectors 40, 44, electric wetmate connectors (such as inductive couplers 46, 48), hydraulic wetmate connectors, and/or control line wetmate connectors, as described in greater detail below. For example, the upper completion 36, e g. stinger 38, can include one or more upper fiber optic wetmate connectors 40 and/or one or more electrical connectors 46, such as the first component 46 of an inductive coupler pair. The lower completion 34, for example, the receptacle 42, can include one or more lower fiber optic wetmate connectors 44 and/or one or more electrical connectors 48, such as the second component 48 of the inductive coupler pair.

[0041] As further illustrated in Figure 7, the wetmate system 32 also can include one or more hydraulic wetmate connections 56, 58 in the upper completion 36 and lower completion 34, respectively. The wetmate connections 56, 58 enable hydraulic flow along one or more hydraulic flow lines 60. Additionally, the wet mate system 32 can include one or more control line wetmate connectors 62, 64 in the upper completion 36 and lower completion 34, respectively, as further illustrated in Figures 8-11. The control line wet mate connections 62, 64 are able to connect one or more control lines 66. By way of example, one or more, e.g. four, hydraulic lines 60 can be installed or disposed around the outer diameter of the receptacle 42 and stinger 38. Examples of hydraulic flowline systems can be found in, for example, US 7,640,977 and US 8,496,064, the entirety of which are incorporated by reference herein.

[0042] As shown in Figures 8-11, the wetmate system 32 can include one or more control lines 66 extending parallel to and offset to either side of the fiber optic wetmate connectors 40, 44. Once the control line connectors 62, 64 of the upper and lower completions 36, 34 (e.g., the stinger 38 and receptacle 42) are coupled, optical fiber can be pumped from the surface through the control lines to reach the lower completion 34. Such fiber optic systems and methods can include various features described in, for example, US 7,640,977, which has been incorporated by reference herein. When used in combination with fiber optic wetmate connectors 40, 44 as described herein, the control line wetmate functionality can advantageously allow for pumping of fiber cables as a backup option (for example, if the fiber optic wetmate connection fails or becomes damaged) and/or to extend the life of the downhole completion.

[00431 In some configurations, see Figure 12 for example, the control line wetmate connectors 62, 64 can also allow fluid, such as cleaning fluid, to be pumped into the control lines 66; into connectors 62, 64; into the fiber optic wetmate connectors; and/or into various lines. The pumped fluid may be used to aid in flushing debris that may have accumulated around the connector areas prior to mating the upper and lower completions 36, 34. It should be noted that other features such as rupture discs 68 and seal stacks 70 may be used to keep the control lines 66 free from debris and to facilitate wetmate connection when the upper completion 36 is coupled with the lower completion 34.

[0044] In some configurations, the wetmate system 32 includes combined fiber optic connectors 40, 44, electrical connectors 46, 48 (e.g., in the form of an inductive coupler pair), and hydraulic connectors 56, 58, to allow for fiber optic, electrical, and hydraulic communication between the upper and lower completions 36, 34 respectively, as illustrated by the embodiment in Figures 13 and 14. Each of the connectors 40, 44, 46, 48, 56, 58 can be located or contained in a separate part or component of the completions 34, 36. In other words, the electrical connectors 46, 48 and hydraulic connectors 56, 58 are not incorporated into or with the fiber optic connectors 40, 44 in this embodiment. With such a configuration, failure of one or two of the connections could be isolated and not necessarily lead to a failure of the other connection(s).

[0045] In some configurations, the fiber optic 40, 44, hydraulic 56, 58, and electric 46, 48 (inductive coupler) connections are located above a packer 72 when installed. As shown in Figures 13 and 14, the coupled fiber wetmate connectors 40, 44 can be positioned above or uphole of the coupled hydraulic connectors 56, 58 as well as above or uphole of the coupled electric connectors 46, 48. The lower completion 34 can include an eccentric crossover 74 disposed axially between the fiber connector 44 and the hydraulic connector 58/electric connector 48. By way of example, the fiber optic connectors 40, 44 (as well as other connectors) can include one or more debris protection features. Examples of debris protection features may be found in PCT/US2021/059923, the entirety of which is hereby incorporated by reference herein.

[0046] Figure 15 illustrates an example configuration of a portion of the wetmate system 32 including the hydraulic connectors 56, 58 and electric connectors 46, 48. As further illustrated in Figures 16 and 17, hydraulic lines 60 may be disposed about the body of the receptacle 42, and corresponding hydraulic lines 60 are disposed about the body of the stinger 38. A plurality of ports 76 may be disposed between seal rings 78, e.g. between seal rings 78 located on the outer diameter of the stinger 38. A stinger sleeve 80 can be used to cover the ports 76. As the stinger 38 is inserted into the receptacle 42, the sleeve 80 is displaced axially to expose the ports 76. The stinger ports 76 then align, overlap, and/or are placed in fluid communication with corresponding ports 76 in the receptacle 42, thus allowing hydraulic connection and fluid communication between the upper completion 36 and the lower completion 34. Examples of suitable hydro-electric wetmate connector systems can be found in WO 2017/213726, the entirety of which is incorporated by reference herein.

[0047] Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and/or within less than 0.01% of the stated amount. As another example, in certain embodiments, the terms “generally parallel” and “substantially parallel” or “generally perpendicular” and “substantially perpendicular” refer to a value, amount, or characteristic that departs from exactly parallel or perpendicular, respectively, by less than or equal to 35 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, or 0.1 degree.

[0048] Although a few embodiments of the disclosure have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments described may be made and still fall within the scope of the disclosure. It should be understood that various features and aspects of the disclosed embodiments can be combined with, or substituted for, one another in order to form varying modes of the embodiments of the disclosure. Thus, it is intended that the scope of the disclosure herein should not be limited by the particular embodiments described above.