Pioneering Hydraulic Wet-Mate Connection in Intelligent Completions with ESP: A Case Study of 70 Successful Deployments

Abstract The operator sought a cost-effective solution to integrate intelligent completions into wells equipped with Electrical Submersible Pumps (ESP), aiming to enhance reservoir management and optimize production in mature fields. The utilization of hydraulic downhole wet-mate connector technology in these wells facilitated the advantages of Intelligent Completions to manage multizone production while concurrently reducing intervention costs and operational challenges of ESP replacements. Recognizing the challenges of managing multizone production in wells with an ESP, and the complexities inherent in ESP replacements, the Intelligent Completions were equipped with a hydraulic downhole wet-mate connector. This integration allowed retrieval of the upper completion, including underperforming ESPs or safety valves, without killing the well and or necessitating the removal of Intelligent Completion system components including the zonal isolation packers and Interval control valves (ICVs). The downhole wet-mate connector enabled seamless disconnection and subsequent upper completion replacement followed by the re-establishment of connectivity to the intelligent completion hydraulic control system. This effectively restored the functionality of the ESP and safety valves, without the need for a complex workover operation. Over 70 successful and consecutive intelligent completion installations have been completed for an operator in the Middle East utilizing the hydraulic wet-mate connector. This enabled optimized production and enhanced reservoir management for these mature reservoirs requiring ESPs for artificial lift. Moreover, more than 7 ESP replacement workovers were executed flawlessly, with zero Non-Productive Time (NPT) incurred. Post-workover assessments confirm that the Intelligent completion systems maintained their full functionality. Furthermore, the wet-mate connector granted the operator flexibility in initially installing completions without an ESP. Subsequently, during a later stage of the well's life, the ESP could be installed without necessitating a comprehensive workover of the entire completion string. With the existing lower completion components remaining intact and functional, the existing ICVs were left in closed position, preventing fluid loss and providing full reservoir isolation during workover operations thus reducing health, safety and environment (HSE) exposure, saving time, and optimizing operational costs. The soft-release technology of the Hydraulic wet-mate connect provides up to eight field configurable methods of activation. This feature prevents uncontrolled movement / shocks to the upper and lower completion string during the decoupling of the wet-mate and during workover operations helping to preserve the downhole system integrity. The wet-mate connection system, run in conjunction with control line set hydraulic packers, also enables a single-trip solution that has demonstrated a reduction in installation time by 39 hours by combining the installation of upper and lower completion.