Development of a Through-Tubing Smart Completion Solution

Abstract This paper presents the development and qualification of a novel wired and powered tubing/casing system designed to enhance smart completions. It outlines key use cases, the engineering workflow, and extensive component validation that led to achieving Technology Readiness Level (TRL) 4, as per the API TRL scale. It also describes the ongoing planning and preparation for workshop testing to advance to TRL 5 and subsequent field trials for TRL 6. The development followed the API TRL framework. System requirements were defined through market research and use case analysis, targeting improvements in reliability and cost over existing smart completions. Hardware was designed using CAD, FEM, and CFD tools and fabricated in-house. Multiple iterations of pipe ID evaluation, including MBG testing, led to a refined connection design that maintains mechanical integrity while accommodating powerline for production kits. Prototype tubing strings were equipped with the new components and subjected to analytical simulations and bench tests. The new system introduces a protected cable pathway inside the tubing using an internal galvanic slip-ring type connector and conduit. This design eliminates the need for external cable connectors and protectors, reducing installation time and minimizing non-productive time (NPT) during completions. Traditional smart completions often suffer from cable damage or installation delays due to external cable routing. This solution addresses those challenges by relocating and shielding the cable internally. To validate the concept, various software simulations were conducted. While simulations and component tests confirm the design's theoretical feasibility (TRL 4), upcoming workshop testing (part of the future work) will validate real-world assembly processes prior to advancing to TRL 5. This phased approach ensures risks are mitigated before field deployment. This work introduces a next-generation smart completion system that improves reliability, reduces NPT, and lowers cost by internalizing and protecting critical cabling. The technology's qualification to TRL 4 demonstrates its feasibility and readiness for further workshop and field validation, contributing novel solutions to the evolving landscape of intelligent well completions.