New Downhole Wet-Mate Design Resulted in Capex Reduction

Abstract Intelligent completions in multizone wells require hydraulic control lines connected to the surface to maintain functionality. To reduce capital expenditure (Capex) of failed equipment, such as an electrical submersible pump (ESP), the industry required a reliable method to remove the upper completion without the complexity and uncertainty of unsetting one or more packers and pulling out the entire completion. This paper will discuss the essential aspects of a new hydraulic wet-mate design, its qualification, and installation methods over numerous ESP wells combined with an intelligent completion that resulted in zero nonproductive time (NPT), with full control of the lower intelligent completion. Additionally, the future of this technology will be discussed, such as the addition of a direct-connect electrical wet mate that requires no orientation to the hydraulic wet-mate design for a complete two-trip intelligent completion. The downhole wet-mate connector success is directly related to the design simplicity. The tool is concentric and requires no specific orientation for a successful wet mate. It also has the ability to run in highly deviated wells with a wide range of casing sizes without modifications from 7 into 9 5/8 in. Another crucial design feature is the soft-release mechanism that allows for the removal of the upper portion of the wet mate (male) from the lower portion (receptacle), without excessive overpull, such as overcoming a shear ring or snap latch. This ability allows the wet mate to be separated without excessive overpull that could damage the tool permanently. The qualification process included multiple iterations of pressure and temperature testing around the performance envelope, debris testing, and for the electrical portion, a test with high-salinity brine while recording the downhole pressure and temperature gauges. De-completing an intelligent completion well can be complex, particularly when multiple packers require release. ESPs typically have a life span of approximately 5 years. The downhole wet-mate tool enables ESP replacement without disturbing the intelligent completion, which provides a significant advantage, especially in a multizone well equipped with multiple hydraulic-controlled interval control valves (ICVs). Cost savings: Overall risk reduced by removing the need to retrieve the entire intelligent completion from the well and the re-spooling of additional control lines and related clamps and accessoriesStab in and stab out without rotation Efficiency improvements: Soft-release device reduces the risk of system damage This paper will discuss the aspects of a reliable wet-mate completion tool and highlight the concurrent successful installations that prove the design and deployment methods are sound.