Abstract:
Disclosed herein is a control line protector including a matrix having at least one bumper and at least one receptacle. Further disclosed herein is a method for protecting a bare control line by positioning a protector having a matrix at least one bumper and at least one receptacle configured to accept the control line.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application claims the benefit of an earlier filing date from U.S. Provisional Application Serial No. 60/464,818 filed Apr. 23, 2003, the entire disclosure of which is incorporated herein by reference. 
     
    
     
       BACKGROUND  
         [0002]    In the hydrocarbon exploration and recovery arts, control lines have long been an important component of successful operations downhole. These may be hydraulic, electrical, fiber, etc. Control lines are needed to communicate with devices positioned downhole and therefore remote from a surface location at which personnel may be stationed.  
           [0003]    Because of the harsh downhole conditions, including chemical and mechanical stress, among others, protection of control lines is desirable.  
           [0004]    To this end, the industry has produced tubing encapsulated conductors (TEC) which configures an electrical or other conductor, inside a tube of usually {fraction (1/4)} inch diameter. TEC line is very effective but unfortunately still suffers from stresses in the downhole environment.  
           [0005]    In order to improve longevity, the industry has created what is commercially known as a “flat pack”. A flat pack is matrix of material, usually a polymer, into which is embedded a control line and cables for crush resistance. The control line is completely encapsulated which is beneficial but the concept suffers in application due to the need at certain downhole tools to strip off the flat pack in order to pass the control line through the device. A packer is one such device. The result of a pass through is an exposed control line for a length which may be quite extended. The exposed length of control line is subject to all stress factors. This has been avoided by using many splices in the line (i.e., no real feed-throughs, just breaks and splices at devices). There has been, however, no practical solution to the problem.  
         SUMMARY  
         [0006]    Disclosed herein is a control line protector including a matrix having at least one bumper and at least one receptacle.  
           [0007]    Further disclosed herein is a method for protecting a bare control line by positioning a protector having a matrix at least one bumper and at least one receptacle configured to accept the control line. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]    Referring now to the drawings wherein like elements are numbered alike in the several figures:  
         [0009]    [0009]FIG. 1 is a cross-sectional representation of a first embodiment of a retrofit protector;  
         [0010]    [0010]FIG. 2 is a cross-sectional representation of a second embodiment of a retrofit protector;  
         [0011]    [0011]FIG. 3A is a cross-sectional representation of a third embodiment of a retrofit protector;  
         [0012]    [0012]FIG. 3B is an elevation view of the protector of FIG. 3A;  
         [0013]    [0013]FIGS. 3C-3F are alternate elevation view like  3 B but with distinct constructions of the protector;  
         [0014]    [0014]FIG. 4 is a cross-sectional representation of a fourth embodiment of a retrofit protector; and  
         [0015]    [0015]FIG. 5 is a cross-sectional representation of a fifth embodiment of a retrofit protector. 
     
    
     DETAILED DESCRIPTION  
       [0016]    Referring to FIG. 1, a first embodiment of a retrofit protector is illustrated. The protector  10  comprises a matrix  12 , at least one bumper  14  and at least one receptacle  16 . The matrix comprises a material capable of being formed to a configuration substantially as shown and holding that shape. In addition the matrix comprises a material that is resistant to vibration, abrasion, erosion, chemicals and mechanical compression or tension. In one embodiment the material is polymeric. Bumper(s)  14  comprise any relatively strong material having both tensile and compression resistant characteristics such as steel cable. Since flexibility is also desirable, stranded cable may be indicated for some embodiments. In each of the embodiments illustrated the matrix and bumpers are similar but the receptacle  16  is distinct.  
         [0017]    Still referring to FIG. 1, receptacle  16   a  is configured to extend into a control area  20  of matrix  12  from one side  22  of protector  10 . In this particular embodiment receptacle opening  24  is of a dimension smaller than a control line (not shown) to be housed in receptacle  16   a  to a degree calculated to provide retention of the control line in receptacle  16   a  while taking into account deformability of matrix  12  such that a control line is “snappable” into receptacle  16   a  by hand or by suitable equipment, depending upon application. For example only, one embodiment employees a receptacle bore  26  of about 6½ millimeters whereas the receptacle opening  24   a  is about 4 millimeters wide. It should be noted that in this and some of the embodiments discussed below, that receptacle  16   a  is offset from a centerline of the protector  10  in the longer direction depicted. This position reduces insertion force of the control line and increases protection of the control line by enhancing crush resistance particularly from crushing against a casing or open bore wall of a wellbore in which the protector is run.  
         [0018]    In a second embodiment, referring to FIG. 2, receptacle opening  24   b  is provided with an angle to ease installation of a control line. The angle is of about 5° to about 25° and reduces the force required to insert the control line into receptacle  16   b , while still requiring passage through a smaller dimension area calculated to retain the control line. Depending upon the type of control line being inserted, this system may be helpful in that it will tend to be more gentle on the control line.  
         [0019]    A third embodiment is illustrated in FIG. 3. This embodiment provides closure of the receptacle opening discussed in the previous embodiments. The embodiment of FIG. 3 includes a living hinge  30  on surface  32 . Surface  32  as illustrated is shown continuous. This is because receptacle opening  24   c  is configured to overlap itself when the protector  10  is in the closed position. In order to insert a control line in protector  10 , protector  10  is bent such that surface  32  becomes V-shape to open receptacle opening  24   c , thus allowing a control line to be installed into receptacle bore  26 . Protector  10  is then bent back to straighten surface  32 , and close receptacle opening  24   c  around the control line. In such configuration the control line is well protected 360° around the line. To illustrate the receptacle opening  24   c , FIG. 3B is provided which is taken on line  3 B- 3 B in FIG. 3A. Alternate overlapping structures visible on the  3 B view are illustrated in FIGS. 3C-3F.  
         [0020]    Referring to FIG. 4, another embodiment of protector  10  is illustrated. In this embodiment receptacle  16   d  is simply U-shaped and cut into surface  22 . In this embodiment the retention of the control line may be provided by an adherent such as a thermo fixed glue or an epoxy formulation or other glue applied to the receptacle before or after installation of the control line. Alternatively a polymer or other type of stick tape is similarly employable. It is also contemplated that mechanical compression against the control line occasioned by the protector  10  being clamped to a tubular with the receptacle opening toward the tubular and the clamp positioned perimetrically around both to clamp the protector to the tubular. Due to the curved outside surface of the tubular, the protector is urged into an arcuate condition when considered in cross-section. Because of the arcuate condition the sides of the receptacle opening are urged toward each other effectively pinching the control line in place. It will also be appreciated that each of the foregoing methods for retention may be combined in whole or in part.  
         [0021]    Finally, referring to FIG. 5, a receptacle  16   e  is fully enclosed to both of side  22  and side  32  of protector  10 . In this embodiment, bore  26   e  is in fact a closed bore through the center area of a matrix  12 . In this embodiment the control line  26  is fed through receptacle bore  26   e  from one end.  
         [0022]    In each of the embodiments illustrated herein a control line, which by prior art means would have to be left exposed in the wellbore, or could be protected by an excess number of splices can be effectively protected without the drawbacks inherent in the prior art.  
         [0023]    While preferred embodiments of the invention have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation.