Disclosed are methods and devices for testing downhole connector electrical systems and cable integrity during installation of a permanent completion, including a customized retrievable plug arm assembly connectable to the completion during RIH, the tool mimicking a retrievable ESP, but without motor, and can be employed with or without pressure isolation. Another method employs a slidable starpoint located within the downhole wet mate connector of the completion to provide continuous electrical contact between the phases when no retrievable assembly is in place. When a retrievable assembly is later put in place, the slidable starpoint is moved into a second position that no longer provides electrical contact between the phases. Another method uses fusible links installed between two conductors within the downhole electrical connector system of the completion to provide similar electrical contact between phases, the fusible link configured to melt away once motor current is sent through the conductors.

A wet connector for a downhole tool string includes an insulating material body, a conductive core and an insulating piston. The insulating material body is provided with a first chamber, and the first chamber is filled with insulating oil. A conductive core chamber of the conductive core is communicated with the first chamber. The insulating piston is hermetically connected to a first opening through a first sealing lip. When a male connector abuts against the insulating piston and moves toward the bottom of the conductive core chamber, the male connector is in contact with and electrically connected to the conductive core chamber, so that the insulating oil in the first chamber is compressed, and a pressure of the insulating oil in the first chamber is enabled to be greater than a pressure of well fluid outside the wet connector.

A cable system for use downhole includes a connector assembly having a body and a bore formed therethrough; a conductor disposed through the bore of the connector assembly; and a first insulation layer disposed around the conductor. An insulator tube is disposed around the conductor and has an end attached to the first insulation layer. The insulator tube may be made of a thermoplastic material. A graphite containing sealing member is disposed in the bore and disposed between the insulator tube and the body of the connector assembly.

A self-retracting coiled cable having a variable length along a center line can include an outer insulator sleeve having a longitudinal axis. The self-retracting coiled cable can also include a spring material extending along the longitudinal axis of the outer insulator sleeve. The spring material can hold the outer insulator sleeve in a helical shape around the center line. The spring material can also allow the self-retracting coiled cable to expand upon an application of an axial force to an end of the self-retracting coiled cable, thereby increasing a length of the self-retracting coiled cable, and to retract upon a removal of the axial force from the end of the self-retracting coiled cable, thereby reducing the length of the self-retracting coiled cable. The self-retracting coiled cable can further include multiple wires extending along the longitudinal axis of the outer insulator sleeve and disposed symmetrically around the spring material.

A completion system and method for intelligent control of multilateral wells. A completion deflector defines a hollow interior that is fluidly coupled with a uphole tubing and downhole main completion strings. Hydraulic, electric, and/or fiber-optic communication line segments extend between the uphole end and downhole end of the completion deflector for providing power, control or communications between the surface and production zones associated with the main wellbore. The communication line segments are located outside the completion deflector interior and may be located within longitudinal grooves formed along the exterior wall surface of the completion deflector. A self-guided, wet-matable connector is provided at the uphole end, which connects the both interior flow path and communication lines, and which may allow connection at any relative radial orientation. The uphole end of the completion deflector has an inclined upper surface for deflecting various tools and strings into a lateral wellbore.

Electrically insulated connector bands for Downhole Electrical Disconnect Tools provide power and/or data communication downhole are made from metal having sufficient strength and corrosion resistance to eliminate the need of any vacuum and sealed pressure compensation assembly while being exposed to wellbore fluids. The electrical insulation is achieved by having portions of the connector bands coated with electrically insulating material. An uncoated section of each connector band will provide the electrical path between the male and female mandrels.

The transmission line for wired pipe applications includes an inner conductor, an insulating material surrounding the inner conductor, the insulating material having an initial outer diameter, and a wire channel surrounding the insulating material and the inner conductor for at least a portion of a length of the transmission line. The wire channel is formed from at least two profiles forced together to compress the insulating material such that it has a final outer diameter that is less than the initial outer diameter.

A conductive device includes a housing, a glass insulator, and a conductor. The housing comprises an opening. The glass insulator is located within the opening, wherein a seal is formed between the housing and the glass insulator. The conductor is located at least partially within the glass insulator and comprises at least one of conductive ceramic, cemented carbide, and cermet. A seal is formed between the glass insulator and the conductor.

The present disclosure provides a current monitoring circuit for monitoring current in a electromagnetic telemetry system. The circuit includes a transmitter configured to generate an output current. One or more current monitors are positioned to detect current at or near the electrode stations or at positions along the one or more loops. Measured current data is transmitted back to the transmitter, which may be shut down if necessary. Methods for monitoring current in an electromagnetic telemetry system are also provided.

An improved gap sub assembly that can withstand the rigors of directional drilling, while still being cost effective and easy to deploy at the drill site. Embodiments can be assembled by sliding a mandrel into a housing without any threading or clocking, filling the gap between the housing and mandrel with an electrically isolating material, and curing the electrically isolating material to mechanically couple the housing and mandrel. In some embodiments, the interior surface of the housing and the outer surface of the mandrel comprise a plurality of complimentary axial sections having staggered diameters so that a constant dielectric gap is maintained. In some embodiments, the interior surface of the housing and the outer surface of the mandrel comprise non-overlapping right- and/or left-handed helical grooves that, when filled with a cured electrically insulating material, forms a complex 3D shear resistance mechanism optimized to resist torsion or twisting.