WO2006005895A1

WO2006005895A1 - Forming a control line protector by injection molding

Info

Publication number: WO2006005895A1
Application number: PCT/GB2005/001941
Authority: WO
Inventors: Iain Baxter
Original assignee: Schlumberger Holdings Limited; Schlumberger Cananda Limited; Schlumberger Surenco S.A.; Schlumberger Oilfield Assistance Limited; Schlumberger Overseas S.A.; Prad Research And Development N.V; Schlumberger Services Limited; Services Petroliers Schlumberger; Schlumberger Technology B.V.
Priority date: 2004-07-09
Filing date: 2005-05-19
Publication date: 2006-01-19
Also published as: GB0415412D0; GB2415932A

Abstract

An apparatus and method of making a control line protector comprises adjusting an injection molding tool according to a target specification of the control line protector, and performing an injection molding process with the injection molding tool to form the control line protector.

Description

FORMING A CONTROL LINE PROTECTOR BY INJECTION MOLDING

BACKGROUND OF THE INVENTION Field of the Invention

[0001] Oil, gas, or water wells commonly employ the use of some form of control lines to communicate with or to provide power to downhole equipment. Examples of control lines used in a downhole environment include electrical lines, hydraulic lines, and fiber optic lines. For example, downhole sensors may communicate measurements to surface equipment over electrical cables or fiber optic lines. Also, hydraulic power can be provided to control downhole components, such as to operate valves or set downhole packers, using hydraulic lines or other lines for communicating fluid pressure. If unprotected, control lines may be easily damaged during deployment of tool strings into the well, or by other movement or operation of downhole components.

[0002] Control lines, such as electrical cables, are especially susceptible to damage near the joints between tubing or pipe sections because of the presence of extra components (such as a coupling mechanism) used for attaching the joints. Cable protectors are usually provided at such pipe or tubing couplings to provide protection for electrical cables.

Description of Related Art

[0003] A cable protector for protecting electrical cables typically includes a body section, in which the electrical cables are accommodated, with the body section coupled to a clamp piece to enable fastening of the cable protector to a tubing or pipe section. However, a specifically manufactured conventional cable protector is rather limited in the types of cable and tubing couplings that it can be used with. As the requirements of a well operation change, tubing or pipe sizes may also need to change. When this occurs, existing cable protectors may not be suitable for use with the different tubings or pipes. As a result, in anticipation of such changes, a well operator may have to keep various different types of cable protectors on hand. This increases the number of components that must be kept by the well operator, which may increase the cost of well operation.

[0004] Also, economically efficient manufacturing techniques have generally not been available to alter cable protectors to different dimensions. As a result, increased operating costs are experienced by well operators who must use cable protectors of different dimensions.

BRIEF SUMMARY OF THE INYENTION

[0005] According to one embodiment of the invention, a method of making a control line protector includes adjusting an injection molding tool according to a target specification of the control line protector, and performing an injection molding process with the injection molding tool to form the control line protector.

[0006] Other or alternative features will become apparent from the following description, from the drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Fig. 1 illustrates a tubing string positioned in a wellbore, according to one example.

[0008] Fig. 2 is a perspective view of an assembly of tubing sections, a coupling, electrical control lines, and a cable protector assembly in accordance with an embodiment.

[0009] Fig. 3 is a perspective view of a guard section of the cable protector assembly of Fig. 2.

[0010] Fig. 4 shows a portion of the guard section of Fig. 3, which includes a vertical key element.

[0011] Fig. 5 is a perspective view of an end section that is configured to mate with the guard section of Fig. 3. [0012] Fig. 6 is a different perspective view of the end section of Fig. 5, with a portion of the housing of the end section removed.

[0013] Fig. 7 is a longitudinal sectional view of the assembly of Fig. 2.

[0014] Fig. 8 is a sectional view of a smaller portion of the assembly of Fig. 2.

[0015] Fig. 9 is a perspective view of an assembly of tubing sections, a coupling, and a control line protector assembly according to another embodiment.

[0016] Fig. 10 is a perspective view of a guard section of the control line protector assembly of Fig. 7.

[0017] Fig. 11 illustrates a portion of the guard section of Fig. 10.

[0018] Fig. 12 is a bottom perspective view of an end section configured to be mated with the guard section of Fig. 10.

[0019] Fig. 13 is a different perspective view of the end section of Fig. 12.

[0020] Fig. 14 is a perspective view of a control line protector formed by an injection molding process, according to another embodiment.

[0021] Fig. 15 shows a male mold block and a female mold block in an injection molding tool, according to one embodiment of the invention, for forming the control line protector of Fig. 14.

[0022] Fig. 16 shows another embodiment of a female mold block that has a variable length.

[0023] Fig. 17 shows another embodiment of a male mold block that has a variable length.

[0024] Fig. 18 illustrates the male mold block and female mold block of Fig. 15 assembled together.

[0025] Figs. 19A-19B are different views of an insert for the control line protector. [0026] Figs. 20A-20B are different views of the insert of Figs. 19A-19B integrated into the control line protector.

DETAILED DESCRIPTION OF THE INVENTION

[0027] In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments are possible.

[0028] Fig. 1 illustrates a tubing string 102, according to one example, positioned in a wellbore 100. The tubing string 102 has multiple tubing sections 2 that are coupled to each other by coupling mechanisms 3. One or more control lines 4 are routed along the outside of the tubing string 102, with the control lines 4 running over the coupling mechanisms 3. Examples of the control lines 4 include hydraulic control lines, electrical cables, fiber optic lines, and the like. Control line protector assemblies 19 according to some embodiments are provided at each of the coupling mechanisms 3 to protect the one or more control lines 4.

[0029] Although reference is made to a tubing string in the described embodiments, the control line protector assembly 19 according to some embodiments may be employed with other types of tool strings used in a well. A tubing string may have multiple tubing sections. More generally, a tool string can have multiple string sections.

[0030] A portion of the tubing string 102 is shown in greater detail in Fig. 2 (cross- section shown in Fig. 7). The portion shown in Fig. 2 includes tubing sections 2, a coupling mechanism 3, and a control line protector assembly 19. In Fig. 2, the tubing sections 2 are shown as tubing section 2A and tubing section 2B, with the two tubing sections 2 A and 2B coupled by the coupling mechanism 3. As used here, a "tubing" refers to any structure, cylindrical or otherwise, that is run into a wellbore in sections that are attached by a coupling mechanism. The "tubing" can be a solid structure, or it can be a hollow structure with a longitudinal bore. [0031] As also shown in Fig. 2, one or more control lines 4 (e.g., an electrical cable) are run along the outer surface of the tubing sections 2 A, 2B. The control lines 4 are especially vulnerable at the sections that run over the outer surface of the coupling mechanism 3 because the coupling mechanism 3 is raised above the outer surface of the tubing sections 2A₅ 2B. To protect the control lines from damage in the region proximate the coupling mechanism 3, the control line protector assembly 19 is mounted over the control lines 4, as shown.

[0032] For improved flexibility in accordance with some embodiments, the control line protector assembly 19 has a number of sections or segments that are attached together. The dimensions of the sections or segments of the control line protector assembly 19 are adjustable by a manufacturer (such as by cropping, cutting, and the like) to adjust the control line protector assembly to fit with tubing sections and coupling mechanisms of various sizes. More generally, the sections or segments of the control line protector assembly 19 can be tailored to suit a given arrangement (e.g., size and length) of at least one of the coupling mechanism 3 and the tubing sections 2 A, 2B.

[0033] The tailoring of one or more segments of the control line protector assembly 19 can be performed. This enables a manufacturer to keep one type of control line protector assembly 19 for multiple possible arrangements of coupling mechanisms 3 and tubing sections 2 A, 2B.

[0034] The control line protector assembly 19 includes a guard section 5 that fits over a portion of the housing of the coupling mechanism 3. The guard section 5 is engaged with end sections 6 (illustrated as 6 A, 6B in Fig. 2) at the two ends of the guard section 5. The guard section 5 and end sections 6 are separate elements that can be lockingly engaged to enable fastening of the control line protector assembly 19 to the rest of the tool string. As described further below, profiles in the guard section 5 can be adjusted to modify the dimensions of the guard section 5 so that the control line protector assembly 19 can be fitted with components (e.g., the coupling mecham^'sm 3, the pipe sections 2A, 2B) of varying sizes and configurations. In other embodiments, profiles of the end sections 6 can also be modified. [0035] In the embodiment shown in Fig. 2, the guard section 5 does not extend around the entire circumference, but rather it extends less than the entire circumference. This is best seen in Fig. 3, which shows the guard section 5 having a generally arcuate main body 202. Alternatively, the guard section 5 can be generally tubular in shape to completely enclose portions of the tubing sections 2 A, 2B and the coupling mechanism 3.

[0036] Longitudinal side members 204 and 206 extend downwardly from the arcuate main body 202. In the implementation of Fig. 3, the arcuate main body 202 and the longitudinal side members 204, 206 are integrally connected. However, in other embodiments, the main body 202 and side members 204, 206 are separate pieces that are connected to each other. The arcuate main body 202 and side members 204, 206 define an inner longitudinal groove 205 for receiving an outer surface of the coupling mechanism 3 and/or outer surfaces of the tubing sections 2 A, 2B.

[0037] The side members 204 and 206 are connected to outwardly protruding vertical key elements 17, with each key element having a vertical segment 208 that is spaced apart from the outer wall of a respective side member 204, 206. Each key element 17 also has a connector member 209 that connects the vertical segment 208 to the side member 204, 206. In one embodiment, the side member 204, 206, connector member 209, and vertical segment 208 are all integrally connected. In other embodiments, the different pieces can be separate elements that are bonded or attached together.

[0038] The guard section 5 has four discrete key elements 17, with one at each corner of the guard section 5. Each key element 17 extends some length Ll along the longitudinal axis of the guard section 5.

[0039] As best seen in Fig. 4, the upper portion of the vertical segment 208 of each key element 17 has a snap lock projection 18 that protrudes inwardly toward the outer wall of the respective member 204, 206. A gap 210 exists between the key element 17 and the outer wall of the side member 204, 206. This gap 210 enables insertion of each key element 17 into a corresponding structure of an end section 6. [0040] Each end section 6 is shown in greater detail in Figs. 5 and 6. As shown in Fig. 5, vertical slots 12 are provided on the two lateral sides of the end section 6 to receive respective key elements 17 on the two lateral sides of the guard section 5. Note that each of the vertical slots 12 is completely enclosed to provide an enclosed slot or duct. A rear perspective view of the end section 6 is shown in Fig. 6, with a portion of the housing of the end section 6 removed to illustrate the slots 12. Within each slot 12 is a snap lock ledge 13, which is designed to engage the snap lock projection 18 of a respective key element 17. Once the key element 17 is pushed upwardly into the slot 12, and the snap lock projection 18 engages the snap lock ledge 13, the end section 6 and the guard section 5 are engaged and locked with respect to each other in the manner shown in Fig. 2. Because the slot 12 is enclosed, the length Ll (Fig. 3) of the key element 17 is adjusted (by cropping or cutting the key element 17) such that the length Ll is equal to the width W (Fig. 5) of each slot 12.

[0041] More generally, the key element 17 is referred to as a "first engagement member" and the slot 12 and snap lock ledge 13 are collectively referred to as a "second engagement member." In other embodiments, other types of first and second engagement members may be employed.

[0042] The end section 6 also has a generally arcuate main body portion 220, with protruding members 222 and 224 extending in a first direction from the arcuate main body portion 220. Locking and clamping segments 226 and 228 extend from the other side of the arcuate body portion 220 of the end section 6. The locking and clamping segments 226 and 228 define the slots 12 for receiving the key elements 17. The inner profiles of the arcuate body portion 220, protruding members 222, 224, and the locking and clamping segments 226, 228 are shaped to receive portions of the pipe sections 2A, 2B and coupling mechanism 3.

[0043] The arcuate body portion 220 has a control line conduit structure 14, which defines plural grooves 232 through which the control lines 4 can extend. In one example implementation, one type of control line (e.g., an electrical cable) runs through a first one of the grooves 232, a second type of control line (e.g., a hydraulic line) runs through a second one of the grooves 232, and so forth. The control line conduit structure 14 is designed to slightly bend the control line 4 to provide support for the control lines 4. In one embodiment, as best shown in Fig. 8, the conduit structure 14 has a sloped inner surface 240 to bend the portions of the control lines 4 in the grooves 232. The sloped surface 240 is achieved by providing one end 234 with a larger inner diameter than a second end 236.

[0044] Further, an outer groove 230 (Fig. 5) is provided in each of the locking and clamping segments 226 and 228. Holes 15 and 16, which extend generally in a longitudinal direction of the end section 6 extend through rear portions of locking and clamping segments 226 and 228, respectively. The holes 15 and 16 are provided to receive a hinge pin and barrel fastener assembly. It should be noted, however, that the barrel does not require holes for attachment, but may alternatively be attached using a recess.

[0045] As shown in Fig. 2, two collar clamps 7 A, 7B are hingedly joined to respective end sections 6 A, 6B, with hinge pins extending through the holes 15 and 16. The control line protector assembly 19 is clamped to the tubing sections 2A, 2B with swing barrel 9 and bolt 10 arrangements. A swing barrel 9 A and bolt 1OA arrangement attaches the end section 6A to tubing section 2 A, and a swing barrel 9B and bolt 1OB arrangement attaches the end section 6B to tuning section 2B. When assembled, each of the swing barrel and bolt arrangements 9, 10 is locked in place by the use of a respective lock washer HA, HB, which is designed to prevent the bolt from being backed fully out of the barrel. Effectively, the use of the lock washers 1 IA, 1 IB ties the bolt and barrel into an integral assembly.

[0046] As further shown in Fig. 2, the control line protector assembly 19 covers portions of the control lines 4, which are routed through one of the conduits defined in the control line conduit structure 14 of the end section 6.

[0047] Fig. 9 shows an alternative embodiment of a tubing string that includes a different control line protector assembly 119 for protecting control lines (not shown in Fig. 9) extending along the outside of tubing sections 2 A, 2B. A guard section 105 (Fig. 10) and end sections 106 A, 106B (that are attached to the two end portions of the guard section 105) of the control line assembly 119 have different designs from the guard section 5 and end sections 6A, 6B, respectively, of the control line assembly 19 described above.

[0048] As shown in Fig. 10, the guard section 105 has continuous key elements 117 on the two lateral sides of the guard section 105 (unlike the discrete vertical key elements 17 of Fig. 3). The outer surface of each of the key elements 117 has a series of vertical ridges 122 that run along the longitudinal direction of the guard section 105. Also, each key element 117 defines a continuous snap lock projection 118 on its inner surface that extends the length of the guard section 105. The length of the guard section 105 (and of the key elements 117) is selected based on the expected size of the tubing sections 2A, 2B and the expected range of length of the coupling mechanism 3.

[0049] As shown in Figs. 12 and 13, the end section 106 defines open slots 112 (unlike the enclosed slots 12 of the first embodiment) to receive respective key elements 117. Because of the open slot 112 arrangement of the second embodiment, the key elements 117 do not need to be cut to fit into the slots 112 after cropping of the guard section 105. A first inner surface of each slot 112 contains vertical ridges 121 that are designed to be aligned with the ridges 122 of the guard section 105. The other inner surface of the slot 112 has a snap lock ledge 113 for locking engagement with the snap lock projection 118 of the key element 117. As with the first embodiment, each end section 106 has a generally arcuate body portion 302, with locking and clamping segments 304, 306 extending from one side of the arcuate body portion 302. Holes 115 and 116 are formed through the locking and clamping segments 304, 306 to receive a hinge pin 108 (Fig. 9) and barrel fastener, respectively.

[0050] The body portion 302 also has a control line conduit structure 114 having plural grooves 308 through which control lines are routed.

[0051] In operation, using the arrangement according to the first embodiment of the control line protector assembly 19 (Fig. 2), the guard section 5 is initially prepared by cropping the overall length to suit the particular coupling mechanism 3. Next, the vertical key elements 17 may be cropped to suit the length of the slots 12 in the end sections 6 A, 6B. The guard section 5 and the end sections 6A, 6B are then joined together by placing the end sections 6A, 6B over the top of the guard section 5 to lockingly engage the key element 17 inside the slots 12. Once the key elements 17 and slots 12 are lined up, the two are pressed together so that the snap lock ledge 13 and the snap lock projection 18 engage. The two collar clamps 7A₅ 7B are then made up to the assembly with hinge pins. The swing barrel and bolt arrangement 9, 10 is then installed in the collar clamp 7 and the lock washer 11 is engaged to the bolt 10.

[0052] In the second embodiment (Figs. 9-10), to make up the control line protector assembly 119, the guard section 105 is initially prepared by cropping the overall length to suit a given coupling mechanism 3. Unlike the first embodiment, however, the length of the key elements 117 does not need to be adjusted to fit into slots 112 of the end sections 106A, 106B. The two collar clamps 107 A, 107B are then made up to the assembly using hinge pins 108, with the barrel and bolt arrangement in the collar clamps 107 A, 107B. The lock washer is then made up.

[0053] The various pieces of each control line protector assembly 19, 119 can be made of various materials, such as steel, plastic, or a composite material. Certain pieces can be made of steel, while other pieces made of plastic, or a combination thereof. Also, in addition to metal or plastic, other types of materials, such as composites, can also be used.

[0054] The guard section 5, 105 can be manufactured by casting, molding, extruding, or by other means appropriate to the materials of the guard section. The guard section has a width and height selected to accommodate the expected range of control line sizes, coupling diameters, coupling lengths, and tubing sections. The end sections 6, 106 are manufactured by casting, molding, extruding, or by any other means appropriate to the material of the end sections.

[0055] According to another embodiment, instead of forming discrete pieces as described above, an injection molding process may be used to form a control line protector. The injection molding process employs an injection molding tool that is configurable to form control line protectors of different configurations. Using the injection molding process, a single-piece control line protector can be formed according to specifications of a well operator or other user. The benefit this offers over the embodiments discussed above is that a well operator or other user does not need to perform post-molding tailoring to suit a particular tool string. Instead, the control line protector of the desired configuration can be specified in advance, with the specification provided to an injection molding manufacturer. The control line protector is then formed by the injection molding process according to the specification.

[0056] Fig. 14 shows a control line protector 400 with various configurable portions. The control line protector 400 has two end portions 404 and 406. Connecting the two end portions 404 and 406 is an intermediate section, which can be one of intermediate sections 402A, 402B, and 402C. The intermediate sections 402A, 402B, and 402C are of different lengths. The intermediate section 402A has a first length, the intermediate section 402B has a second length longer than the first length, and the intermediate section 402C has a third length longer than the second length. In other embodiments, additional intermediate sections of different lengths can also be provided.

[0057] Selection of one of the intermediate sections 402A, 402B, and 402C enables the overall length of the control line protector 400, and the length of cut-out 417 therein, to be varied. Cable inserts 408 and 410 (connected to end portions 404 and 406, respectively) are also configurable. The cable inserts 408 and 410 have channels 412 and 414, respectively. The channels 412 and 414 of the cable inserts 408 and 410 can be varied in size for fitting over control lines of different dimensions. The number of channels 412, 414 can also be varied according to the configuration of the tool string.

[0058] Another configurable aspect of the control line protector 400 is shoulder pads 416 and 418. The shoulder pads 416 and 418 can have different sizes to fit different couplings in tool strings.

[0059] Although shown as different parts in Fig. 14, the various parts of the control line protector 400 are integrated into a single-piece unit by the injection molding process according to some embodiments of the invention. Fig. 15 shows a portion of the injection molding tool, with the depicted portion including a male mold block 500 and a female mold block 502. The male mold block 500 includes a protrusion 504 of generally semi-cylindrical shape that is shaped to fit into a cavity 506 in the female mold block 502.

[0060] The cavity 506 in the female mold block 502 has a corresponding semi-cylindrical shape. The cavity 506 is larger in size than protrusion 504. As a result, when the male mold block 500 and female mold block 502 are assembled, a mold cavity 520 (Fig. 18) is formed between the male mold block 500 and the female mold block 502. This mold cavity 520 has a semi-cylindrical shape that corresponds to the semi-cylindrical shape of the control line protector 400 shown in Fig. 14. - Shoulder inserts 508 and 510 are also provided on either side of the semi-cylindrical protrusion 504 of the male mold block 500 to enable formation of the cut-outs 417 depicted in Fig. 14. Varying the length of the shoulder inserts 508 and 510 causes the length of the cut-outs 417, and shoulder pads 416 and 418, to change.

[0061] When assembled (as depicted in Fig. 18), a melted material, such as a polymer or composite, is injected into the mold cavity 520 between the male mold block 500 and the female mold block 502. The injection is usually performed by an injection tool 522 that injects the melted material under pressure into the mold cavity 520. Once a sufficient amount of material has been injected into the mold cavity 520, the injection tool is 522 held under pressure until the injected material cools and sets hard inside the mold cavity. Once the injected material cools and hardens, the injection tool 522 is removed and the male mold block 500 and female mold block 502 are separated to produce the control line protector 400.

[0062] Figs. 16 and 17 show an alternative embodiment of the male mold block 550 and a female mold block 552. The male mold block 550 has three sections: end sections 550A and 550C, and an intermediate section 550B. The intermediate section 550B is selectable to several different lengths such that a control line protector 400 of different lengths can be manufactured. Different intermediate inserts 550B having different lengths are used to provide the variable length male mold block 550. [0063] Similarly, the female mold block 552 has three sections: end sections 552A and 552C and an intermediate section 552B that is selectable to different lengths. Shoulder inserts 554 and 556 are provided on either side of protrusions 558A, 558B, and 558C before the male mold block 550 is inserted into the cavities 560A, 560B, and 560C of the female mold block 552. Once assembled, the assembly of the male mold block 550 and female mold block 552 is similar to the assembly of the male mold block 500 and female mold block 502 of Fig. 18, except the length of each of the male mold block 550 and female mold block 552 can be varied.

[0064] According to some embodiments, a metallic insert 600 (two different views shown in Figs. 19A- 19B) may be molded into the control in protector 400. As shown in Figs. 20A-20B, the insert 600 is provided into a receptacle 602 on a side of the end portion 404 or 406 of the control line protector 400 (Fig. 14). The insert 600 has a generally U-shaped slot to receive a bolt or screw. The insert 600 also defines an inner cavity 604 to receive an end portion of a bolt or screw. The insert 600, molded into the end portion 404 and/or 406 of the control line protector 400, provides reinforcement so that a bolt or screw can be torqued to a desired level.

[0065] While the invention has been disclosed with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover such modifications and variations as fall within their scope.

Claims

CLAIMSWhat is claimed is:

1. A method of making a control line protector, comprising: adjusting an injection molding tool according to a target specification of the control line protector; and performing an injection molding process with the injection molding tool to form the control line protector.

2. The method of claim 1 , wherein adjusting the injection molding tool according to the target specification is based on dimensions of sections of a tool string and a coupling to couple the sections of the tool string.

3. The method of claim 1 , wherein adjusting the injection molding tool comprises adjusting the injection molding tool to one of plural dimensions.

4. The method of claim 3, wherein the injection molding tool comprises a male mold block and a female mold block, the male mold block having a protrusion and the female mold block having a cavity to receive the protrusion, the method further comprising: adjusting a length of each of the male mold block and female mold block; and assembling the male mold block and the female mold block.

5. The method of claim 4, further comprising: injecting a material as part of the injection molding process into a mold cavity between the male mold block and the female mold block to form the control line protector.

6. The method of claim 5, wherein forming the control line protector comprises forming a control line protector to cover a portion of a control line for use with a string having sections and a coupling to couple the sections.

7. The method of claim 5, wherein the male mold block has two end sections and an intermediate section, the method further comprising selecting one of plural lengths for the intermediate section between the end sections of the male mold block.

8. The method of claim 7, wherein the female mold block has two end sections and an intermediate section, the method further comprising selecting one of plural lengths for the intermediate section of the female mold block between the end sections of the female mold block.

9. The method of claim 5, further comprising providing side inserts on either side of the protrusion to create cut-out portions in the control line protector.

10. The method of claim 9, further comprising selecting one of plural lengths of the side inserts to vary lengths of the cut-out portions.

11. An inj ection molding tool comprising: a first mold block and a second mold block to define a mold cavity, the mold cavity shaped to form a control line protector.

12. The injection molding tool of claim 11 , wherein the first mold block has a generally semi-cylindrical protrusion, and the second mold block has a generally semi- cylindrical cavity to receive the protrusion, the mold cavity defined between the protrusion and the cavity.

13. The injection molding tool of claim 12, wherein the first mold block has plural segments, at least one of the segments selectable to have different lengths to vary a length of the first mold block.

14. The injection molding toOi of claim 13, wherein the second mold block has plural segments, at least one of the segments of the second mold block selectable to have different lengths to vary a length of the second mold block.

15. An apparatus comprising: a male mold block having a plurality of segments; and a female mold block having a plurality of segments, wherein at least one segment of the male mold block is selected from a plurality of candidate male mold block segments having different lengths, and wherein at least one of the segments of the female mold block is selected from a plurality of candidate female mold block segments having different lengths, wherein the male mold block and female mold block are adapted to be assembled.

16. The apparatus of claim 15, wherein the male mold block and female mold block define a mold cavity adapted to form a control line protector.

17. The apparatus of claim 16, further comprising an injection tool to inject a material into the mold cavity.

18. A method of forming a control line protector for use in a wellbore to protect one or more control lines, comprising: assembling an injection molding tool; and injecting molding material into the injection molding tool to form the control line protector.

19. The method of claim 18, wherein assembling the injection molding tool comprises assembling a male mold block with a female mold block that define a mold cavity shaped to form the control line protector.