Beacon Lid Pressure Sensor Segmentation for Downhole Accuracy

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Solution Overview

Problem

Existing downhole tools face challenges in accurately measuring downhole fluid pressure due to space constraints and the need for pressure sensors to be in direct contact with the borehole annulus, which is not feasible with existing arrangements.

Innovation Solution

The downhole tool incorporates a lid with an intermediate layer containing electronic hardware, including a pressure sensor, that is positioned to directly contact the borehole fluid, allowing for accurate fluid pressure measurements by projecting the sensor into a port filled with potting compound, which communicates fluid pressure to the sensor.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a pressure sensor is installed in the beacon housing to measure downhole fluid pressure, then pressure measurement capability is improved, but space constraints within the housing prevent the sensor from being positioned to directly contact the borehole annulus

Engineering Contradiction:

Improvefluid pressure measurement accuracyVSAvoidhousing internal space

Core Design Contradiction:

Measurement precisionVSVolume of moving object

Solution Approach 1:

The housing is divided into separate functional zones: the beacon housing contains the magnetic dipole and basic electronics, while the lid housing contains the pressure sensor and communication electronics. This segmentation allows the pressure sensor to be positioned in the lid where it can access fluid pressure through the port, rather than being constrained within the compact beacon housing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A port filled with potting compound serves as an intermediary medium between the borehole annulus fluid and the pressure sensor. The potting compound transmits fluid pressure to the sensor diaphragm, enabling accurate pressure measurement without requiring the sensor to be in direct contact with the annulus, thus solving the space constraint problem.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If the pressure sensor is positioned to directly contact the borehole annulus, then measurement accuracy is improved, but the complex housing arrangement prevents feasible sensor placement

Engineering Contradiction:

Improvefluid pressure measurement accuracyVSAvoidhousing arrangement complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The lid is designed to integrate multiple functions: it closes the housing opening, provides structural support, houses the pressure sensor, contains communication electronics, and provides the fluid access port. By merging these functions into a single component, the design avoids the complexity of separate structures while enabling the sensor to be positioned for accurate measurement.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The lid serves as a multi-functional component that simultaneously acts as a closure element, sensor housing, electronics platform, and fluid interface structure. This universal design eliminates the need for additional specialized components, reducing overall device complexity while achieving the required sensor positioning for accurate pressure measurement.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Loss of information

If electronic hardware is added to the housing, then downhole communication capability is improved, but space for beacon components is reduced

Engineering Contradiction:

Improvedownhole data transmissionVSAvoidbeacon housing space

Core Design Contradiction:

Loss of informationVSVolume of moving object

Solution Approach 1:

Electronic hardware for downhole communication is segregated into the lid housing, separate from the beacon housing. This segmentation preserves the beacon housing space for the magnetic dipole and essential beacon components, while providing dedicated space in the lid for communication electronics, batteries, and associated hardware.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This configuration enables precise measurement and transmission of downhole fluid pressure, detecting anomalies such as cross-bore or frac-out scenarios, enhancing drilling operation control.

Implementation Method 1

a beacon configured to generate a magnetic dipole field

Methodology Applied

Scientific EffectMagnetic dipole field: Magnetic Field

Implementation Method 2

a pressure sensor that is positioned to directly contact the borehole fluid

Methodology Applied

Scientific EffectPressure sensing:

Data Source

PatentUS11319797B2Beacon housing lid with built-in pressure sensor

Publication Date: 2022.05.03 CHARLES MACHINE WORKS INC

AI summary

A lid for use with a downhole tool configured to house a beacon. The lid has an exterior and interior surface. A board is attached to the interior surface of the lid and electronic hardware is positioned between the board and the interior surface of the lid. The electronic hardware includes a pressure sensor. The pressure sensor is installed within the lid so that it is communicable with the exterior surface of the lid. When the downhole tool is positioned within an underground borehole, the pressure sensor measures the fluid pressure of any fluid surrounding the downhole tool. Measurements taken by the pressure sensor are transmitted to the beacon housed within the downhole tool. The beacon subsequently transmits such measurements to a tracker located at the ground surface.