Non-invasive Capacitive Pressure Sensor for High-Pressure Drilling
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Solution Overview
Problem
Existing high-pressure sensors in hydrocarbon drilling and extraction operations are invasive and prone to overpressurization, requiring additional components like leakage lines that increase costs and are susceptible to clogging.
Innovation Solution
A non-invasive pressure measurement system using capacitance-based sensors that measure pressure without direct contact with the fluid, eliminating the need for leakage lines by correlating capacitance changes with fluid pressure, and integrating with a high integrity pressure protection system (HIPPS) to control valve positions based on pressure thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If invasive pressure sensors are used to measure high-pressure fluids, then pressure measurement capability is achieved, but the system becomes susceptible to overpressurization and requires additional components like leakage lines
Solution Approach 1:
The patent introduces a capacitive sensor as an intermediary device that measures pressure without direct contact with the high-pressure fluid. The sensor comprises a first electrode in contact with the fluid and a second electrode separated by an insulating layer, creating a capacitive measurement system that acts as a mediator between the measurement need and the fluid, eliminating direct mechanical contact and its associated risks
Solution Approach 2:
The patent replaces traditional mechanical pressure sensors with a capacitive sensing system. Instead of using mechanical elements that directly contact and respond to fluid pressure, the system uses electrical capacitance changes across an insulating barrier to measure pressure, substituting a mechanical measurement approach with an electrical field-based approach that is inherently more resistant to overpressurization
2Reliability
If leakage lines are added to protect against overpressurization, then system safety is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the need for leakage lines and other protective components by fundamentally changing the sensing approach. The capacitive sensor design inherently protects against overpressurization through its non-contact measurement mechanism, allowing the removal of additional safety components and simplifying the overall system
Solution Approach 2:
The capacitive sensor structure provides its own protection against overpressurization through the insulating layer that prevents direct fluid contact. The sensor serves its measurement function while simultaneously providing its own pressure protection, eliminating the need for separate protective mechanisms
3Measurement precision
If leakage lines are used in the pressure measurement system, then pressure monitoring is enabled, but the lines are susceptible to clogging and increase system cost
Solution Approach 1:
The patent replaces mechanical pressure transmission lines with an electrical field-based capacitive sensing system. The measurement is taken through electrical capacitance changes across an insulating barrier, eliminating the need for physical leakage lines that could become clogged with debris or contaminants in the hydrocarbon fluid
4Measurement precision
If direct contact pressure sensors are used, then measurement accuracy is achieved, but the sensors are vulnerable to damage from high pressure
Solution Approach 1:
The patent introduces an insulating layer as an intermediary barrier between the pressure sensor electrodes and the high-pressure fluid. This layer allows the electrical field to penetrate for measurement purposes while physically protecting the sensor components from direct exposure to damaging high pressures
Solution Approach 2:
The patent replaces mechanical contact-based pressure sensing with electrical field-based capacitive sensing. The measurement is achieved through changes in electrical capacitance caused by pressure-induced changes in the insulating layer properties or electrode spacing, without requiring mechanical contact between the sensor and the high-pressure fluid
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
The non-invasive system reduces costs and prevents clogging by accurately measuring high pressures up to 1,000,000 PSI without direct contact, enhancing safety and efficiency in hydrocarbon extraction systems.
Implementation Method 1
A non-invasive pressure measurement system using capacitance-based sensors that measure pressure without direct contact with the fluid, eliminating the need for leakage lines by correlating capacitance changes with fluid pressure
Data Source
AI summary
A system includes a safety system having one or more valves configured to block a flow of fluid from a source to a destination, a non-invasive pressure measurement system having a plurality of non-invasive pressure sensors configured to monitor a pressure of the fluid without directly contacting the fluid, and a controller configured to receive feedback from the non-invasive pressure measurement system and to adjust a position of the one or more valves of the safety system based on the feedback.