Conditioned Isolation Elements for Downhole Sensor Assemblies

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Solution Overview

Problem

Conventional sensor isolation elements in harsh environments, such as downhole oil and gas wells, are susceptible to hydrogen permeation, embrittlement, and chemical degradation, leading to inaccurate measurements and component damage due to material diffusion and corrosion.

Innovation Solution

A conditioned isolation element is formed by subjecting a preformed isolation element structure to thermal annealing, reducing hydrogen permeability and enhancing resistance to physical and chemical degradation, thereby creating a structure that is less susceptible to hydrogen-based issues and corrosion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional isolation elements are used in harsh environments, then the sensor can perform measurements, but the isolation element is susceptible to hydrogen permeation, embrittlement, and chemical degradation

Engineering Contradiction:

Improveisolation element durabilityVSAvoidhydrogen permeation and chemical degradation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The isolation element undergoes thermal annealing treatment that changes the microstructural parameters of the material, specifically reducing dislocation density and refining grain structure. This parameter change in the material's internal structure reduces hydrogen diffusion pathways and improves resistance to hydrogen embrittlement and stress corrosion cracking, directly addressing the reliability issue in harsh environments

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The thermal annealing process is performed as a preliminary treatment before the isolation element is installed in the harsh environment. This preliminary action pre-conditiones the material to resist future hydrogen exposure and chemical degradation, preventing damage before it occurs rather than addressing it after exposure

Inventive Principle:

Principle #10Preliminary action

2Measurement precision

If isolation elements are exposed to hydrogen-containing environments, then measurements can be taken, but material diffusion deforms components and reduces measurement accuracy

Engineering Contradiction:

Improvepressure measurement accuracyVSAvoidhydrogen diffusion through isolation element

Core Design Contradiction:

Measurement precisionVSLoss of substance

Solution Approach 1:

Thermal annealing changes the microstructural parameters of the isolation element material, reducing dislocation density and refining grain structure. These parameter changes create a more dense material structure with fewer diffusion pathways for hydrogen, thereby reducing hydrogen permeation and preventing component deformation that would compromise measurement precision

Inventive Principle:

Principle #35Parameter changes

3Speed

If thin-walled isolation elements are used, then the sensor response is faster, but the components deteriorate over time when exposed to corrosive fluids

Engineering Contradiction:

Improvesensor response speedVSAvoidisolation element service life

Core Design Contradiction:

SpeedVSDuration of action of stationary object

Solution Approach 1:

The thermal annealing process changes the microstructural parameters of the thin-walled isolation element, reducing internal stresses and refining the grain structure. This improves the material's resistance to stress corrosion cracking and chemical degradation, extending the service life of thin-walled elements while maintaining their fast response characteristics

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention enables the use of thin-walled isolation elements that would normally have short service lives in corrosive environments. By applying thermal annealing, the effective service life is extended significantly, making these otherwise short-lived components suitable for long-term deployment in harsh downhole conditions

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 thermal annealing process enhances the durability and reliability of sensor assemblies by reducing material diffusion and chemical degradation, leading to more accurate and long-lasting measurements in hostile environments.

Implementation Method 1

subjecting a preformed isolation element structure to at least one thermal annealing process to form a conditioned isolation element structure substantially less susceptible to at least one of hydrogen permeation, hydrogen-based embrittlement, and hydrogen-based stress-cracking

Methodology Applied

Scientific EffectThermal annealing: Annealing

Data Source

PatentUS10118257B2Conditioned isolation elements and sensor assemblies

Publication Date: 2018.11.06 CHAMPIONX LLC

AI summary

A method of forming a conditioned isolation element for a sensor assembly comprises subjecting a preformed isolation element structure to at least one thermal annealing process to form a conditioned isolation element structure substantially less susceptible to at least one of hydrogen permeation, hydrogen-based embrittlement, and hydrogen-based stress-cracking. Conditioned isolation elements and sensor assemblies are also described.