Downhole Force Measurement via Pressure Differential
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Solution Overview
Problem
In extended-reach well systems, it is challenging for operators to determine if well tools have contacted or coupled with each other and to quantify the force of contact due to the large distance between the surface and the well tools, which complicates hydrocarbon extraction operations.
Innovation Solution
A pressure-sensing device is coupled to the well tool, featuring multiple pressure sensors that detect pressures within different chambers and transmit data to a computing device, which calculates pressure differentials to determine contact and force of contact between well tools, using sealing devices to enhance accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pressure sensors are installed in chambers within the well tool to detect contact forces, then measurement precision of downhole forces is improved, but device complexity increases due to multiple sensors and chambers
Solution Approach 1:
The well tool is divided into multiple sealed chambers (first chamber and second chamber) with distinct pressure sensing zones. By segmenting the internal structure into separate pressure zones, the system can independently measure contact forces from different directions (e.g., compression vs. tension), thereby improving measurement precision while managing complexity through functional segmentation
Solution Approach 2:
A fluid medium is introduced as an intermediary between the contact force and the pressure sensors. The fluid transmits mechanical contact forces as pressure changes within the sealed chambers, allowing indirect but precise measurement of downhole forces without requiring direct mechanical contact between sensors and tool surfaces, thus improving measurement capability
2Reliability
If multiple pressure sensors and sealed chambers are used to accurately detect contact forces, then reliability of force detection is improved, but ease of operation deteriorates due to complex data interpretation requirements
Solution Approach 1:
The system continuously monitors pressure differential between chambers and provides real-time feedback about contact force status. By establishing pressure thresholds that correspond to specific contact conditions (e.g., tool-to-tool contact, tool-to-wall contact), the system automatically interprets complex pressure data and provides clear operational feedback, improving reliability while maintaining ease of operation through automated decision support
Solution Approach 2:
Instead of directly measuring contact force with complex mechanical sensors, the invention inverts the approach by measuring pressure changes in sealed chambers that result from contact forces. This indirect measurement method simplifies the sensing mechanism while improving reliability, as pressure sensors are more robust and provide clearer signals than direct mechanical force sensors would in this application
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 system effectively determines whether well tools have contacted or coupled, and the force of contact, enabling operators to manage well operations more effectively and prevent potential damage by providing precise pressure data.
Implementation Method 1
determine a pressure difference between a first pressure and a second pressure... determine whether the well tool contacted another well component... determine a force with which the well tool contacted the other well component based on the pressure difference
Data Source
AI summary
A system can include an upper completion string including an outer mandrel and an inner mandrel positioned coaxially within the outer mandrel. The upper completion string can include a first pressure sensor in communication with a first chamber via a first channel extending through an outer housing of the outer mandrel for detecting a first pressure within the first chamber and transmitting an associated sensor signal. The first chamber can have a boundary that is defined at least in part by (i) an outer surface of the inner mandrel, (ii) an inner surface of the outer mandrel, and (iii) at least two protrusions positioned between the outer surface of the inner mandrel and the inner surface of the outer mandrel. The system can include a computing device in communication with the first pressure sensor for determining a pressure difference between the first pressure and another pressure.