Downhole Motor Sensor Package for Real-Time Performance Monitoring

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Solution Overview

Problem

Current downhole motor systems for directional drilling lack real-time monitoring and accurate estimation of power output and rotational speed, relying on lab-based static motor dynamometers that do not account for actual downhole conditions.

Innovation Solution

A downhole motor system equipped with a sensor package including pressure sensors, accelerometers, and a gyroscope, which measures rotational speed, power output, and whirl rate, allowing for real-time estimation and monitoring of performance curves.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If lab-based static motor dynamometers are used to estimate performance curves, then performance estimation is possible beforehand, but the estimation does not account for actual downhole conditions

Engineering Contradiction:

Improveperformance estimation accuracyVSAvoiddownhole condition adaptability

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent replaces lab-based mechanical dynamometer systems with a downhole sensor-based measurement system. Sensors including pressure sensors, accelerometers, and gyroscopes are installed directly in the downhole motor to measure actual performance parameters in-situ, eliminating the need for lab-based mechanical testing and providing accurate measurements that reflect actual downhole conditions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces sensors as intermediary devices between the downhole motor components and the performance measurement system. These sensors act as mediators that directly measure pressure, acceleration, and rotational parameters within the motor, transmitting this data to surface systems for real-time performance curve generation without requiring physical extraction or lab testing.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If downhole sensors are installed in the rotor assembly, then real-time monitoring of rotational speed and power output is enabled, but the device complexity increases

Engineering Contradiction:

Improvereal-time measurement accuracyVSAvoidsensor package complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent merges multiple sensing functions into a single integrated sensor package that is installed within the rotor assembly. The sensor package combines pressure sensors, accelerometers, and gyroscopes into one unified unit, reducing the number of separate components and simplifying installation while enabling comprehensive real-time monitoring of motor performance parameters.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sensor package serves multiple functions simultaneously: measuring differential pressure across the motor, detecting rotational speed through accelerometers, determining orientation and whirl rate through gyroscopes, and providing data for generating performance curves. This multi-functionality reduces the need for separate measurement systems and simplifies the overall device architecture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11187041B2Sensor equipped downhole motor assembly and method

Publication Date: 2021.11.30 NAT OILWELL VARCO LP

AI summary

A downhole motor for drilling a borehole includes a stator assembly including a helical-shaped stator, a rotor assembly rotatably disposed in the stator assembly, wherein the rotor assembly includes a helical-shaped rotor, and a sensor package received in the rotor assembly, wherein the sensor package includes a first pressure sensor, a second pressure sensor, and a plurality of accelerometers.