Downhole Plug Sensor for Real-Time Obstruction Detection

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Solution Overview

Problem

Conventional downhole plugs in hydrocarbon wells lack mechanisms for real-time monitoring and efficient removal, particularly in longer wells where coiled tubing cannot reach, and there is no effective method to detect plug dissolution or downhole obstructions like sand bridges.

Innovation Solution

Incorporating a sensor and actuation mechanism into downhole plugs to form a fluid seal and detect parameters such as obstructions and fluid conditions, allowing for real-time monitoring and communication of data to the surface, and enabling selective release mechanisms for plug removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Difficulty of detecting and measuring

If conventional plugs are used without sensors, then device complexity is reduced, but the ability to detect downhole obstructions and monitor plug status is lost

Engineering Contradiction:

Improvedetection of downhole obstructions and plug dissolutionVSAvoidcomplexity of plug structure

Core Design Contradiction:

Difficulty of detecting and measuringVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical detection systems with electronic sensors that can detect obstructions, plug position, and dissolution status through electrical or electromagnetic means, reducing mechanical complexity while improving detection capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The sensor system is designed to perform multiple functions including detecting obstructions, monitoring plug position, and determining dissolution status, eliminating the need for separate specialized devices for each detection function

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If dissolvable plugs are used in longer wells, then plug removal becomes feasible without coiled tubing, but there is no mechanism to identify when the plug has fully dissolved

Engineering Contradiction:

Improveplug removal capabilityVSAvoidinformation about plug dissolution status

Core Design Contradiction:

Ease of operationVSLoss of information

Solution Approach 1:

The sensor provides continuous feedback on the plug's dissolution status, allowing operators to monitor when the plug has fully dissolved and make informed decisions about well operations, eliminating information loss about plug status

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The sensor system enables the plug to self-report its dissolution status and position, eliminating the need for separate monitoring operations or methods to determine plug status

Inventive Principle:

Principle #25Self-service

3Productivity

If conventional plugs without sensors are used, then manufacturing costs are reduced, but time-consuming manual removal processes are required

Engineering Contradiction:

Improveplug removal efficiencyVSAvoidmanufacturing complexity of plug with sensor

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent integrates electronic sensors into the plug structure, replacing the need for mechanical retrieval operations with automated sensor-based monitoring and control, significantly improving removal efficiency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The sensor system monitors changes in physical parameters such as position, pressure, and dissolution rate, enabling automated control of the plug removal process and improving overall productivity

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11408275B2Downhole plugs including a sensor, hydrocarbon wells including the downhole plugs, and methods of operating hydrocarbon wells

Publication Date: 2022.08.09 EXXONMOBIL UPSTREAM RESEARCH COMPANY(US)

AI summary

Downhole plugs including a sensor, hydrocarbon wells including the downhole plugs, and methods of operating the hydrocarbon wells. The downhole plugs include a sealing structure, an actuation mechanism, and the sensor. The actuation mechanism is configured to selectively transition the sealing structure between a disengaged state, in which the downhole plug is free to move within a tubular conduit of a downhole tubular of the hydrocarbon well, and an engaged state, in which the sealing structure operatively engages with the downhole tubular, forms a fluid seal with the downhole tubular, and resists motion of the downhole plug within the tubular conduit. The sensor is configured to detect a sensed parameter within the tubular conduit and to generate a sensor signal indicative of the sensed parameter.