Downhole Position Sensor Using Resistance Measurement
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Solution Overview
Problem
Existing systems for controlling and monitoring the flow of fluid from multiple zones in oil and gas wells are imprecise and require expensive, complex electronics, making it difficult to accurately control the position of valves used to isolate and manage fluid flow from different hydrocarbon reservoirs.
Innovation Solution
A hydraulic system with two conductor lines and an electrical system that uses solenoid-operated valves and position sensors, such as potentiometers, to control and monitor the position of production tubing valves, allowing for precise incremental control and positioning of valves without the need for complex electronics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hydraulic control lines and flow regulators are used to control valve position, then the system can control fluid flow from multiple zones, but the positioning precision deteriorates and trial and error methods are required
Solution Approach 1:
The patent introduces position sensors that provide feedback signals about the actual valve position to the control system. This closed-loop feedback mechanism allows the system to monitor and adjust valve positions accurately, eliminating the trial-and-error method and achieving precise positioning control for multiple zones.
Solution Approach 2:
The patent replaces the purely mechanical hydraulic control system with an electro-hydraulic system that incorporates electrical sensors and control electronics. This substitution enables more precise control and measurement capabilities while maintaining the hydraulic actuation mechanism for valve operation.
2Measurement precision
If permanent gauges with complex electronics are used for position sensing, then measurement precision improves, but device complexity and cost increase
Solution Approach 1:
The patent extracts the sensing function from complex electronic gauges and implements it through simpler position sensors that detect valve position mechanically or electromechanically. This extraction maintains measurement precision while significantly reducing the complexity and cost of the electronic system.
Solution Approach 2:
The patent employs relatively simple, cost-effective position sensors rather than expensive permanent gauges with complex electronics. These sensors provide sufficient measurement precision for valve positioning while being more economical and easier to maintain, effectively replacing high-cost sensing solutions.
3Ease of operation
If hydraulic control systems are used for valve operation, then ease of operation improves, but measurement and monitoring capability deteriorates
Solution Approach 1:
The patent merges the hydraulic control system with an electronic monitoring system by integrating position sensors into the existing hydraulic valve actuation mechanism. This combination maintains the ease of hydraulic operation while adding comprehensive position detection and monitoring capabilities for accurate feedback.
Solution Approach 2:
The patent introduces position sensors as intermediary devices that bridge the hydraulic control system and the monitoring system. These sensors translate mechanical valve position into measurable signals without interfering with the hydraulic operation, enabling accurate detection while preserving operational simplicity.
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
Enables precise and independent control of fluid flow from multiple zones, reducing the need for expensive gauges and improving the accuracy of valve positioning, thereby enhancing the efficiency of oil and gas production operations.
Implementation Method 1
A position sensor system may include a downhole tool, a position sensor attached to the downhole tool such that resistance of the position sensor changes with position of the downhole tool
Implementation Method 2
A hydraulic system with two conductor lines and an electrical system that uses solenoid-operated valves and position sensors
Data Source
AI summary
A system and method for a position sensor system in a well system. A position sensor system may comprise a downhole tool, a position sensor attached to the downhole tool such that resistance of the position sensor changes with position of the downhole tool, a first conductor attached to the position sensor, and a second conductor attached to the position sensor as an electrical ground. A method for determining position of a downhole tool may comprise taking a first measurement of a line resistance and moving the downhole tool, wherein moving the downhole tool increases or decreases the line resistance. The method may further comprise taking a second measurement of the line resistance, wherein the second measurement provides an indication of the position of the downhole tool.