Downhole Tool Pressure Sensor Integration for Charge Verification
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Solution Overview
Problem
Downhole tools with pressurized gas chambers face uncertainty regarding their charge status before and during service due to the lack of external pressure indicators, leading to potential malfunction or failure, especially since they cannot be externally tested without risking damage.
Innovation Solution
Integration of a sensor and transmitter within the tool to monitor pressure in real time, capable of sending surface signals corrected for depth, temperature, and fluid density, using various signal modes through the control line or annulus, allowing for remote monitoring and detection of charge status and leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If external pressure gauges are added to indicate internal pressure, then pressure monitoring capability is improved, but the risk of device breakage during run in increases
Solution Approach 1:
The pressure sensing and transmission functionality is extracted from external gauges and integrated into the downhole tool's internal chamber structure. The sensor is mounted inside the pressurized chamber and the transmitter is positioned to send signals through the control line, eliminating external components that could break during run in while maintaining continuous pressure monitoring capability
Solution Approach 2:
The control line serves as an intermediary medium to transmit pressure information from the downhole tool to the surface. Instead of using external gauges that physically connect to the tool, the system uses the existing control line to carry acoustic or electrical signals that convey pressure status, eliminating the need for fragile external pressure indication devices
2Loss of information
If the tool is picked up and mounted in a test fixture for function testing, then charge status verification is improved, but the time and complexity of service preparation increases
Solution Approach 1:
The sensor and transmitter system is pre-installed and activated within the downhole tool during assembly, enabling charge status verification to be performed immediately upon charging without requiring subsequent removal and mounting in test fixtures. The system continuously monitors pressure from the moment the tool is charged, eliminating the need for separate testing procedures
Solution Approach 2:
The downhole tool performs self-verification of its charge status through the integrated sensor and transmitter system. The tool autonomously monitors its own pressure levels and transmits this information to the surface, eliminating the need for external testing equipment and procedures that would require picking up and mounting the tool in test fixtures
3Device complexity
If no pressure monitoring is implemented, then device complexity is reduced, but the ability to detect malfunctions and prevent failures is worsened
Solution Approach 1:
The sensor and transmitter system serves multiple functions: it monitors charge status before service, provides continuous pressure monitoring during service, detects malfunctions, and enables early warning of potential failures. By integrating these multiple functions into a single system within the downhole tool, the patent achieves comprehensive monitoring without proportionally increasing device complexity
Solution Approach 2:
The transmitter continuously sends pressure information signals back to the surface through the control line or annulus, providing real-time feedback on the charge status of the pressurized chamber. This feedback mechanism enables operators to monitor tool health, detect malfunctions, and take preventive actions without increasing the physical complexity of the downhole tool itself
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 immediate verification of charge status before service, real-time monitoring during service, and early detection of potential failures, facilitating planned shutdowns and reducing the risk of tool malfunction.
Implementation Method 1
A sensor and transmitter is employed with a pressurized chamber of a downhole tool to be able to tell at a glance when the tool is delivered for service that it is properly charged
Implementation Method 2
The signal can be acoustic through the control line or the annulus or delivered through a fiber optic cable or signal wire run in the hydraulic control line, an auxiliary line or through the annulus
Data Source
AI summary
A sensor and transmitter is employed with a pressurized chamber of a downhole tool to be able to tell at a glance when the tool is delivered for service that it is properly charged. The sensor and transmitter can be integrated within the tool so as to be protected from damage during run in. While in service the sensor and transmitter can monitor pressure in real time and include a capability to send surface signals for real time monitoring of chamber pressures corrected for the service depth, temperature and density of the hydraulic fluid, for example. The signal can be acoustic through the control line or the annulus or delivered through a fiber optic cable or signal wire run in the hydraulic control line, an auxiliary line or through the annulus.