Downhole Sensor Retrofit via Acoustic Pulse Telemetry

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Solution Overview

Problem

Existing oil and gas wells, especially mature assets, lack permanent downhole pressure and temperature monitoring sensors, necessitating a suitable retrofit solution for long-term measurement and wireless data transmission to improve reservoir management and production efficiency.

Innovation Solution

Integration of sensors with wireless telemetry using pressure pulses and acoustic signals through production tubing for real-time data transmission, eliminating the need for removing completion hardware and reducing maintenance costs by using hybrid tools with power generators and slip mechanisms to secure the system within the wellbore.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If permanent downhole monitoring systems are installed in existing wells, then continuous pressure and temperature measurement capability is improved, but device complexity and installation difficulty increase due to the need to pull production tubing

Engineering Contradiction:

Improvecontinuous monitoring capabilityVSAvoidinstallation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system is divided into separate functional modules: a monitoring device with sensors, a separate data transmission system using existing tubing as conduit, and a surface reception system. This segmentation allows the monitoring device to be installed independently without requiring removal of production tubing, thereby reducing installation complexity while maintaining continuous monitoring capability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system uses existing well infrastructure (production tubing, wellbore) for multiple purposes: both for hydrocarbon production and for data transmission. The production tubing serves dual functions as both a production conduit and a transmission medium for pressure and temperature data, eliminating the need for separate dedicated monitoring infrastructure

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If downhole sensors are installed for real-time monitoring, then production optimization capability is improved, but maintenance cost and intervention frequency increase

Engineering Contradiction:

Improveproduction optimizationVSAvoidmaintenance cost

Core Design Contradiction:

ProductivityVSEase of repair

Solution Approach 1:

The system replaces complex mechanical data transmission mechanisms with acoustic pressure pulse signaling through the production fluid. This substitution simplifies the overall system, reducing the number of moving parts and potential failure points in the downhole environment, thereby lowering maintenance requirements while enabling real-time production monitoring and optimization

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system utilizes the existing production fluid flow and wellbore infrastructure to transmit data, rather than requiring separate powered transmission systems. The acoustic pulses ride on the existing fluid dynamics, eliminating the need for additional energy sources or complex transmission hardware that would require maintenance

Inventive Principle:

Principle #25Self-service

3Reliability

If traditional cable-based data transmission is used, then data reliability is improved, but device complexity and installation time increase due to cable management requirements

Engineering Contradiction:

Improvedata transmission reliabilityVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system uses acoustic pressure pulses transmitted through the production fluid (hydraulic medium) to convey data from downhole to surface. This pneumatic/hydraulic approach eliminates the need for physical cable installation and management, significantly reducing installation time while maintaining data transmission reliability through the use of coded pulse sequences

Inventive Principle:

Principle #29Pneumatics and hydraulics

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 continuous monitoring and optimization of hydrocarbon production, extending the life of artificial lift systems and reducing interventions, while providing reliable and cost-effective digital data communication within the wellbore.

Implementation Method 1

transmit the data wirelessly to a surface location using acoustic waves

Methodology Applied

Scientific EffectAcoustic wave transmission: Sound

Implementation Method 2

pressure sensor adapted to be disposed within a wellbore and detect pressure data of a hydrocarbon fluid

Methodology Applied

Scientific EffectPressure sensing:

Implementation Method 3

temperature sensor adapted to be disposed within a wellbore and detect temperature data of a hydrocarbon fluid

Methodology Applied

Scientific EffectTemperature sensing:

Data Source

PatentUS11236607B2Real time downhole pressure and temperature sensor for retrofitting into producing wells

Publication Date: 2022.02.01 TUBEL

AI summary

A system that can be deployed through production tubing in existing wells aid in eliminating the necessity to remove tubing from the well to install a gauge on the outside the production tubing or as part of the tubing string. The system comprises a hybrid tool which comprises a gauge system capable of being deployed through tubing to a pre-determined depth in the well. The gauge system comprises one or more wireless gauges to provide real time data from downhole to a surface location where the data are transferred to the surface using acoustic pressure travelling through production pipe and/or pressure pulses travelling through the produced fluid to the surface.