Downhole Sensor Array Weld Joint Void Design

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Solution Overview

Problem

Conventional temperature sensor arrays using optical fibers are prone to failure due to bending, fragility, and vulnerability to shock and vibration in downhole environments, and the bonding methods required to secure them expose sensitive components to excessive heat, compromising their robustness under extreme pressures and temperatures.

Innovation Solution

A downhole distributed sensor array design featuring sensor housings with weld joints that connect cable segments with a void between the conductor and jacket, allowing for robust bonding without exposing sensitive components to excessive heat, using insulation removal to create voids and prevent contamination, and employing electrical conductors for reliable data transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is used to bond sensor housings to cable jackets, then connection robustness is improved, but sensitive components are exposed to excessive heat

Engineering Contradiction:

Improveconnection robustnessVSAvoidheat exposure to sensitive components

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The cable structure is segmented into distinct regions: an inner conductor region and an outer jacket region. The insulation material is removed from a portion of the cable to create a bonding zone where only the jacket remains. This segmentation allows welding to be applied to the jacket without transferring heat to the conductor or sensitive sensor components inside the housing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulation material is extracted (removed) from a specific portion of the cable segment proximate to the bonding location. This removal creates a void space that isolates the conductor from the welding heat while maintaining the structural integrity of the cable. The conductor is effectively taken out of the heat exposure zone during the welding process.

Inventive Principle:

Principle #2Taking out (Extraction)

2Measurement precision

If optical fibers are used for temperature sensing, then continuous temperature profile is achieved, but fibers are fragile and prone to failure under shock and vibration

Engineering Contradiction:

Improvecontinuous temperature profileVSAvoidfiber fragility under shock and vibration

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent replaces fragile optical fibers with more robust electrical conductors and electronic sensors. While optical fibers provide continuous temperature profiles, they are replaced with solid-state electronic components that are inherently more resistant to shock and vibration. The system uses conventional electrical wiring and electronic temperature sensors (such as thermocouples or RTDs) that can withstand harsh downhole conditions without the fragility of glass fibers.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Strength

If robust housings are used to withstand extreme pressures, then sensor protection is improved, but bonding methods must provide sufficiently robust connections

Engineering Contradiction:

Improvehousing strength under pressureVSAvoidbonding connection complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The cable jacket and sensor housing are merged into a single bonded structure through welding. The jacket is welded directly to the housing, creating an integrated assembly that combines the pressure-resistant properties of both components. This merging eliminates the need for separate bonding mechanisms and simplifies the overall connection structure while maintaining robustness under extreme pressures.

Inventive Principle:

Principle #5Merging (Combining)

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

The solution provides a robust and reliable sensor array capable of withstanding extreme downhole conditions, preventing damage to sensitive components and ensuring accurate data transmission, while avoiding the fragility issues of optical fibers and heat-related degradation.

Implementation Method 1

A weld joint bonds a sensor housing of the sensor housings to a jacket of a cable segment of the cable segments

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS10018033B2Downhole distributed sensor arrays for measuring at least one of pressure and temperature, downhole distributed sensor arrays including at least one weld joint, and methods of forming sensors arrays for downhole use including welding

Publication Date: 2018.07.10 CHAMPIONX LLC

AI summary

A downhole sensor array includes sensor housings, and each sensor housing contains one or more of a pressure sensor and a temperature sensor. Cable segments connect the sensor housings. A weld joint bonds a sensor housing to a jacket of a cable segment, and a conductor of the cable segment and the jacket of the cable segment may be separated by a void proximate the weld joint. Methods relate to forming such sensor arrays.