Downhole Sensor Deployment Assembly with Pivotable Arms
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Solution Overview
Problem
Existing downhole sensor deployment methods face challenges in protecting EM sensors from abrasion and crush forces during wellbore operations, particularly when using swell packers or spring centralizers, which can lead to costly and inefficient sensor deployment and potential damage.
Innovation Solution
A downhole sensor deployment assembly with pivotably coupled arms and sensor pads that can be extended radially from a completion string, featuring actuators and centralizers to maintain protection and secure contact with the wellbore formation without additional cables for arm actuation, allowing for effective resistivity measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If EM sensors are deployed on swell packers or packer elements, then the sensors can be positioned close to the formation, but the sensors are exposed to abrasion and crush forces during conveyance
Solution Approach 1:
The deployment system segments the sensor protection function from the sensor contact function. The sensor is housed within a protective deployment mechanism that can be conveyed through the wellbore, then deployed to position the sensor close to the formation. This segmentation allows the sensor to be protected during conveyance while still achieving close formation contact for measurement.
Solution Approach 2:
A deployment mechanism acts as an intermediary between the completion string and the EM sensor. This intermediary protects the sensor during conveyance through the wellbore, then facilitates controlled deployment to position the sensor close to the formation. The intermediary absorbs the mechanical stresses of conveyance while enabling precise sensor positioning for measurement.
2Reliability
If EM sensors are deployed on spring centralizers, then the sensors can be conveyed through the wellbore, but the sensors drag against the formation and risk abrasion damage
Solution Approach 1:
The deployment mechanism employs dynamic elements such as pivotable arms that can change position during conveyance and deployment. During conveyance, the arms are retracted or positioned to minimize contact with the formation. Upon deployment, the arms extend or pivot to position the sensor close to the formation, dynamically adapting to the operational phase to balance protection and measurement needs.
Solution Approach 2:
The system performs preliminary protection during conveyance by keeping the sensor enclosed or retracted within the deployment mechanism. Before the sensor needs to contact the formation for measurement, the mechanism is deployed to transition the sensor from a protected state to a measurement state, ensuring protection is established before any potential abrasion risk occurs.
3Adaptability or versatility
If multiple EM sensors are deployed using swellable packers, then each sensor can be positioned independently, but the cost increases due to requiring machined packers for each location
Solution Approach 1:
The deployment mechanism is designed as a universal system that can deploy multiple EM sensors at different locations along the completion string. Rather than requiring custom-machined packers for each sensor location, a single standardized deployment mechanism design can be used repeatedly for multiple sensors, reducing manufacturing costs while maintaining the ability to position sensors independently at various depths.
Solution Approach 2:
Instead of creating unique custom packers for each sensor location, the system uses replicated standard deployment mechanisms that can be deployed at multiple locations. The design is copied and reused for different sensor positions, eliminating the need for expensive custom machining while maintaining adaptability to different deployment scenarios.
Data Source
AI summary
A downhole sensor deployment assembly includes a body attachable to a completion string and one or more arms pivotably coupled to the body. A sensor pad is coupled to each arm and movable from a retracted position, where the sensor pad is stowed adjacent the completion string, and an actuated position, where the sensor pad is extended radially away from the completion string. One or more actuators are pivotably coupled to the body at a first end and pivotably coupled to a corresponding one of the one or more arms at a second end, the one or more actuators being operable to move the sensor pad to the actuated position. One or more sensor devices are coupled to the sensor pad for determining a resistivity of a formation, the one or more sensor devices comprising at least one of a sensing electrode, a transceiver, and a transmitter.