Downhole Multi-Sensor Manifold for Fewer Leak Paths
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Solution Overview
Problem
Existing downhole sensor assemblies in oil and gas production face challenges such as damage to hydraulic control lines during deployment, difficulty in verifying integrity, and the need for redundant sensor setups that increase the risk of leak points and require multiple assemblies, leading to inefficiencies and increased maintenance.
Innovation Solution
A multi-sensor assembly combining multiple sensors into a single unit with a manifold and internal channels, allowing for integrated monitoring and reduced leak paths, enabling reuse and flexible configuration for various downhole systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple separate sensor assemblies are used to monitor downhole systems, then measurement coverage is improved, but device complexity and number of leak points increase
Solution Approach 1:
The patent combines multiple pressure sensors (tubing pressure sensor, annulus pressure sensor, hydraulic device pressure sensor) into a single integrated sensor assembly. This consolidation maintains comprehensive measurement coverage while reducing the total number of separate assemblies deployed downhole, thereby reducing potential leak points and simplifying the overall system configuration.
Solution Approach 2:
The sensor assembly is designed as a universal multi-functional unit that can simultaneously monitor multiple parameters (tubing pressure, annulus pressure, hydraulic device pressure) through a single integrated structure. This multi-functionality eliminates the need for multiple specialized sensor assemblies, reducing complexity while maintaining comprehensive monitoring capabilities.
2Ease of manufacture
If hydraulic control lines are exposed externally on production tubing, then ease of installation is improved, but reliability deteriorates due to abrasion and damage
Solution Approach 1:
The hydraulic control lines are nested within the production tubing rather than being exposed externally. This nested configuration protects the hydraulic lines from abrasion and damage during deployment while maintaining ease of installation, as the lines are routed through the tubing structure itself rather than requiring external protection mechanisms.
3Adaptability or versatility
If lower completion is installed independently with majority of hydraulic control lines, then adaptability is improved, but difficulty in verifying integrity increases
Solution Approach 1:
The sensor assembly is installed during the lower completion installation to preliminarily monitor hydraulic line integrity before the upper completion is added. This preliminary monitoring capability allows verification of hydraulic system integrity early in the deployment process, eliminating the waiting period until upper completion installation and enabling early detection of potential issues.
4Reliability
If redundant sensor setups are used to ensure monitoring capability, then reliability is improved, but loss of time and maintenance requirements increase
Solution Approach 1:
Multiple pressure sensors are integrated into a single unified sensor assembly rather than being distributed across multiple separate assemblies. This merging maintains redundant monitoring capability through multiple sensors while consolidating them into one removable unit, significantly reducing the time and complexity of installation and maintenance operations.
Data Source
AI summary
Embodiments of a multi-sensor apparatus for use downhole in a wellbore, a system, and a method for using a multi-sensor apparatus are disclosed herein. In one embodiment, an apparatus for use in a wellbore, comprises a manifold, the manifold having a plurality of ports; a housing connected with the manifold; at least three sensors positioned within the housing; and a first internal channel and a second internal channel for enabling fluid flow through the manifold. In another embodiment, a system includes a removable downhole tool and a multi-sensor apparatus coupled with the removable downhole tool.