Downhole Sensor Systems With Plug And Play Architecture
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Solution Overview
Problem
Conventional downhole sensor systems are inflexible and require redesign for adding or removing sensors, leading to increased tool size, complexity in testing new sensor designs, and inefficiencies in data acquisition across different tool systems.
Innovation Solution
A plug and play sensor system architecture with discrete, independent sensors that have standardized power supply, communication, and mechanical interfaces, allowing for easy attachment and removal without hardware modifications, and enabling uniform data acquisition across various tool systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sensors are made as integral part of the module with fixed configuration, then the system structure is simplified and easier to manufacture, but the system loses flexibility and requires redesign for adding or removing sensors
Solution Approach 1:
The sensor system is divided into discrete, independent sensor units that can be individually attached to or removed from the downhole tool. Each sensor unit operates independently with its own control and communication capabilities, allowing flexible reconfiguration without redesigning the entire module.
Solution Approach 2:
The downhole tool is designed with universal interfaces and standardized mounting mechanisms that can accommodate multiple types of sensors. The system can be reconfigured for different sensor arrays depending on the specific application requirements, making the tool multi-functional and adaptable.
2Quantity of substance
If the sensor array size is increased to accommodate more sensors, then the sensing capability is improved, but the overall tool size has to be increased
Solution Approach 1:
Multiple sensor units are arranged in a compact, nested configuration within the downhole tool housing. The discrete sensor units can be positioned in series along the tool body or arranged in concentric patterns, maximizing the sensor array density without proportionally increasing the overall tool volume.
3Reliability
If new sensor designs are tested by building new tool prototypes, then the sensor performance can be evaluated, but the development complexity and time are increased
Solution Approach 1:
The sensor units are extracted from the tool prototype and made as standalone, interchangeable components. This allows new sensor designs to be tested by simply replacing existing sensor units in the tool, eliminating the need to build entirely new prototypes for each sensor design iteration.
4Ease of repair
If repair of one or more sensor units requires shipping the complete tool, then the sensor can be replaced, but the downtime and operational efficiency are reduced
Solution Approach 1:
Sensor units are designed as easily extractable components that can be removed and replaced at the wellsite without requiring the entire tool to be shipped back. The discrete sensor units can be accessed through service ports or by simple mechanical detachment mechanisms.
Data Source
AI summary
A sensor module for a sensing apparatus configured for operation downhole, within a borehole. The sensor module comprises a sensor array having a plurality of sensors to sense selected formation parameters and a control system for selective and independent operation of each sensor of the sensor array. Each sensor of the sensor array is configured or designed as a discrete sensor unit for individual and independent communication and control. Each sensor of the sensor array may have an associated electronics module that provides standardized electronic connectivity with the control system.