Downhole Sensor Sub for Real-Time Completion Control
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Solution Overview
Problem
Existing methods for measuring and controlling downhole parameters during completion operations in petroleum production, such as fracturing, are inaccurate due to the large distances involved, leading to potential misrepresentation of actual downhole conditions.
Innovation Solution
A system comprising a tool string with a sensor sub that measures downhole parameters like force, torque, pressure, and temperature, and transmits data to a surface control unit to adjust operations in real-time, ensuring accurate control of completion operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If sensors are located at surface location to measure downhole parameters, then the measurement system is simpler and easier to operate, but the measurement precision deteriorates due to large distances involved
Solution Approach 1:
The measurement system is segmented into surface equipment and downhole sensor components. The sensor sub is separated and placed at the downhole location where measurements are needed, while surface equipment handles data processing and control. This segmentation allows each component to be optimized independently - the sensor sub for measurement precision and the surface equipment for ease of operation.
Solution Approach 2:
A tool string acts as an intermediary mechanism to deliver the sensor sub from the surface to the downhole location. The tool string serves as a mediator that transports the sensor sub through the wellbore, enabling the sensor to be positioned at the measurement location while still allowing surface-based operation and control.
2Device complexity
If calculations are performed to determine downhole parameters from surface measurements, then the system complexity is reduced, but the manufacturing precision of downhole parameter representation deteriorates
Solution Approach 1:
The patent replaces the mechanical/electrical transmission system with an optical fiber-based communication system. Optical fibers are used to transmit measurement data from the downhole sensor sub to the surface, eliminating the need for complex mechanical linkages and enabling more precise data transmission with minimal signal degradation over distance.
Solution Approach 2:
Instead of directly transmitting physical measurements through complex mechanical systems, the patent creates an optical copy or representation of the measurement data that can be transmitted through the wellbore. The optical fiber transmits a digital or optical representation of the sensor readings, allowing accurate data transfer without direct mechanical connection throughout the entire wellbore.
3Measurement precision
If direct downhole measurement is implemented, then the measurement precision improves, but the device complexity increases due to additional sensor sub and tool string components
Solution Approach 1:
The sensor sub is designed as a multi-functional module that can measure multiple downhole parameters (force, torque, pressure, temperature) using a single integrated downhole location. This universal sensor assembly reduces the need for multiple separate measurement systems, thereby limiting the increase in overall device complexity while maintaining high measurement precision across different parameters.
Solution Approach 2:
The sensor sub is nested within the tool string assembly, with the sensor components integrated into the downhole end of the tool string. This nested configuration allows the sensor sub to be positioned at the measurement location while minimizing the additional complexity visible from the surface equipment perspective.
Data Source
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AI summary
A method, computer-readable medium and apparatus for delivering a material to a downhole location in a formation is disclosed. A device is operated at a surface location to produce an action at the downhole location related to delivery of the material to the formation. A downhole parameter is measured at the downhole location, wherein the downhole parameter is affected by the operation of the device at the surface location. The downhole parameter is measured using a sensor proximate the downhole location. The measured downhole parameter is used to alter operation of the device at the surface location to deliver the material to the formation at the downhole location.