Downhole Tool Wear Sensor Using Segmented Conductive Layers
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Solution Overview
Problem
Current well site operations lack effective methods for accurately monitoring wear and position of downhole tools, particularly reamer components, which can lead to inefficiencies and increased non-productive time due to the inability to detect wear and position changes in real-time.
Innovation Solution
A sensor assembly is introduced, comprising a wear sensor with conductive layers and vias that generate signals detectable upon wear, and a position sensor using magnetic references, both connected to electronics for real-time data collection and analysis, enabling precise monitoring of tool wear and position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional downhole tools are used without sensors, then the device complexity is low, but the measurement precision and real-time monitoring capability are insufficient
Solution Approach 1:
The wear sensor is segmented into multiple conductive layers stacked at different depths within the core, with each layer monitored by separate vias. This segmentation allows precise detection of wear at different depth levels, enabling accurate measurement of wear progression while maintaining a manageable structural complexity through modular layering.
Solution Approach 2:
The sensor assembly employs a nested structure where multiple conductive layers are stacked within the core, and vias are nested within the conductive layers. This nested arrangement allows multiple sensing functions to be integrated within a compact volume, improving measurement precision without proportionally increasing overall device complexity.
2Measurement precision
If multiple conductive layers and vias are used in the wear sensor, then the measurement precision improves, but the manufacturing precision requirements increase
Solution Approach 1:
The sensor is divided into discrete conductive layers and vias that can be manufactured and positioned independently. Each via connects to specific conductive layers at defined depths, allowing for controlled manufacturing processes where alignment tolerances can be managed through standardized positioning features and sequential assembly steps.
Solution Approach 2:
The conductive layers and vias are positioned at specific local depths within the core to detect wear at different stages. This local quality approach allows manufacturing precision to be focused on critical alignment points rather than requiring uniform high precision throughout the entire sensor assembly, as each via-conductor interface is optimized for its specific detection depth.
3Productivity
If real-time monitoring of downhole tools is implemented, then the productivity improves by reducing non-productive time, but the device complexity and energy consumption increase
Solution Approach 1:
The sensor assembly serves multiple functions: detecting wear depth through conductive layers, monitoring position of movable components, and providing real-time data on tool condition. This multi-functionality allows a single integrated system to deliver comprehensive monitoring capabilities that improve productivity without requiring separate specialized devices for each measurement type.
Solution Approach 2:
The sensor assembly provides continuous feedback on wear depth and component position, enabling real-time monitoring of tool performance. This feedback mechanism allows operators to detect wear progression and position changes immediately, facilitating timely decisions to optimize drilling operations and reduce non-productive time associated with tool failure or inefficiency.
4Loss of time
If continuous monitoring is performed downhole, then the loss of time is reduced, but the use of energy increases
Solution Approach 1:
The wear sensor operates passively by detecting changes in electrical continuity through the conductive layers and vias as wear progresses. The sensor structure itself serves as the detection mechanism, eliminating the need for active power-consuming components. This self-service approach enables continuous monitoring with minimal energy input, as the sensor responds automatically to physical wear without requiring active interrogation or power-intensive processing.
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
This solution allows for real-time monitoring of downhole tool wear and position, reducing non-productive time by providing operators with critical data on tool performance and condition, potentially eliminating the need for additional testing and improving drilling efficiency.
Implementation Method 1
a plurality of vias extending through the plurality of conductive layers and to the base... generate a signal through the plurality of vias whereby, upon wear of each of the plurality of conductive layers, a change in the signal of a corresponding one of the at least two of the plurality of vias at a depth of the wear is detectable
Implementation Method 2
a position sensor using magnetic references
Data Source
Figure 1
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Figure 2B
AI summary
A sensor assembly for a downhole tool including a tool body and a movable component movably positionable about the tool body is disclosed. The sensor assembly may include a wear sensor and/or a position sensor. The wear sensor may include a core with conductors at various depths to send a signal, whereby, upon wear of the core, a change in the signal at the depth of the wear is detectable. The position sensor may be carried by the movable component, and may be used with references comprising magnets distributed about the tool body. The position sensor includes magnets having polarity responsive to polarity of the references whereby a position of the movable component is determined. The sensor assembly may also include a chassis housing electronics coupled to the position sensor and/or the wear sensor.