Embedded Wellbore Logging Sensors for Minimal Equipment Modification
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Solution Overview
Problem
Existing downhole equipment lacks reliable data acquisition and monitoring capabilities due to the reluctance to modify mechanical components, and integrating electronic sensors is constrained by size and cost considerations, especially for existing equipment.
Innovation Solution
Wellbore logging devices with embedded sensors and power sources are designed to fit within instrumentation recesses of downhole components, allowing for data collection without significant modification, using modular designs that can be removably installed and protected by pressure caps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If electronic sensors are integrated into existing downhole equipment, then data collection capability is improved, but device complexity and modification cost increase
Solution Approach 1:
The electronic sensor assembly is nested within a recess formed in the outer surface of the downhole equipment component. The recess is sized to receive the sensor assembly, allowing it to be embedded without significantly increasing the overall external dimensions of the equipment. This nesting approach enables data collection capability while minimizing impact on the original equipment structure and complexity.
Solution Approach 2:
A pressure cap is introduced as an intermediary component to seal the recess and protect the electronic sensor assembly from the downhole environment. The pressure cap creates a sealed chamber that allows electronic components to function in harsh downhole conditions without requiring extensive modification to the original equipment structure.
2Measurement precision
If electronic sensors are added to downhole equipment, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The recess is pre-formed in the downhole equipment component during manufacturing, creating a prepared receptacle for the electronic sensor assembly. This preliminary action allows the sensor to be integrated without requiring post-manufacturing modifications such as drilling or extensive machining, thereby maintaining ease of manufacture while enabling precise measurements.
Solution Approach 2:
The electronic sensor assembly is designed as a relatively simple, replaceable unit that can be manufactured at lower cost compared to modifying entire downhole equipment systems. The modular nature of the assembly allows for cost-effective production and replacement if needed.
3Reliability
If existing equipment is modified to include sensors, then reliability of data is improved, but structural integrity may be compromised
Solution Approach 1:
The sensor assembly is nested within a recess that is specifically designed to accommodate the sensor without requiring removal of material that would compromise structural integrity. The recess is formed in a location and with dimensions that maintain the strength and load-bearing capacity of the original equipment component.
Solution Approach 2:
The pressure cap serves as a mediator that seals the recess while distributing loads and protecting the internal sensor assembly from external downhole forces. This allows reliable data collection without exposing the equipment's structural weaknesses that would result from an open recess.
Data Source
AI summary
A wellbore logging device incorporating selected electronic sensors and a power source is sealingly and removably embeddable within an instrumentation recess formed in a new or existing downhole equipment component such as a downhole tool or other component of a bottomhole assembly (BHA) in a tubular string such as a drill string. The logging device may be a modular device comprising an electronics module incorporating the electronic components, and a power module incorporating one or more energy cells. The electronics module and power module are engageable to form the logging device for insertion into an instrumentation recess, and to enable energization of the sensors and data transfer between the modules. In alternative embodiments, the logging device is a unitary device incorporating both the electronic components and the energy cells.