Flexible Sensor Embedded in Downhole Elastic Element

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Solution Overview

Problem

There is a need to monitor the condition of elastic elements such as seals and inflatable packers in downhole tools to prevent failure in harsh oilfield or gasfield environments, where existing solutions lack effective monitoring capabilities.

Innovation Solution

A method and system utilizing flexible-type sensors, such as fluoropolymer sensors, to acquire output signals for estimating the condition of elastic elements, including strain and stress, and a processor to optimize internal pressure and predict the working time of secondary seals after primary seal failure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If flexible-type sensors are installed in elastic elements to monitor condition, then reliability of downhole tool is improved, but device complexity increases

Engineering Contradiction:

Improvereliability of downhole toolVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The flexible-type sensor is embedded within the elastic element itself, with the sensor structure nested inside the seal or packer body. This integration allows condition monitoring without adding external components, resolving the contradiction between improved reliability through monitoring and increased device complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The sensor and elastic element are combined into a single integrated structure where the sensor is permanently installed within the elastic element. This merging eliminates the need for separate monitoring devices and reduces overall system complexity while maintaining reliability benefits.

Inventive Principle:

Principle #5Merging (Combining)

2Duration of action of stationary object

If real-time monitoring of elastic element condition is implemented, then operational life of secondary seals is extended, but loss of time for data acquisition and processing increases

Engineering Contradiction:

Improveoperational life of secondary sealsVSAvoidloss of time

Core Design Contradiction:

Duration of action of stationary objectVSLoss of time

Solution Approach 1:

The system continuously monitors and estimates the condition of the primary seal in advance, predicting remaining operational life before actual failure occurs. This preliminary assessment allows for proactive decision-making about when to retrieve or replace seals, extending the effective operational life of secondary seals by preventing premature failure without requiring constant real-time intervention.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The processor continuously receives sensor output signals and updates the estimated condition of the elastic element in real-time, creating a feedback loop that automatically adjusts monitoring based on actual wear patterns. This feedback mechanism reduces unnecessary data processing while maintaining accurate predictions of operational life.

Inventive Principle:

Principle #23Feedback

3Measurement precision

If flexible polymer-type sensors are used to sense strain and stress, then measurement precision of elastic element condition is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvemeasurement precision of elastic element conditionVSAvoidmanufacturing precision

Core Design Contradiction:

Measurement precisionVSManufacturing precision

Solution Approach 1:

The sensor design utilizes the inherent flexibility and elastic properties of polymer materials to convert mechanical strain and stress into measurable electrical signals. By changing the physical parameters of the sensor material (using flexible polymers instead of rigid sensors), high measurement precision is achieved while reducing manufacturing precision requirements through material selection.

Inventive Principle:

Principle #35Parameter changes

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

Enables real-time monitoring and optimization of elastic element conditions, extending the operational life of secondary seals and improving the reliability of downhole tools by predicting failures and adjusting internal pressures accordingly.

Implementation Method 1

The sensor senses at least one of strain and stress of the elastic element

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

A method and system utilizing flexible-type sensors, such as fluoropolymer sensors, to acquire output signals for estimating the condition of elastic elements, including strain and stress

Methodology Applied

Scientific EffectPiezoresistive effect: Piezoresistive Effect

Data Source

PatentUS10746014B2Method and system for monitoring a condition of an elastic element used in a downhole tool

Publication Date: 2020.08.18 SCHLUMBERGER TECH CORP

AI summary

A method and a system for monitoring a condition of an elastic element used in a downhole tool are provided. The method comprises acquiring an output signal from a flexible-type sensor installed in the elastic element, the sensor sensing at least one of strain and stress of the elastic element, and estimating a condition of the elastic element based on the output signal from the sensor. The system comprises a flexible-type sensor installed in the elastic element, the sensor sensing at least one of strain and stress of the elastic element and a processor to acquire an output signal from the sensor and estimate a condition of the elastic element based on the output signal from the sensor.